IPJ 1500

User Instructions: Operations, Maintenance

Operations & Maintenance Manual

InLine Pressure Jig
IPJ 1500
Revision 1.0

Revision 1.0

IPJ 1500
User Instructions: Operations, Maintenance

CLIENT NAME
EQUIPMENT LOCATION
SITE
PROJECT
MODEL

IPJ 1500

Internal Pressure (kPa)

10 - 200

Volume (L)

1600

Approx Power Requirement

2.2 kW, 3 ph, 415 V (standard)

Feed Capacity (t/hr)

0 50

Concentrate (t/hr)

0.5 20

Tails (m /hr)

0 - 120
3

Feed Flow (m /hr)

0 - 100

Hutch Water (L/s) @ Supply (kPa)

2 8 @ +350 kPa

Pulse Rate (cyc/min)

50 250

Stroke Length (mm)

0 - 20

Hydraulic Pressure Range (kPa)

2500 10000

Hydraulic Temperature ( C)

< 70

CLIENT NOTES

ii

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IPJ 1500
User Instructions: Operations, Maintenance

CHANGE RECORD

iii

Revision

Date

Author

Sections/Pages
Affected

Remarks

0.1

25/02/11

S. Waters

All

Draft manual for review

1.0

13/04/12

S. Waters

All

Release

Revision 1.0

IPJ 1500
User Instructions: Operations, Maintenance

FOREWORD
Gekko Systems specialises in the design, development and distribution of innovative mineral processing equipment
and systems with a particular focus on gravity separation. Long-term relationships based on trust and mutual
benefit, as well as an emphasis on innovation are the cornerstones of our philosophy.

Gekko is the world leader in modular pre-concentration and gravity gold recovery circuits. Manufacture and
assembly of the modular components can be managed in-house utilizing both skilled engineering staff and our
network of key suppliers. Because of this, we have implemented a range of significant step-change lean mineral
processing systems, the most recent of which is an underground processing plant. The Python Underground
Processing System is a modular, transportable processing plant for use on the surface or in underground drifts with
little to no additional excavation. It provides miners with a flexible, robust, low cost, low energy pre-concentration
process for the recovery of gold and/or heavy minerals.
Gekko also offers a range of proprietary equipment including:

iv

The InLine Pressure Jig

The InLine Leach Reactor

The InLine Spinner

Electrowinning cell

G-Rex Resin Column

Revision 1.0

IPJ 1500
User Instructions: Operations, Maintenance

Table of Contents
1.0 GENERAL INFORMATION ..........................................................................................................................7
1.1 About this Manual ..............................................................................................................................8
1.1.1 Manual Purpose ...................................................................................................................8
1.1.2 Manual Scope ......................................................................................................................8
1.1.3 Manual Use and On-site Application ....................................................................................8
1.1.4 Disclaimer.............................................................................................................................9
1.1.5 Warnings, Cautions and Notes ............................................................................................9
1.2 Safe Work Procedures .....................................................................................................................10
1.2.1 General ...............................................................................................................................10
1.2.2 Guarding.............................................................................................................................10
1.2.3 Isolation Procedures ..........................................................................................................10
1.2.4 Stored Energy ....................................................................................................................11
1.2.5 Working at Heights .............................................................................................................12
1.2.6 Housekeeping Standards ...................................................................................................12
1.2.7 Personnel Qualification & Training .....................................................................................12
1.2.8 Noise Levels .......................................................................................................................13
1.2.9 Recycling and End of Product Life .....................................................................................13
2.0 EQUIPMENT INFORMATION ....................................................................................................................14
2.1 IPJ Key Features ..............................................................................................................................15
2.1.1 IPJ General Assembly ........................................................................................................15
2.1.2 Screen ................................................................................................................................17
2.1.3 Ragging ..............................................................................................................................18
2.1.4 Control System ...................................................................................................................19
2.1.5 Air Release Systems ..........................................................................................................21
2.1.6 Alarms, Indicators and Protective Devices (where fitted) ..................................................22
2.3 Handling, Transport and Storage .....................................................................................................23
2.3.1 Lifting ..................................................................................................................................23
2.3.2 Storage Short Term .........................................................................................................23
2.3.3 Storage Long Term .........................................................................................................23
3.0 OPERATIONAL GUIDELINES ...................................................................................................................24
3.1 Pre-start Checks ...............................................................................................................................25
3.2 Operational Requirements ...............................................................................................................25
3.2.1 Pressure Differentials .........................................................................................................25
3.2.2 Feed Preparation ...............................................................................................................26
3.2.3 Hose Sizes and Expected Flows........................................................................................26
3.2.4 Concentrate Transport .......................................................................................................27
3.2.5 Flushing Points ...................................................................................................................27
3.2.6 Power Requirements ..........................................................................................................28
3.2.7 Water Addition ....................................................................................................................28
3.2.8 Ragging ..............................................................................................................................30
3.2.9 Ram Stroke Ratio ...............................................................................................................30
3.3 Start-Up Procedure...........................................................................................................................31
3.4 Shut-Down Procedure ......................................................................................................................32
3.5 Influence of Key Variables on Output ...............................................................................................33
3.6 Operator Checklist ............................................................................................................................34
3.7 Hazard control ..................................................................................................................................35
3.8 Isolation ............................................................................................................................................35
3.9 Unscheduled stops ...........................................................................................................................35
3.10 Emergency .....................................................................................................................................35
4.0 MAINTENANCE ..........................................................................................................................................36
4.1 Maintenance Management System ..................................................................................................37
4.2 Maintenance Alert.............................................................................................................................37
4.3 InLine Pressure Jig (IPJ) Schedule ..................................................................................................38
4.3.1 Schedule ............................................................................................................................38
4.3.2 Lube Schedule ...................................................................................................................39
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4.3.3 Procedures .........................................................................................................................40

5.0 TROUBLESHOOTING................................................................................................................................66
5.1 IPJ Troubleshooting Quick Guide.....................................................................................................67
*5.2 IPJ Supplementary Troubleshooting Guide ....................................................................................69
5.2.1 Pulse Stopped .....................................................................................................................69
5.2.2 IPJ Wont Reach Desired Pulse Rate .................................................................................69
5.2.3 Coarser Particles in Concentrate than Screen Aperture .....................................................70
5.2.4 Blockages ............................................................................................................................71
5.2.5 PID Controller Not Responding ...........................................................................................72
5.2.6 Ram Mechanical Issues ......................................................................................................73
5.2.7 Ragging ...............................................................................................................................74
5.2.8 Screen .................................................................................................................................74
6.0 OPERATOR TRAINING SIGN OFF SHEET ..............................................................................................75
7.0 OTHER RELEVANT DOCUMENTATION AND INFORMATION ...............................................................77
7.1 Design Designation ..........................................................................................................................78
7.2 Foundation Loadings ........................................................................................................................78
7.3 Battery Limits ....................................................................................................................................78
7.4 Certification and Supplementary Manuals .......................................................................................78
7.5 Change Notes ...................................................................................................................................78
8.0 GEKKO SYSTEMS PTY LTD WARRANTY ...............................................................................................79
8.1 Warranty And Defects Liability Period ..............................................................................................80
8.1.1 Defects Liability Period .......................................................................................................80
8.1.2 Extent of Warranty .............................................................................................................80
8.2 Defects After Taking Over ................................................................................................................81
8.2.1 Defects Liability Period .......................................................................................................81
8.2.2 Making Good Defects .........................................................................................................81
8.2.3 Notice of Defects ................................................................................................................81
8.2.4 Extension of Defects Liability Period ..................................................................................81
8.2.5 Failure to Remedy Defects.................................................................................................81
8.2.6 Removal of Defective Work ................................................................................................82
8.2.7 Further Tests on Completion..............................................................................................82
8.2.8 Right of Access ..................................................................................................................82
8.2.9 Joint Occupancy .................................................................................................................82
8.2.10 Defects in Companys Designs ........................................................................................82
8.2.11 Gekko to Search for the cause of the Defect ...................................................................82
8.2.12 Schedule of Defects .........................................................................................................82
8.2.13 Limitation of liability for Defects:.......................................................................................83
9.0 APPENDICES ............................................................................................................................................84
APPENDIX A: IPJ TECHNICAL SPECIFICATIONS .............................................................................85
APPENDIX B: SPARE PARTS LISTS...................................................................................................86
APPENDIX B-1: RAGGING ...................................................................................................................89
APPENDIX B-2: ADDITIONAL SPARE PARTS PHOTOS ...................................................................90
APPENDIX C: IPJ OEM MANUALS LISTING .......................................................................................94
APPENDIX D: IPJ 1500 HYDRAULICS SCHEMATIC ..........................................................................97
APPENDIX E: TORQUE GUIDE FOR BOLT TIGHTENING.................................................................98
10.0 FURTHER ASSISTANCE .........................................................................................................................99

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