2. Quarry water level control:
Company Name:
AfriSam
Presenter:
Edwin Swanepoel
Institute of Quarrying Annual Conference
Date: 10 April 2014

3. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 3
Introduction
 Introduction (Olifantsfontein pumping system)
 Sudden increase of water flowing into quarry experienced
 Existing pumping system capacity not adequate
 Could eventually have a negative influence on mining plan
 Contents of presentation
 Determining water Influx and required pump capacity
 Dispersing large amounts of water into the environment
 Selecting the best pump for the application
o System resistance curve vs. Pump performance curves
o Actual vs. Required flow rate
o Testing installed system performance and identifying problems

4. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 4
Determining water Influx and required pump capacity
 Why determine influx?
 Sustainability
 Where does it come from?

7. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 7
Determining water Influx and required
pump rate
 Calculate Influx
 Water level rise X Surface Area
 Divide by total time

8. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 8
Determining water Influx and required
pump rate
 Quarry water level change as a function of time
 Old fashioned Total station measurement
 Many other ways to measure if you apply your mind...

9. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 9
Determining water Influx and required
pump rate
 Quarry surface area measurement/Calculation
 Old Fashioned way
 Draw water line on existing quarry map and calculate

10. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 10
Determining water Influx and required
pump rate
 Important points to consider while conducting
measurements
 Rain
o Heavy rain will influence measurements.
 Current pumping system performance
o Make sure of total volume dispersed during
measuring period.

11. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 11
Dispersing large amounts of water into the
environment
 What does the law say
 Every person in control of a mine or activity must take reasonable
measures to-
o Prevent water containing waste or any substance which
causes or is likely to cause pollution of a water resource from
entering any water resource, either by natural flow or by
seepage, and must retain or collect such substance or water
containing waste for use, re-use, evaporation or for purification
and disposal in terms of the Act;
o Minimise water flow of any substance or floodwater into mine
workings, opencast workings, etc.
 However, water may be discharged provided quality of this water
is maintained or improved relative to that of the receiving
stream(s)

12. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 12
Water quality
 Measurements of water quality at various points
 Better than upstream quality – OK TO DISPERSE
 Worst than upstream quality – Treatment needed
 Continuous measurements must be taken to ensure water
quality stays within guideline ranges

13. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 13
System resistance Calculation

14. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 14
Static Head
 The static/geodetic head of the system is the difference
between the suction and discharge altitudes (Water
level!!!)

15. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 15
Pipe Size
 Discharge: Capital Cost vs. Running cost
 1.8m/s > V < 2.5m/s Discharge pipes.
 Friction Head Proportional to V2 (Haaland)
 Suction: To reduce cavitation
 V < 1m/s (NPSHavailable vs. NPSHrequired)

16. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 16
Selecting the best pump for the application

17. Actual vs. Required flow rate
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TotalHead(m)
Flow rate (m3/hr)
System Resistance curves vs. Pump Curve
Actual Flow rate = 692m3/hr
Required Flow rate = 600m3/hr

18. Actual vs. Required flow rate
30
34
38
42
46
50
54
58
62
66
70
74
78
82
86
90
94
98
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
440
460
480
500
520
540
560
580
600
620
640
660
680
700
720
740
TotalHead(m)
Flow rate (m3/hr)
System Resistance curves vs. Pump Curve
Determine Pump Head at
required flow rate

19. Actual vs. Required flow rate
30
34
38
42
46
50
54
58
62
66
70
74
78
82
86
90
94
98
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
440
460
480
500
520
540
560
580
600
620
640
660
680
700
720
740
TotalHead(m)
Flow rate (m3/hr)
System Resistance curves vs. Pump Curve
(Increase Resistance Head)
Install regulating valve & Set at
predetermined pressure.

20. Quarry water level control: (Olifantsfontein pumping system) Edwin Swanepoel10 April 2014 20
Monitoring Installed system
 Remember pump can only perform on Pump curve:
 Sudden change in either flow rate or discharge pressure:
o Check for leaks
o Check pump impellor
 However, if both the pressure and Flow rate changes
o Compare new Duty point with pump curve:
o If it falls on pump curve but:
o Pressure ↑ and Flow rate ↓ or vice versa:
 Pump √
 Change in static head
 Restriction in pipeline