Mesa Courier analyzer training

At the end of the course of this training, it is expected that the trainees have the proven ability to safely operate the slurry analyzer system Courier X to:

• Accurately identify the core components of the system
• Fully aware of the present risks and means of control 
• Understand their roles and responsibilities

• Functional description and sample measurements
• Brief description of the XRF principles
• PCS – Probe Control Set
• PRS – Probe Set
• CLI – Courier Local Interface (HMI)
• CSA – Calibration Sampler Assembly
• CCA – Cooling Cabinet Assembly
• AWC – Automated Window Changer
• Basic specifications and ambient conditions of operation 
• Visual indicators
• Analyzer communications – internal and external
• Review of operating guides and IOMS manuals

• Powering Off/On analyzer subunits
• Placing analyzer in standby and shutting down the analyzer
• Critical warnings and alarms
• Clearing warnings and alarms – Operator/Service technician level 
• Temperature control system
• Assays calculations, display and histogram
• Remote operation
• Central control room data readings and controls
• Review of operating guides and IOMS manuals

• Sample lines layout and specifications
• Metso measurement sample transfer pumps (client-specific) 
• Types of primary samplers (client-specific)
• Flow rates
  • Specifications, configurations, measurement, histogram, starting, stopping 
  • Validating, sample lines flushes, common troubles and solutions
• Primary samplers operating controls
• User interface and sampling
• Review of operating guides and IOMS manuals

• Physical and functional description
• General specifications
• Operating panel
• Measurement process - phases
• Water flushing system
• Instrument air operation
• User interface – symbols and controls 
• Common problems and solutions
• Daily sampling (Composite/Shift)
  • Physical and functional description
  • User interface
  • Operating controls
  • VFU (client-specific)
  • VFU physical and functional description
  • VFU operating controls
  • Stopping and starting a VFU
  • Configurations, amount of material, collection frequency 
  • Common problems and solutions
  • Review of operating guides and IOMS manuals

• Risk assessment
• Present hazards and means of control
  • X-ray radiation
    • Radiation safety: Controls by design
    • Radiation safety: Controls by standard operating procedures 
  • Automated motion controls
  • Pressurized air
  • Pressurized water
  • Slurry
  • Sharp edges
  • Chemical substance (Solid Be, coolant) 
  • Electrical
  • Spent materials (consumables) classification 
  • Awareness of local regulations
  • Review of the IOMS MANUAL SAFETY

This is to ensure the highest level of quality of knowledge is attained on the general and
essential details of the material presented and practiced on. The techniques involve trainers' observations, oral and written questions. Errors will be corrected; conflicting concepts will be clarified.

Speed reading of the manuals, standard operating procedures, and quick guides.

At the end of the course of this training, it is expected that the trainees have the proven ability to:

• Accurately collect samples for laboratory analysis
• Perform one-point calibration
• Perform multi-point calibration with the use of OUTOCAL application
• Verify and measure the ability of the analyzer to produce accurate results 
• Manage calibration data
• Perform integrity checks on the core measurement devices
• Perform renormalizations
• Maintain life cycle equipment calibration
• Assist instrument technicians in troubleshooting faults

• Functional description and sample measurements
• Brief description of the XRF principles
• PCS - Probe Control Set, PRS - Probe Set, CLI - Courier Local Interface (HMI) 
• CSA - Calibration Sampler Assembly, CCA - Cooling Cabinet Assembly
• AWC - Automated Window Changer
• Basic specifications and ambient conditions of operation
• Visual indicators
• Analyzer communications (internal and external)
• Review of operating guides and IOMS manuals

• Powering Off/On analyzer subunits
• Placing analyzer in standby, shutting down the analyzer
• Critical warnings and alarms, clearing warnings and alarms – Operator/Service technician level
• Temperature control system
• Assays calculations, display and histogram
• Remote operation
• Central control room data readings and controls 
• Review of operating guides and IOMS manuals

• Requirements for sample collection
  • Running state of the plant, process circuit operation state 
  • Sample line state of operation checks
  • Evaluation of flow rates
  • Analyzer running state and integrity
• Collection procedure and validation – Lab analysis 
• Processing data for regression analysis

• Why calibrate?
• Principles of slurry calibration - XRF theory
• Measurement time selection criteria
• OUTOCAL - Metso regression analysis application 
• Applying and testing a model
• Maintaining calibration

This is to ensure the highest level of quality of knowledge is attained on the general and
essential details of the material presented and practised on. The techniques involve trainers' observations, oral and written questions. Errors will be corrected; conflicting concepts will be clarified.

Speed reading of the manuals, standard operating procedures, and quick guides.

• Overview of primary samplers purpose in metallurgical slurry sampling 
• Understanding different models (Fixed cutters, Multi-stage samplers, Metallurgical Samplers)
• Process flow and working principle
• Components and their functions (fixed and moving cutter set, underflow gates, sample tank, flushing system, integration with analyzers)
• Typical process applications

• Safety guidelines and warnings (ISO 3864 standards) 
• Identification and meaning of safety symbols
• Mechanical, electrical, and chemical hazards
• Emergency stop function and safety guards
• Personal Protective Equipment (PPE) requirements
• Lock-out-tag-out

• Transportation instructions and precautions
• Handling and inspecting the delivered equipment
• Storage conditions (temperature, humidity, UV exposure) 
• Long-term storage and preservation techniques

• Primary sampling lines installation - Specifications 
• Visual and functional checks and required tools
• Lifting procedures and best practices
• How it is installed:
  • Assembling the sampler
  • Positioning and mounting
  • Connection to process stream, water, and air supply 
  • Control system integration
• Post-installation checks and validation 
• Practical exercises

• Dry test run and wet test run procedures
• Initial start-up with slurry
• Adjusting underflow gates and cutter sets
• Verifying air, water, and power connections

• Intended use and operational limitations
• Operator’s duties and responsibilities
• Start-up, normal operation, and shutdown procedures
• Handling emergency shutdowns and power failures
• Sample collection and analysis overview
• How to check and adjust flows
• How to operate the samplers with the analyzers and plant automation

• Routine maintenance tasks:
  • Weekly, monthly, and annual checks
  • Cleaning and flushing procedures 
  • Inspecting wear components
• Planned maintenance schedules
• Troubleshooting common issues (mechanical, electrical, pneumatic)
• Replacement of damaged parts (cutter sets, rubber linings, pneumatic components)
• Environmental considerations and waste disposal
• Practical exercises