DOCUMENTS PACKAGE TRANSMITTAL

KVAERNER METALS C00423 FACTIBILIDAD PROYECTO TRANSICION UJINA-ROSARIO COMPAIA MINERA DOA INES DE COLLAHAUSI KMS-18/01/2001-10:58:26 PAGE 1

TO: CIA. MINERA DOA INES DE COLLAHUASI AV. ANDRES BELLO N 2687, PISO 11 LAS CONDES - SANTIAGO ATTN: R.DELUCCHI

FROM: KVAERNER METALS AV. NUEVA TAJAMAR N 481, PISO 19 LAS CONDES SANTIAGO

PACKAGE ID: KX0-045

DOCUMENT ID
141E-TS001

Documento aprobado
DESCRIPTION TYPE
SPECIFICATION

DATE: January 18, 2001

COPIES
ELECTRONICA

REV. AND DATE

P 18/01/2001

GEARLESS DRIVES FOR SAG AND BALL MILLS

DISTRIBUTION LIST: ALEX FALCK FRANCISCO CAICHAC VICTOR VALDES

Please sign and return: Received By

Sincerely,

ALEX FALCK

Date

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PROJECT N C-423

COMPAIA MINERA DOA INES DE COLLAHUASI SCM

UJINA - ROSARIO TRANSITION PROJECT FEASIBILITY STUDY / BASIC ENGINEERING

Specification N 141E- TS001 Gearless Drives for SAG and Ball Mills
Kvaerner Metals
Av. Nueva Tajamar 481, Piso 19 Las Condes, Santiago
REV. DATE BY CHK.

CLIENT APPROVAL: DATE:

APPROV. DESCRIPTION

A M P

18/12/00 03/01/01 18/01/01

VVE VVE VVE

VVE / JA JASJj VVE / JA VVE / JA

FMC / AF FMC / AF FMC / AF

Issued for internal coordination Issued for Client approval Issued for Feasibility Study

DISTRIBUTION

10

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

INDEX

Page

1.0

SCOPE

2.0

CODES AND STANDARDS

3.0

OPERATING AND DESIGN CONDITIONS

4.0

DESIGN REQUIREMENTS

5.0

PAINTING

24

6.0

QUALITY ASSURANCE, INSPECTION, AND TESTING

25

7.0

LIST OF ATTACHMENTS

26

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

1.0

SCOPE 1.1 Equipment Identification The Vendor shall furnish gearless drive systems for SAG and Ball mills, complete with motor, cycloconverter controllers, associated transformers and related equipment in the quantity indicated for the Ujina Rosario Transition Project, property of Compaa Minera Doa Ins de Collahuasi SCM, Chile. Item
1

Qty
1

Equip. No.
141ML001A

Description
SAG mill motor 20,500 kW, synchronous motor.(Mill Size: 40 ft diam x 20 ft long)

141ML002A 141ML003A

Ball mill motor 14,000 kW, synchronous motor.(Mill Size: 26 ft diam x 40 ft long)

141VY901

Cycloconverter Cubicles for SAG mill drive

141VY902 141VY903

Cycloconverter Cubicles for Ball mill drives

141CO901

Drive Control Panels for SAG mill

141CO902 141CO903

Drive Control Panels for Ball mills

141XF901 141XF902 141XF903

24 kV transformers 3-phase, 50 Hz, primary and appropriate secondary voltage suitable for the SAG mill drive system.

141XF904 141XF905 141XF906 141xF907 141XF908 141XF909

24 kV transformers 3-phase, 50 Hz, primary and appropriate secondary voltage suitable for the Ball mill drive systems. HOLD

141SG901

Switchgear 34.5kV class indoor type (for operation at 24 kV), with 600 A discconnect switch, and 1200 A circuit breaker, 3 phase, 50 Hz, ahead of the primaries of cycloconverter SAG mill transformers

10

141SG902 141SG903

Switchgear 34.5kV class indoor type (for operation at 24 kV), with 600 A discconnect switch, and 1200 A circuit breaker, 3 phase, 50 Hz, ahead of the primaries of cycloconverter Ball mill transformers

11

141SG904

Switchgear indoor type, with 600 A discconnect switch,

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A
3 phase, 50 Hz, ahead of the SAG mill motors terminals.

12

141SG905 141SG906

Switchgear indoor type, with 600 A discconnect switch, 3 phase, 50 Hz, ahead of the Ball mill motors terminals.

13

141EX901

Synchronous rotor exciter system panel for SAG mill cicloconverters

14

141EX902 141EX903

Synchronous rotor exciter system panel for Ball mill cicloconverters

15

141ER901

Prepackaged, containerized electrical building to house items 3, 5, 9, 13 and other panels and components necessary for operation of the gearless SAG mill drive system.

16

141ER902 141ER903

Prepackaged, containerized electrical building to house items 4, 6, 10, 14 and other panels and components necessary for operation of the gearless Ball mill drives system.

17

141HF901

Harmonic filter. 24 kV, four stages of filtering, 20 MVA and studies.

18

Lot

Special tools and equipment

19

Lot

HOLD

Replacement spare parts recommended for one year operation. Spare parts shall be itemized and individually priced.

1.2

Work Included Vendor shall furnish drawings, data and descriptive information for the above items in detail and quantity specified in the attached Form ENG-44. Preliminary dimensioned drawings are required with the bids for all equipment furnished under this specification. Vendor shall furnish a detailed harmonic filtering and compensation study and shall be responsible, with the Mill Supplier, on coordination of studies for vibration analysis.

1.3

Work excluded

a. b. c.
2.0

Receive at site, unload, store, and install the equipment Foundations, including anchor bolts and other embedded metals External field wiring and conduit

CODES AND STANDARDS

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

The equipment shall be designed, fabricated, assembled and tested in accordance with the following standards: NEC ANSI IEEE IEC NEMA ASTM ASME UBC UL NFPA NESC NOSA National Electrical Code American National Standards Institute Institute of Electrical and Electronics Engineers International Electrotechnical Commission National Electrical Manufacturers Association American Society for Testing and Materials American Society of Mechanical Engineers Uniform Building Code Underwriter's Laboratories National Fire Protection Association National Electrical Safety Code

National Occupational Safety Association, CMDIC

All applicable country state and local codes. If the equipment does not comply with these standards, the Vendor shall so state, fully describe each exception taken, and indicate the standards that the equipment will meet. Where conflict exists between referenced standards, the most stringent standard shall be used. Equipment, materials, components, and functions designed, built, rated, tested and performing in accordance with other standards such as JIS, DIN, and IEC are acceptable provided that they meet supplemental requirements which will make them equivalent to those specified in 3.1 above. Such supplemental requirements shall be explicitly stated in Sellers proposal and they are subject to mutual agreement between the Purchaser and Seller.

3.0

OPERATION AND DESIGN CONDITIONS

3.1
-

Operating Conditions
The motor will be used to drive mills for grinding copper ore and will be subject to dust, slurry and moisture encountered in a wet milling process. Equipment shall be capable of operating successfully with input power supply voltage fluctuations of plus 5% and minus 15% and frequency variation of 1 Hz. Cycloconverter cubicles, high voltage switchgear, exciter cubicles, low voltage motor control and other control panels and devices shall be installed in a prepackaged containerized electrical building (E-house). The transformers for the Cycloconverter will be installed outdoors. Site data and general engineering requirements are specified in Appendix A attached. Special attention is drawn to the elevation of the site which is 4,400 meters above sea level. All equipment shall be rated for the site conditions.

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

Power will be available to supply the drive systems at 24 kV. The power system will be 3 phase, 50 Hz, wye connected, low resistance grounded. The available symmetrical short circuit capacity of the 24 kV system will be 700 MVA. The available short circuit current of the 380/220 V system will be 60 kA. The total WK2 of the SAG and Ball mills are to be obtained from the mills Vendor, including structural analysis and foundations. In order to obtain the Sellers most accurate drive system efficiency, the Purchaser intends to assess a penalty of US$ 5,000/kW on the purchase price of the drive for any reduction in actual efficiency from the Sellers stated efficiency. Seller shall provide the detailed kW losses for the entire drive system including motor, cycloconverter, power transformers and auxiliary equipment. The kW losses shall be furnished for 75% and 100% torque at rated speed.

3.2

Environmental Conditions Plantsite conditions are specified in Appendix A attached. All equipment supplied herein shall be suitable for service at the plantsite conditions. Switchgear will be installed in a ventilated, air conditioned switchgear room (Ehouse). The room will be pressurized to prevent entrance of dust.

3.3

Seismic Design The seismic analysis for electrical equipment, its parts, and foundations, shall be made based in two horizontal directions, perpendicular to each other, and one vertical, acting simultaneously, being the magnitude of vertical force equal to + of the horizontal forces. The equipment shall be designed to withstand seismic loads without damage accordance with Zone 4 of the latest edition of the Uniform Building Code (UBC 4). Horizontal forces shall be evaluated considering: Seismic Zone: 4 Site Geology and Soil characteristic: S3 = 1,5 Occupancy category: Essential facilities (I) Importance factor: I = 1,5 Horizontal Force factor: Cp = 2 Equipment susceptible to fragile failure Cp = 0,75 Motors, transformers, switchgear and similar

3.4

System Ratings The switchgear, including power circuit breakers, bus, bus supports, enclosure, and auxiliary devices, shall be designed and constructed for operation on a 50 Hz power system, with the following characteristics:

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

Duty [kV] 220 23 7.2 3.3 0.38 0.22 0.115 0.125 0.115

Rated [kV]

Sec [kV]

Earthing

Service Main incoming Voltage

24 7.5 3.45 0.40 0.231 0.12 0.125 0.12

24 7.2 3.45 0.40 0.231 0.12

Resistance grounded High Resistance Resistance grounded Solidly grounded Solidly grounded Solidly grounded

Site Primary Distribution Voltage Mine Equipment Process Medium Voltage Motors Low voltage motors and loads Lighting loads Control Voltage DC Control voltage AC Control Voltage

Vendor shall be entirely and solely responsible for the design, procurement of materials and components, fabrication, assembly, quality inspection, testing and guarantee of the equipment performance.

4.0

DESIGN REQUIREMENTS
4.1 4.1.1 General Requirements The mill drives and auxiliary equipment shall be Sellers latest design, proven in service to meet the requirements and intent of this Specification, and the attachments. All components and materials shall be new, unused, and of current Manufacture by generally recognized well established firms in the industry. Replacement parts required for normal maintenance shall be readily available from Vendors stock. The mill drive systems shall be capable of delivering 130 percent of rated torque for 30 seconds for mill starting purposes under all operating and service conditions. The drive system shall be capable of making at least three starts per hour. The inrush during starting of the mill shall not exceed 130 percent of the full load kVA of the drive system. During continuous operation, the drive systems shall regulate the speed of each mill to within 1 percent under all operating and service conditions. The mill drive systems shall shut down automatically with all components reverting to the off or drive stopped condition under partial or total loss of primary and/or auxiliary power. All components of the mill drive systems shall be rated for use in the conditions listed in Section 3 herein.

4.1.2

4.1.3

4.1.4

4.1.5

4.1.6

4.1.7

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

4.2

Drive Rating and Mill Data SAG mill Drive concept Gearless SAG Mill Drive (Cycloconverter-fed synchronous motor) 20,500 1.0 Variable 78 % HOLD 60 80 % HOLD 60 78 % HOLD 78 80 % HOLD 0 80 % HOLD 1.3 RPM 0.3 RPM In both directions 130 % for 30 sec 130 %

Rated power, kW Service Factor Mill speed, RPM Mill Rated critical design speed Mill critical speed operating range Mill speed, constant torque Mill speed, constant power Speed Range (normal) Inching speed Creeping speed Operation Start-up torque Creeping Ball mill Drive concept

Gearless Ball Mill Drive (Cycloconverter-fed synchronous motor) 14,000 1.0 Variable 78 % HOLD 60 80 % HOLD 60 78 % HOLD

Rated power, kW Service Factor Mill speed, RPM Mill Rated critical design speed Mill critical speed operating range Mill speed, constant torque

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

Mill speed, constant power Speed Range (normal) Inching speed Creeping speed Operation Start-up torque Creeping 4.3 SAG Mill Synchronous Ringmotor 4.3.1 Stator Sections: a.

78 80 % HOLD 0 80 % HOLD 1.3 RPM 0.3 RPM In both directions 130 % for 30 sec. 130 %

The wrap-around motor design shall be based on the mill design, taking into consideration the following: Torque transmission directly to the mill shell, not through torque tubes. Stability of the mill as a result of mill (including bearings) stiffness and motor stator stiffness. Reference of thermal expansion of mill and stator at the same level. Axial shifting capability of stator for maintenance and inspection purposes. Minimum floor-space requirements

b.

The stator assembly shall be fabricated and shipped in as few pieces as practical, considering the available transport facilities from Manufacturers location to the jobsite, and the facilities at the site installation. Bidder shall state the number and location of proposed shipping splits in their proposal, based on the site information given with this inquiry. Stator frame and enclosure shall be of welded steel plate and sheet, to form a rigid, self supporting and torsion resistant assembly after installation. The maximum magnetic pull that occurs during starting and maximum permissible rotor eccentricity shall not cause any permanent distortion of the stator. Bidder shall indicate in their proposal the limit values for magnetic pull and eccentricity and the spring constants of the stator assembly. The stator structure shall have adequate facilities for lifting, leveling, aligning, and anchoring the entire stator. For maintenance purposes it shall either be possible to move the entire stator assembly axially, or to give access to both, stator coils and rotor poles during maintenance and/or repair. Bidders shall indicate the above facilities in their preliminary outline drawings that are part of their proposal. Type of motor enclosure shall be totally enclosed, water - air cooled IP54 (TEWAC). The air/water heat exchangers used in TEWAC enclosures shall be accessible for inspection and for easy replacement even under operating conditions. Internal cooling air circulation shall be by at least two auxiliary electric motor driven fans of suitable rating with provisions for air-flow

c.

d.

e.

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

adjustments. Air filters of the replaceable type shall be installed in an accessible location. f. The high-voltage three-phase stator winding system shall use class F insulation materials and shall be vacuum-pressure impregnated (VPI) before insertion into the stator slots. During normal operation, the temperature rise of the winding shall be limited to that of class B materials, i.e. 80C at site. Class F temperature rises are permissible for short overload periods only. The insulation system used shall be totally insensitive to moisture. Field-splices at shipping splits shall be kept to an absolute minimum. The proposed method of splicing shall result in joints that exhibit equal electrical and mechanical properties as the windings themselves and shall be explained in Bidders proposal. Connections to the supply cables shall not interfere with the possible axial movement of the stator assembly. Mechanical stresses on the windings encountered during normal and fault conditions shall not lead to fracture, deformation, or loosening of the windings. Field repairs to the VPI insulation system shall be possible. Service voltages for stator and rotor windings shall be determined by Manufacturer during his optimization process for the entire drive system. The selected voltages and resulting currents shall be indicated in Bidder's proposal. The air gap of the motor shall be monitored prior to and during mill operation by suitable sensors. Excessive static deviations from the nominal airgap shall prevent the mill from being started, and shall lead to an immediate shutdown if detected during operation. Two sets of temperature detectors RTD's, 100 ohm platinum in stator slots connected to the auxiliary termination box for external wiring, whereby one set should be in operation and one should be in stand-by. The number of RTD shall be recommended by Bidder. One RTD for each cooling air circuit. One RTD for each outlet cooling air circuit. One RTD for each cooling water supply. One RTD for each cooling water outlet.

g.

h.

i.

j.

k.

l. m. n. o.

4.3.2

Rotor Sections a. Pole-segments preferably consisting of several poles, shall be quoted which are ready for on-site installation to the mill body. Number and size of field poles shall be determined by the motor Vendor, taking into account the mill

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

design and required performance data into account. Design shall minimize the installation time and labor.

b.

The mill Vendor will make available a suitable mounting flange, or other superstructure, to accept the field poles or pole-segments. The mounting flange or superstructure will be machined to the required tolerances by the mill manufacturer according to the data given by the motor Manufacturer. Bidder shall state their required machining tolerances for radial and axial runout, and the number of bores required. Design of rotor elements shall minimize the number of bores and bolts. Installation procedures also shall be stated in Bidders proposal. If all or part of the cross section of iron required to carry the magnetic field flux is part of the mill body, Bidder shall indicate this required cross-section in his proposal. Field poles may be laminated or solid iron at the discretion of the motor Vendor, however laminated poles are preferred. The electrical connections between field poles shall be bolted. Rotor windings shall be executed with class F insulation materials suitable for maximum temperature rises. However, during normal service, the temperature rise values of class B materials, i.e. 80C shall be utilized. Class F temperature rises are permissible for short overload periods only. All components of the field circuit shall be sized to continuously satisfy the maximum flux demand of the synchronous motor that corresponds to the maximum torque required by the drive. The excitation power to the field winding shall be transmitted via a rotor mounted slip ring assembly. Access via an oversized inspection door shall be provided for inspection and maintenance of the excitation ring brushes. The motor field circuit shall be separately excited from a static power supply. The cycloconverter shall shut down on loss of field supply.

c.

d. e.

f.

g.

4.3.3

Motor Sealing System a. The motor shall be sealed against entry of dust, water and grinding slurry. The sealing system shall consist of lubricated multilipped seals, sealing chambers and dual sealing brushes. The sealing lip shall be lubricated with water resistant grease to assure a satisfactory seal lip life. A set of two sealing brushes per rotor side shall be installed outboard of the rubber seals. The first shall remove slurry and other one the coarse contaminants. In addition, the air space between the brushes and the inner seal shall be pressurized to further assist the brush sealing action where necessary by design. Seals, brushes and other parts requiring maintenance shall be easily accessible by means of inspection doors of simple design. Bidders may propose and alternative sealing arrangement different from above, providing a full description of the system for evaluation.

b.

c.

d.

e.

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

4.3.4

Air Gap Monitoring System a. The motor air gap shall be monitored by two independent measuring systems. One system shall use proximity limit switches and the other shall be based on a Hall effect measuring system. Two sets of proximity switches shall be located at 90C intervals around the motor circumference. One set shall be used for warning and the other set for motor tripping purposes. The switches shall also be operational while the motor is at stand still. The second air gap monitoring system shall be capable of continuously measuring the motor air gap while the motor is running. A set of Hall crystals shall be positioned at 90, so that each pair is capable of measuring the air gap in the horizontal and vertical direction. The output of the measuring network shall be calibrated for Video Maintenance Display. In addition, deviation limits shall be programmed into the motor controller, so that automatic alarm and shutdowns are initiated as soon as set limits are exceeded.

b.

c.

4.3.5 Anti-Condensation a. Heating elements shall be provided, and shall be metal-clad with terminal enclosure to prevent exposure to live parts, and with full protection against fire risk by inadvertent contact with heated parts. Heating elements up to 2000 watt maximum shall be rated for a single phase operation. Higher wattage heaters shall be suitable for 3 - phase operation. Heaters shall be sized to raise the temperature approximately 5C above the dew point temperature for the specified ambient conditions when the motor is not in operation.

b.

c.

4.3.6

Isolation switches Isolation switches shall be provided to disconnect stator and the field supply at the motor terminal box. Necessary interlocks shall be provided to prohibit inadvertent operation of the switches while motor is in operation. The isolation switches shall be provided in a NEMA 4 enclosure.

4.4

Coordination with Mill Manufacturer 4.4.1 Due to the fact that the rotor of a wrap-around motor is actually a part of the mill body, and the motor has no bearings of its own, the motor Manufacturer also has no direct control over the airgap of the motor. Coordination between mill and motor Manufacturer thus becomes an important item. Determination of the actual air gap as well as the minimum air gap shall be responsibility of the motor Manufacturer. The mill Manufacturer will furnish to the motor Vendor the following data:

4.4.2

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

- rated horsepower required at mill shell - rated speed range and torque - speed curve of mill - nominal mill diameter and minimum hole - pitch circle of field - pole mounting flange. - bearing geometry and type of lubrication - maximum wear of bearings and maximum permanent deformation of mill cylinder at motor location - thermal growth data of mill - maximum dynamic eccentricities of mill during operation. The motor Manufacturer shall supply to the mill manufacturer the following data: - maximum one - sided magnetic pull at standstill and rated speed of mill - maximum static & dynamic eccentricity of rotor at field-pole mounting flange - field - pole mounting hole geometry & tolerances The mill Manufacturer shall run a system stiffness study using finite element models. The input data for that study shall be determined in close cooperation with the motors Manufacturer, a system stiffness of mill / motor / bearing / foundation, etc. is of essential importance for a successful operation. The necessary coordination shall be the mutual responsibility of the mill and motor manufacturers. In designing the motor, the Manufacturer shall pay due attention to the location of the liner retainer bolts. It must be possible to remove any liner retainer without the need to access to the motor interior. The sealing mechanism employed to shield the motor interior from the environment shall give continuous service for at least 12 months without the need for replacement. Stationary sealing strips inside the motor enclosure and rotating sealing surfaces shall be part of motor Vendors delivery. Sealing surfaces on the mill shell itself is not a preferred solution. Bidders shall submit detail drawings of their proposed sealing system with their offer. Buyer shall review the structural stress analysis of the stator during the design phase. Power Section Power to operate the low speed gearless drive shall be at the voltage levels in accordance with section 3.4 of this document. All necessary power transformation, conversion and protection functions required for a safe and satisfactory operation shall be responsibility of the drive system supplier.

4.4.3

4.4.4

4.5

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

34.5 kV class Circuit Breaker for operation at 24 kV. 1,200 A circuit breaker, vacuum type, a switch disconnector and all the necessary disconnecting / protecting equipment shall be provided ahead of the primary of the converter transformers inside the E - House. The battery limit of the supply shall be 24 kV. The BIL of the breaker and disconnector at sea level shall be 200 kV. Breaker control voltage shall be 125 V DC supplied from a battery provided by the Seller. Breaker shall conform to applicable ANSI standards for application at the site elevation. 4.6 4.6.1 Cycloconverter Transformers Transformation from the incoming line voltage down to the cycloconverter input voltage, and thereby isolation of the two systems, shall be done via three-phase, oilfilled, self cooled outdoor transformers. Within the constraints stated else-where in this specification, ratio, impedance voltages, and number of transformers and windings shall be chosen by the Manufacturer to obtain optimized system performance and efficiency, and to keep disturbances of the incoming line to a minimum. The quoted design shall take shipping size limitations and the effects of earthquakes into account. The additional harmonic loads and the increased dynamic stresses typical for thyristor-equipment loads shall be duly considered in the design. Tolerance for impedance voltages and electrical displacement of parallel windings shall be kept smaller than in regular power transformers to minimize the creation of harmonic. Standard off load taps shall be furnished on 24 kV primary windings. BIL at 24 kV shall be 200 kV at sea level. Lightning arresters shall be provided at the primary terminals within the primary terminal box. Primary terminal box shall be sidemounted with high voltage bushings, lightning arresters and terminal connectors for cable entry from the bottom. Terminal chamber shall be provided with space heaters with thermostat control, for connection by others into 220 VAC power source. Transformer secondary voltage shall be Manufacturers standard as required for the drive system. BIL for the secondary winding shall be as required by ANSI for the elevation of 4,400 meters above sea level. Secondary terminal box shall be sidemounted with low voltage bushings and terminal connectors for cable entry from the bottom. Terminal chamber shall be provided with space heaters with thermostat control, for connection by others into 220 V AC power source. The transformers shall have tanks designed for full vacuum filling. The insulation liquid preservation system shall be a sealed tank system. Each transformer shall be furnished with but not limited to the following accessories: a. One oil temperature indicator with resettable maximum pointer and three sets of sequenced contacts, for annunciation, and tripping the main secondary protective device. (26 QT). A winding hot spot temperature indicator with alarm and trip contacts (49). One oil level gauge with low level alarm contacts. (71 QL). Valves and connections to facilitate draining and refilling the tank, oil sampling and conditioning.

4.6.2

4.6.3

4.6.4

4.6.5

b. c. d.

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

e. f.

One pressure/vacuum gauge (63). One mechanical oil pressure relief device with mechanical indication of operation. A bolted manhole cover on the top of the tank. One stainless steel or brass diagrammatic nameplate to state the following: Connection diagram (terminal markings) Rate kVA at the various temperature ratings Voltage ratings at no load, all taps Polarities of windings Impedance percentages Weights Insulating liquid type and contents in liters Secondary current at full load In addition, the following information shall be given on the nameplates or on the diagram plate: Year of manufacture Type of cooling Pressure in mm Hg.

g. h.

i.

Protection relays with the appropriate ANSI functions shall be recommended by Bidder and located in the Electrical Room.

4.7 Thyristor Cycloconverter The cycloconverters shall be designed as a twelve pulse system to minimize disturbances on the feeding line by harmonic currents, or interference with other electrical equipment on the same supply bus. To improve the power factor of the converter, trapezoidal control voltages for the power thyristors shall be used. Anticipated harmonic disturbances shall be indicated in Bidders proposal. 4.7.1 4.7.2 Cycloconverters shall be metal enclosed in IP42 (NEMA 1) enclosure. Firing pulse generators, pulse amplifiers and distributors, gating supervision circuits and associated devices shall be assembled from standardized, industrial plug-in modules, using solid state components to the largest extent possible. Cooling of the power thyristor modules shall be by means of a closed loop circulated liquid. Bidder shall be responsible for the complete internal cooling part of the cycloconverter and details of the proposed systems shall be explained in his proposal. The cycloconverters shall have bus bar construction with NEMA copper bus bar drilling for the external power cables. All joints for bus bars operating above 70 C shall be silver plated.

4.7.3

4.7.4

4.7.5

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

4.7.6

A ground bus running the full length of each converter shall be provided. Each ground bus shall be drilled for 13 mm ( inch) bolts on 44 mm (1- inch) centers to accommodate two hole lugs for Purchasers ground cables at each end. The cycloconverters shall be fully self-protected for all internal and external fault and surge conditions, including loss of utility supply voltage to the plant. Solid state components shall be burned in to eliminate the components subject to infant mortality. Seller shall certify that all solid state components have been burned in. Auxiliary power for each cycloconverter shall be 380 V, 3 phase, 3 wire, 50 Hz from the local low voltage MCC, supplied by Vendor in the Electrical Room.

4.7.7

4.7.8

4.7.9

4.7.10 Each cycloconverter shall have automatic shutdown and alarms or self-diagnostics for at least the following: a. b. c. d. e. f. g. h. Open phase or missing gate Commutation failure Shorted thyristor leg Loss of gate power Over voltage protection line side and variable frequency side Voltage supervision Loss of thyristor Current limitation

4.7.11 All access to the interior of the cycloconverter which is required for installation or maintenance shall be through hinged doors.

4.8

Excitation System The excitation supply and control shall provide sufficient power for the field of the motor to generate the magnetic flux associated with the maximum required mill torque. This power shall be available continuously. The excitation control system shall provide for a constant torque mill operation from zero to rated speed, and for constant power operation from rated speed to maximum speed. Excitation power shall be derived from a separate source 380 V, 3 phase, 50 Hz, supplied by Ownwer. An isolation transformer and a controlled six-pulse thyristor rectifier with surge protection and a closed loop control system shall deliver the required DC power to the field windings of the motor. Power thyristor and control equipment shall be installed in dead front steel cubicles. Thyristor bridge shall be standardized modular assemblies from Manufacturers product line. Field current and voltage shall be indicated on the front of the supply cubicle. Protective circuitry shall include but not be limited to the following: Ground fault Loss of control power Under voltage of AC line Current limitation

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5.9

Loss of thyristor Current flow supervision Voltage supervision Loss of synchronizing voltage Over voltage protection AC and DC side.

Drive Control Panel A panel shall be furnished to provide integrated control on each drive system with provision for remote control and monitoring from the SAG and Ball mill locations or a control room via a serial data communication link. The panel shall have a IP42 (NEMA 1) enclosure. The drive control cubicle shall include Vendors Programmable Logic Controller (PLC) system which shall be used to perform all logic and computational functions. The PLC system shall be capable of interfacing with the Purchasers DCS system. The PLC system shall consist of but not be limited to the following: a. b. c. d. e. f. g. h. CPU AC/DC isolated input modules AC/DC isolated power contact output modules 4-20 mA isolated analog input modules 4-20 mA isolated analog output modules Serial communication processor card I/O racks and power supplies with at least 100 percent spare capacity Interface equipment with the Purchasers DCS.

The panel shall include the following control power system: a. b. A lockable disconnect switch for 220 V AC single phase incoming power Internal distribution to all drive controls

The drive control panel shall have a first out annunciation for the drive system. The annunciation shall have a clear message display to indicate the alarm, fault, and trip status of all components as well as set point and actual value of the drive system The panel shall have identified terminals for all external wiring. External wiring shall not be connected directly to any components inside the panel (including the PLC I/O racks) The panel shall have only hinged doors and swing out panels for access to all interior components. The local control panel shall have a copper ground bus running the full width of the enclosure. The ground bus shall have a clamp type lug for Purchasers copper ground cables at each end. All components requiring grounding shall be wired individually to the ground bus.

Local Control Panel:

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The panel shall have manual controls for the drive. These controls shall include selection of the operating modes and provisions for making operating tests of the system. Control voltage shall be 120 V AC, single phase, 50 Hz. The panel shall have push-to test 120 V AC transformer type pilot lights to indicate the operating status of all active components of the drive system. RUN pilot lights shall be red and OFF or STOPPED pilot lights shall be green.

4.10

Motor Control Center Vendor shall provide all power to motor related auxiliaries such as coolers, fans, power supplies, heaters, containerized electrical building lighting, HVAC, mill lube system and other mill auxiliaries. All mill and motor related auxiliaries shall be sequence controlled and properly interlocked. Motor Control Center shall be NEMA class I, Group B wiring with IP42 (NEMA 1A) enclosure. Each starter shall have its own control power transformer 380120 V, 1 phase, 50 Hz.

4.11

Prepackaged Containerized Electrical Building ( E - house ) The Containerized Electrical Building shall be a fabricated and assembled metal building. It shall be a portable structure for indoor installation but with outdoor design, totally self - supporting from the base and for mounting directly to framework, piers, pads or foundations with all equipment installed. The prefabricated electrical building shall be completely assembled, with all components wired and tested to power and control the ring motor and its associated auxiliaries The Containerized Electrical Building shall be equipped with: Roof mounted HVAC unit of redundant configuration, provided with individual disconnect switches. Interior fluorescent lighting in sufficient quantity to maintain 500 lux at 700 mm from the floor including emergency lighting. Fire Suppression Unit (using FM-200). A pressurized air system, for a gauge pressure of 5 mm of water column, inside the building.

The Containerized Electrical Building shall be designed to house and environmentally protect the following equipment of the gearless drive systems: 24 kV (34.5 kV class) metal clad circuit breaker and disconnector cubicles 125 V DC battery for control of the circuit breaker Cycloconverters Excitation Systems Drive control cubicles Programmable Logic Controllers (PLCs) Video Monitoring Systems Motor Control Centers (MCCs)- Low voltage Water Control Units for Cycloconverter Power Electronic UPS

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Structural Loading: Containerized Electrical Building shall be engineered to UBC seismic zone requirements identified in Appendix A attached. E houses for mills shall be installed indoors to protect from wind blown dust. Doors, walls and roof panels shall be reinforced by braces, stiffeners and/or structural members to provide rigid structure. Base shall be constructed using welded I-beams, channels and angle supports and shall be sized to withstand the loads required during shipping, installation and normal operation. Skid beams shall be incorporated into the base where required. Lifting lugs shall be provided with a flat surface for jacking. These lugs shall be removable to eliminate a tripping hazard. When the Electrical Building is shipped in separate sections, each section shall have its own lifting lugs. Floor: The floor shall be constructed of 6 mm (1/4 in.) thick, ASTM-A36 level galvanized steel plate welded to the base framework with an ASA #61 skid resistant epoxy finish. Insulating floor mats shall be provided in front of all electrical equipment. Computer-type false floors with removable panels shall be provided. Floor space shall be used for internal wiring and piping. Wall: Wall panels shall be galvanized steel 16 GA minimum, formed in an interlocking design and meet the structural requirements listed herein. All electrical equipment mounted on the building walls will have reinforcement channels provided to support the subject equipment adequately. Roof: Roof panels shall be 18 GA galvanized steel in a standing rib design eliminating the possibility of water entry in addition to withstanding winter loading conditions discussed in Appendix A. The roof shall be designed to withstand damage during lifting, installation, and maintenance. Doors: Two personnel doors (W 1m x H2.25m) shall be provided. Doors shall be ANSI/SDI-100, Grade III extra heavy duty, model 4, with 16 gage galvanized face sheets, gasketed using neoprene gasket material, complete with stainless steel panic bar, hardware and door closers. Doors shall be keyed alike using tamperproof locks. Door frames shall be ANSI/SDI-100, 14 gage extra heavy duty. The equipment door when opened, shall provide an opening large enough to pass the largest equipment section installed inside the building. Personnel doors shall be Type V (Vee) provided with a tempered safety glass vision panel. Doors shall have polyurethane insulation with a minimum R value of 11.0. Painting: Base Weldment and exterior walls- primed with (2) part epoxy primer and finish coated with (2) part Acrylic Urethane. Color ANSI light gray. Interior walls shall be coated with (2) part epoxy primer finish coat. Color white. Doors and jambs shall be primed and then finish coated to match interior and exterior paint thickness and colors using applicable coating system. Grounding: Two ground bars (7 mm x 50 mm.) copper bar shall be located throughout the length (two sides only) of the building, 150mm above the floor. This copper bar shall be connected to a ground pad welded to enclosure base at four locations. All electrical equipment inside the building shall be grounded (looped) to these ground buses. Fire Protection: Fire detection system shall include smoke sensing fire detectors according to NFPA 72. Smoke detectors shall be UL listed, dual chamber, ionization type. Sensitivity shall be adjustable. Actuation of the smoke detectors shall

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energize an external revolving alarm beacon. The fire suppression system shall use FM-200. Two portable type fire extinguishers suitable for electrical fires shall be located inside the electrical building beside each exit doors. Fire extinguishers shall be portable type, UL classification 10-B:C, 20 lbs., in accordance with NFPA 10. The outside width of the electrical building shall not exceed 11 meters. For shipping purposes, dimensions of the each piece shall not exceed 5.5 meter wide, 4 meter high and 12 meter long. 4.12 Control System Seller shall provide a closed loop control system, PLC sequence control, fault message system, diagnostics, interfaces and special control features as required. It is the intent of the Buyer to get the state-of-the-art equipment with an utmost of handling and operating comfort. Maintenance and trouble shooting shall be simplified by means of diagnostic functions. Seller shall describe in detail the offered functions and demonstrate the successful use in the mining industry. The Manufacturer shall provide a completely integrated system of control, regulation, protection, monitoring, alarming and diagnostic equipment for the entire mill drive system and its auxiliary equipment. The control system shall comprise exclusively of modular, standardized solid-state components on plug-in printed or preassembled circuit boards of industrially Manufactured grade. Control systems shall be mounted in free standing steel-cubicles, using standardized equipment frames with easily accessible front and rear sides. If wall mounting is required, swivel-frames shall be installed to allow access to the wiring side of the equipment. Assembled cubicles shall be factory wired to terminal strips in the bottom or rear of the cubicles and shall be functionally tested before installation into the Containerized Electrical Building. Close Loop Control: The closed loop control system shall be fully digital microprocessor based system without exception. The advanced features of such a fully digital control system with respect to detailed fault messages, tracing of control values and communications to other systems shall be used to the fullest extent. Importance is placed to on automatic documentation of the closed loop control circuits to provide the engineer with an error free documentation when changes were programmed at any time. Preferably the closed loop control shall operate in the same platform as the control system. The closed loop control system shall contain but should not be necessarily limited to the following: Current controllers Speed controller Flux controller Field orientation Ramp controller Inching controller Creeping controller Process controller Accelerate, decelerate controllers for smooth start and stop to standstill,with mill load electrically balanced. Frozen charge protection

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Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

The control shall have a high dynamic performance and accuracy to limit disturbances to the network and to the mill shell. Speed control accuracy shall be 1% or better. Seller shall indicate in his proposal the amount and frequency of torque harmonics introduced to the mill. Programmable Logic Control: Programmable Logic Controllers (PLC) shall be assembled from standardized, modular components of a design proven in process plant applications. Programs shall be stored on read-only memory chips that cannot be erased accidentally but can be reprogrammed in the field by means of portable programming devices. PLCs shall be used to control the complete SAG and Ball mill drive systems and shall include but not be limited to the following: 4.13 Automatic sequence control Start of auxiliaries and main drive Stop of main drive and auxiliaries Operation supervision Status Interlock Emergency off Interface control with others Measuring value collection Fault indication collection

Fault Message System The Fault Message System shall be an integral part of the PLC control. The minimum requirements shall be: First in, first out Unambiguous message identification Plant code identification per message Message identification for incoming and outgoing message per message 40 characters plain text per message Date and text per message

Seller shall indicate with the bid the kind and number of messages provided. Message shall be displayed on a continuous basis on a Video DIsplay Unit screen and shall be printed parallel on a printer. 4.14 Operator Interface Seller shall provide a VDU based operator control system based on the following requirements: operating values (current voltages, speed etc.) plant flowcharts bar diagram of measured values short time trend curves of measured values

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- plant status identification - alarm group messages Vendor shall state in the bid, number and kind of flow charts, bar diagrams and curves. Vendors PLC shall provide a serial link to Buyers central control room automation system and shall guarantee the compatibility of his controller and Owners DCS.

4.15

Diagnostic and Information System The Diagnostic and Information System shall be PC based suitable for the ore processing industry to reduce downtime. Besides the diagnostic part, the system shall provide information to the process personnel, enabling them to control the process. The performance of such a diagnostic and information system shall incorporate, but not be limited to, the following functions: Measured value acquisition Measured value curve displays Fault and operating message acquisition Tracing of transient control values Archiving Maintenance list Maintenance instructions Spare part list

Seller in his proposal shall describe in detail his approach to use such an information system. 4.16 Special Control Features Frozen Charge Protection: Seller shall provide a Frozen or Baked charge protection and indicate in his bid complete details and descriptive literature and examples of successful operation. Short Time Network Interruptions: The gearless drive system shall survive short time supply interruptions up to 200 ms without shut down of the complete mill drive. Transient changes of speed are acceptable. The mill motor system should acknowledge the network disturbance but shall survive the same without shut-down. Shut down after 200 ms of network interruption is acceptable. 4.17 Current Transformers Current transformers shall conform to the applicable requirements of the latest ANSI Standard C57.13. They shall be dry type or compound-insulated type and shall be provided with a suitable means of mounting and for grounding the frame. Current transformer accuracy shall be ANSI accuracy Class C100 or better. All current transformers shall be provided with a means of shorting the secondary circuit terminals. 4.18 Potential Transformers

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The potential transformers shall be of the indoor dry or compound-filled type with a minimum insulation class and full-wave basic impulse level as indicated in ANSI Standard C57.13. The potential transformers shall have high and low voltage fuses and shall be mounted on drawout carriages in separate compartments. The high-voltage terminals shall be disconnected and grounded and the secondary shall be disconnected when the carriage is withdrawn to permit safe replacement of fuses. High-voltage fuses shall be of the current-limiting type. The potential transformers shall conform to ANSI Standard C57.13, 0.3X, 0.3Y and 1.2Z for the applicable voltage class. 4.19 Wiring All outgoing wires from the apparatus and all unused contacts shall be terminated in permanently identified 600 V terminal blocks for Buyers external connections. Shorting type terminals shall be provided for current transformer circuits. Sellers wiring shall be restricted to one side of the terminal blocks. Fifteen percent of spare control and instrumentation terminals shall be provided. The terminals for each low level signal or instrument circuit shall be grouped with a dedicated terminal for the cable shield of the circuit. Soldered connection shall be used only on printed circuit boards. All external connections to printed circuit boards shall be plug-in type. All control and instrumentation wires shall be marked at each termination with wire markers. 4.20 Nameplates Nameplates shall be provided for each device and each terminal strip. A nameplate bearing Purchasers equipment number shall also be provided for each item of the equipment. Plastic nameplates shall be white by NOSA, CMDIC procedures. 4.21 Efficiencies and Power Factor The efficiency and power factor values shall be stated for the motors, power conversion, auxiliary equipment and the overall drive system. Seller shall provide power factor correction capacitors and necessary controls for correcting the power factor to 0.96 at the incoming side of the transformers. Capacitors can be incorporated as part of the harmonic filter equipment. Seller shall state the method or standard used in determining the motor efficiencies and enclose a copy of said standard.

5.0

PAINTING

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The equipment shall be cleaned, primed and finish painted in accordance with Sellers standard specification suitable for the service conditions listed in this specification.

6.0

QUALITY ASSURANCE, INSPECTION, AND TESTING 6.1 Quality Assurance Program Bidder shall furnish details of the quality assurance program to be applied during the preparation and fabrication of the equipment. Program shall describe the measures to be used to control activities affecting the quality of equipment to be supplied in compliance with this Specification. Quality level and minimum quality requirements shall be in accordance with the attached Vendor Quality Plan (VQP). Written certificates shall be furnished by Bidder indicating that the equipment has been manufactured in compliance with the quality assurance program and the requirements of the procurement documents Quality Surveillance Instructions AB04 W, and Quality Program Requirements AB-04 Y. These certificates will be the basis of Purchaser's final payment of Purchase Order. 6.2 Inspection and Testing Equipment furnished will be subject to expediting and shop inspection by the authorized representatives of the Buyer. It is the intent of this specification to have the drive systems fully tested at the component level, subassembly level and system level. Bidder shall submit in his proposal a complete list of tests and test methods to achieve this intent to the fullest extent possible. The transformers, converters, auxiliary motors and auxiliary systems shall be shop assembled for verification of dimensions and testing before shipment. Seller shall notify to Buyer with a minimum of two weeks in advance of the date scheduled for testing. An authorized representative of the Purchaser shall have free entry at all times during testing of the equipment. Five (5) certified copies of all factory test reports shall be furnished to the Buyer within two (2) weeks after completion of the tests. The results shall be in such form as to provide a means of determining compliance with the applicable standards for the equipment tests. Converters: After assembly, voltage shall be applied to the equipment, and the Manufacturer's standard test, including any NEMA or IEEE or UL standard tests, shall be performed. A functional test shall be performed at the factory on all metering, control, and protective relay circuits and devices. This shall be accomplished by introducing

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operating and tripping currents and voltages at the secondary terminals of the instrument transformers. Buyer shall be notified before this test is performed.

Transformers: a. ANSI C57.12.00 Routine tests (tests and certification required on the transformer furnished). Manufacturer's design tests performed on identical or similar transformers shall also be furnished. ANSI C57.12.90 Standard Tests Code for Distribution, Power and Regulating Transformers, and Shunt Reactors. Transformer shall be tested for polarity, ratio, resistance, impedance, core loss, excitation current, efficiency, regulation and insulation. The transformer shall meet the short-circuit qualification requirements given in Short-Circuit Test Code prepared by IEEE and withstand the effects of through fault current.

b.

c.

d.

Motor: Motor test according to ANSI 7.0 LIST OF ATTACHMENTS The following documents are attached and shall be considered a part of this specification: Appendix A Standard Technical and Site Data 000E-DW101 Electrical Single Line Diagram Equipment Data Sheets (to be filled by Vendor) VQP-141E-TS001 Vendor Quality Plan Form ENG 44 Drawing and Data Requirements

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EQUIPMENT DATA SHEETS (Vendor shall complete these data sheets and submit to Purchaser with the proposal) Page 1 of 6 Equipment Name: Cyclo-converter 1. Outline drawings of equipment showing dimensions of the converter, connections and accessories. 2. Complete equipment descriptions and design data, catalogs, brochures, etc. as required, to describe the construction and operation of equipment offered. 3. Assembled Converter Lineup: Length, mm. Depth, mm. Height, mm. Weight, kg. Earthquake withstand rating UBC Zone Minimum to gnd clearance, mm. Minimum to clearance, mm. 4. Converter Ratings: Rated maximum voltage Operating voltage range Operating frequency range/speed range Input power Output power Linear acceleration/deceleration time(adjustable) Describe operation of the system. Torque limits, adjustable (% of full load rating) Inrush power at starting (adjustable) Number of thyristors Peak reverse voltage (PRV) rating 5. Insulation Class 6. Cooling Air Flow 7. Specify test procedures 8. Exception to specification, instructions and terms and conditions 9. Name and location of Principal Manufacturer 10. Name and location of Suppliers of major components Equipment No.:

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EQUIPMENT DATA SHEETS Page 2 of 6 Equipment Name: Transformers 1. Outline drawing of equipment showing dimensions, connections and accessories 2. Complete equipment descriptions and design data, catalogs, brochures, etc., as required to describe the construction and operation of the equipment offered. The information shall cover the following: a) Transformer core, winding and insulation material b) Tap arrangement and connection diagram c) Tank construction, material thickness and type of weld d) Type of oil and cooling system e) Bushing details and CTs (if applicable) f) Instrumentation and relays 3. Dimensions Length, mm. Depth, mm. Height, mm. 4. Information of the additional harmonic load and the increased dynamic stresses and additional heating typical for thyristor load shall be furnished.. 5. With specified primary voltage and associated drive load, provide the following information: a) KVA b) Transformation ratio c) Number of windings d) Connections e) Full load copper loss f) Iron loss g) No load current h) Magnetizing inrush current (est) i) Regulation at full load and applicable power factor for the drive load. Equipment No.:

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EQUIPMENT DATA SHEETS Page 3 of 6 Equipment Name: Transformers (Contd) j) Efficiency at: 0.5 load 0.75 load 1.00 load k) Continuous rating for 55/65C temperature rise at the plant elevation l) Insulation class of windingH. V. side L. V. side 6 Transportation weight of transformer 7. Weight of core and coils 8. Weight of tank and accessories 9. Weight of oil 10. Weight of complete transformer 11A. Bushing 50 Hz wet flashover voltage at 1000 meter elevation 11B. Bushing 50 Hz wet flashover voltage at 4400 meter elevation 12A. Bushing/Winding BIL at 1000 meters a) HV side b) LV side 12B. Bushing/Winding BIL at 4400 meters a) HV side b) LV side 13. Describe test procedures 14. Exception to specification, instructions or terms and conditions. Equipment No.:

15. Name and location of Principal Manufacturer 16. Name and location of suppliers of major components

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EQUIPMENT DATA SHEET Page 4 of 6 Equipment Name : Synchronous Motor 1. Outline drawing of equipment showing dimensions of the motor 2. Complete equipment descriptions and design data, catalogs, brochures, etc. as required to describe the construction of the equipment offered. 3. The bidder shall furnish as part of bid documents the following information: Weights and Dimensions: Total weight of the stator Total weight of the rotor(poles) Motor kW (Horsepower) Motor voltage at rated output Current at rated output Starting inrush Frequency at rated output Rated speed Number of poles Power factor at rated output Reactances: Xd, Xd, Xd in PU Efficiency at full load Efficiency at load Efficiency at load Full load current Exciter Panel dimensions : Length, mm. Depth, mm. Height, mm. Exciter field current at rated output Exciter field voltage at rated output Excitation power requirements Temperature rise at full load at the plant elevation at 40C ambient Insulation Class (NEMA) Type of enclosure Cooling: Number of fans, kW/Volts Heat exchanger type Water Requirements Space heaters : Number of heaters Watts and voltage RTDs resistance at 0C Number of RTDs RTD type Exceptions to specifications, instructions and terms and conditions

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EQUIPMENT DATA SHEET Page 5 of 6 Equipment Name : Synchronous Motor Synchronous Motor (Contd) Name and Address of Principal Manufacturer:

Name and Address of Suppliers of major Components:

Guaranteed Losses: a) Motor kW b) Cooling fans kW c) Cycloconverter kW d) Transformers kW e) Excitation System kW f) Total Losses (PV) kW g) Overall System Efficiency= PM/(PM + PV) % Where PM = Rated power output of the motor. Motor Construction: Stator: Number of pieces Shipping dimension of pieces Rotor: Number of pole segments Number of poles per segment Shipping dimensions Motor Sealing System ( Detail Description )

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EQUIPMENT DATA SHEET Page 6 of 6 Equipment Name : Containerized Electrical Building Dimensions: Overall Width in meters Overall Length in meters Overall Height in meters Weight: Total assembly w/ equipment, kgs Max. Shipping dimensions Length m Width m Height m Number of shipping sections Shipping weighteach section in kgs HVAC System - Capacity - Manufacturer - Air filter units - Horsepower

Note to the Bidder Bidder is requested to confirm the data filled in the right hand column and fill in any blank lines as completely as possible. Please type or print and stay within the lined area.

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ENGINEERING DRAWINGS AND DATA REQUIRED WITH THIS INQUIRY/ORDER The following data constitute a part of the Inquiry and Purchase Order and are to be supplied as indicated. Specific exceptions must be noted on this form and returned with the Bidder's Proposal. Legend: "P" - Designates manufacturer's standard print - Maximum "E" size (34" x 44") "T" - Designates a full size transparency from which legible prints may be made - Maximum "E" size "C" - Designates a photocopy - Either 8-1/2" x 11" or 11" x 17" is acceptable "D" - Designates a 3-1/2" computer diskette - CAD files in Intergraph or DXF format. E Designates a CD ROM multimedia file. Time Limits: Bidder shall submit a draw ing list submittal schedule with his Proposal. This schedule will form the basis for the agreed schedule which will be incorporated into the Purchase Order. This schedule shall accommodate the following engineering requirements: A) B) C) D) Approval drawings and data required no later than Final certified drawings and data required no later than Manuals required for approval no later than Final certified manuals required no later than 4 weeks after order 8 weeks after order 12 weeks after order 16 weeks after order

Vendor's drawings and data will be reviewed and approved only as to arrangement and conformance to the specification and related drawings, and approval shall not be construed to relieve or mitigate the Bidder's responsibility for accuracy or adequacy and suitability of materials and/or equipment represented thereon. A) PROPOSAL DRAWINGS AND DATA shall be manufacturer's standard drawings and data in sufficient detail to lay out equipment, drives, access for maintenance/operation, and design of foundations/supports. B) APPROVAL DRAWINGS AND DATA shall be complete with equipment number(s) and Purchase Order number. Initial drawings and data must show all information necessary for Purchaser's design of foundations and any connections to other equipment. C) FINAL DRAWINGS AND DATA shall be complete with equipment number(s) and Purchase Order number, marked "CERTIFIED FOR CONSTRUCTION," and SIGNED by an authorized person. Certification warrants equipment shall conform to the final drawings, specifications, and data. Should equipment fail to conform, Bidder shall furnish all materials, labor, and equipment required to correct all deficiencies to the satisfaction of Kvaerner Metals and/or Owner. D) MANUALS shall include the following information as a minimum, published in Spanish. Instructions for Installation Instructions for Operation Instructions for Maintenance, including lubrication schedule, list of special tools, list of recommended spare parts for long lead time items, and a list of recommended spare parts for two years of operation. Spare parts list must include the manufacturer's name and part number, lead time, and current unit price. Complete parts list including Bidder's and original manufacturer's part number Cross section with parts description Code certificates, if applicable Certified performance data Completed Data Sheets (Equipment and Motor) Motor nameplate information and/or calculations. Manuals submitted for approval need not include all of the above, as long as an index is provided with tabs showing where the required information will be included in the final manuals. It is recommended, but not required, that separate manuals be sent for installation and operation/maintenance. One copy of the manual must be included in the box with the equipment at the time of shipment (included in the total quantity requested). E) COMPUTER DATA DISKETTES shall include Computer Aided Design (CAD) design files of dimensionally accurate drawings and data. Catalog type drawings with dimension tables will not be acceptable. The drawings shall be suitable for layout purposes on Kvaerner Metals project drawings, including plan and elevation views. Design files shall preferably be in Intergraph MicroStation CAD format. DXF or Autocad CAD formats are acceptable. CAD files shall be submitted on MS-DOS formatted 3-1/2" computer data diskettes. Bidder shall state in his proposal the CAD file format he intends to use.

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Form Eng-44 Drawings and Data Requirements Project N C-423 Specification N 141E-TS001 Rev A

Equipment : Gearless Drives for SAG and Ball Mills

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Description Number and Form Required With each Proposal Issued After Receipt of Purchase Order Approval GENERAL Final

Item

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Brochures Preliminary Drawing List with Schedule for Submittal Outline Dimensions & Foundation/Mounting Req. Anchorage and Loading Diagram (Static and Dynamic) Cross Section with Parts Description Shop Detail Drawings Erection Drawings Instructions for Erection Completed Kvaerner Metals Equipment Data Sheets Certified Performance Data Installation, Operation, and Maintenance Manuals Complete Parts List Including Vendor's and Original Manufacturer's Part Number List of Recommended Spare Parts for One Year of Operation with Prices List of Spare Parts Recommended During Commissioning with Prices List of Special Tools Recommended for Erection, Testing, and Maintenance Lubrication Schedule Code Certificates Bill of Materials Calculations ELECTRICAL/INSTRUMENTATION Catalog Cut Sheets Wiring Diagrams Completed Kvaerner Metals Motor Data Sheet Motor Name Plate and/or Calculations Control System Description Control System Layout Drawing & Ladder Logic Control System Power and Grounding Drawings Control System Intercabling Schedule Cabinet Intercabling Cabinet and I/O Layouts, I/O Module Listings I/O Terminal Block Assignments Program/Configuration Documentation Completed Kvaerner Metals Instrument Data Sheets Control System Site Planning Manuals Instrumentation Bill of Materials Form ENG-44 Drawings and Data Requirements Equipment Gearless Drives for SAG and Ball Mills

3C 3C 3P 3P

1D + 3P 1D + 3P 1D + 3P 1D + 3P 3C 3C 3C 3C + 3E 3C

1D + 5P 1D + 5P 1D + 5P 1D + 5P 5C 5C 5C 5C + 5E 5C

3C

3C 3C 3C 3C 3C 5C 5C

1D + 3P 3C

5C 1D + 5P 5C

4C

3C 1D + 3P 1D + 3P

5C 1D + 5P 1D + 5P

4C 4C

3P 1D+ 3P Project No. C-423

5P 1D + 5P

Specification No. 141E-TS001

Rev P

P:\C423\ELE\docs\archivo\espec\141E-TS001\141E-TS001 Gearless drive for sag and ball mill-p.doc

Kvaerner

Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

KVAERNER
DOCUMENT NO.: QUALITY SYSTEM STANDARD: Kvaerner QA. STD. (If required ):
ITEM NO.

VENDOR QUALITY PLAN

VQP-141E-TS001 PROJECT: EQUIPMENT DESCRIPTION: CHECKED & APPROVED BY: VV

(VQP)

Quality Requirements for Manufacturers

REQ. NO.: DATE:

UJINA ROSARIO TRANSITION PROJECT DRIVES FOR SAG AND BALL MILLS

* HOLD
ITEM POINT

WITNESS

INSP.

VERIFY

CERT REQ'D

FINAL DOCS

INSP. INIT. DATE ACCEPT.

REMARKS

SPECIAL REQUIREMENTS

1. 2. 3. 4. 5. 6. 7. 8. 9.

Approved Drawings Material Test Reports Test Pieces Heat Treatment Weld Procedures Prototype Tests Trial Assemb. Match Marking Functional Test Performance Test X

X X X

10. Running Test 11. Balancing 12. Continuity/Megger Test 13. Certificate of Compliance 14. M & TE Calibrations 15. Paint Thickness Test 16. Visual Inspection 17. Drawing Dimensions 18. Packing 19. Tagging/Marking 20. Release for Shipment 21. 22. KVAERNER ENGINEER TO WITNESS TEST NOS.: ______________ BY KVAERNER: ALL PROCEDURES WITH QUALITY PLANS AND ASSOCIATED DOCUMENTATION MUST BE SUBMITTED FOR REVIEW. X X X X X X
REV. DATE PREPARED BY CHECKED /APPR. BY

A M

Dec/00 Jan/01

VV VV

JA JA

* CONTACT KVAERNER PRIOR TO PROCEEDING

P:\C423\ELE\docs\archivo\espec\141E-TS001\141E-TS001 Gearless drive for sag and ball mill-p.doc

Kvaerner

Project NC-423 Specification N141E-TS001 Gearless Drives for SAG and Ball Mills Rev A

P:\C423\ELE\docs\archivo\espec\141E-TS001\141E-TS001 Gearless drive for sag and ball mill-p.doc