Control Systems Design Criteria

Job No.24017- DJ-0001, Rev. 0

BECHTEL CHILE LTDA.

CONTROL SYSTEMS DESIGN CRITERIA

24017-DJ-0001

FOR

MINERA ESCONDIDA LIMITADA

ESCONDIDA PHASE IV EXPANSION PROJECT

0 10Dic98 Issued for Design

B 11Nov98 Issued for Approval AT AC AT LdJ CL MC
A 8Oct98 Issued for Review AT AT
REV. DATE REASON FOR REVISION BY CHECK EGS VEM PE PEM CLIENT
JOB NO. 24017 SHEET 1 OF 19
BECHTEL CHILE LTDA. SPECIFICATION NO. REV.
24017 – DJ - 0001 0

\\Infoworks\Specificationsjob24017\controlsystems\rjr
04/02/19
Page 2 of 19
 TABLE OF CONTENTS

1.0 DESIGN BASIS

2.0 SOURCE CODES

3.0 CONTROL ROOM AND PANELS

4.0 DISTRIBUTED CONTROL SYSTEM

5.0 FIELD INSTRUMENTS

6.0 CONTROL VALVES

7.0 CODES AND STANDARDS

\\Infoworks\Specificationsjob24017\controlsystems\rjr
04/02/19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

SOURCE
CODE
1.0 DESIGN BASIS

1.1 The instrumentation and control system will be an integrated system A,C
of local and centralized control. The system will provide the control
elements required for the immediate system needs and be capable of
expansion as the plant is expanded.

1.2 The extent of field instrumentation will be as shown on the process C

and instrument diagrams (P&IDs). The extent of the programmable
logic controller (PLC)/distributed control system (DCS)-based
instrument functions will be defined in a simplified representation of
the P&ID and loop diagrams, and in a detailed representation on the
PLC network program and the DCS configuration documents.

1.3 The controls and instrumentation will be designed for a 24 hour day, B, C
7 day a week operation. All instruments with internal
microprocessors shall be Year 2000 (Y2K) compliant/certified.

1.4 All instrumentation furnished will be catalog products of standard C

manufacture. Where practical, identical components will be used to
allow interchangeability in order to minimize the variety of spare
parts, and to simplify servicing and repairs.

1.5 All equipment vendors supplying instrumentation as part of a A,C

package will supply devices that are compatible with the major
instruments selected for the plant.

1.6 Electrical power for instruments and control equipment is 115 VAC, A,C
50 Hz, 2 wire grounded single phase. Per previous agreement with
the owner, the vendor can provide their standard voltages (24 VDC,
etc.). Plugs shall be North American types for 115 VAC and Chilean
standard type for 220 VAC.

1.7 The DCS system will be powered from a redundant on line UPS A
system. The UPS will provide at last 1 hour power back up. The
UPS system will be feed from the main power grid and from
emergency grid.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 2 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

1.8 All electronic field instrumentation will be analog type, with an C

isolated 4-20 mA signal transmission. Pneumatic instruments and
control valves will utilize a 20-100 kPag (3-15 psig) signal
transmission. Smart transmitters using HART protocol will be used
where possible.

1.9 Annunciation systems will be the hard-wired window type where C

required locally. Alarm contacts will open on the alarm condition.
Alarms will be handled through digital data logging and the cathode
ray tube (CRT) displays in the main control room (MCR).

1.10 The process plant will employ a DCS. All main plant process A,C
control will be from the main control room (MCR), which will be
located in the grinding building.

1.11 PLCs will be used for control equipment located remote from the A,C
process plant. This includes primary crusher, coarse ore conveyors,
fresh water supply, concentrate pipeline valve stations and reclaim
water pump stations. The PLCs will be linked with the main control
room through fiber optic or radio communication, depending of site
conditions. The expansion of Coloso filter plant will be controlled
through a extension of the existing PLC-based control system

1.12 Fiber Optics will be extensively used for DCS and PLC A,C
communications. All communication busses extended outdoors will
be fiber optic cable installed in a conduit or suspended along the
power lines. Fiber optic cable will be preferred for indoor
communication but due to higher system cost evaluation whether to
use fiber optic will be made on the case to case bases.

1.13 DCS and PLC fiber optic communication cables are dedicated for C
plant process control. Fiber Optic cables for Voice and Data
communication is not in the control system scope.

1.14 Monitoring and control of the slurry pipeline will be through the C
existing fiber optic channels, and services at all remote stations will
be taken from the existing circuits at these stations. Only the first
two slack flow monitoring stations will require new power sources.

1.15 All scales, charts and documents on the project will be prepared C
using metric units. Project-approved units and symbols are noted
below:

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 3 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

Measured Parameter Unit Symbol

Steam Flow Rate Kilograms per hour Kg/h

Gas Flow Rate Normal Cubic Meters per hour Nm3/h
Liquid Flow Rate Cubic Meters per hour M3/h
o
Temperature Degrees Celsius C
Pressure (Gauge) Kilo Pascals gauge KPa
Pressure (Absolute) Kilo Pascals absolute KPa (a)
Pressure (Vacuum) Millimeters of mercury mm Hg
Pressure (Diff.) Kilo Pascal (Kilograms per KPa (Kg/cm2)
square centimeter)
Density Grams per cubic centimeter Gm/cm3
Level 0 – 100 percent %

Note: Charts, if used or provided by others, will be direct reading except for flow C
charts which may be 0-10 square root or 0-100 linear.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 4 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

2.0 SOURCE CODES

The source code letters listed for each criterion refer to the origin of that
criterion value. Where an integer is entered with a source code letter, this
code number refers to specific source documents that are referenced in
Section 6. In certain cases, two source codes may be referenced. The
following letter code designators are used:

Code Description

A Criteria provided by Minera Escondida

Limitada
B Standard industry practice
C Bechtel recommendation
D Vendor-originated criteria
E Criterion from process calculations
F Engineering handbook data
G Assumed data
H Criteria provided by “Technology Supplier”
I Metallurgical test results

3.0 CONTROL ROOMS AND PANELS

3.1 The MCR will be located in the grinding area. The room will be C
sized and arranged to accommodate the operator’s console, printers
and closed-circuit television (CCTV) consoles. Additionally, the
room will be designed to allow extension of the room. The room
will be air-conditioned and pressurized to provide a suitable
environment for the installed equipment.

3.2 The MCR will have a raised floor; cable entries generally will be C
from the bottom.

3.3 The control room will have a smoke and fire detection system with C
the alarm annunciator located in the MCR and an alarm in the DCS
system.

3.4 The control room doors will open outwards and open to A,C
environmentally controlled air lock.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 5 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

3.5 A computer room will be located adjacent to the MCR. This room A,C
will contain the DCS engineers’ workstation, the x-ray analyzer
workstation, and will provide space for the future addition of a
management information system server and a supervisory computer
and its auxiliaries. This room will be air-conditioned, pressurized,
and have a raised floor.

3.6 A DCS equipment room will be located next to the computer room.
This room will contain the DCS console electronics and the DCS
cabinets associated with the grinding facility. The room will be
air-conditioned, pressurized and have a raised floor.

3.7 A termination cabinet room will be located in a room adjacent to the

DCS equipment room. This room will contain the DCS termination
cabinets associated with the grinding facility. This room will be
air-conditioned, pressurized and have a raised floor.

3.8 Environmentally hardened DCS operator panel will be located in the

lime plant area, concentrate pumping area and the main electrical
substation to provide local control.

3.9 DCS cabinets, containing input/output (I/O) modules and field wire C
terminations, will be located in the various electrical rooms
throughout the plant. These cabinets will be interconnected by the
DCS data highway. Motor monitors, such as Multilins, will be
connected to the DCS system via an RS232/485 port.

3.10 Local control panels will be provided for some of the specialized C
electrical equipment packages such as gearless motors. These panels
will be PLC-based where practical and will communicate with the
DCS via the PLC data highway.

3.11 Cabinets containing new PLC and I/O hardware will be located at C
the electrical room for expansion of Coloso Filter plant. This PLC
will provide control for all new equipment of the Coloso plant,
including concentrate reception, filters, stockpile and ship loading
system. New PLC will be connected with the Control Room CP-4
through the existing Data Highway.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 6 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

4.0 DISTRIBUTED CONTROL SYSTEM

4.1 The DCS will be arranged as shown on Distributed Control System C

Block Diagram. The entire plant can be monitored and controlled
from the MCR operator’s console. The DCS will provide
equipment and process control.

4.2 The system will utilize redundant hardware and data highways such A,C
that no single equipment failure can result in a system failure. The
DCS will have at least 25% spare capacity for I/O and control
logic.

4.3 The MCR operator’s console will consist of video display units C
(VDUs) and operator’s keyboard units. All VDUs will be identical
and interchangeable. Normally, one unit would be dedicated to
alarm management and one unit used for trending. The other
VDUs would be used for plant monitoring and control.

4.4 The operator’s console, along with the system printers will provide: C

 Equipment control stations and status

 Analog process control

 Analog indications

 Interactive process and equipment graphics

 Alarm management and logging

 Automatic shift and production reports

 Real-time trending

 Historical trending

 System diagnostic

4.5 Environmentally hardened operator consoles will be provided for A

local plant control of the reagent plant area, the lime plant area, the
flotation area and the main electrical substation.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 7 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

4.6 DCS cabinets containing multifunction controllers, I/O modules, C

field wiring terminators, etc., will be located in the following
electrical rooms:

 Grinding plant and Coarse Ore Feed electrical room

 Flotation and regrind electrical rooms

 Lime plant electrical room

 Concentrate Thickening and Pumping electrical room

 Main Electrical Substation

The area within the electrical room will be pressurized.

4.7 The DCS will interface to the vendor-supplied PLC systems and C
remote located PLC via gateway devices that will address PLC I/O
as if it were DCS I/O.

4.8 The DCS will use mostly fiber optic as communication media C
between electrical rooms, control room and local control panels.
Fiber optic links will be redundant, routed on different ways and
including spare fibers for additional communications services.

5.0 FIELD INSTRUMENTS

5.1 Control systems will be of the electronic type using a 4-20 mA dc A,B
current as a transmission signal. Field transmitters will be of the
two-wire type where practical. The signal conductor pair between
the field-mounted transmitter and the panel-mounted receiver
instrument will supply power to the transmitter, as well as conduct
the measured variable signal. “Smart” transmitters will be used
wherever possible. All transmitters will have local indicators.

5.2 All field-mounted instruments and devices will be suitable for B

operating under the environmental conditions (indoor or outdoor)
prevailing at their installed location. For outdoor locations, when
necessary, heated enclosures will be used.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 8 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

5.3 All field-mounted instrument enclosures and devices will be C

water-and dust-tight, in compliance with a NEMA 4 rating. Epoxy
coating will be utilized to obtain a NEMA 4X rating for corrosion
resistant. Plating is not acceptable as a means of obtaining the “X”
rating.

5.4 Instruments subjected to splatter and washdowns will have C

enclosures and other exposed parts made of or protected by
corrosion-resistant materials. Materials such as aluminum, copper,
and zinc, which are suitably protected with corrosion-resistant
coatings, will be used only when ferrous materials are not available.

5.5 Pneumatic tubing typically will be copper. Stainless steel tubing C

will be used where it is subject to splatter or washdowns from acid
or caustic solutions.

5.6 Local indicators will be selected on the basis of readability, rugged B,C
construction, unbreakable glass, process connections with generous
hub sizes, and liquid filled where desirable.

5.7 Field instruments will be mounted on the building steel or on B,C

separate stands or supports, as applicable, with due consideration
given to its remoteness from heat or vibration sources, as well as
water and material spillage. Field instruments will be located so
that they are accessible from grade or adjacent platforms, but will
not obstruct walkways or passageways.

5.8 FIELD INSTRUMENT SPECIFICS

5.8.1 CCTV SYSTEM A

A CCTV system will be furnished to monitor following

areas:
- Primary Crusher
- In Pit Conveyors
- Overland Conveyors
- Transfer Conveyors
- Coarse ore stockpile
- SAG mill feed conveyor
- SAG mill feed end

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 9 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

- Rougher flotation area

- Cleaner area
- Tailings thickening area
- Main distributor to Laguna Seca impoundment
- Tailings underflow box
- Pebble crusher

Remote-controlled cameras with pan, tilt, and zoom

controls will be supplied. One monitor for every three
cameras will be mounted on a console in the MCR. Any
required pan, tilt, and zoom controls also will be mounted
on the console.

5.8.2 DENSITY INSTRUMENTS B,C

Nuclear density gauges will be used for slurry density

measurement and for mass flow computation. The
transmitters will have a linear 4-20 mA isolated output with
adjustable time constant.

5.8.3 FLOW SWITCHES C

Thermal dispersion or positive displacement type flow

switches will be used to detect low flow conditions in clear
liquids. Vane type switches may be used in utility
applications.

5.8.4 GAS FLOW MEASUREMENT A

To measure the gas flow to the flotation cells, heat

dissipation method will be used; in other applications
averaging pitot tube elements with differential pressure
transmitters will be given primary consideration, with orifice
plates given secondary consideration.

Cone type differential pressure or positive displacement C

meters will be used on the gas burner trains. All gas flow
meters will have a 4-20 mA output signal

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 10 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

5.8.5 LEVEL INSTRUMENTS

Ultrasonic instruments will be used for measuring the solids C

levels in bins, and the liquid and slurry levels in sumps and
tanks.

Where froth or other conditions make direct ultrasonic level A

measurement impractical a floating device shall be used to
provide the appropriate level signal to the level sensor. In
other cases, pressure type instruments, microwave, or radio
frequency capacitor type instruments will be used.

Conductivity type level switches will, in general, be used for C

water, slurries, and other conductive, nonflammable liquids.
The switches will be electronic and of the differential
control type which require a minimum of two electrodes
and a ground connection.

Tilt, microwave and ultrasonic type level switches will be C

used for plugged chute detection. They also will be used
for high level detection in bins containing dust or granular
material.

Where conditions exist to make tilt, microwave or C

ultrasonic level switches impractical, nuclear type level
switches will be used.

Microwave, ultrasonic or tilt type level sensors will be used

to detect high pile level and “material-on-belt” conditions.
The switch control units will have an adjustable time delay
to prevent false operation.

5.8.6 LIQUID FLOW MEASUREMENT C

Slurry flow measurements will be made with magnetic

flowmeters, that will provide 4-20 mA output signal.

To measure the process liquid flow, magnetic flowmeters

will be given primary consideration, and orifice flowmeters
will be given secondary consideration. Coriolis flowmeters
will be used on nonconductive liquids and reagents.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 11 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

5.8.7 pH and ALKALINITY SENSORS/TRANSMITTERS C

Immersion type electrode assemblies connected to a locally

mounted indicating transmitter will be used for pH
measurement. The transmitters will provide isolated 4-20
mA signals. The electrodes will be ruggedized and have a
type of mounting that allows easy removal for cleaning and
calibration.

5.8.8 PRESSURE GAUGES C

Each pressure gauge will have a 152.4 millimeter (6 inch)

diameter dial (white face with black graduations), phenolic
turret case, blow-out protection, and 15 millimeter (1/2
inch) NPT process connections if directly connected or a
minimum 25 millimeter (1 inch) NPT connections if they are
diaphragm protected. Root valves will be installed for
isolating the pressure indicators. For viscous, corrosive, or
slurry service, diaphragm seals will be provided. Liquid-
filled (glycerin) type will be used for all services.

5.8.9 PRESSURE SENSOR/TRANSMITTERS C

Pressure sensors/transmitters will be used for pressure

measurements. The signal transmission will be two wire,
isolated 4-20 mA. The sensor will have a carbon steel body
of the appropriate pressure rating and a 316 stainless steel
diaphragm. The appropriate materials will be specified when
the process fluids are incompatible with any of the
sensor/transmitter’s wetted parts.

The pressure sensors/transmitters will have two-valve

manifolds to facilitate isolation and calibration. For slurry
service, open-diaphragm type sensors/transmitters or
diaphragm seals will be used.

5.8.10 SOLIDS FLOW MEASUREMENT A,C

Where possible, solids flow will be weighed by gravimetric

conveyor belt scales. The scale electronics will be
microprocessor-based and belt-speed compensated. The
transmitted weight-rate signal will be an isolated
4-20 mA signal.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 12 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

Belt scales will be designed to provide ± 1/2 percent

accuracy for the in-plant systems. For systems involving
product sale, the scales will be designed to provide
± 1/4 percent accuracy.

Calibration chains with troughs will be provided for the

SAG mill feed conveyor and pebble recycle conveyor

Nuclear type belt scales will be used only where physical

restraints preclude the use of gravimetric scales. These
scales will be microprocessor-based, belt-speed
compensated, and will provide an isolated 4-20 mA output.

5.8.11 TEMPERATURE SENSOR/TRANSMITTERS C

Temperature sensor/transmitters, close-coupled to the

appropriate measuring elements, will be used for
temperature measurements. The signal transmission will be
two-wire, isolated 4-20 mA. Platinum RTDs, 100 ohm
three-wire type, will be used for temperature measurements
of up to 260°C. Type K (chromel-alumel) thermocouples
will be used for temperatures of up to 1250°C.

5.8.12 THERMOMETERS C

Thermometers will be the dial types, bi-metallic with a

1250 millimeter diameter and a 6 millimeter stainless steel
stem. Thermometers will be supplied with stainless steel
wells.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 13 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

5.8.13 VIBRATION MONITORS A,C

Vibration monitoring will be accomplished by displacement

sensitive vibration monitors. For monitoring motor-bearing
vibration, proximity type vibration sensors will be used.

The number and location of vibration monitors will be per the

equipment supplier recommendations. Vibration transmitters
will be provided by the mechanical equipment suppliers for
the following equipment:

- SAG Mill
- SAG Screen Undersize Pumps
- Ball Mills
- Primary Cyclone Feed Pumps
- Regrind Mills
- Concentrate Slurry Main Pumps
- Plant Air Compressors

The signals from the vibration transmitters will be

connected to the DCS (or PLC) system to be used by
Escondida for the preventive maintenance program. The
transmitter signals will be used in the DCS (or PLC) logic
for alarm and shutdown.

Vibration switches shall be provided by the mechanical

equipment suppliers for the following equipment:

- Coarse Ore Transfer Conveyor

- In Pit Conveyor
- Transfer Conveyor
- CO Overland Conveyors
- SAG Mill Feed Conveyor
- Second Cleaner Feed Pumps
- Regrind Cyclone Feed Pumps
- First Cleaner Feed Pumps
- Flotation System Blowers
- Column Flotation Air Compressors
- Pebble Crusher
- Tailings Thickener Overflow Pumps
- Monturaqui Fresh Water Booster Pumps
- Reclaim Water Pumps and Booster Pumps

The vibration switches will connected to the DCS (or

PLC) and will be used for alarm only.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 14 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

5.8.14 ZERO-SPEED SWITCHES C

Noncontacting type speed switches will be used. A startup

time delay, adjustable as required for application, will be
provided.

5.8.15 MILL MEASUREMENTS A

Static pressure transmitters will be used to measure mills

bearing pressure (SAG and Ball mills). As a secondary
system load cells will be used.

Sound measurement instrumentation will be used for

measuring the SAG mill sound. The signal transmission will
be isolated 4-20 mA.

6.0 CONTROL VALVES

6.1 Control valve configurations and flow characteristics will be B

selected on the basis of the fluid or slurry properties, and the
response required.

6.2 Construction materials for control valves will be selected on the B

basis of the physical and chemical properties of the controlled
media.

6.3 Control valves will be located so as to be accessible from grade or A,C

from elevated platforms that already form part of the required
access routes of the plant. They also will be accessible with a
service or portable type crane.

6.4 Control valves will have manual isolation and bypass valves as C
shown on the P&IDs.

6.5 Manual valves and the associated instruments will be located for A,C
ease of readability of the instrument while the valve is being
operated. Knife gate valves, 200 millimeters (8 inches) and larger,
will have air operated actuators. Knife gate valves, 500 millimeters
(20 inches) and larger and subject to process pressures over
315 kPa (45 psi) will have hydraulically operated actuators.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 15 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

6.6 Automatic control valve operators will be selected on the following

basis:

 On-off control valves 40 millimeters (1-1/2 inches) or

smaller or clear process fluids will be electrically operated
valves.

 On-off control valves over 40 millimeters (1-1/2 inches)

will have pneumatic diaphragm or pneumatic cylinder
actuators, solenoid operated.

 Failure positions will be fail open, fail close, or fail as-is,

depending on the process requirements. The fail position
will be shown on the P&IDs.

 Control valves for the modulating services will have

pneumatic diaphragm or cylinder actuators with positioners
responding to the 4-20 mA control signal that is connected
to valve-mounted transducers.

 Self-contained (flow and pressure) regulators will be used in

instances where a manually adjustable fixed-flow rate or
pressure is required.

6.7 Position limit switches for fully open and fully closed indication will
be provided where required. The valve data sheets will specify the
number and type.

6.8 The control valve body size will be shown on the P&IDs.

7.0 CODES AND STANDARDS

7.1 All instrumentation work performed, and materials and equipment

furnished, including electrical, electronic, and air systems, will
conform to the applicable portions of the latest edition or revision
of ANSI, IEEE, NFPA, and NEMA standards and shall comply
with the US National Electrical Code, the Mine Safety and Health
Administration (MSHA) Regulations and Standards Applicable to
Metal and Non-Metal Mining and Milling Operations. The work
also will conform to any Chilean laws and regulations.

7.2 All burner management systems will conform to Factory Mutual

requirements.

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 16 of 19
 Control Systems Design Criteria
Job No.24017- DJ-0001, Rev. 0

\\Infoworks\Specificationsjob24017\controlsystems
04/02/19
Page 17 of 19