BECHTEL CORPORATION SUPPLIER DOCUMENT REVIEW eed 2 C Bevge ane Renz ey Petie Set ror rear ot Goges noe 2 D fog an Reset ve Sepnteaee? «Ppp 5 lone Pate. Ft Sears otc sn cra, ‘Buon Stages sus ts ‘Ter an coe ot tava ftom ka conplanc wi cara! Sie a CET eon HEC SESH FORGTASE GRDERNS MR | 20097 M2 | den SooMTTHL| WPTEND EQUENO._| VP. NO. uP. iA A! DdDouwment wo. NOT ASSIGHEL eev. —FUNCTIONAL DESCRIPTION Cooling Tower Chemical Feed and Control Marley Cooling Towers, Antamina Project Bechtel PO 24097-M-204-AC Customer has recirculating cooling water tower with a recire rate of 1200 m3/hr and a delta T of 10C. Customer requires feed and control systems for a chemical program based on acid feed to control pH, corrosion inhibitor feed to passivate system surfaces, dispersant feed to control scaling tendency, and oxidizing biocide feed to control microbiological growth. Control will be exercised locally. Control of inhibitor and dispersant will be manual. Control of oxidizing biocide will be ON-OFF based on ORP. Control of sulfuric acid for pH control will be ON-OFF based on pH. Chemistry Control Strategy: 1. Sulfuric acid is fed to control pH. Control is by local pH analyzer. pH output is available for output to customer DCS. 2, Bleach is fed to control ORP. Control is by local ORP analyzer. ORP output is available for output to customer DCS. 3. Tower blowdown is controlled by Conductivity. Control is by local Conductivity analyzer. Control output is a dry contact closure, with blowdown valve by customer. Conductivity output is available for output to customer DCS. 4. Inhibitor and dispersant chemicals are fed and adjusted manually, A provision for future automatic control by Nalco Trasar is provided should Trasar based chemicals become available in Peru, 5. System receives a GO/NO GO signal from customer DCS. System will only control and feed chemical when receiving GO signal. GO signal will be dry contact closure, with contacts wetted by Nalco system, 6. System includes a sample flow switch. System will only control aad feed chemical when sample flow is sensed. System will provide loss of flow alarm to customer, incorporated in the remote trouble alarm. Alarm will be dry contact, open on alarm. ‘Summary of Project Seope of Worl 1. Mechanical Equipment 1.1. Tankage for specialty chemicals (inhibitor and dispersant) is offered in drums of 30 USGal. 1.2. The Nalco Portafeed system is not available in Antamina, Tankage for sulfuric acid is a 450 gallon SS tote. Tankage for bleach is a $50 gallon polyethylene intermediate bulk container. 1.3. 3-plex analyzer/pump skid for inhibitor, dispersant, & bleach 1.4. Duplex pump skid for sulfuric acid 2, Instrumentation ~ 3-plex pump/analyzer skid to include: 2.1. PH analyzer 22. ORP analyzer 2.3. Conductivity analyzer Functional Description for Manual.doc 10/23/00, Page 12.4. Flow switch 3. Export packaging — wooden containers over plastic wrap Detailed description of Analyzer Enclosure Electronic Circuitry: I. General Layout: A. Enclosure Door 1. The pH , Conductivity, and ORP analyzers are face mounted on the analyzer enclosure door. Operation of these analyzers is provided by the keypads on the face of the instruments. 2. All pumps switches are also mounted on the door as follows: Inhibitor pump (0720-PPZ-091) Dispersant pump (0720-PPZ-093) Bleach pump (0720-PPZ 097) Acid pump # 1 (0720-PPZ-095) Acid pump # 2 (0720-PPZ-096) A switch is also provided to operate the blow down valve. 3. Trouble lights: Lights are provided on the Analyzer Enclosure door to help quickly troubleshoot the source of a remote trouble alarm, The respective light will illuminate should there be a problem with a process variable (pH, conductivity, ORP, or loss of sample flow) or a problem with any of the three analyzers. This saves time in troubleshooting and repair. B. Enclosure Back Panel Circuitry is organized on Terminal Boards (TB’s) as follows: 1, TB-1 is located at the top, and includes all circuit breakers, incoming L1 and L2 circuit feeds as well as ground, all circuit breakers (CB’s), and all relays. 2. TB-2 is located just beneath TB-1 and on the left of the back panel and contains all outputs to the customer’s DCS that are low voltage analog outputs. Analog outputs (4-20 mA) are provided for pH, conductivity, ORP, and Trasar (future). 3. TB-3 is located just to the right of TB-2 and is used to make all connections to the instrumentation sensors (pH, conductivity, and ORP). Functional Description for Manual.doc 10/23/00 Page 24. TB-4 is located beneath TB-4. Here all connections are provided for the trouble light indicating circuitry, and the remote trouble alarm, 5. TB-S is located to the right of TB-<4 and is used to make all pump connections and the blowdown output signal connection, C. Electrical Schematics: Branch 100: Power from L1 is provided via CB-2 to all pump switches and the GO/NO GO relay. A dry contact closure by the customer (Remote Enable Contact) allows CR1 to be powered via contact CR7 (is shut with correct sample flow), With CR-1 powered, contact CR1 (NO) shuts and provides power to all pump switches. The CRS contact (NO) is jumpered since Trasar is not installed, Contact CR4 (NO) is shut by CR4 when powered from the ORP analyzer based on steeping. A low ORP ‘measurment below setpoint powers CR4, which tums on bleach pump if in “auto” to add bleach to the Cooling tower. Contact CR2 (NO) shuts by CR2 when powered from the pH analyzer. This allows the acid pump(s) to turn on to add acid should the pH measurement be above setpoint Branch 200: This branch contains all of the trouble alarm and indicating circuitry. The Remote Trouble Alarm Relay (CR8) is deenergizes providing a “open on alarm” indication if any of the following occur: Loss of analyzer enclosure power Loss of flow — flow switch contact opens, deenergizing CR7, shutting contact CR7 (NC), thus energizing control relay CR6, causing contact CR6 (NC) to open, and deenergizing CR8. * Malfunction of pH analyzer! sensor or pH out of specification energizes CR6... Malfunction of Conductivity analyzer/ sensor or conductivity out of specification energizes CR6.... * Malfunction of ORP analyzer/ sensor or ORP out of specification energizes CR6... Any of the above conditions except a total loss of power also illuminates the respective trouble indicating light. Functional Description for Manual. doc 10/23/00 Page 3Branch 300 Power is provided to the pH analyzer and sensor. Allows automated pH control by acid feed in automatic using control relay CR2. An analog output to customer's DCS is provided as well. Branch 400 Power is provided to the Conductivity analyzer and sensor, Allows automated conductivity control by blow down in automatic using control relay CR3. An analog output to customer’s DCS is provided as well. Branch 500 Power is provided to the ORP analyzer and sensor. Allows automated ORP control by bleach feed in automatic using control relay CR4. An analog output to customer’s DCS is provided as well. Functional Description for Manual. doc 10/23/00 Page 4