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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems

25800-220-3PS-JQ07-00001, Rev. 2

TABLE OF CONTENTS

SECTION PAGE

1.0 INTRODUCTION 5
1.1 Scope 5
2.0 CODES, REGULATIONS AND STANDARDS 5
2.1 Standards 5
2.2 Specific standards 6
3.0 UNITS OF MEASUREMENT 7
4.0 TECHNICAL REQUIREMENTS 9
4.1 General requirements 9
4.2 Operating and Design Conditions 9
4.3 Instrumentation 10
4.4 Control System 12
4.5 Control System supplied by Seller 13
4.6 Instrumentation Power distribution 16
4.7 General Control Modes 16
4.8 Motor Control 17
4.9 Valves and Gates Control 17
4.10 Vendor Packages Control Modes 17
4.11 Control Panels 19
4.12 Wiring 20
4.13 Fiber Optic 20
4.14 Surge and Lightning Protection, Grounding 21
4.15 The cable cover color shall be as indicated to follows the project standard: 21
4.16 Colors Project Standards 21
4.17 Colors for pushbuttons, strobe lights and panel lights 23
5.0 INFORMATION BY SELLER 23
5.1 General 23
5.2 Information Supplied with Proposal 24

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

TABLE OF CONTENTS (Cont’d)

SECTION PAGE

5.3 Information Supplied After Receipt of Purchase Order. 24


5.4 Technical documents for system maintenance 25
6.0 RESPONSIBILITY 28
7.0 PACKAGING AND SHIPPING 28
8.0 STANDARDIZATION 29
ATTACHMENTS 30
Attachment A. Approved instrument brands 30
Attachment B. Instructions for instrument tagging 34
Attachment C. Vendor Control Systems Components 35
Attachment D. Project Standard Vendors Control System Architecture 35
Attachment E. Instrument tagging convention 36
Attachment F. P&ID symbology for PCS and alternate controller 37
Attachment G. Instruments list format 39
Attachment H. I/O list format 41

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

LIST OF ACRONYMS, DEFINED TERMS, AND ABBREVIATIONS

Term Definition

AFD Adjustable frequency drive

CAT Configuration acceptance test

C&ID Control and instrumentation diagram

CCTV Closed circuit television

CCR Central Control Room

FAT Factory acceptance test

HMI Human machine interface

I/O Input/output

IOC Integrated operation center

MCC Motor control center

MPR Motor protection relay

OWS Operator work station

P&ID Process and instrumentation diagram

PCS Process control system

PLC Programmable logic controller

RTD Resistance temperature detector

SCADA Supervisory control and data acquisition

UPS Uninterruptible power supply

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

1.0 INTRODUCTION

1.1 Scope

This specification defines the requirements for instruments and control systems furnished as part of,
or in connection with, all types of mechanical and electrical equipment for packaged systems and its
auxiliaries, for Quebrada Blanca Fase 2 project.

Functional requirements of the instrumentation to be furnished with the equipment included in a


packaged system are defined in the equipment specification.

The purpose of this specification is to ensure that:

 Instruments and control systems, which are associated with packaged systems, shall conform
to this specification as set forth for other instruments on the project

 Complete information is provided by the Seller concerning instruments which will be


furnished with packaged systems, including P&IDs, instruments list, control schematics,
wiring drawings, user manuals and installation instructions

 All instruments and control system equipment shall be tagged by the Seller before shipment
to allow proper identification of each item at the jobsite. Instrument tag numbers shall be
assigned by the Buyer in accordance with the project tagging standard

 All instruments will be standard solution in mining industry. Prototypes will not be accepted.
All instruments shall be identified on Seller’s drawings and documents. All instruments shall
be prepared for shipment to the jobsite

 Instrumentation and controls are fully integrated to the plant PCS

2.0 CODES, REGULATIONS AND STANDARDS

2.1 Standards

Instruments and control system equipment, materials, components, and functions will be designed,
built, rated, tested, and will perform in accordance with the latest applicable standards, requirements,
recommendations, and guides of the following organizations:

 ANSI, American National Standards Institute

 ASME, American Society of Mechanical Engineers

 ASTM, American Society for Testing and Materials

 FM, Factory Mutual

 IEC, International Electrotechnical Commission

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

 IEEE, Institute of Electrical and Electronics Engineers

 ISA, International Society of Automation

 ISO, International Organization for Standardization

 MSHA, U. S. Mine Safety and Health Administration

 NEMA, National Electrical Manufacturers Association

 NIST, National Institute of Standards and Technology

 NFPA, National Fire Protection Association

 OIML, International Organization of Legal Metrology

 OSHA, U. S. Occupational Safety and Health Administration

 UL, Underwriters Laboratories

 DIN, Deutsches Institut für Normung

2.2 Specific standards

The instruments and control system design and construction will conform to the requirements of the
following more specific standards:

 ANSI/ISA 5.1-2009, Instrumentation Symbols and Identification

 ANSI/ISA-18.2-2009 Management of Alarm System for Process Industries

 ANSI/ISA-95.00.01-2000, Enterprise-control system integration

 ANSI/ISA-100.11a-2011, Wireless systems for industrial automation: Process control and


related applications

 ANSI/ISA-RP74.01-1984, Application and Installation of Continuous-Belt Weighbridge


Scales

 ANSI/ISA- S7.0.01, Quality standard for instrument air

 ISO-11064, Ergonomic design of control centers

 IEEE C2, National Electrical Safety Code (NESC)

 NCh 2562.Of2001, Instrumentos de Pesaje No – Automáticos – Requisitos Metrológicos y


Técnicos – Ensayos, 1995

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

 NFPA 70, National Electrical Code (NEC)

 OIML-R50-1, Continuous totalizing automatic weighing instrument (belt weighers). Part 1:


Metrological and technical requirements – Test

 OIML-R51-1, Automatic catch weighing instruments. Part 1: Metrological and technical


requirements – Test

 OIML-R61-1, Automatic gravimetric filling instruments. Part 1: _ Metrological and technical


requirements – Test

 OIML-R76-1, Non-automatic weighing instruments. Part 1: Metrological and technical


requirements - Test

 NIST HANDBOOK 44 – 2009. Specification, tolerances, and other technical requirements


for weighing measurement devices

In addition to the above codes and standards, instruments and control system design and construction
will conform to the following Chilean regulations and laws:

 NCh 4/2003, Norma Chilena, Instalaciones de Consumo en Baja Tensión

 Marco Normativo Aplicable de la Subsecretaría de Telecomunicaciones (SUBTEL), Chile

 D.S. No 127, Plan general de uso del espectro radioeléctrico, 2006

 D.S. No 133, Autorizaciones para instalaciones radioactivas o equipos generadores de


radiaciones ionizantes, personal que se desempeña en ellas, u opere tales equipos y otras
actividades afines

 D.S. No 594, Reglamento sobre condiciones sanitarias y ambientales básicas en los lugares
de trabajo

 D.S. No 3, Reglamento de protección radiológica de instalaciones radioactivas

 D.S. No 132, Reglamento de Seguridad Minera

Where conflicts occur between the codes requirements, the most stringent standard shall prevail. Final
interpretation shall rest with the owner or the Buyer.

3.0 UNITS OF MEASUREMENT

All scales, trends and documents covered by this specification shall be based in the international
system of units SI, metric units and project approved units and symbols as noted below:

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

Measured Units Symbol


Parameter
Angles degree °
Area square meter m2
Current ampere A
kilobits per second kbps
Data transfer speed
megabits per second Mbps
Density kilograms per cubic meter kg/m3
Electrical conductivity micro Siemens per centimeter μS/cm
Energy joule J
Frequency hertz Hz
Gas flow rate normal1 cubic meters per hour Nm3/h
Length meter m
0 -100 % %
Level
meter m
Liquid flow rate cubic meters per hour m3/h
Memory megabytes Mb
pH non-dimensional pH
Power watt W
Pressure (absolute) pascal absolute Pa (a)
pascal Pa
Pressure (diff.) mm of Mercury mm Hg
meter of water column mwc
pascal gauge Pa (g)
Pressure (gauge)
pounds per square inch gauge psig
pascal Pa
Pressure (vacuum) mm of Mercury mm Hg
meter of water column mwc
Solids flow rate ton per hour t/h
meter per second m/s
Speed
0-100 % %
Temperature Celsius degrees °C
second s
minute min
Time
hour h
day d
newton meter Nm
Torque
0-100 % %
Voltage volt V
kilogram kg
Weight
ton t

1
At normal conditions of 0°C and 101.325 kPa

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

4.0 TECHNICAL REQUIREMENTS

4.1 General requirements

The design and construction of packaged equipment systems shall consider safety, environment and
equipment care prior to operation. The seller shall define safety interlocks to accomplish these
requirements.

Design and construction shall be in accordance with all regulatory codes and standards applicable at
the job site. Materials shall be new, of first quality, and the standard product of the manufacturer. All
materials required to interconnect or install instrument devices located on the package unit shall be
supplied as part of the package (e.g., thermowells for RTDs).

All interconnections between items supplied in the package unit (electrical, pneumatic, etc.) shall be
supplied by the Seller and shall be prewired, prepiped, etc., except where shipping constraints make
necessary dismantling the unit. In such case interconnecting cables, pipe, tubing, etc. shall be clearly
tagged for reconnection at the jobsite, and an assemble drawing shall be supplied.

For instruments tagging see Attachment B, Instructions for Instrument Tagging.

4.2 Operating and Design Conditions

All installations intended for outdoor use shall be capable of functioning under the ambient conditions
established at the General Specification for Site Condition (25800-220-3PS-G000-00001).

Seller shall consider surge protection for all analog and digital signals of control systems,
instruments, I/O devices and other electronic devices located 2000 meters above sea level (m.a.s.l.) or
higher.

Instruments, control systems and electronic devices specifications shall consider the operating
conditions of altitude above sea level. So, manufacturers and suppliers shall include a third party
certification or a list of their equipment currently operating above 4000 m.a.s.l. A derating analysis to
describe explicitly the effects over their efficiency, reliability, lifetime and accuracy must be done by
the Seller, applying the altitude correction factors for derating to the equipment to be located at the
concentrator and mine site, based on the altitude of 4380 m.a.s.l. in accordance with the applicable
ANSI standards and codes for current and IEC standard (IEC 62271-1) for voltage. Current derating
factor for cables shall be applied at altitude 2000 m.a.s.l. or higher.

For operational and installation conditions the components of the control system will be designed to
operate in a mining industrial environment. Therefore, it must be protected from:

 High airborne dust (consider corrosive and conductive dust)

 Ratio frequency interference

 Switch control bounce

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

 Power line disturbances caused by load switching and lightning

 Corrosive gas like H2S (Molybdenum Plant)

And for instruments and field infrastructure it will also consider:

 High mechanical vibrations

 Water and slurry splashes


2
 High humidity (Concentrator and Molybdenum Plant)

 Classified areas consider only a part of facility “0390 Reagent”, including level instruments
over storage tanks of fuel oil and other reagents. The rest of the instruments will be located
beyond of classified limit area.

All equipment enclosure will be as follows:

 NEMA 4 (or IP66): Outdoor industrial areas

 NEMA 4X (or IP66 corrosion resistant): Outdoor corrosive areas. 2

 NEMA 12 (or IP54): inside electrical rooms

Plating or painting is not acceptable for NEMA 4X cabinets. Stainless steel or FRP/thermoset plastic
is acceptable.

All electrical instruments shall be UL or FM approved for the hazardous area classification indicated
on the applicable data sheet.

4.3 Instrumentation

Electronic intelligent type instruments with 4-20 mA with HART protocol shall be considered. This
includes the HART option for I/O modules on Seller’s PLC when applicable.

For certain special applications, where electronic intelligent type instruments are not available, use of
4-20 mA analog instruments are acceptable with Buyer’s approval.

All the intelligent electronic type instrument parameters shall be easily changeable, including the tag
number, calibrated range, display units, etc. without removing the instrument via a hand held
programming unit or through the Buyer’s PCS.

EtherNet/IP protocol is the preferred choice for remote I/O boxes for discrete signals collection on
Seller PLC. An alternative can be accepted where there is a special interest associated with
instruments or equipment being offered.

All transmitters shall include a local indicator with LED or LCD numerical display in engineering
units.

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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Transmitters will be used for process indication and alarms. Use of switches should be specifically
approved by Buyer.

Transmitters may be used for process interlocks but not for safety interlocks. In this case, switches
will have two isolated contacts, one for hardwired trip and another for PCS connection. Any field
adjustable switches shall have local indication for allowing easy field configuration.

Two switches or instruments may share a single process tap if each branch to the respective switch or
instrument can be isolated.

All primary actuating devices or switches shall be furnished with two single-pole, double-throw
(SPDT) isolated contacts rated for 1 A at 120 Vac, unless otherwise specified. Switches shall be
hermetically sealed. The use of mercury-contact switches on vibrating equipment is not acceptable.
Solid state optically coupled contacts could be accepted by the Buyer only when no instruments with
dry contacts are available.

All process temperature-sensing instruments shall be furnished with thermowells. Thermowells


material shall be at least 304 stainless steel (SS), unless other materials are required due to corrosive
service applications. Thermowells shall be constructed from solid bar stock, not built up from piping
or tubing. Insertion length must be selected from standard U-dimensions listed in the Seller’s
literature.

Valves or instruments with pneumatic actuators shall use 20.7 to 103.35 kPag (3-15 psig) air signals
for transmission and control. If required, filter/regulators (5 microns with manual drain) shall be
provided for pneumatic instruments or valves.

Position switches shall be heavy-duty, water-tight and dust-tight hermetically sealed. Magnetic
proximity, limit switches, capacitive sensor or another type of position switches shall be defined
according to the application.

Plant instrument air supply will be available for instruments or valves with pneumatic actuators.
Instrument air minimum pressure will be 520 kPag and maximum pressure will be 760 kPag, dry and
oil free, -40 °C dew point, in accordance with ISA-S7.0.01, quality standard for instrument air. If the
packaged system requires its own compressor to provide the required air, the air being distributed
shall comply with the same standard.

If required, lubricators shall be installed near the actuators in such a way that the oil cannot enter to
sections of the air distribution system serving valves, transmitters or other pilot containing devices.
2
Process tubing shall be ½” outside diameter and 0.049” wall thickness, 316 SS seamless tubing.
Process tubing fittings shall be 316 SS compression type, SWAGELOK or similar.

2
Steel channels or thin-wall conduit will continuously support individual tubing runs exceeding one
meter or where mechanical damage may occur. Runs exceeding four single tubes shall be supported
in raceway rack.

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

For arrival segment of pneumatic piping for installations subject to high vibration or where the
connection moves polyethylene or polyurethane UV protected tubing
2
Instruments shall be mounted to provide easy access for operation and maintenance. Instruments
requiring shop calibration shall be installed with unions and isolation valves to allow removal.
Isolation valves shall be provided so that in-line valves and instruments can be removed for
maintenance without draining tanks or reservoirs and without depressing entire systems. Integrated
isolation, equalizing and purge valves shall be provided on the instrument impulse sensing lines, to
allow for easy calibration and zero adjustment. Process connections for instruments on vessels shall
be dedicated to the instrument and not shared with process piping. A root and vent valve shall be
installed to isolate the instrument from the process for maintenance.

Standard manufacturer calibration and alignment of all instruments shall be performed by the Seller
prior to shipment, except for the level instrument which will be set on site. 2
Pressure sensors, which have contact with slurry, shall include a flange diaphragm seal. A 2” flanged
connection will be preferred.

Flowmeters and regulating control valves shall have bypass and isolation manual valves to allow its
removal without interrupting the associated process, unless associated equipment is defined as not
operative without these instruments. Seller shall follow all installation requirements established by
instrument manufacturer (in particular magnetic flowmeters). 2
Densimeters shall be installed over a spool, to allow its removal and calibration.

Wireless instruments will be considered only where clear functional advantages are shown.

Electrical multi-variable measurement devices and other electrical devices shall communicate with
the PCS/SCADA system digitally. The communication protocol shall be IEC-61850, Modbus TCP or
Profibus DP, being IEC-61850 the preferred option.

4.4 Control System

Plant control philosophy considers as much as possible the integration of all the controls in the plant
PCS. This integration can be classified as follows starting with the preferable option:

a) Fully integrated by Seller. The Seller shall provide all instruments and a Control System
(typically PLC based) that will be fully communicated to the PCS controllers using dedicated
links. In this case, there are two options: 2

o Seller will provide MCC (within Seller’s E-room) for controlling the motors within their
scope (Gearless drives, etc.)

o The motors within Seller’s scope are connected to Buyer’s MCC and the control is
hardwired to the Seller’s PLC instead of connected to the Buyer’s PCS. (Crushers,
blowers, etc.)

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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b) Fully integrated by engineering. The Seller shall provide the equipment and instruments, and
engineering information for control system design. All control logic will be developed in the PCS
by the PCS seller. (Flotation cells, column cells, etc.)

c) Fully integrated by PCS. The Seller shall include Remote I/O hardware prewired to instruments
and will provide all the engineering information as before (hydro-cyclone cluster panel) 2

d) The Seller shall include at least 20% of spare in the memory and processing capacity and 20% of
spare space inside the cabinet and I/Os.

The Seller shall provide all the control system engineering, even in case control system is not part of
the scope. This shall include at minimum:

 P&IDs or C&IDs

 Instrument loop diagrams or wiring diagrams

 Instrument list

 I/O list

 Alarm list

 Control system block diagrams

 Logic diagrams, cause and effect diagrams, functional block diagrams, sequential function
charts and/or control narratives describing in detail the control functions required according
to Seller design

 Operation and maintenance manual

 Technical support for clarifying documentation

In case of packages fully integrated by Seller, the seller shall define a configuration acceptance test
(CAT) protocol in order to test the communication between Seller’s PLC and PCS or other specific 2
devices.

If fully integrated by engineering or PCS, Seller shall attend the PCS-CAT to confirm that the system
is performing according Seller design. This CAT will be executed at Buyer’s facilities. 2

The use of electromechanical control relays will be avoided, except as required for safety interlocks
(thickeners case).

4.5 Control System supplied by Seller

If control system is supplied by Seller, as described in 0.c, it shall be PLC based. Other type of
controller shall be specifically approved by Buyer, and just if this is the only standard of the Seller.

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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In either case a full integration with the PCS is required. The Seller PLC based controller (or other
approved) shall have the capabilities to be fully integrated in the PCS. HMI or at least a Local Panel
will be provided for local control and operation.

When the package includes a PLC based control system, it shall include a redundant communication
link for the integration with the PCS with EtherNet/IP protocol. If the equipment is supplied with a
dedicated controller, other protocols approved by the Buyer could be used, and the integration will be
done without redundant communication. A heart bit shall be included to detect communications status
between PCS and vendor controller.

According to the above, the Seller shall provide two communication switches with at least one single
mode fiber optic port and two copper ports. Fiber optic interfaces shall be included.

The control system required by packaged equipment shall be based on Allen-Bradley products:
ControlLogix PLC and PanelView with 1024x768 resolution and 16 millions of colors as minimum
features. Any other model shall be approved by the Buyer. 2

In any case, the supplied system must be a fully open system. This means that the Buyer shall be able
to edit the program developed for the application. The Seller shall provide a fully documented system.
Seller shall provide the licenses without time limitation or expiration.

Seller shall provide redundancy for power supplies for any PLC supplied with packaged systems.
Redundancy for processor will be evaluated case by case. PLC shall be supplied with cabinet doors
having shock resistant glass windows, to allow monitoring without opening the cabinet doors.

The operating mode will be defined by the IOC operator, and not by the field operator. Availability of
the local control panel for local operation will be authorized by the IOC operator. However, if PCS-
PLC communication is lost the Vendor’s local HMI will be enabled to switch to local operation.

System field I/O wiring, either PCS or PLC based, shall be connected through simple push-in 600 V
type terminal boards, so, field wiring will not terminate directly on the I/O card boards. Terminals
shall allow two conductors of 14 AWG size. If I/Os need to be powered, they shall be done in
terminal boards through fuses with circuit breakers for groups up to 16.

All trip and alarm switches shall be fail safe, i.e., an abnormal condition shall cause a loss in output
signal. Upon loss of power, control circuits and alarms shall go to the failsafe condition. Solenoid
valves and actuating relays shall be normally energized, and shall de-energize on protective action or
alarm. All alarm contacts shall open to alarm. When contacts are controlled by a pneumatically
loaded device, the device shall be normally loaded and shall vent to create the alarm or shutdown
condition.

As much as possible, a signal initiating an interlock or shutdown will also activate a separate pre-
alarm point to indicate that an abnormal condition exists and failure to take corrective action will 2
result in a shutdown of the affected equipment.

The Seller shall indicate any signal which interfaces with the Buyer’s PCS and provide termination
points for easy Buyer connection. All critical signals shall be hardwired instead of communicated.
Dry contacts I/O shall be used.

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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The Seller’s shall develop a factory acceptance test (FAT) to their PLC system. That FAT shall be
protocol driven, which will be previously agreed with the Buyer.

When the supply includes a system or any equipment or instrument to be communicated with the
Buyer’s PCS, Seller shall provide the input/output signal interchange list (data transfer list) to the
Buyer, including tagging, ranges, engineering unit, logical status meaning and any necessary
information for clear understanding.

If any logic is required to be developed in the Buyer’s PCS system, it shall be clearly stated and
declared in the control philosophy and logic diagrams documents.

All configurable equipment shall be configured and/or programmed, in accordance with their
application, and all necessary documentation for erection, startup and system maintenance shall be
provided.

Seller shall include the programming software necessary to make any change in any configurable or
programmable equipment.

If HMI is provided, the software for development shall be included with all the options that could be
necessary for the startup.

Seller shall include EtherNet/IP protocol as a base, and Modbus TCP/IP as an option.

Packaged equipment control system shall consider hardwired control of motor starters, which will be
provided by Buyer and located in the Buyer’s MCC. Seller shall consider a start/stop command
output and five inputs (local start/stop push buttons; emergency stop push button; motor running
confirmation; and motor status enable/fault). In case of FVR, Seller shall consider two outputs
(forward and reverse command) and seven inputs (local start forward/reverse/stop push buttons;
emergency stop push button; forward and reverse motor running confirmation, and motor status). 2
Finally, for adjustable frequency drives, Seller shall consider discrete inputs/outputs like FVNR
motor starter, and additionally an analog output (speed reference) and an analog input (speed
feedback) in the packaged equipment control system. Seller shall review typical motor control
schematics in order to verify that all signals are included to properly control the drive from PLC.

All information and status of Motor Protection Relay (MPR), Adjustable Frequency Drive (AFD) or
another electrical device in the MCC, will be collected by PCS through Ethernet based network. In
case of packaged equipment, where the motor starter of Buyer’s MCC is hardwired to the Seller’s
2
PLC, the PCS may require some additional information (such as power, current by phase, faults, etc.)
from MPR or AFD to show it in the PCS-HMI, this information will be retrieved by PCS directly
through Ethernet based network link.

In case equipment packaged system will include a HMI, this will be connected to one EtherNet/IP
switch, which shall include type LC fiber optic ports for redundant fiber optic network, and also
enough RJ45 ports for connect HMI, a EtherNet/IP communication module and a laptop, which will
be required in field activities.

A suggested Vendor Control Systems Architecture is show in Attachment D.

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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Seller’s P&IDs shall be designed according to ISA 5.1-2009 standard and instrument tagging
convention defined by project for. See Attachment E.

For local or alternate controller (PLC) in packaged equipment system, consider the symbology shows
in Attachment F. The alternate controller numbering for the project, is defined in “Alternate
Controller List” (Document no. 25800-220-J0X-0000-00010)

HART instruments shall be connected in a point-to-point topology (analog/digital) to the control


system, and 4-20 mA shall be used for the control function. HART protocol will be used for
diagnostic and maintenance, and the information shall be available at the central control room.

4.6 Instrumentation Power distribution

The Seller shall provide instrument power panels, 120 Vac, 50 Hz, separated from non-instrument
power panels.

Each instrument shall have its own circuit breaker for power disconnecting and protection. This is
also valid for motor or solenoid actuated valves.

Control System and analyzers shall be UPS powered, via instrument power distribution panels.

4 wire instruments shall be powered from power distribution panels fed by UPS.
2
Other instruments defined as critical for the process or useful in case of a power blackout would be
powered from a power distribution panel powered by the UPS.

4.7 General Control Modes

The Buyer´s PCS will have an Integrated Operational Center (IOC), which will provide the following
logic selector for operation:
2
 Remote / Local

 Automatic /Manual

Selection between local or remote operation will be available from the IOC. Remote mode shall be
the normal mode of operation, local mode should only be used for maintenance purpose or for
specific operational requirements (start-up, equipment test, etc.).

Selectors “Remote/Local”, “Automatic/Manual” available in the PCS´s OWSs allow the following
combinations:

 Remote – Manual: In this mode of PCS operation, equipment will be started and stopped by the
operator action at the PCS OWS. In this mode, safety and process interlocks are always active.
Functional groups (see below) have no meaning in manual mode

 Remote – Automatic: In this mode of PCS operation, equipment will be started and stopped
automatically by process signals connected to the PCS or a logic sequence configured into the
PCS. In this mode, the operator commands to start/stop pre-configured sequences or batch loops.
"Automatic" mode is when functional groups are controlled automatically and in sequence by the
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control system. A functional group is a set of items such as motors, valves, etc. which are
operated by a single operator action. In this mode, safety and process interlock are always active.
The remote mode will be the normal plant operation state, with equipment being operated in
either the automatic or manual mode through the PCS. Those process interlocks which are
required once the equipment has started (i.e. seal water, pump discharge pressure, etc.) should
include a delay before being activated, allowing transient changes during the starting process, the
final value of those delays will be tuned during start-up or commissioning.

 Local: This mode of PCS operation allows an operator to run individual plant equipment from the
field for maintenance purposes. The hardwired safety circuits and critical equipment-protection
interlocks will remain operational, but process interlocks and start and stop functions from the
PCS become inoperative. Local mode enables field push buttons (start/stop or open/close). In
local mode the PCS will be monitoring all actions in field and log any maintenance operation for
maintenance reports.

Switching a motor from remote to local will stop the motor (if the motor is running), but switching it
from local to remote will keep the running status, unless a process interlock stops the equipment.

4.8 Motor Control

For Seller’s PLC, motor control will be done hardwired using “Start/Stop” and “Running” signals.
MPR will be digitally connected to the PCS for diagnostics and monitoring, and Seller’s PLC could
receive any additional information, if required, by communication from the PCS. For variable speed
motors, the Seller’s PLC will use the following hardwired signals to AFDs; “Start/Stop”, “Running”,
“At speed”, “4-20 mA set point speed”. In this way, the equipment can be operated locally when the
Seller’s PLC-to-PCS communication link is lost. Any other signal required to operate the AFD in a 2
proper and safe way shall be included by Seller.

4.9 Valves and Gates Control

Valves, gates, diverters, etc. might require automatic operation, either local or remote through the
PCS, Seller PLC or both. The same concept that the rest of equipment shall be applied for valves.
Selection between local or remote operation will be available from the IOC. Remote mode shall be
the normal operation mode; local mode should only be used for maintenance purpose or for specific
operational requirements (start-up, equipment test, etc.).

ON/OFF automatic pneumatic / hydraulic valves: These valves will include position limit switches,
directional valves (with one or two coils depending on fail condition). A local panel with the
directional valves including open/close pushbuttons, position light indicator and local status light 2
shall be provided per valve, when applicable.

4.10 Vendor Packages Control Modes

Vendor packages with a PLC based control system shall be integrated with the PCS. The normal
condition of operation for these systems shall be remote operation from the Central Control Room
(CCR). These shall include a local panel (HMI or equivalent) required for local operation. For these
packages, the following scenarios shall be followed:

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Motor (part of mechanical


PCS package) Field Push Buttons
Vendor Local Panel Display
Selector
Local Emergency-
Start /Stop stop
Remote In this mode, the whole equipment shall be commanded from field push Will stop the
the CCR, either in automatic or manual mode. In this case buttons motor in any
automatic or manual mode condition will be embedded in the (start/stop) are condition
mechanical package control system (vendor PLC), and will be not available for
selected from the CCR (PCS OWSs). This mode will behave as operation
follows:

In remote - automatic Mode: The mechanical package shall


start/stop the whole system (or partial units, i.e. lubrication
system, cooling system, etc.) in a safe, preconfigured way,
defined by the vendor. The PCS will send the Start/Stop
commands, and the vendor control system shall follow the
automatic start/stop sequences.
In remote - manual Mode: The CCR operator will start each
element (or partial units, i.e. Lubrication system, etc.)
manually. The PCS will be able to operate each component (or
partial units) of the system manually.

In this mode, safety and process interlocks (for each element


and the whole system part of the mechanical package) are
always active. In remote mode, process coordination (external
process interlocks and coordination) between the mechanical
Packages and the process plant, where this package is located,
are always present.
Local In this mode the whole system will be managed thought the field push Will stop the
mechanical package Local display HMI. buttons motor, in any
(start/stop) are condition.
Due to the mechanical packages including their own control enable for
system, with automatic-manual sequence embedded, local operation only
mode will allow: in maintenance
mode
Local –Automatic: In this mode, field operator (through the
local display) will be able to start/stop the equipment (or partial
units, i.e. lubrication system, cooling system, etc.) in a
preconfigured way, defined by the vendor.

In this mode, all safety and process interlocks of the


mechanical package are always present.

Local - manual: In this mode, the field operator (through the


local display) will be able to start/stop (or open/close) each
element (or partial units, i.e. lubrication system, cooling
system, etc.) based on his criteria, in this mode just safety and

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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critical interlocks are present.

In local mode, process coordination (external process


interlocks and/or coordination) between the mechanical
Packages system and the process plant where this package is
located, are disable.

Local - Maintenance: This mode (selected from the package


control panel HMI, only in local mode) enables field push
buttons for field operation of a specific motor, this mode is
defined just for maintenance purposes. If a motor is running
and the mode of operation changes from local -manual to local-
maintenance, the motor shall stop. In this condition, just motor
safety interlocks will be present.

If the packaged system, during normal operation, has a PCS-PLC communication failure, the
equipment shall go to a secure condition as defined by Vendor. This could include stopping the
equipment. However, the equipment will be able to be operated in local mode. 2

4.11 Control Panels

Local control panels for packaged equipment shall be furnished by the Seller unless otherwise
specified. The Buyer will assign a Panel Tag Nº to each panel according to Buyer’s standard. Seller
shall show the panel tag numbers on their design documents.

Local control panel enclosures shall be in accordance with the requirements of the associated
electrical area classification.

Layout of local control panels shall be such that displays and indicators are on the top section of the
panel. Devices requiring operator access (such as controllers, push buttons, and selector switches)
shall be located in the middle section of the panel at eye level.

Even when the system logic is programmed in the plant PCS, local control panel shall include all the
necessary components for allowing local operation as suggested by Seller design. Local components
shall be wired to the PCS and included in the logic.

Ground terminal block, in control panel, shall be considered for braided shield or drain cable of the
instrument cables.

Local control panel operator interface, if supplied, shall be based on a color flat screen and keyboards
to allow commands, alarm acknowledge, and it shall include dynamic process graphic display,
including Spanish messaging and labels.

The communication cabinets shall be 19” standard rack.

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4.12 Wiring
2
All signal and power wiring, associated with instrumentation connected to the packaged equipment
shall be terminated in Seller-supplied junction boxes (except for direct instrument connections).
Similar signal types shall be grouped into separate boxes to avoid electrical interference between
signals and to allow the Buyer to easily connect cables to the terminals. All entry to and exit from the
junction boxes shall be through the bottom, using either rigid/flexible conduit, with low point drains,
and seals as required for the hazardous area.

In general, all wiring terminations shall be at terminal blocks with no pigtails. All wiring and
terminations shall be clearly marked and identified with permanently printed heat shrink-type wire
markers and shall be placed at each end of every wire (adhesive markers are not acceptable). For
other electrical requirements such as minimum wire size for instrumentation, colors of lights, and
others, refer to Packaged Equipment Electrical Specification 25800-220-3PS-EKP0-00001.

Separate wire ways shall be provided for internal panel wiring. Terminal strips shall be provided to
connect all field wiring, and for panel interconnections where required. Terminal strips and wire ways
shall be segregated by voltage levels as follows:

 Digital communication signals for electronic intelligent type instrument’s 24 Vdc

 Vac power and control wiring

 mA, 24 Vdc analog signals

 Intrinsically safe (if required)

Wire ways and instrument tubing runs shall not interfere with removal or prevent routine maintenance
of instruments or any other equipment.

Terminal blocks for external wiring shall be suitable for two 14 AWG (2.5 mm2) wires.

2
4.13 Fiber Optic

Where fiber optic link be considered, these design lines shall be as follows:

 Inside rooms links between Buyer’s equipment shall be fully supplied by Buyer

 In external links between rooms, or to field equipment, the scope of the Buyer limits is on
patch panels

 Communication equipment for electrical or control rooms shall be 19” rack-mounted

 Communication equipment for field installation shall comply with paragraph 4.2.4/5,
Weather Protection

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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 When fiber optic patch panels are supplied, they shall be extractable type with LC type
connectors

4.14 Surge and Lightning Protection, Grounding

The instruments, and electronic equipment with external wired circuits exposed to lightning strikes
and/or its secondary effects, switch contact bounce and power line disturbances at 2000 m.a.s.l. or
higher, shall be provided with surge protection. Besides, the electronics board shall have a design for
protection against:

 Electrostatic Discharge

 Radio Frequency Interface

 Switch contact bounce

 Load switching

In case of equipment fully integrated by Seller, surge and lightning protection will be considered in
the field instrument and in the control cabinet, before the input/output point.

All grounding of shielded instrument cables will be done by connecting the shields directly to the
ground bus terminal in cabinets or ground pins at one end only.

There will be no separate isolated grounding system for instruments, computers and electronic
packaged equipment; they shall be connected to the plant ground grid, which is unique.

4.15 The cable cover color shall be as indicated to follows the project standard:

 Blue: Instrumentation cable

 Violet: Profibus DP

 Orange: Fiber Optic multimode jumper

 Yellow: Fiber Optic single-mode jumper

 Black: Fiber Optic cable

 Grey: Control system UTP/STP cable (RJ45) Blue: UTP/STP cable for any other system
(RJ45)

4.16 Colors Project Standards

For PCS and Seller’s PLC or controllers, the following color convention are shown herein as options
for dynamic process graphic displays, however, the preference is the ASM standard (Abnormal
Situation Management), which recommends gray and non-highlighting colors for depicting normal

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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conditions of equipment and devices, and highlight the abnormal situation such as alarms and trips
with red or more attract-attention colors. 2
 Motors:

Condition Color Ref Code:


HTML (Hex)
Stopped but ready to run Red FF000

Running Green 00FF00

Fail Amber FFD700

Stopped by interlocks or E-stop Blinking Amber FFD700

(blinking stop once reset the condition)


Start fail or feedback fail Amber FFD700

 Valves:

Condition Color Ref Code:


HTML (Hex)
Close Red FF000

Open Green 00FF00

Fail Amber FFD700

During travel (opening or Last position color blinking, if after a


closing) time never get the final position, color FFD700
should be Amber
(For control valves (throttling),
an indication of open percentage
should be displayed)

 Process Lines, for process displays:

Condition Color Ref Code:


HTML (Hex)
Tailings Gray 808080

Pulp Brown A52A2A

Moly concentrate Purple 800080

Cu and bulk concentrate Orange FFA500

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Process and recovery water Blue 0000FF

Fresh and sea water Cyan 00FFFF

Cal lime White FFFFFF

Reagent Pink FAAFBE

 Line type and width

Condition Representation Example

Main process line Thick solid lines

Secondary process line Thin solid lines


(reagent, wash water, etc.)
Temporally or future line Dashed thin line

4.17 Colors for pushbuttons, strobe lights and panel lights

Condition Color

Pushbuttons
Start / Open Green
Stop / Close Red
Strobe Light Red
Valve Panel Lights
Close Red
Open Green
Fail Ambar

5.0 INFORMATION BY SELLER

5.1 General

The bid documents will indicate the type and quantities of drawings to be supplied with the Seller’s
proposal. The required documents will cover buy-out equipment as well as Seller manufactured
equipment. It is especially necessary to supply specified quantities of installation and operating
instructions for all complex or multi component instrumentation, which includes control valves.

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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The Seller shall provide instruction manuals and part lists for all instrumentation. If standard manuals
are supplied which cover models, styles, and instructions for others than those supplied, the Seller
shall either mark out all matter which does not apply, or clearly identify which does apply. Labels
must be added to the covers of all instrument manuals which include the instrument tag number,
reference to the purchase order number and the item number on the purchase order.

English or Spanish manual and documentation are accepted but operation and maintenance manuals
shall be in Spanish. Labels or message for the operator shall be in Spanish (for examples alarm
messages).

The Seller shall provide documentation for each instrument which includes as a minimum:

 Instrument tag number

 Manufacturer

 Model number (complete part number including accessories)

 Scale range (if applicable)

 Calibration range (if applicable)

 Set point (if applicable)

 Dead band (if applicable)

 Instruction, installation and maintenance manuals (including parts list)

 Recommended spare parts list for startup and commissioning

 Recommended spare parts list for one year of operation

5.2 Information Supplied with Proposal

The Seller’s proposal shall include P&IDs showing all necessary piping, equipment, instrumentation,
etc. In addition, a written description of the functionality of the equipment for normal operation, for
normal and emergency shutdown, for startup, and for other significant operations shall be submitted.

5.3 Information Supplied After Receipt of Purchase Order.

The Seller shall submit process or mechanical flow sheets, and sufficient information (complete with
pressures, temperatures, flow rates, specific gravities, alarm points, ranges, and others) to completely
describe Seller’s equipment to be supplied. In all cases, instrument list document, and if a control
system is included, data transfer list and I/O list documents, shall be delivered considering
Attachment G and Attachment H in Microsoft Excel forms included in this specification.

All pneumatic, electronic, and electrical drawings shall be submitted to the Buyer for approval. See
the purchase order attachments for the specific information required and the quantities for each type.

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When an instrument list is required in material requisition (MR), it shall include the tag number,
service, make, model number and complete part number, including accessories, hook up number (for
loose instruments) and a remark if the instrument is supplied and wired as skid part. See Attachment
G for instrument list format.

Seller’s drawings must clearly label all connections into and out of the package in the same manner as
the actual identification on the unit.

Descriptions of all programmed or sequenced operations shall be submitted to the Buyer for approval,
as well as all graphic displays and theirs labels and alarm messages.

A list of external utility and process requirements and capacities, including power, is required.

A control system signals list, including both, hard signals belonging to digital and analog instruments,
actuators and motors, and soft signals, to be communicated with PCS. When the mechanical package
includes its own control system, an input/output list shall be supplied using the Attachment H as
format.

5.4 Technical documents for system maintenance

The following information shall be included in the Seller´s documentation.

System level would include:

 Functional description, block diagrams and signal flow path, and main components of the
equipment

 Interconnection or equivalent diagram, between cards and main components of the equipment

 Control system block diagrams of the equipment

 PLC cabinet wiring diagrams 2

 Functional description and features of the communication system between the main
components of the equipment

 General procedures for equipment calibration, setting and adjustments

 General procedures for equipment diagnosis

 Complete parts list, with prices for cards and main components of the equipment

 A price list of minor and consumable equipment parts, including a recommendation for one
year of operation for system or equipment having several parts, as metallurgical analyzers,
particle size meters, PLC based control systems which controls major mechanical equipment,
etc.

Components level would include:

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 Functional description, block diagrams and signal flow of each card or main electronic
component of the equipment

 Electronic schematics of each card or main electronic component of the equipment

 Physical layout (isometric disassembly) of each electronic card (mechanical device) or main
component of the equipment

 Identification of setting points, characterization of signals and calibration procedures of each


card or main electronic component of the equipment

Introductory software manual: This manual must include a general description of the software
capabilities and resources indicating their main features and organization. It must provide a general
view of the following aspects:

 Operating system

 Programming languages

 Application software

 Editing and debugging capabilities

 Available support software

 Communication software

 Available diagnosis software

Operating system manual: The manual shall provide information about the main features of the
operating system, and a general view of the available resources for the user’s system administrator.
The manual also shall include the organization of the operating system and a functional description of
every software module. The manual must include all the necessary documents which will permit the
user to understand and administer the following aspects of the operating system:

 Initiation and loading of the operating system

 Communication and commands for the Operator

 Usage capabilities of the storage units

 Programming according to the different capabilities of the operating system

Programming manual for high level language: This manual must include the description and ways of
using every available instruction and command for programming on this level, plus a description of
its utilization in the offered system.

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Editing and debugging manual. It must be mentioned whether the system includes these capabilities
or not. If available, they must be included in the reference and utilization manuals in order for the
user to employ them.

Application program manual: This manual presents a description of the application program, with a
general view of its organization and the specific features of its software modules. It will include all
the necessary information for the user to understand and manage the following aspects of this
program:

 Obtaining and processing of process signals

 Handling and output of discrete commands to process

 Handling and exit of analogous signals

 Analysis and calibration tasks

 Model adjustment

 Alarm processing

 Operation supervision

Supporting software package manual: If resources of this type are available in the offered system
(statistics, graphics data management, etc.) all the necessary information must be supplied so that the
user can understand and manage these packages.

Diagnosis software manual: It must include a functional description of the diagnosis software
indicating the system components which may be susceptible to diagnosis under this modality. Each of
the diagnosis programs must include detailed information on the following aspects:

 Resources of the systems employed

 Description of each test performed by the program

 Scope and level of each test

 Utilization procedures, commands and operation modalities

 Interpretation of error and output messages

 Functional description and flow chart of the program

 List of program instructions

Communication interface manual: It must include a functional description, technical features,


electronic schemes and a list of spares for the interface hardware; the software’s documents will
include all the necessary information for programming and using this interface.

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Enlargement and updating capabilities: The Seller must clearly explain the available capabilities for,
expanding and updating the system, with respect to software and hardware.

6.0 RESPONSIBILITY

The Seller is responsible for furnishing instruments and/or instrument systems which have been
designed with consideration of the following criteria:

 Safety

 Quality construction and installation

 Maintainability

 Reliability and accuracy

 On line diagnostics

 Optimum operation of the process (if applicable)

Buyer’s furnishing of additional instrumentation for Seller's equipment in no way lessens the Seller’s
responsibility to provide the basic design for instrumentation and control system of its packaged
supply.

The Seller shall point out what he considers to be errors in the Buyer’s documents, and instances
where the Buyer’s requirements are inconsistent with the proper use or application of the particular
type of instrumentation proposed.

If some feature specified in the Buyer’s documents necessitates nonstandard instrumentation, and
therefore increased cost, the Seller shall inform it and quote as an alternative the equivalent standard
instrument.

The Seller is responsible for pointing out, in writing, any exceptions he takes to requirements of
Buyer’s documents.

Buyer’s approval of Seller’s drawings or data sheets does not in any way relieve the Seller of the
preceding responsibilities.

Seller is responsible to provide all the technical documentation for system maintenance purposes.

7.0 PACKAGING AND SHIPPING

The Buyer desires to minimize the amount of field installation of packaged instrumentation. The
Seller shall factory mount pipe, tube and wire all instrumentation to the maximum extent possible.
Only items which cannot be factory assembled shall be shipped loose for field assembly.

Loose instruments shall be packed in shipping crates that are dust tight, moisture resistant, and
substantial enough to withstand ocean shipment and warehouse handling, and to prevent damage to

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equipment. Shipping containers shall contain only instruments and be clearly marked with the
Buyer’s Purchase Order number and instrument tag numbers.

Where the Seller establishes that special warehousing requirements are necessary between time of
receipt and installation, he shall so advise the Buyer as part of his proposal. After award of a purchase
order, the Seller shall repeat special warehouse requirements on a separate document which can be
forwarded to the Jobsite.

8.0 STANDARDIZATION

The buyer reserves the right to select a specific manufacturer for purposes of standardizing the
instrumentation used in the plant. The list of approved instruments brands as listed in Attachment A,
is indicative of the type and quality of instrumentation to be furnished as part of packaged equipment.

Model number of all instruments to be used with the packaged equipment must be submitted for
Buyer’s review with the Seller’s proposal. Proposed substitutions of manufacturers or models must be
completely described and submitted with the Seller’s proposal. Proposal that do not indicate
substitutions shall be assumed to comply fully with the list of acceptable manufacturers that follows.

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

ATTACHMENTS

Attachment A. Approved instrument brands

Type of Instrument or Equipment Brand (Company name)


Ashcroft
Pressure, gauges Wika
Ametek
Rosemount (Emerson)
Pressure, transmitters ABB
Endress+Hauser
Ashcroft
Pressure, switches Danfoss
Endress+Hauser
Ashcroft
Temperature, local indicators
Wika
(bimetallic)
Tel Tru
Temperature, thermocouples & RTD’s Seller standard
Rosemount (Emerson)
Temperature, transmitters ABB
Endress+Hauser
Ashcroft
Temperature, switches Danfoss
Endress+Hauser
Endress+Hauser
Level, capacitive transmitter Vega
K-Tek
Endress+Hauser
Siemens
Level, ultrasonic transmitter
Rosemount (Emerson)
Vega
Endress+Hauser
Level, radar transmitter Rosemount/Emerson
Vega
Endress+Hauser
Level, switches (conductive,
K-Tek
capacitive, vibrating)
Vega
Rosemount (Emerson)
Endress+Hauser
Flow, magnetic flowmeter
Krohne 2
YOKOGAWA

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

Type of Instrument or Equipment Brand (Company name)


Endress+Hauser
Flow, sonic flowmeter Siemens
Krohne
Krohne
Flow, variable area indicator/switch Kytola
(rotameter) UFM
2
Kobold
UFM
Flow, mass flowmeter (thermal) Sierra
FCI (switches only) 2
Rosemount (Emerson)
Flow, differential pressure ABB
Endress+Hauser
Rosemount (Emerson)
Flow, vortex flowmeter ABB
Endress+Hauser
Rosemount (Emerson)
Flow, mass flowmeter (Coriolis) Endress+Hauser
Krohne
UFM
FCI
Flow, switches
Magnetrol 2
Kobold
Flow, sonar SONARtrac (Cidra Minerals Processing)
Hycontrol
Level switches, microwave type Vega
Hawk
Conveyor Components Controls
Level switches, tilt type
Ramsey
Endress+Hauser
Conductivity Rosemount (Emerson)
ABB
Endress+Hauser
pH Rosemount (Emerson)
FOXBORO 2
Bently Nevada
Vibration
SKF
Valves, throttling control valves Fisher (Emerson)
(globe, butterfly, and segmented Metso
valves) Samson

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

Type of Instrument or Equipment Brand (Company name)


Valves, throttling control valves Saunders
(diaphragm type valves) Tecfluid (Valam)
Valves, on-off service valves (butterfly Fisher (Emerson)
and ball valves) Metso
Saunders
Valves, on-off service valves (pinch or Valam
diaphragm valves) RF Valves
Red Valve
Clarkson
Valves, on-off service knife valves
Weir
Festo
Valves, directional valves (pneumatic) SMC

Rexroth
Valves, directional valves (hydraulic)
Parker

Fisher (Emerson)
Valves, air pressure filter/regulators SMC
Norgren
SMC
Valves, pneumatic actuator for dart
Neles (Metso)
valves
Fisher (Emerson)
Auma
Valves, electric actuator Rotork
Limitorque
Fisher (Emerson)
Valves, pressure regulator
Bermad
Process controller/
ABB: AC800M / AC 800PEC
Power drive controller
Siemens: PCS-7 / Sinamics
(for gearless power drive system for
mills and conveyors)
Allen-Bradley (Rockwell Automation),
Packaged system controller or
ControlLogix
PLC – programmable logic controller
Other models shall be specifically approved
Allen-Bradley (Rockwell Automation),
PanelView
HMI for PLC (same brand of PLC)
Rockwell Software (Rockwell Automation),
(just if specifically approved)
FTView
Other models shall be approved

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

Type of Instrument or Equipment Brand (Company name)


Allen-Bradley
Communication switches
Cisco

Corning
Fiber Optic Hardware Siemon
Furukawa

Cabinet Rittal
Surge Protection DHEN
H2S Analyzers MSA 2

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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Attachment B. Instructions for instrument tagging

Each instrument, control valve, electrical device and loose accessory shall be tagged with a stainless steel or
plastic tag as shown below securely affixed to the instrument by 150mm 316 stainless steel wire rope, in such a
manner that it does not need to be removed for installing the instruments.

Tagging information shall include the buyer’s assigned tag number, the buyer’s purchase order number and PO
item number engraved on the tag, as shown below.

To instrument
90 mm

316 SS 2mm
oval sleeve (both
ends) Buyer’s assigned
tag number
40 mm

P.O. item
1.5 mm 7x7 strand number
#316 SS wire rope
(150 mm long)

Buyer’s purchase
order number

Tag specifications are:

Parameter Specification
Size 40 mm high by 90 mm long
 laminated plastic (thickness: 3 mm approx.) – general areas
Material
 stainless steel (thickness 1.5 mm approx.) – corrosive areas
Tag color White
Symbol color Black

Symbols size 6 mm
Font type Arial
firmly attach by a 150 mm stranded 316 stainless steel wire rope, not to
Attachment
impair enclosure IP or NEMA ratings or interfere with instrument mounting

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
25800-220-3PS-JQ07-00001, Rev. 2

Attachment C. Vendor Control Systems Components

For large vendor control systems with more than 30 I/Os, ControlLogix PLC shall include a CPU 1756-L72, 2
Logix5672 Processor with 4 Mbytes of memory. In case of small systems with less than 30 I/Os a CompactLogix
model could be approved with a CPU 1768-L43ER, CompactLogix L43 Processor.

Attachment D. Project Standard Vendors Control System Architecture

CONTROL ROOM ELECTRICAL ROOM FIELD


COMMUNICATION CABINET LOCAL OPERATOR
SERVERS
PANEL
FO

PCS CABINET

Ethernet IP

Ethernet based
protocol

FIELD INSTRUMENTS

4-20mA HART
HARDWIRED

(Command &
Confirmation)

LV MCC VENDOR CONTROL CABINET


(Electrical Room or Field)

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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Attachment E. Instrument tagging convention

Instruments and valves shall have a unique tag in all project’s facilities. This criterion includes mechanical and
electrical packaged system. Instrument tagging has the following frame:

WWWW-XXXXX-YYYYYZZZ

Facility Code Instrument Description Sequential Loop Numbering Suffix

0210 Primary Crushing Identification letters according to The first two digits refer to process The suffix will be used when
project symbology and ANSI/ISA area. The following 3 digits refer to more than one similar loop
0220 Coarse Ore Conveying 5.1-2009 standard. sequential loop number. component (valves, switches,
etc.).
0230 Coarse Ore Stockpile e.g.: The loop number will include all
instruments, valves, controllers, Suffix, if is used, shall start
0240 Coarse Ore Reclaim FIT Flow Indicator Transmitter indicators or alarms belonging to with one letter, and followed
the control loop. by one or two digits or letters.
0310 Grinding PAHH Pressure Alarm High
e.g.: The suffix will use preferably
0320 Pebble Crushing TSL Temperature Switch Low letters. E.g.: A, B, C, etc.
21100
0330 Flotation and Regrind LIC Level Indicator Control Numbers could be used if
letter will be defined for show
0340 Concentrate Thickening specific characteristic.
Area 0210 Loop number 100 Numbers will be after the
0370 Molybdenum Plant letter.
The first two digits for area 0310
0390 Reagent Facilities will be 30 for grinding line 1, and e.g.:
31 for grinding line 2.
0410 Tailing Thickening 22406A10: Pull cord number
10 in the right side.
0920 Yard Piping System
22406B10: Pull cord number
10 in the left side.

In the P&ID diagrams, in the instrument symbol only will be showed “Instrument Description”, “Sequential Loop
Numbering” and “Suffix” sections. The symbols will be according ANSI/ISA 5.1-2009 Standard and Project
Symbol Standard.

Instrument
Description (ISA)
XXXX
X
YYYYYZZZ
Sequential Loop Number Suffix (could be out of symbol)

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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Attachment F. P&ID symbology for PCS and alternate controller

Local controllers (PLC) and local HMI for packaged equipment system will be represented according the
following symbols:

PCS Function, accessible to operator for


display and control on the PCS consoles.

n Alternate controller function, accessible


to operator for display and control on the
PCS consoles

n Alternate controller function, accessible


to operator for display and control on the
PCS consoles and alternative console.

“n” indicates the alternate controller numbering in the plant according to “Alternate Controller List” (Document
no. 25800-220-J0X-0000-00010)

Instrument tag range for mechanical equipment systems will be provided for each vendor.

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Attachment G. Instruments list format

The instrument list format is according to “Data Exchange Map – VEND04” (Document no. 25800-220-G5I-GAN-00076), and Seller shall use the last version of this document.

(Excel file attached; A3 size printing)

V e ndor: Compa ny N a me
Be chte l D ocume 25800-220-V
nt N : 1A-..
R e vision:
D a te :

Instrume nt T a g P roce ss S e rvice S yste m S yste m I/ O S igna l D a ta S he e t P &ID Instrume nt E le ctrica l Insta lla tion Loop S kid / R a ck R a nge - R a nge R a nge - Ca libra tion - Ca libra tion - Ca libra tion -
Loop N umbe r Nr Instrume nt T ype Function T ype D e scription T ype I/ O T ype T ype Nr D ra wing Loca tion D ra wing Conne ction D ra wing D ra wing D ia gra m Line N o Mounte d (Y / N ) Min - Ma x U nits Min Ma x U nits Mode l Ma nufa cture r Insta lle d by S ta tus Inst. R e v R e ma rks
Example:
0330-F-33001 0330-FIT-33001 Flow Transmitter - Magnetic FLOW Floculant flow PLC DI 120VAC Vendor format Vendor format Vendor format Vendor format Vendor format Vendor format Vendor format Y 0 100 m3/s 0 100 m3/s Model name Manufacturer name Vendor or Bechtel NEW A Comments

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Technical Specification for Instrumentation and Controls for Packaged Equipment Systems
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Attachment H. I/O list format

(Excel file attached; A3 size printing)

TECK
QUEBRADA BLANCA FASE 2 PROJECT
PLC I/O LIST
Document N°: (Bechtel document reference number)
Revision:
Mat. req. N°:

Configuration
Controller Remote I/O Service References
Calibration Notes
Slo Por Channe Dir P&ID Logic Diagram
Tag Type Protocol Chassis Terminal Block Terminals Tag Bus Tag Type Chassis Slot Channel Terminal Block Terminals Signal Tag Description Service Equipment Range LO LO HI HI
t t l
0310-COA-0001 Analog Input 4..20mA+H R01 S01 --- 2 SPAI01 I2+/I2-/SH --- --- --- --- --- --- --- --- 0330-FIT-33002 Magnetic Flow meter Pump 0330-PPS-035 flow discharge 0330-PPS-0035 0-1500 m3/h --- 1000 m3/h --- --- M6-0330-00012 J3-0330-00001 LAM 21
0370-COA-0001 Analog Input 4..20mA+H R01 S01 --- 8 SPAI01 I8+/I8-/SH --- --- --- --- --- --- --- --- 0370-LT-37130 Radar level transmitter Sump 0370-SSU-051 level 0370-SUU-0051 0-6 m 1,5m --- --- 5,5m M6-0370-00002 J3-0370-00001 LAM 21

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