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LE14188A 0000 0430 DCR 00001 - Rev0
LE14188A 0000 0430 DCR 00001 - Rev0
DESIGN CRITERIA
ELECTRICAL
Number of
LE14188A-0000-0430-DCR-00001
Document:
Rev. Date Description Prepared Reviewed Approved
by by by
A 03/12/2019 Issued for internal review V. Yucra R. Flores L. Ramos
B 18/12/2019 Issued for Client Approval V. Yucra R. Flores L. Ramos
0 09/06/2020 Issued for Use V. Yucra R. Flores L. Ramos
COMMENTS:
This document replaces the specification: 25635-220-3DR-E12-00001 of Bechtel, May 31st, 2018 in
Rev. 0
DESIGN CRITERIA - SITE SPECIFIC (LAS BAMBAS)
TABLE OF CONTENTS
1 GENERAL.............................................................................................................................................4
1.1 PURPOSE ....................................................................................................................................................................... 4
1.2 REFERENCE CRITERIA ............................................................................................................................................... 4
1.3 SITE CONDITIONS ..................................................................................................................................................... 4
1.4 UNITS .............................................................................................................................................................................. 5
1.5 DESIGN AND CONSTRUCTION PHILOSOPHY ................................................................................................ 5
1.6 CLASS FACILITIES ....................................................................................................................................................... 6
2 CODES AND STANDARDS .................................................................................................................6
2.1 PERUVIAN CODES, AND REGULATIONS .......................................................................................................... 6
2.2 STANDARDS ................................................................................................................................................................ 7
2.3 REGULATIONS ............................................................................................................................................................. 7
2.4 ALTERNATIVES STANDARDS ................................................................................................................................. 7
3 DESIGN REQUIREMENTS ...................................................................................................................8
3.1 POWER SUPPLY SOURCES ..................................................................................................................................... 8
3.2 POWER DISTRIBUTION ............................................................................................................................................ 9
3.3 POWER DISTRIBUTION NOMINAL AC VOLTAGES ....................................................................................... 9
3.4 RATED UTILIZATION VOLTAGES AND PREFERRED LOAD RANGES .................................................... 10
3.5 DESIGN SUMMARY ................................................................................................................................................. 10
3.6 VOLTAGE DROP........................................................................................................................................................ 12
3.7 LOAD CRITERIA ......................................................................................................................................................... 12
3.8 LIGHTING .................................................................................................................................................................... 13
3.9 LIGHTNING ................................................................................................................................................................. 14
3.10 GROUNDING ............................................................................................................................................................. 14
3.11 ELECTRICAL EQUIPMENT DERATING ............................................................................................................... 15
3.12 ELECTRICAL EQUIPMENT ENCLOSURES ......................................................................................................... 16
4 ELECTRICAL EQUIPMENT AND MATERIALS ................................................................................. 17
4.1 ELECTRICAL ROOMS ............................................................................................................................................... 17
4.2 POWER TRANSFORMERS AND UNIT SUBSTATION ................................................................................... 17
4.3 DISTRIBUTION TRANSFORMERS ....................................................................................................................... 18
4.4 DRY TYPE TRANSFORMERS ................................................................................................................................. 18
4.5 SWITCHGEAR ............................................................................................................................................................. 19
4.6 PANELBOARD ............................................................................................................................................................ 20
4.7 MOTOR CONTROL CENTERS .............................................................................................................................. 22
4.8 MOTORS ...................................................................................................................................................................... 23
4.9 ADJUSTABLE FREQUENCY DRIVES .................................................................................................................... 24
4.10 EMERGENCY GENERATORS ................................................................................................................................. 25
4.11 CAPACITORS .............................................................................................................................................................. 26
4.12 BUS OR CABLE DUCT ............................................................................................................................................. 26
4.13 CABLES ......................................................................................................................................................................... 26
4.14 RACEWAYS ................................................................................................................................................................. 29
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1 GENERAL
1.1 PURPOSE
This design criteria establishes the basic criteria to be used in the electrical design of the Las Bambas
Project.
The intention of these criteria is to provide the basis on which the designs of the electrical
installations will be developed, establishing the basic calculation parameters, the systems to be
used, the methodology of execution of the respective designs, and the selection of the equipment
and electrical materials.
The reference documents that complement this specification are the following:
The site conditions applicable for all facilities and electrical equipment’s parts located in Las Bambas
Project (including Sulfobamba and Chalcobamba) are the following:
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Las Bambas location, climate, seismicity and other site conditions are included in the latest revision
of the "Technical Specification for General Site Conditions for Las Bambas Project", document N°
LE14188A-0000-0410-ESP-00013.
If the site location is at an altitude above sea level of 3300 feet or 1000 meters for the high and
medium voltage electrical equipment or 6600 feet or 2000 meters for low voltage electrical
equipment, ratings will be derated per the following derating factors from IEEE C62.82.1, and IEC
60071-2, 600721-2, 600721-3 in its last years of publication.
1.4 UNITS
The units of measures indicated in the project will be based on the international system of units (SI).
Due to the remoteness of the Las Bambas site, lodging limitations and site conditions that cause
substantial work stoppages during the wet season, when electrical storms are common, the design
and construction philosophy to be implemented by all engineering consultants shall consider as a
preferred alternative
▪ Lean design including selection of materials that provide the best value for Las Bambas
▪ Modularization of construction taking into consideration transport and erection
requirements
▪ Skid mounting of cluster units
▪ Remote assembly and fabrication of construction modules and skids
▪ Minimization of construction work at site
▪ Maintainability and operability of the plant shall always be considered together with the
safety of personnel and equipment
Consultants are required to consider these requirements from the proposal preparation stage and
need to justify during design and constructability reviews whenever deviations from this philosophy
occur, be it by cost/benefit, legal requirements or the type of work or components being installed.
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Whenever the consultant considers there are materials that deviate from those specified by Las
Bambas but provide better value, a recommendation should be done, and approval sought for the
utilization of the alternative materials
For the classification of the equipment, the following table should be considered as a guide.
Always prevail national codes and regulations, when conflicts occur or there is no adequate technical
support between them, the most stringent standard shall prevail, but if there was the opportunity
to choose more than one standard, IEC standards shall prevail, under NEMA / IEEE Standards.
In addition to the requirements of international standards, the electrical system must comply with
national and local regulations, which are mandatory.
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2.2 STANDARDS
The electrical design and construction have to be according to the requirements of the following
codes in the latest revision:
2.3 REGULATIONS
The electrical design has to be according to the latest applicable regulations of the following
organizations:
When required for special purposes, products conforming to the standards, requirements,
recommendations, and guides of the following organizations may be substituted for those listed in
above:
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3 DESIGN REQUIREMENTS
Power for the mine and concentrator facilities will be obtained from a utility substation and
transmitted to the main substation at 220 kV or specific project voltage via a single or double circuit
overhead transmission line.
A standby power supply and automatic transfer control scheme shall be provided for semi-critical
loads, not requiring uninterruptible power and supply necessary lighting to facilitate an orderly
plant or unit shutdown in case of complete failure of the electrical power supply. In addition, the
design will provide standby power for all operations where loss of power would create dangerous
conditions to personnel or would cause environmental problems (mainly spills).
Standby power supply will be obtained from diesel generators located in the plant. The standby
diesel generator will be provided and will be connected to a 480 V essential load center/MCC. This
bus will service those loads deemed essential to personnel safety and required to safely shutdown
the plant. This bus will be fed normally from the plant auxiliary supply. Upon loss of normal power,
the standby diesel generator will be automatically started.
The diesel generator will be sized to support those essential loads, required for the plant.
Diesel generator testing facilities will be provided to facilitate synchronization of the generator to
normal station power. Testing features will be designed for local initiation and control by the plant
operator.
Each standby diesel generator will have control package system, which will be connected to the
plant control system for monitoring.
All switchgear used for the electrical emergency system will have measures to open and lock it to
the main breaker to allow the maintenance can be done without risk of electrocution.
ITEM VALUES
3.1.4 Las Bambas Project Major Equipment and Facilities Power Distribution Voltage
For the Las Bambas Project, the overhead power distribution for truck shop, primary crusher,
conveying system, tailings, filter & molybdenum plants, fresh water supply and camp will be in 33
kV and for mine loop, the power distribution will be in 22.9 kV.
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For power distribution to Sulfobamba and Chalcobamba will be defined in its engineering studies
33kV power distribution to concentrator plant, truck shop, primary crusher, conveying system,
tailings, fresh water supply and camp, will be delivered through either overhead lines with poles,
MV cable in underground duct bank or in cable trays, or combination of all.
Generally, medium voltage power distribution for mine, overland conveyors, and camp will consist
of radial systems.
When a ring topology is used at 33 kV distribution system to feed several substations, the
protections of the incoming feeders must allow for automatic faulted line segment isolation by
means of directional overcurrent relays and real time communications.
Generally, 33kV power distribution of direct buried cables within concentrator, facilities and port
site will be using armored cables Teck type.
22.9kV power distribution will be used to the mine loop, will be delivered through either overhead
line with poles, MV cable in underground duct bank or in cable trays, or combination of all.
7.2kV power distribution will be used to the mobile mining equipment, will be delivered by
distribution cables using direct buried armored cables, or standard cables in tunnels, in
underground duct banks, cable trays, or combination of all.
4.16 y 0.48kV power distribution will be used to the mobile mining equipment, will be delivered by
distribution cables using direct buried armored cables, or standard cables in tunnels, in
underground duct banks, cable trays, or combination of all.
The following voltages in 60 Hz will be the nominal AC voltages used for power distribution, the
ground protection must be validated according to power studies.
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The following voltages in 60 Hz power systems will be the rated AC voltages for utilization
equipment which will be preferably restricted to the indicated load ranges.
▪ 33 kV, 3-phase for the SAG mill and ball mill drives.
▪ 6.9 kV, 3-phase for mobile mining equipment.
▪ 4 kV, 3-phase for motors equal or larger than 187 kW (250 HP).
▪ 460 V, 3-phase, 60 Hz, for motors equal or larger than 0.37 kW (½ HP) and smaller than 187
kW (250 HP) DOL start.
▪ 460 V, 3-phase, 60 Hz, for motors equal or larger than 0.37 kW (½ HP) and smaller than 448
kW (600 HP) fed by adjustable frequency drive.
▪ 220 V, 1-phase, 60 Hz for single phase motors smaller than 0.37 kW (½ HP), lighting and
other loads.
▪ 380/220V Lighting and Power Outlets.
▪ 480V Welding outlets.
▪ 120V, 1 phase, for general Control and Instrumentation.
▪ 125VDC, for 22.9, 33 and 220 kV Switchgear control systems.
Note:
Motors larger than 187 kW (250 HP) but smaller than to 448 kW (600 HP) fed by variable frequency
drives shall be supplied at low voltage instead of medium voltage.
The use of soft starters will be evaluated according to an engine starting study.
The system shall have a steady state voltage regulation of plus or minus 3 percent. It shall be able
to start the largest connected motor with a minimum of 80 percent voltage at the motor terminals,
while simultaneously supplying the remainder of the connected loads.
In the case of loss of the main supply, auxiliary power will be provided through diesel power
generation groups. Auxiliary electric power generators will be installed for loads where the
consequence of the failures of the normal distribution system is determined as unacceptable.
The generator sets will generate voltage at 480 V, 60 Hz, and will be installed next to the electrical
rooms, must be contained, soundproofed and with a base fuel tank for a minimum autonomy of 8
hours.
After a power failure, the generators will start automatically. The electrical panel of the generator
set must be interlocked with the transfer system and emergency bar of the Switchgear board of
480V of the electrical substation.
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The studies of power flow and short circuit will be carried out with the Digsilent Power Factory
program.
The tension control will be carried out by means of 5 position manual tap changers in 2.5 % steps
(-5%, -2.5%, 0%, 2.5%, 5%). The tolerances admitted on the nominal tensions of the points of power
delivery, at all Stages and at all voltage levels, is up to ± 5.0%.
The low voltage fault current will not be limited. The available fault current in bars and the earthing
resistance will determine the magnitude of the fault current.
The values to be considered for the level of insulation of electrical equipment in air or gas; at the
height of 4,800 m.a.s.l are listed below:
The power factor in the 220-kV bar will remain at 0.96 or greater under normal load conditions.
Additional equipment will be installed to improve the power factor to this value, if necessary.
3.5.8 Metering
Metering will be installed in the main medium voltage substations, switchboard and incoming motor
control centers, to monitor power, energy consumption, voltage and current. These will be equipped
with multifunction energy meters with IEC 61850 communication capability. Similar metering in
480V load centers as required.
The total harmonic distortion must be in accordance with the requirements of the standard: IEEE
519- “IEEE Recommended Practice and Requirements for Harmonic Control in Electric Power
Systems”, over the available voltage and current ranges.
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3.6.1 General
The permissible voltage drops in points 3.1.3 of this document are based on the following:
▪ The connections between the power transformers and the secondary switch will be short
sections of busbars or cables, so that the voltage drops are minimal.
▪ The transformer regulation will not be considered for normal operating conditions.
▪ The impedance of the transformer and the impedance of the system will be considered for
the calculation of voltage drop during the start of large motors and the re-acceleration
motors will be grouped.
3.6.2 Starting of motors
In all cases of motor starting, the voltage at the motor terminals should be enough to ensure proper
starting and acceleration of the motor. In general, the permissible voltage drops of the system at
the source bars during motor starting cannot exceed the following values:
The permissible voltage drops in the cables, based on full load, shall not exceed the following values
in accordance the National Electricity Code:
The following criteria will be used as a basis for the selection of transformer capacity based on the
installed power.
The installed power of the project will consist of the nominal power of all the loads in normal
operation: nominal power of the motors of the project and of the motors considered in future
planned expansions, the mechanical equipment, the lighting, air conditioning, heating and others
miscellaneous loads.
Motors considered as stand by will not be included in the installed design power.
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All equipment in the substation must be sized for the maximum capacity of the transformer.
The conductors and bars used must comply with the site temperature conditions and the
surrounding conditions.
The design should allow 20% growth during the engineering phase.
The minimum impedance for two winding transformers shall be in accordance with Table No. 1 of
the IEC 60076.-5 standard.
The impedances of the transformers must be selected to do not exceed the short-circuit capacity
of the switchgear.
Maximum 3-phase short circuit at Las Bambas 220 kV bus level 1989 MVA
Minimum 3-phase short circuit at Las Bambas 220 kV bus level 1875 MVA
Maximum phase to ground short circuit at Las Bambas 220 kV bus level 2.08 kA
Minimum phase to ground short circuit at Las Bambas 220kV bus level 2.06 kA
3.8 LIGHTING
The lighting intensities for the different areas of the plant are provided in table 7, the
recommendations of the IESNA and the D.S. No. 024-2016 for areas not included:
Yard 10 lux or 1 FC
Roadways 10 lux or 1 FC
Substations 50 lux or 5 FC
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If it is required to define the lighting level of other areas, the values indicated in the IESNA, The
Lighting Handbook will be used.
Special attention will be given to lighting in moving machinery, checkpoints and critical instruments.
Maintenance factor:
3.9 LIGHTNING
Buildings, tanks, and other structures will be protected against lightning in accordance with the
requirements of NFPA 780 “Standard for the Installation of Lightning Protection Systems”.
3.10 GROUNDING
The general grounding requirements shall be projected in accordance with the provisions of the
standards indicated in item 2.0.
The main ground loop must be # 4/0 AWG, the equipment must relate to # 2/0 AWG cables.
In cases of isolated systems, the main earth mesh may use # 2/0 AWG cable, if it meets the minimum
values required in the respective study.
Grounding will be in accordance with the requirements of ANSI/NFPA 70. Outdoor high voltage
substation grounding will be in accordance with the requirements of ANSI/IEEE 80.
The maximum recommended value of ground system resistance for 220 kV equipment will be 1
ohm; the maximum recommended value of ground system resistance for electrical rooms, and
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facilities will be 5 ohms; for isolated conditions, the grounding resistance of the grounding electrode
should not exceed 25 ohms.
The interconnection of grounding meshes will be carried out by means of 2 points with copper
conductors of 4/0 (120mm2).
The grounding conductors of the main mesh will be buried at a minimum depth of 600mm below
the natural or compacted ground and will be installed loosely between the connections.
Connections and splices will be of the compression type. The exposed grounding wire connections
will be the mechanical type.
3.10.2 Computer/instrumentation
The maximum recommended resistance value of the earth system for control and instrumentation
systems will be 5 ohms, unless the vendor of the control and instrumentation equipment requires
otherwise.
An insulated ground bus shall be installed in the control room for instrument grounds. This bus shall
be isolated from power grounding conductors and building structures. It shall be connected to a
cluster of ground rods near the building and from there be tied at one point to the main ground
loop.
In addition, a grounding system for control and instrumentation (IE) will be installed, which will be
interconnected with the deep ground mesh in a single point with # 2/0 AWG bare copper wire, the
instrumentation grounding mesh will be connected to an insulated ground bar.
If the location of the site is at an altitude above sea level of 3300 feet or 1000 meters, the electrical
characteristics shall be reduced in accordance with the altitude correction factors indicated in the
following equation detailed in IEC 60071-2 standard Section H.3.4:
𝐻−1000
𝑘𝑎100 = 𝑒 𝑚𝑥 8150 (Eq. 3.1)
Where:
m = Factor takes into account the discharge behavior of the considered air gap
The value of m = 1 will be considered as the most conservative case in according to IEC 60071-2
standard, Section H.4.1.
These shall be used for altitudes up 4800 m.a.s.l, and is shown in the following table:
4800 1.59
4600 1.56
4400 1.52
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4200 1.48
4000 1.44
3.12.1 Switchgear
All enclosed switchgear will be metal-enclosed. Medium voltage circuit breaker switchgear will be
metal - enclosed.
Enclosures for switchgear indoor the electric room will be NEMA 1 / IP 42.
Enclosures for switchgear installed outside of electrical equipment rooms will be dust resistant.
Metal-enclosed switchgear installed outdoors will be weatherproof NEMA 4 / IP 66.
All motor control centers will be metal enclosed with dust tight and drip tight NEMA 12 enclosures.
Motor control centers installed outdoors and in wet areas will be installed in rainproof and sleet
resistant NEMA 3R electrical equipment housings.
3.12.3 Motors
Motors will be totally enclosed, either fan cooled, unit cooled, or non-ventilated, with the following
exceptions:
▪ Large low speed synchronous motors will be modified drip-proof guarded for updraft
ventilation with rain hoods and screens. The ventilating air will be drawn up from the motor
pit.
▪ Large motors located outdoors may have totally enclosed enclosures TEFC, TEAAC (IP54
minimum).
▪ Small motors located in clean and dry indoor areas may have drip-proof guarded (DPG)
enclosures.
▪ All totally enclosed motors up through 373 kW (500 HP) will be severe duty type.
3.12.4 Dry Type Transformers
Dry type transformers installed indoors in clean dry areas such as offices and electrical equipment
rooms may have ventilated enclosures. Dry type transformers installed in dirty or wet areas will have
non-ventilated enclosures.
Other electrical equipment will have the following NEMA types of enclosures or equivalent when
NEMA enclosures do not apply:
▪ General purpose NEMA type 1 for use in control rooms and offices.
▪ Dust tight and drip tight NEMA type 12 for use in all dry areas. These enclosures may have
filtered ventilation.
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▪ Dust tight, rain tight, and sleet resistant NEMA type 3 for general use outdoors in non-
process areas.
▪ Watertight and dust tight NEMA type 4 for use in occasionally wet process areas and all
outdoor process areas.
▪ Watertight, dust tight, and corrosion resistant NEMA type 4X for use in all frequently or
continuously wet areas.
▪ Oil tight and dust tight NEMA type 13 for use in areas subject to spraying or dripping oil or
coolant.
▪ Electrical equipment and lighting fixtures for outdoors installations shall have NEMA 4
enclosure protection.
▪ Indoors and outdoors corrosive environments like gases, marine, etc. shall have NEMA 4X
enclosure for electrical equipment. For freezing, excepting lighting fixture, the equipment
shall have NEMA 3R enclosure protection.
▪ NEMA1 could be accepted for variable speed drives, only when they shall be installed inside
clean, ventilated and pressurized electrical rooms.
The electrical room will be prefabricated type container and the roof will have a slope of 15%.
The electrical room must be equipped with adequate air conditioning and filtered ventilation
(pressurized). The air conditioning equipment of the Electrical Room will be installed outside in an
adjacent area, on its own bases, to allow maximum use of the interior space, or it will be installed at
a suitable distance as independent units and will be connected with pipelines to the Room Electric.
The air conditioning in the electrical room will be controlled by a thermostat, and will be set to
maintain an indoor temperature below 30 °C.
The electrical rooms must have a minimum positive pressure of 2.5 mm of the water column. This
pressure will be maintained within the electrical room to restrict the entry of dust and dirt.
Detection, alarm and CO2 extinguisher systems will be installed in the electrical room. The detectors
will be connected to the fire alarm panel and alarms will be centralized in the main control room.
In cable entry and exit of the electrical room, cable transit sealing systems will be installed.
Power transformers and unit substation will be manufactured with the standard IEC 60076-1,
The power transformers will be considered from 10,000 kVA, including this power.
In general, the transformers will have approximately 20% spare capacity under the worst-case
operating condition.
▪ Automatic on-load tap changer at delta primary, ±10 %, 16 steps, 0.625 % above and 16
steps, 0.625 % below rated voltage.
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Distribution transformers will be manufactured with the standard IEC 60076-1, Distribution
transformers will be considered up 10,000 kVA not including this power.
In general, the transformers will have approximately 20% spare capacity under the worst-case
operating condition.
▪ Automatic on-load tap changer at delta primary, ±5%, 2 steps, 2.5 % above and 2 steps, 2.5
% below rated voltage,
▪ Oil filter plant for automatic on-load tap changer and
▪ Automatic/manual voltage controller suitable for paralleling of transformers.
▪ The connection group will be Dyn5
▪ Forced ventilation will be used for distribution transformers from 5,000kVA.
Transformers for indoor and outdoor in all cases will be of the dry type. The three-phase
transformers will be connected in a delta on the primary side and star on the secondary side. The
transformers will have class 220 ° C insulation and allow a temperature rise of 115 °C.
Windings will be manufactured to cooper or aluminum and will be sized for a maximum voltage of
1000 Volts. They will have a delta type connection system on the primary and star side with an
accessible neutral grounded on the secondary side. Its capacity will be sized considering a power
reserve of 20% on the initial demand calculated.
For the selection of transformer powers, the following standard values shall be considered according
to IEC:
▪ Three-phase transformers: 10, 16, 20, 25, 32, 40, 50, 63, 80, 100, 125, 160, 200, 250, 315,
400kVA.
▪ Single phase transformers: 3.15, 4, 5, 6.3, 8, 10kVA.
Dry transformers will be installed inside electrical rooms, for auxiliary services, for energy distribution
in camps and facilities.
The voltage reducing transformers will be of the dry type, transformation ratio 480 / 400-231V.
The voltage reducing transformers will be of the dry type, transformation ratio 480 / 208Y-120 V.
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4.5 SWITCHGEAR
Switchgear shall consist of grouped assemblies of free-standing, vertical, dead-front steel structures
containing power buses, removable power circuit breakers, necessary auxiliary control devices,
instrument transformers, relays, meters, and control and meter switches.
▪ Switchgear assemblies for installation in electrical rooms or buildings shall be the indoor
type.
▪ Switchgear assemblies for installation outdoors shall have weatherproof, bird-proof,
rodentproof, fully gasketed enclosures, adequately lighted and ventilated, and shall be
provided with space heaters to prevent internal condensation.
4.5.1 High Voltage Switchgear
High voltage switchgear for 220 kV service will be gas insulated switchgear (GIS) type and will be
manufactured according to IEC Standards.
For 33 kV and 22.9 kV service (for Mobile Mining Substations) will be gas insulated switchgear (GIS)
type. The value of short circuit current of 33 and 22.9 kV Bus Bar will be 25kA, unless the power
study indicates otherwise.
Medium voltage switchgear for 7.2 kV and 4.16 kV service will consist of one- high metal-enclosed
vacuum circuit breaker switchgear and one-high metal-enclosed fused load-interrupter switchgear.
Outdoor gang operated air-break switches (with or without fuses) and hook stick operated fused
cutouts will be used for pole mounted switches on overhead lines. Power fuses will preferably be
current limiting type whenever such fuses are available. The value of short circuit current of 7.2 and
4.16 kV Bus Bar will be 31.5kA, unless the power study indicates otherwise.
For medium voltage switchgear installed in process plant, they shall be arc resistant designs or
features at the freely accessible exterior (front, back and sides) of the equipment only (type 2, per
ANSI C37.20.2).
For medium voltage switchgear installed outside the process plant, they can be designed without
arc resistance, if it is accompanied by an arc flash study
Each power circuit breaker and disconnect load switches must include accessories for mechanical
padlocking in open position
Disconnectors under load shall have linkage for manual operation on the floor, with vacuum bottles
that allow opening under load, the insulators support will be made of porcelain; they will have
sufficient mechanical resistance to withstand the efforts by opening and closing, as well as those
due to earthquakes.
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The value of short circuit current of 33 and 22.9kV Bus bar will be 25kA, unless the power study
indicates otherwise.
The disconnectors shall have metal bases and perforations for fixing to wooden posts.
4.5.4 Recloser
It will be Vacuum and SF6 Gas Insulated, designed for the highest mechanical and electrical
reliability.
It will have a control panel with input and retrieval of information through the integrated keyboard
or a computer through the RS232 port.
The value of short circuit current of 33 and 22.9kV Bus bar will be 25kA, unless the power study
indicates otherwise.
For 480 V service will be power circuit air breaker type switchgear, it will be selected to 600V and
below shall be metal enclosed.
Circuit breakers shall be draw out type, manually or electrically operated, with stored energy type
operators.
Each power circuit breaker shall include solid state protection device incorporated with the following
independent adjustable functions, overload, instantaneous phase overcurrent, time delay phase
overcurrent, instantaneous ground overcurrent, time delay ground overcurrent.
A minimum of 12 percent spare or at least one feeder circuit breaker will be provided in each LV
switchgear.
Each power circuit breaker shall include accessories for mechanical padlocking in open position.
The bus bar shall be covered with flame retardant and auto extinguishing, arc resistant and track
resistant insulating material.
All low voltage switchgear must have communications in a SCADA compatible protocol for control
and monitoring.
4.6 PANELBOARD
The distribution boards will be of the type of mounting assembly. All circuits will be equipped with
thermo-magnetic circuit breakers of the molded case type, bolt-on or differential switches. They will
be sized considering a minimum circuit reserve of 10% over the amount of circuits required.
The low voltage board will be sized for an insulation class of 1000 Vac, with dead front, steel plate,
with main bars, ground bar, power switches, safety interlocks, auxiliary control devices, and specified
transformers for instruments, relays, meters, and control and measurement switches. Each controller
or device will be fully accessible from the front.
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The board will be designed with spare spaces for future expansions unless otherwise indicated.
Adequate space will be provided for the entry of pipes and wiring from the top or bottom without
structural interference.
All boards in low voltage must be equipped with lockout systems in their operating crank.
The force panels shall be of the superimposed type for wall or structure mounting, equipped with
molded case type thermomagnetic circuit breakers.
The panels will be connected to an electrical system with the following characteristics:
The switches will be of the molded type box for heavy duty, three-pole with an interruption capacity
according to the short circuit levels on the board.
Lighting boards will have thermomagnetic switches with a minimum breaking capacity of 10 kA. The
panels will be connected to an electrical system with the following characteristics:
The cover of each panel must be removable in order to allow easy access to the internal wiring.
The force panels shall be of the superimposed type for wall or structure mounting, equipped with
molded case type thermomagnetic circuit breakers.
The panels will be connected to an electrical system with the following characteristics:
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▪ Phases: 1
All boards in low voltage must be equipped with lockout systems in their operating crank.
The switches will be of the molded type box for heavy duty, one-pole with an interruption capacity
according to the short circuit levels on the board.
The Medium Voltage Motor Control Centers will be designed by NEMA standards.
Medium voltage motor control centers for MV motors shall be arc resistant including vacuum
contactors and R rated current limiting fuses.
The Medium Voltage Motor Control Centers installed indoors will be metal enclosed with dust tight
and drip tight NEMA 12 enclosures.
The Medium Voltage Motor Control Centers installed outdoors and in wet areas will be installed in
rainproof and sleet resistant NEMA 3R
Motor starters shall be of the “plug-in” type, consisting of motor circuit protectors (MCP’s) and
magnetic 3-pole contactors with solid state relay protection.
For loads other than motors, the medium voltage control center will be equipped to load-interrupter
switches (with or without fuses).
Twenty percent (20%) or a minimum of one spare starter will be provided for each medium voltage
motor control center.
Each motor starter must include accessories for mechanical padlocking in open position.
The Medium Voltage Motor Control Centers will be equipped with communication protocol Device
Net or PROFIBUS DP
The Low Voltage Motor Control Centers will be designed by NEMA standards.
Low voltage motor control centers for LV service will be of the intelligent type and will use
combination motor starters having motor circuit protector (MCP)
The Medium Voltage Motor Control Centers installed indoors will be metal enclosed with dust tight
and drip tight NEMA 12 enclosures.
The Medium Voltage Motor Control Centers installed outdoors and in wet areas will be installed in
rainproof and sleet resistant NEMA 3R type instantaneous trip circuit breakers, air contactors up
through NEMA size 4 and vacuum contactors above NEMA size 4 (or per manufacturers standard).
Molded case thermal magnetic circuit breakers or magnetic only circuit breakers (as used for
lighting) will be in motor control centers to supply loads other than motors.
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The minimum rated interrupting capacity for low voltage motor control centers will be 65kA
symmetrical, higher ratings will be specified based on results of system fault calculations specific to
site.
Ground Fault Relay (GFR) will be provided on all motor and non-motor loads. The minimum size for
combination motor starter shall be NEMA size 1.
The bus bar shall be covered with flame retardant and auto extinguishing, arc resistant and track
resistant insulating material.
A minimum of Twenty percent (20%) spare starters and feeder circuit breakers will be provided for
each low voltage motor control center.
Each motor starter shall include an intelligent protection device with communication port to PCS
using Device-Net, Profibus DP or other standard protocol. The final selection shall depend on the
suitability of the MCC manufacture and PCS technology (see item 6.1.19 on Instruments and Control
System Design Criteria document No LE14188A-0000-0440-DCR-00004).
Gateway or any special interfaces for communications to PCS shall not be accepted.
The motor protective relay should implement at least: thermal modeling, current unbalance and
ground fault.
Enclosures containing motor starters shall include external resets for overload relays. Contactors
used to control non-motor loads shall not include overload elements.
Control voltage for general purpose, including low voltage motors and heaters using contactor type
controllers will be 120 VAC.
The MCC supplier shall include all other power sources necessary to provide voltages different as
established as standard on this design criteria, to feed the protection intelligent devices.
Each motor starter must include accessories for mechanical padlocking in open position.
4.8 MOTORS
Motors larger than 250 horsepower shall be equipped with space heaters. The type of enclosure
and conditions at the motor location shall determine the need for a space heater in motors of 250
horsepower and lesser. In each case, leads for the space heater shall be brought into a junction box
separate from the main junction box.
Motors above 250 HP shall include winding (6) RTD’S (3 wire, platinum 100 ohms) wired to a
separate terminal box. Motors above 800 HP shall also include bearing (2) RTD’s.
Except for small motor frames and hermetically sealed compressor motors, all LV motors will be
NEMA Premium efficiency, or equivalent, as per NEMA Standards Publication MG-1-2006, tables
12-12 and 12-13, extra-heavy or extra-severe duty mill and chemical type, NEMA T frame medium
(integral) horsepower motors with standard shafts and cast iron connection boxes one size larger
than standard.
All medium motor frame LV motors will be NEMA design B squirrel-cage induction motors with
Class F insulation, 1.15 service factor at Class B Temperature Rise in a 40°C ambient temperature at
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altitude of installation unless other characteristics are required by the driven equipment. Motors will
be manufactured for the specific altitude. Motors with small motor frames will be used only in sizes
where medium motor frames are not available.
LV motors feed with variable frequency drives shall be in compliance with NEMA Standard MG-1.
The motors controlled by adjustable frequency drives shall be rated at a 1.15 service factor at the
altitude installation without exceeding insulation temperature limits.
The manufacturer shall be fully responsible to provide motors designed electrically and
mechanically to be operated with AFD. Technical Characteristics, such as, insulation class,
temperature rating, bearings, etc. must be carefully designed. Low voltage motors to be operated
by Adjustable Frequency Driver shall be designed to operate under the following limit at the motor
terminal, in accordance with NEMA MG1 Part 31.4. V peak: 3.1 Vrated
Motor from 1/3 to 250 HP (187 kW), excluded, will be powered at low voltage system (480 VAC, 60
Hz, 3 phases).
4.8.2 Medium Voltage Motors, equal and larger than 187 kW (250 HP) through 375 kW (500 HP)
Medium voltage direct on line starting motors from 187 kW through 375 kW will be NEMA Premium
efficiency, or equivalent, extra-heavy or extra-severe duty mill and chemical type, NEMA medium
(integral) horsepower NEMA design B squirrel cage induction motors with Class F insulation and 1.0
service factor at Class B rise in a 40°C ambient temperature, manufactured for the altitude
installation unless other characteristics are required by the driven equipment.
Medium voltage motors larger than 375 kW will generally be NEMA large horsepower motors with
Class F insulation and 1.0 service factor at Class B rise in a 40°C ambient temperature at 1000 meters
altitude.
Adjustable frequency controllers will be complete with input isolation transformers (for drives larger
than 30 kW), lockable input and load interrupter switches, circuit breakers or medium voltage
vacuum contactors with fuses; converters; inverters and control equipment suitable for the
requirements of the driven equipment.
Low Voltage Adjustable frequency drivers will be 6 pulses, and if is necessary the harmonic induction
will correct with a compensation system.
Medium Voltage Adjustable frequency drivers will be 24 pulses to comply the THD value
recommended in IEEE 519 “IEEE Recommended Practice and Requirements for Harmonic Control in
Electric Power Systems”
The AFD will be intelligent and will communicate digitally with the PCS using Profibus DP; Device
Net or other standard protocol.
All medium voltage variable speed drives shall be of the DTC (Direct Torque Control) or PWM (Pulse
Width Modulated) type, 12 pulse using either IGBT or IGCT power switching device technology.
The VFD shall have a maximum THD level in accordance with standard IEEE 519 using filters as
required
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Medium voltage VFD’s shall be for operation on a 4.16 kV, 3-phase, 60 Hz, resistance grounded
input voltage, with an AC to AC converter, and regulate the current and clamp the output voltage
to a level which will not degrade the insulation of a standard induction motor. Each unit will be
capable of a 110% overload current for one minute and 200% for five seconds with a 0 - 4.0 kV
output voltage.
For regenerative loads the type of Medium Voltage Adjustable Frequency Drive will be Active Front
End (AFE) using IGBT or IGCT power switching device technology, ensuring bi-directionality.
Low voltage VFD’s shall be for operation on a 0.4 kV, 3-phase, 60 Hz, solidly grounded input voltage,
with an AC to AC converter, and regulate the current and clamp the output voltage to a level which
will not degrade the insulation of a standard induction motor. Each unit rated for variable torque
will be capable of a 110% overload current for one minute and 200% for five seconds with a 0 - 380
V output voltage. Each unit rated for variable torque will be capable of a 150% overload current for
one minute and 200% for five seconds with a 0 - 380 V output voltage.
All low voltage variable speed drives shall be PWM (Pulse Width Modulated) type, 6 pulse using
either IGBT or IGCT power switching device technology.
Low voltage VFD’s rated 50 kW (75 HP) and smaller will be wall mounted. Low voltage VFD’s rated
75 kW (100 HP) and above will be free standing type.
Input line filters or isolation transformers shall be sized and provided as required by the variable
frequency drive manufacturer to ensure compliance with IEEE standard 519 at the point of
connection of the power supply.
For regenerative loads the type of low Voltage Adjustable Frequency Driver will be Active Front End
(AFE) using IGBT in the step of rectification, ensuring bidirectionality.
Emergency generators shall be sized to support the continuous operation of all the critical loads
defined in the project, plus a minimum reserve of 30% for future expansions.
Each substation or process area shall have an independent emergency switchboard, which shall
include all power and control devices suitable to support the critical loads.
The sizing shall be based on the adjusted operational load necessary to start up immediately after
an electrical failure.
This operational load shall not be at any time greater than the maximum load that can be connected
simultaneously to the emergency generator, once rated voltage has been reached after a start-up.
After this, other loads may be fed until reaching 100% of the generator rated power in continuous
operation.
When using existing generators, ensure that the adding of new loads does not compromise start-
up.
Equipment with battery support shall not be considered when sizing generators for start-up and
shall only be connected to the emergency system when long time electrical failure or when battery
voltage drops to the minimum required voltage levels.
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4.11 CAPACITORS
The High and medium voltage capacitors can be located inside or outside of electrical substations,
depending on the available space.
The electrical switchboard with the contactors and other control and command elements (automatic
or manual) shall be located next to (and integrated in) the capacitors rack.
The selection of capacitors type shall be obtained by analyzing the power of all harmonics
generators (rectifiers, speed controllers, etc.) connected to the same busbars as the capacitors,
compared to the short-circuit network power or to the feeding transformers rated power.
▪ A bus or cable duct may be furnished between the transformer secondary terminals, which
are usually located outdoors, and the line side terminals of the main circuit breaker of the
secondary distribution switchgear, which is normally located indoors.
▪ The bus or cable duct shall be rated to carry the full secondary current of the transformer
inclusive of any cooling provisions and shall consist of copper bars or cables properly
braced, insulated, and totally enclosed in a sheet steel housing. The outdoor portion shall
be weatherproof and shall be provided with weather barriers at the point of entrance
through the building wall.
▪ Bus or cable duct shall be used when the nominal current is greater than 2000 A.
4.13 CABLES
All medium voltage cables will be designed by IEC or NEMA standards, the cables sized 250 kcmil
and above shall be class F Stranding, the cables sized less them 250 kcmil shall be class B stranding
(in accordance with ASTM B3 y ASTM B8 standard).
These cables shall be single or multi conductor stranded annealed copper, with semi-conducting
tape and metallic shielding, heat, moisture, sunlight and ultraviolet resistant, flame retardant, low
smoke and halogen free overall PVC jacket, rated for 90°C conductor temperature in wet or dry
service and according to the Table 9.
Classes 5 kV, 8 kV, 28 kV power cables will have extruded cross linked propylene (XLPE) black
insulation.
Medium voltage power cables feeding mine shovels, portable or mobile equipment will be SHD
type with ground check and ground wire conductors # 2/0 AWG and shall be single or multi
conductor.
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33,000 V 35 000 V 133% Yes SAG & Ball Mill Drive and feeders
All 0.6/1kV Class power cables will be type XHHW-2 with 90ºC XLPE insulation and overall sunlight-
resistant PVC jacket
The minimum cable size will be #12 AWG (4 mm2), All cables sized 250 MCM (120 mm2) and above
shall be supplied according F stranding to provide flexibility and facilitate handling and installation.
The outer jacket on all cables will be flame retardant type in compliance with IEEE 383/IEC 60332-1
and halogen free when installed indoor.
The choice of the final section of the conductor will be determined by the requirements of the load,
permanent current capacity, maximum permissible voltage drop (2.5%) and the ability to accept the
maximum expected short circuit, for a minimum period of 1 second.
Fire spread test on a single cable, installed vertically (other standard in this regard is IEC 60332-1)
The cables between non-linear equipment (frequency inverters and soft starters) and their loads will
be shielded, when necessary.
Consideration is to be given to the use of armored type cable for power cables, type CLX (“Teck”
Cable) with PVC counting for long runs where there would be a mechanical-economical advantage
for its use.
All 0.6/1kV Class control cables will be type XHHW-2 with 90ºC XLPE insulation and overall sunlight-
resistant PVC jacket, Control cables will generally be multiconductor.
The minimum gauge for control cables will be # 14 AWG (2.5 mm2).
The quantity of control cables on a multiconductor shall be 3c, Sc, 7c, 9c, 12c, 19c and 26c.
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Instrument cable conductors will be # 16 AWG (1.5 mm2), 300 V insulation, for single group and #
18 AWG (0.75 mm2) for multi-group cables.
Multi-group cables will have each pair or triad individually twisted and shielded, with an overall
aluminum-backed Mylar shield with drain wire.
Fiber optic cable will be 48 fibers, single mode, with coating to preserve intrinsic high tensile
strength of glass, standard color shall be used. A plastic buffer tube with filling compound will
prevent water ingress and migration. The buffer tube shall protect the fiber against mechanical
strength. The core shall be filled with compound. Filler rods will be applied to maintain a cylindrical
core. Dielectric central member shall act as an anti-buckling element to avoid contractions.
Fiber shall have an internal jacket with a rip cord, a rodent protection layer and an external jacket
with sun light protection (UV resistant for outdoor installation).
Wires used for lighting circuits will generally be single conductors 600 V PVC insulated cables with
solid copper conductors. Cables will be as type THWN/THHN for 90°C conductor temperature in
dry locations. The minimum wire size will be # 12 AWG.
Wires used for Fire Alarm Systems shall be fire rated power-limited FPL or FPLR types, as per
ANSI/NFPA-70 NEC article 760.1
Self-supporting cables shall be used in lighting systems, distribution panel and load center installed
outside of process plant. For detail see the technical specification LE14188A-0000-0430-ESP-00027.
▪ 36 kV Class
− Multi conductor: # 2/0 AWG, 250 MCM and 500 MCM.
− Single conductor: # 2/0 AWG, # 4/0 AWG, 250 MCM, 350 MCM and 500 MCM
(optional MCM for SAG).
▪ 25 kV Class
− Multi conductor: 250 MCM (Mine Power Cable).
▪ 8 kV and 5 kV Class
− Multi conductor: # 1/0 AWG, # 1 AWG, # 2 AWG, # 4 AWG and # 6 AWG.
− Single conductor: # 2/0 AWG, # 4/0 AWG, 250 MCM, 350 MCM and 500 MCM.
▪ 600 V Class
− Control cable sizes: # 14 AWG (normal to field) and # 18 AWG for control cable
between MCC and DCS/PLC and control cable between MCC and AFD.
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4.14 RACEWAYS
The cable trays and ladders should be made of corrosion resistant metal or metal with a corrosion
resistant finish, in accordance with NEMA and should be hot galvanized after they are manufactured,
in accordance with the manufacturing specifications to NEMA VE-1, Class C.
Cable trays and ladders will be used for power, control, and instrumentation circuits run above
ground in areas not subject to a high risk of mechanical damage.
Cable trays will generally be heavy-duty hot-dipped galvanized steel ladder type trays, with 150 mm
outside depth and 230 mm maximum rung spacing.
Solid bottom cable tray will be used for instrumentation cables as required to meet the
recommendations of IEEE 518.
The top tray of any stack of horizontal cable trays and any cable tray run separately, will have a
gabled solid tray cover to 13mm height, this when the trays are run outside of clean indoor areas.
Cable trays or ladder with gabled solid cover in corrosive areas will be fiberglass with stainless steel
hardware.
The cable trays or ladder shall have a # 2/0 AWG ground conductor (70 mm2), fixed to the outer
side of the latter, along suitable lengths.
Any pipeline entering or leaving the cable tray or ladder must be grounded through interconnection
bridges.
4.15 CONDUITS
It shall be type RMC (Rigid Metal Conduit) of galvanized steel or RGS (Rigid Galvanized Steel) for
the production plant and IMC (Intermediate Metal Conduit) pipe for facilities, ANSI C80.1 standard.
Preferably, pipes of the following diameters will be used: 3/4” (20mm), 1” (25mm), 1 ½” (40mm), 2”
(50mm), 3” (75mm) and 4” (100mm).
The pipes must be continuous to the point of connection of the equipment by means of flexible
metal pipe. The minimum length of flexible metal pipe will be 0.3 m.
The connection to motors or equipment of control and local instrumentation, must be executed
with flexible metallic pipe in a maximum extension of 1.0 meter.
For lighting and instrumentation circuits, the minimum diameter will be 3/4” (20mm) in diameter.
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Percentage of occupation
The maximum internal area of pipe that can be occupied by the cables must be:
53% 1
31% 2
40% 3 or more
PVC coated galvanized steel conduits will be used in corrosive areas. PVC coated conduits will have
a 40-mil layer of PVC.
4.16 GROUNDING
4.16.1 General
All overhead lines, exposed conductors and main substation equipment will be protected by
overhead static wires.
All ground connections from underground mat will be in positions that the vehicles can’t damage
them.
All grounding of shielded instrument cables will be done by connecting the shields directly to the
ground bus terminal in cabinets or with ground pins at one end only.
Electric motors will be grounded via a ground conductor within the motor power cable. Medium-
voltage motor frames, and low voltage motor frames of 51 kW and above, will be grounded via a
second grounding conductor which will be connected directly to the plant ground grid.
Ground rods, if used, will be constructed of copper clad steel 19 millimeters (3/4 inch) in diameter
and 3.0 meters long.
The substation, all 220 kV and 23 kV power lines and the plant grounding grid are to be
interconnected. All grounding grids are to be tested independently from the substation ground
grid, prior to being interconnected to the substation ground grid.
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Power cable trays will have at least one # 2/0 AWG (70 mm2), 19 strands ground bare copper
conductor along the entire run. Each tray section will be connected to the grounding conductor,
which will terminate at the switchgear or MCC ground bus as applicable.
Grounding of shielded instrument cables will be done by connecting the shields directly to the
ground bus terminal in cabinets or to a ground pin at one end only.
Computer and process control system (PCS) grounding will be in accordance with the equipment
manufacturer's requirements. The computer and PCS grounding system will be connected to the
plant ground grid at a single point.
Minimum size of the ground conductor shall be# 4/0 AWG, for connections to equipment will be #
2/0 AWG.
When required, because of high resistivity of soil, chemical compound shall be used for
improvement of electrical resistance for grounding
All grounding conductors will be copper. All underground connections will be with compressor
connectors.
All grounding of shielded cables will be grounded at one end only and be connected directly to the
ground bus in cabinets.
All motors shall be grounded through the grounding conductor enclosed in the power cable to the
ground bus in the motor control centers
Ground conductors run with duct banks will be installed above the duct banks, in contact with the
soil and not encased in the concrete envelope.
Metallic cable trays shall be grounded to the main grid system through a # 2/0 AWG (70 mm2),
ground conductor along the entire run.
Every grounding conductor liable to mechanical damage shall be protected by an adequate length
of PVC conduit.
The secondary of step-down transformers supplying power to mobile equipment (i.e. mine
equipment, reclaim water system, etc.) will be high resistance grounded through a 25 A extended
time resistor. Power cables feeding mobile equipment will have ground check monitors. Mobile
equipment power supplies will be designed to satisfy NEC 250 - 154 and MSHA requirements.
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All overhead lines and exposed conductors will be protected by an overhead static ground wire.
Said ground wire will be also used to maintain the interconnection between grounding grids into
the plant installations.
All power line structures and/or pole lines will have individual grounding grids, connected to the
overhead ground wire.
220 V outlets shall be grounded by means of a ground wire run with the feeder circuits.
380 V welding outlets shall be directly connected to the ground bus at the MCC or DPB with
conductor size in accordance with NEC.
All 220 and 380 V outlets shall have ground fault protection in the MCC or distribution and/or
lighting panelboard.
An integrated plant grounding design will be utilized for both power and instrumentation systems.
Grounding conductors for sensitive electronic equipment (e.g., computers) will be green with yellow
stripes.
▪ Medium and high voltage switchgear and transformers will be protected against surges by
metal oxide varistor (MOV) surge arresters
▪ Medium voltage motors will be protected against surges by surge capacitors, with the
exception of those motors fed from a frequency converter. Motors rated 6.9 kV and higher
will also be protected against surges by MOV surge arresters.
▪ Transmission Line Arresters (TLA) shall be installed in the 220 kV, 33KV y 22.9 kV lines.
▪ Surge arresting equipment will be provided on all electronic equipment.
4.17.2 Lightning Protection
▪ Lightning protection system design will comply with NFPA 780-2017 utilizing air terminal or
guard cable designs. The calculations will utilize the “rolling sphere” concept, employing a
sphere radius of 46 m.
▪ Lightning protection as attracting air terminals type will be allowed after the lightning
calculation is done.
▪ Overhead power lines will be protected against lightning by the use of overhead ground
wires.
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▪ Every building structure metallic part must be connected to the ground bus. Grounding
conductors shall not have any loops or square angles.
▪ Substations will be protected against lightning by the use of masts or overhead ground
wires.
4.18.1 General
In general, central switching from panel boards will be used for lighting all areas. Local area switches
will be used for electrical rooms, workshops and office lighting. Outdoor lighting will be controlled
by time relays with manual / automatic switch.
Led high bay be used for lighting indoor is designed to deliver intentional up-lighting, in addition
to traditional down-lighting. With this design, it can reduce glare and visual contrast.
Led tube generally be used for lighting offices and equipment rooms.
Led reflector used in the illumination of outdoor spaces and transit areas anodized aluminum body
IP 66 (NEMA 4).
Emergency lighting for all areas will be achieved using individual battery-operated incandescent or
LED (light emitting diodes) emergency lighting units. These battery packs will be fed from the
normal lighting circuits. Battery-powered emergency exit signs will be located at door exits as
required. The batteries for the emergency lights and exit signs will have at least one- hour capacity.
Some of the normal lighting circuits (20 %) in control rooms, substations, switch rooms and process
building should be switched to a standby power supply (generator).
Convenience outlet circuits will have 115 or 220 V, 10 A duplex receptacles installed in offices,
control rooms, laboratories, dining rooms, toilets, and in process areas, electrical or machinery
rooms, corridors, and warehouses (every 30 m or as needed). Receptacle installed in wet areas,
kitchens, toilets, and outdoors will be equipped with ground fault circuit interrupters. All
convenience outlets will be grounded by a separate green ground wire. A maximum of 6 receptacles
shall be connected to one feeder which shall have a differential relay, 10 mA sensitivity.
Lighting will generally be designed for the minimum maintained lighting levels is show in Table 7.
In process areas, 60 A, 480 V, 3 wires, 4 poles welding receptacles with disconnect switches will be
provided within 15 m of process equipment and piping requiring welding.
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Combined receptacles will be provided for portable equipment and for power equipment requiring
frequent removal for maintenance. In process areas, 3x30 A, 480 V and 2x1x15 A, 5 wires, with
disconnect switches will be provided.
Receptacles will be weather resistant, interlocking type permitting safe plug insertion and removal,
in NEMA 4X enclosures, as applicable. Differential protection relays with 300 mA sensitivity, will be
installed in MCC feeding welding receptacles.
Not more than three (3) receptacles will be installed on any feeder.
Batteries and battery charger shall provide the 125 VDC power control supply for circuit breakers,
switchgear and protection devices for 220 kV, 23 kV, 33 kV, 7.2 kV and 4.16 kV.
4.20.1 Batteries
Batteries will be maintenance free type, Ni-Cd, lead calcium or equal. Suitable for the installation in
open area ventilated electrical rooms.
Batteries will be sized to provide a minimum of two close- open cycles of all the connected and
future circuit breakers, switches and breaker position indicating lights following 36 hours of normal
discharge without charging. The connected load used to size the batteries will be the expected
future maximum plus twenty percent spare.
Batteries with battery chargers will be fed from an alternate emergency supply source (to reduce
battery ampere-hour requirements) and will be sized for 4 hours operation after a shutdown, with
a maximum voltage drop of 10%.
The battery chargers will be sized to carry 1.2 times the rated maximum load plus charging fully
discharged batteries within 8 hours. Redundant battery chargers will be provided for the main
substation.
The chargers will include automatic voltage and current controls, A.C./D.C. protection and
instrumentation.
Chargers shall provide for battery equalize charging and they shall have voltage and current
protection logic with the appropriate fault annunciation output.
Constant voltage transformers will be used to provide power to programmable logic controllers and
uninterruptible power supply (UPS) bypass circuits in order to prevent loss of plant controls during
transient voltage conditions.
Uninterruptible Power Supplies (UPS) will be utilized for critical control loads. Nominal rating will be
120 volt, 1-phase (or as required), 60 Hz, for 60 minutes of power outage
Each UPS will include a Ni-Cd battery, a battery charger, an inverter, a static output transfer switch,
and a bypass circuit. The batteries will be sized to provide 30 minutes of service in order to provide
for an orderly shutdown of plant control functions when a general power failure occurs. Whenever
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possible, the bypass circuit will be supplied from a source that is independent of the source used to
supply normal power to the UPS.
All driven equipment will have locally mounted control stations. Start-Stop control devices for a
group of motors may be mounted on a common local panel.
In general, local motor control stations will have "START' and "EMERGENCY STOP" pushbuttons. The
"EMERGENCY STOP" pushbutton must be retained with protection.
Pushbuttons and selector switches will be heavy-duty, corrosion-resistant, dust tight, and oil tight
NEMA 4X/12/13 type. When installed in open outdoor areas, pushbuttons and selector switches will
be installed in the same control enclosures or local panel as the equipment being served.
Local control for conveyor belts will have also a JOG (TEST) pushbutton. High visibility type LED pilot
lights will be provided on switchgear, MCC's and control stations to indicate energized /non
energized status of the outgoing feeder as follows:
The heat tracing cables shall be rated for 220 volts, 60 Hz. Self-regulating type electric heat tracing
cables with overall tinned copper shield and outer jacket, in general, temperature control shall be
via ambient sensing thermostat. Lines and instruments requiring holding temperatures other than
freeze protection shall be controlled by line sensing thermostats.
The electric distribution system will be controlled and supervised by the SCADA system. Electrical
data from medium voltage protections relays (IEDs) and RTUs will be obtained using standard
protocol IEC 61850. On the other hand, electrical data from low voltage equipment will be
concentrated in the RTUs using standard protocols like Modbus or Profibus DP. Therefore, RTUs will
have the gateway capacity between IEC 61850 and Modbus/Profibus DP protocols. Also, RTUs will
have digital Input / Output to concentrate dry contact signals and command electrical equipment.
A cathodic protection system, using sacrificial galvanic anode or impressed current method, will be
provided as necessary to protect metallic piping, tanks and structures from galvanic corrosion.
Cathodic protection equipment will be applied in accordance with the site soils analysis and
resistivity readings. Permanent test stations shall be provided at appropriate locations to
periodically test the system.
The cathodic protection system will be designed in accordance with National Association of
Corrosion Engineers (NACE) recognized criteria and will be coordinated with facility grounding, and
other systems which may affect corrosion rates.
For electrical consumption associated with monitoring stations in the Concentrate Pipeline
installations, the design must consider the use of photovoltaic 125 Vdc and 24 Vdc systems. These
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systems will be electrically independent and autonomous, and the equipment will be sized
according to autonomy requirements defined in the project. Solar panels should be designed
considering the solar radiation in the area.
125 Vdc and 24 Vdc systems must have at least the following equipment:
▪ Solar panels
▪ Transient Protection
▪ Load regulator panel
▪ Primary and secondary protection
▪ Station Batteries and Battery Chargers
▪ Electric Panel Distribution
(*) This system is not used, because the Concentrator Pipeline was removed from the scope of work.
The design shall consider a complete industrial power factor correction system or Synchronous
Condenser, to provide the necessary VAR's to correct power factor reflected to the power source
and to contribute with short circuit capacity to the main 33 kV busbar.
The Synchronous Condenser shall be a rotary type with regenerated true sinusoidal, phase or
voltage relationship output. The basic components of the system shall include a synchronous motor,
power factor controller, a control panel and an elevator transformer to allow the connection to the
33kV bus electrical system.
The operation of the Synchronous Condenser shall be based on automatic control of the motor at
field. The synchronous condenser shall remain connected to the electrical system during normal
operation and shall not require any switching or produce any voltage transients that may affect
other electrical systems.
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ANNEX A:
Table 11: Conversion of IEC enclosure classification designations per IEC 529 second edition (1989-11)
to NEMA enclosure type numbers per ANSI / NEMA 250-1991
IEC NEMA
IP20 (Notes 1 & 2) 1
IP21 (Notes 1, 2, & 3) 2
IP64 (Notes 4 & 5) 3
IP64 (Notes 4 & 5) 3R
IP64 (Notes 4 & 5) 3S
IP66 (Notes 4 & 5) 4
IP66 (Notes 5, 6, & 7) 4X
IP52 (Notes 2 & 3) 5
IPX8 (Notes 4, 5, & 8) 6
IPX8 (Notes 4, 5, 8, & 9) 6P
None (covered by other IEC standards) 7, 8, 9, &10
IP62 (Notes 2 & 3) 12, 12K
IP54 (Notes 2 & 10) 13
Note 1: Plus, limited protection against falling dirt
Note 3: Plus, splash proof for splashes from dripping if floor mounted
Note 4: Plus, corrosion resistance per a 200-hour salt fog test compared to galvanized steel
Note 5: Plus, operable and maintainable with ordinary hand tools under severe external icing
conditions without damage
Note 6: Severe corrosion resistance required per UL 50, Part 13 for sheet steel enclosures and UL
508, Part 6 for other materials
Note 8: No water inside enclosure after test to IEC Clause 14.2.7 with 1.83 m head of water above
the enclosure
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ANNEX B:
Table 12: Harmonic distortion limits
Bus voltage V at PCC Individual harmonic (%) Total harmonic distortion THD (%)
According to IEEE 519- “IEEE Recommended Practice and Requirements for Harmonic Control in
Electric Power Systems”
(a)
High-voltage systems can have up to 2.0% THD where the cause is an HVDC terminal whose
effects will have attenuated at network points where future users may be connected.
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