FSR 2020-10 CobrePanama SAG2 Elec

—
REPO RT
Gearless Mill Drive

Field Service Report (electrical)
PROJECT NAME BASED ON
Cobre Panama Click or tap here to enter text.
PROJECT ID. / REPORT NO. REPORT ID.
FSR_2020-10_CobrePanama_SAG2_Elec N.A.
CUSTOMER DESIGNATION
First Quantum Minerals SAG Mill 2

CUSTOMER PROJECT ID.
n.a.
PREPARED
2020-11-28 Gabor Meszegeto

REVIEWED STATUS SECURITY LEVEL
2020-12-17 Javier Ossa Approved Confidential

APPROVED DOCUMENT KIND DCC
2020-12-22 Guilherme Silva Field Service Report - GMD D00142
OWNING ORGANIZATION DOCUMENT / TEMPLATE ID. REV. LANG. PAGE
IAPI-OE4 3BHS810887_revG2 - en 1/66
CONFIDENTIAL - We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden. Copyright © 2020 ABB Switzerland Ltd. All rights reserved.
G EAR LE S S M I L L D R I V E
FIELD SERVICE REPORT (ELECTRICAL)
Contents
1. Customer and site information................................................................................................ 4
1.1. Service basic information ......................................................................................................... 4
1.2. List of distribution (ABB & customer) .................................................................................... 4
2. Service information ....................................................................................................................5

2.1. Service basic time schedule ..................................................................................................... 5
2.2. Personnel involved (ABB & customer) .................................................................................... 5
2.3. Summary & recommendations ................................................................................................ 6
2.4. Unscheduled & additional performed service activities ..................................................... 7
2.5. Non-performed activities / pending items ........................................................................... 7
2.6. Safety issues and main difficulties .......................................................................................... 7
2.7. Spare parts .................................................................................................................................... 7
2.8. Actual installed drive control Software version ................................................................... 8
2.9. Software and parameter changes .......................................................................................... 8
2.10. Backups & password handling................................................................................................. 8
2.11. Tools 9
2.12. Abbreviations............................................................................................................................... 9
3. Basic technical data of main equipment ................................................................................10

3.1. Ringmotor data ......................................................................................................................... 10
3.2. Cycloconverter data .................................................................................................................. 11
4. Cycloconverter control & mill functions ................................................................................. 12

4.1. Table of overall activities and tests before shutdown...................................................... 12
4.2. Table of overall activities and tests after shutdown ......................................................... 12
4.3. Event analysis ............................................................................................................................. 13
4.4. Parameter settings (snapshot before shutdown) .............................................................15
4.5. Airgap Supervision ....................................................................................................................15
4.6. Drive Control Signals................................................................................................................ 20
4.6.1. Drive control signals before shutdown............................................................... 21
4.6.2. Drive control signals after shutdown ..................................................................22
4.7. Cycloconverter synchronization voltage ............................................................................. 25
4.7.1. Cycloconverter synchronization voltage before shutdown .......................... 25
4.7.2. Cycloconverter synchronization voltage after shutdown ............................. 25
4.8. Mill starting behavior ............................................................................................................... 26
4.9. Trending data via HMI...............................................................................................................27
4.10. Mill functions on request ........................................................................................................ 33
5. Cycloconverter ......................................................................................................................... 34
5.1. Table of overall activities and tests...................................................................................... 34
5.2. Visual inspection ....................................................................................................................... 35
5.3. Check cycloconverter drive control panel +F02 ................................................................. 38
5.3.1. Check control cables of panel +F02 .................................................................... 38
5.3.2. Check cabinet cooling fans of +F02.................................................................... 38
5.3.3. Check earth fault protection relay (stator) ....................................................... 39
5.3.4. Check Stator Ground Fault Protection Device VME 420 ................................ 40
5.3.5. Check safety relay function ...................................................................................41
5.3.6. Time synchronization............................................................................................. 42
5.4. Cycloconverter power part (+CA, +CB, +CC) ...................................................................... 43
5.4.1. Check power cable connections, tightness & torque ..................................... 43
5.4.2. Check tightness of control cable connections and
measurement circuits ............................................................................................ 44
PROJECT NAME PROJECT ID / REPORT NO: DOCUMENT ID. REV. LANG. PAGE
Cobre Panama FSR_2020-10_CobrePanama_SAG2_Elec 3BHS810887_revG2 - en 2/66

5.4.3. Check input current CTs ........................................................................................ 44

5.4.4. Check motor voltage VTs ...................................................................................... 44
5.4.5. Check Power Part resistance on input and output of cyclo (µ-
ohm meter) ............................................................................................................... 45
5.4.6. Check pressure of thyristor stacks ..................................................................... 45
5.5. Cycloconverter cooling unit.................................................................................................... 46
5.5.1. Table of overall activities and tests .................................................................... 46
5.6. Excitation Converter (DCS)..................................................................................................... 50
5.6.1. Table of overall activities and tests .................................................................... 50
5.6.2. Photo of the converter rating plate .................................................................... 50
5.6.3. Visual inspection ......................................................................................................51
5.6.4. Check fuses, door switch and cooling fans, power cables .............................51
5.6.5. Check Power Part resistance on input and output ......................................... 52
5.6.6. Check function of rotor earth fault protection ................................................ 52
5.6.7. DCS parameter backup / update ........................................................................ 53
5.6.8. Check function of rotor thermal protection ..................................................... 53
5.6.9. Check Rotor over voltage arrester by forcing high voltage
from Megger ............................................................................................................ 53
6. Cycloconverter Transformers ................................................................................................ 54

6.3. Functional checks ..................................................................................................................... 54
6.4. Transformer protection relay ................................................................................................ 55
7. Excitation Transformer ........................................................................................................... 56

7.3. Functional checks ..................................................................................................................... 56
8. Ringmotor..................................................................................................................................57
8.3. Ringmotor cooling and overpressure fans ......................................................................... 58
8.4. Rotor brush gear and mill slipring connections ................................................................ 58
9. Off load disconnector switches (OLDS for Stator & Rotor) ................................................ 59
9.1. Table of overall activities and checks for Stator OLDS .................................................... 59
9.2. Table of overall activities and checks for Rotor OLDS ..................................................... 59
9.3. Visual inspections of Stator & Rotor OLDS (during shutdown)..................................... 60
9.4. Check motor start point connection .....................................................................................61
9.5. Check resistance between input - output ............................................................................61
9.6. Check power cable connection ...............................................................................................61
10.E-House..................................................................................................................................... 62
10.2. Visual inspection & general checks ....................................................................................... 64
10.3. Seismic Detection ..................................................................................................................... 65
10.4. MCC (by client) .......................................................................................................................... 65
11. Appendix ................................................................................................................................... 66
12. Revisions ................................................................................................................................... 66
13. Disclaimer ................................................................................................................................. 66

1. Customer and site information

Customer: Country name: Customer representative:
Minera Panama Panama Mr. Luis Cruz Negron
Site: System type: Other:
Cobre Panama GMD
Plant: Unit / Application Other:
Concentrator SAG Mill 2
Mill Supplier: Year of commissioning: Running hours:
Metso 2019 10061 h
1.1. Service basic information

☐ 6m Service ☒ 12m Service ☐ 36m Service ☐ Start-up sup-
port
☐ Service ☐ Upgrade ☐ Retrofit ☐ Trouble-
shooting
☐ Warranty ☐ Site survey ☐ Site manage- ☐ Training
ment
☐ Other:
Service descrip- GMD electrical service inspection
tion:
Service period: 12.10.2020 – 02.11.2020
1.2. List of distribution (ABB & customer)

Name Company Function Country
Johannes Gonser CHABB GMD Engineering manager Switzerland
Luis Cruz Negron Minera Panama Electrical Superintendent Panama
Guilherme Silva CHABB Life Cycle Manager Switzerland

2. Service information
2.1. Service basic time schedule

No. Name of electrical Task from till
service engineer
1 Mr. Gabor Meszegeto Arrival on site 12-10-2020 21-10-2020
Safety induction 21-10-2020 21-10-2020
Briefing with customer 21-10-2020 21-10-2020
Shutdown 22-10-2020 31-10-2020
Leaving site 01-11-2020 02-11-2020
2.2. Personnel involved (ABB & customer)

Name Company Function Country Arrival date Departure
date
Gabor Meszegeto CHABB Comm. Engineer Switzerland 21-10-2020 01-11-2020
Miguel Vega MPSA Especialista Panama
Electrista
Julio Cesar ESERMIN Electricista Panama
Gonzalez Gordon Panama
Arcenio Aizpura ESERMIN Electricista Panama
Vasquez Panama

2.3. Summary & recommendations

A general summary of the service. May also be related to recommendations, feedback from
customer, planning, technical, etc.
For recommendations also to state responsibility (client or ABB).
Item Summary in general

1 The AC unit control PLC is disabled, all 4 AC units are working at the same time.
2 The stator off-load disconnector limit switch is bypassed, for the program looks all
the time closed as the position switch does not provide the expected signal.
3 Message “licenses invalid” on HMI screen.
4 The field E-stop button N° 3 (under the mill) is very dirty.
5 The cycloconverter back doors status contacts are bypassed. This is a safety issue.
6 Cycloconverter Inside door new door switch contacts were installed, functionally
were tested, were working properly.
7 Ride through function was adjusted to improve the performance under grid dis-
turbances
8 There was a loose connection found in the front terminal block in the cycloconvert-
er power part due to a bad termination. The wire-end-sleeve had to be replaced,
termination was repaired.
9 The thyristor stack pressure was found lower than usual, it was re-tightened.
10 There is alarm coming from the airgap sensor N°4 during the mill start. The event
was analyzed with Transient recorder and no measurement abnormality has been
found. The measured signal and the other 2 sensors (N°5 and N°6) show low values
during some seconds. The event shall be analyzed in detail.
11 There is an alarm coming from the warm water temperature in the Ringmotor cool-
ing unit.
12 Cycloconverter cooling unit air pressure has to be pumped too often to keep the
air pressure under the acceptable limits.
13
Item Recommendations Responsible Critical

1 Each pendant connected to MLCP should be place in- Client ☐
side a box to protect them against water and dirt dur-
ing operation and maintenance.
2 Keep the Field E-stop buttons clean for easy access and Client ☐
location.
3 The cycloconverter power part door supervision needs Client ☐
to be back in operation as the lack of supervision is a
safety issue.
4 The flow and temperature from the ringmotor external Client ☐
water circuit shall be kept within the design ratings.
5 Check the condition of the wiring and status of the po- Client ☐
sitioning switch from the stator OLDS.
6 The control of the Air conditioning and outdoor com- Client and ☐
pressors shall be moved to the PLC (hardware and ABB
software task)
7 Choose an ☐
item.

2.4. Unscheduled & additional performed service activities

Pls enter short description of the unplanned or additional tasks performed during this entire
service.
Item Description time

spent
[hrs]
1 Repairing wire termination in Cycloconverter power part low voltage 0.5
terminal.
2
2.5. Non-performed activities / pending items

(pls refer only to main service activities, detailed information about performed tasks see
table of activities of each chapter)
Item Chapter Description Responsible Critical

1 10 Maintenance activities on the fire-fighting Client ☐
system, MCC, E-House.
2 6,7 Cycloconverter and excitation transformer Client ☐
supervision instrument testing. Client to
provide access during the next service.
3 Choose an ☐
item.
4 Choose an ☐
item.
2.6. Safety issues and main difficulties

Safety issues / difficulties observed during the service period.
Item Description Responsible Critical

1 No main difficulty noticed. Choose an item. ☐
2 Choose an item. ☐
2.7. Spare parts

Parts used during commissioning (belonging client), and recommended pieces to be ordered
Item Description / Type pc. pc. identification Location

used to order number (e.g. panel)
1 Air gap signal conditioner 0 1 2010 C Tentative
spare for air-
gap measur-
ing.
2
3

2.8. Actual installed drive control Software version

AC800PEC type: PEC2 ☒ PEC3 ☐
AC800PEC SW version: 5034.3008.1012
Compact Control Builder SW ver- 5.1.01
sion:
Control Terminal SW version: 2.6.0.0
2.9. Software and parameter changes

Pls mark if any software and/or parameter changes have been done during the entire service.
Device Type of SW change Description

Application Parameter
AC800PEC ☐ ☒ Ride through related parameters
PSR2 ☐ ☐
DCS600 / DCS800 ☐ ☐
PLC ☐ ☐
RET670 or other type ☐ ☐
MCC ☐ ☐
Earth Fault Relay Sta- ☐ ☐
tor
Earth Fault Relay Ro- ☐ ☐
tor
2.10. Backups & password handling

Software backups must be implemented on drive monitor and the CHABB network, accord-
ing CHABB guideline.
Backups of all relevant software, parameters & documents must be uploaded.
Note: Passwords will not be mentioned in this report.
If any password has been changed, CHABB Service – LCM and responsible engineer must be
informed, about actual implemented passwords, IP addresses, network configuration, etc.
Task description Done Date Remarks

Check & perform backups on Drive Monitor ☒ 29.10.2020
(on site)
Backup on CHABB network (I-drive, Share- ☒ 29.10.2020
Point)
Backup on common drive like “ABB one ☒ 29.10.2020
drive”.
If passwords have been changed, pls tick the ☐
box.
Back-up 800xA PLC software ☐
Harddrive cleanup on CCT panels ☐
Comments:

2.11. Tools
Item pc. Instrument / type / brand calibrated comment
(yes/no)
1 Multimeter yes
2 Megger MIT525 5kV Insulating Resistance Test- yes
er
3 Low resistance ohmmeter digital Megger - yes
DLRO 10X
4 Set of Hand Tools
5
2.12. Abbreviations
+A1 Left ring motor I/O panel ControlIT PLC programming platform
+A3 Right ring motor I/O panel Cyclo Cycloconverter
+AC01… Air conditioners no. 1 – n DCS Distributed Control System
+CA Cycloconverter power part (U) DM ABB Drive MonitorTM
+CB Cycloconverter power part (V) DRI Drive
+CC Cycloconverter power part (W) DTM Device Type Manager
+CCT Cyclo Control Terminal eth Ethernet (port)
+F01 Excitation control panel FW Firewall
+F02 Cycloconverter control panel FW Firmware
+F03 Auxiliary control panel (Auxiliary PLC) GMD Gearless Mill Drive
+F04 Network panel HMI Human Machine Interface
+F05…nn Motor Control Center panel HVAC Heating, Ventilation, Air Condition-
ing
+F14 Firefighting system panel I/O Input/Output
+F15 Cyclo cooling unit panel LAN Local Area Network
+F16 Stator transformer protection panel MCB Miniature Circuit Breaker
+F17 Lighting panel MCC Motor Control Center
+MLCP Mill Local Control Panel MVB Medium Voltage Breaker
+RIO1 General remote I/O panel no. 1 NLS National Language Support
+RIO2 General remote I/O panel no. 2 OLDS Off Load Disconnect Switch
+UPS Uninterruptible Power Supply OPC Open Platform Communications
IT
800xA ABB's System 800xA Industrial platform PLC Programmable Logic Controller
BMI Refers to as Minerals Solution library Simulink Drive control program. platform
CBM ABB Control Builder M VLAN Virtual LAN

3. Basic technical data of main equipment
3.1. Ringmotor data

Rating plate photo

3.2. Cycloconverter data

Rating plate photo

4. Cycloconverter control & mill functions

4.1. Table of overall activities and tests before shutdown
If tasks are not performed, pls comment in the remark field why not done or not completed
This test and check should be done before the shutdonw, during operation.
Service Date
Description by /done Remarks
period dd.mm.yyyy
Event analysis before shutdown (4.3) always ABB ☒ 23-10-2020
Parameter settings -snapshot (4.4) always ABB ☒ 23-10-2020
Air gap supervision (4.5) always ABB ☒ 23-10-2020
Drive control signals, before shutdown (4.6.1) always ABB ☒ 23-10-2020
Cyclo synchronization voltage (4.7) always ABB ☒ 23-10-2020
Comments:
4.2. Table of overall activities and tests after shutdown
Service Date
period dd.mm.yyyy
Air gap supervision (4.5) always ABB ☒ 31-10-2020
Normal / Max speed operation (4.6) always ABB ☒ 31-10-2020
Drive control signals, after shutdown (4.6.2) always ABB ☒ 31-10-2020
Cyclo synchronization voltage (4.7) always ABB ☒ 31-10-2020
Mill start behavior (4.8) always ABB ☒ 31-10-2020
Trending of data via HMI (4.9) always ABB ☒ 31-10-2020
Mill Creeping and Inching Mode (4.10) on request ABB ☐

Controlled rollback (4.10) on request ABB ☐
Mill Brake control (4.10) on request ABB ☐
Comments:

4.3. Event analysis

(required for 6/12 & 36month service)
Checking of alarm and events on the CCT before shutdown. Read out and analyze the trends,
alarm, events and fault logs.
Item Result / comments:

1 There is a high amount of emergency stop signals during operation, it is recommended that a
normal stop command is used regardless of the operation mode used.
2 Diverse events of overcurrent and overvoltage appears due to the behavior and response of
the ride through function to a network disturbance event. This topic has been discussed and
the relevant recommendation had been given in separate reports.
3 There is a significant amount of alarms coming from the airgap sensors N°7, N°8, N°9. The
client shall address this topic to ABB for further investigation.
4 The client shall keep the external water flow and temperature within the design values to
avoid any further damage on the Cycloconverter power part components.
Photo of trip events during operation 2019/2020
Trip_runnings during period

25
22
21
20
15
10 8 8 8 8
7
6 6
5
5 4
3
2 2 2 2 2
1 1 1 1 1 1 1 1
0
WaterTempSecOut_FaultH2
ExternalHWFaultLINCA3
StallProtection
CriticalInterlock
LineUnderfrequency
LineOverfrequency
ExternalHWFault_CombiIO
ExcitationOvercurrent
RotorCBIsTripping
MotorOvervoltArrester_PhaseW
OvercurrentLINCC1
EmergencyStopPressed
DCFTripped
Motor_DifferentialFaultV
LineUndervoltage
DoorsAreOpen
LineOvervoltage
ExcitationEarthFault
ThyristorFault
EmergencyStopPendant
ExcitationLineUndervoltage
MotorUnbalancedCurrent
OvercurrentLINCA1
EarthFault_Stator
OvercurrentLINCA3

Photo of alarm events during operation 2019/2020
Alarm_runnings during period

1200
1043
1000
800
600
400 332
267
165
200
78
34 26 14 13 11 8 4 3 3 3 3 1 1
0

4.4. Parameter settings (snapshot before shutdown)

Compare parameters from backup and actual settings.
The actual parameter setting has been compared with a backup from
Date: 07.07.2019.

1 During this service there has been parameter changes related to the ride-through function
performance. In addition, a zero current detection parameter has been implemented to im-
prove the Cycloconverter performance. There is no other parameter change related to the PEC
software since commissioning.
2
4.5. Airgap Supervision

Check the air gap supervision measurement & instrumentation.
Service Date
period dd.mm.yyyy
Check air gap supervision and record trends 6/12/36m ABB ☒ 31-10-2020
Compare electrical measurements of the air 36 month ABB ☐ Not applicable for 12
gap signals with mech. measurements with months service
feeler gauge (4.5.1)
(Mechanical measurement performed by MSV)
Check conditioner box: note type & serial num- on request ABB ☐ Not applicable for 12
ber installed in ringmotor terminal box. months service
(if ringmotor terminal boxes are accessible)
Check condition of the extension cables, con- on request ABB ☐ Not applicable for 12
nector & connector cable between sensor and months service
extension cable inside the ringmotor.
Type of extension cables installed inside the on request ABB ☐ Not applicable for 12
ringmotor. months service
Check proper shielding of the extension cables on request ABB ☐ Not applicable for 12
inside terminal box months service
It is recommended that the airgap measuring system gets upgraded in order to improve the
Comments:
quality of the measured signal.

Check air gap supervision and record trends with transient recorder of all signals, before the shut-
down.
Result: No offset problem was detected between sensors in same position.
Air gap 1, 2 and 3 located at 6 o’clock (bottom, view from feed side)
Air gap 4, 5 and 6 located at 9 o’clock (left, view from feed side)

Air gap 7, 8 and 9 located at 12 o’clock (top, view from feed side)
Airgap 10, 11 and 12 located at 3 o’clock (right, view from feed side) :

Check air gap supervision and record trends with transient recorder of all signals after the shutdown.
Result: No offset problem was detected between sensors in same position.
Air gap 1, 2 and 3 located at 6 o’clock (bottom, view from feed side)
Air gap 4, 5 and 6 located at 9 o’clock (left, view from feed side)
Air gap 7, 8 and 9 located at 12 o’clock (top, view from feed side)

Airgap 10, 11 and 12 located at 3 o’clock (right, view from feed side)

4.6. Drive Control Signals

(required for 6/12 & 36 month service)
Recording of the drive control signals before and/or after shutdown, like
-Normal and max speed operation

-Ringmotor current & voltage
-Ringmotor power & mill speed
-Excitation current
-MV-network voltage (synchronization voltage)
-etc.

4.6.1. Drive control signals before shutdown

Result: Motor voltage readings without abnormality.

4.6.2. Drive control signals after shutdown

Result: Control signals and motor output signals without distortion.



4.7. Cycloconverter synchronization voltage

Check of the voltage shape and levels of the synchronization voltage (= network voltage)
during running (before and after the shutdown).
4.7.1. Cycloconverter synchronization voltage before shutdown

Result: No distortion
4.7.2. Cycloconverter synchronization voltage after shutdown

Result: No distortion

4.8. Mill starting behavior

Trends of the mil starting behavior, before and after the shutdown.
Result: The mill Starting was observed only after shutdown. No abnormality found from the signals
plotted using the HMI computer.
Airgap 4 alarm: During start of the mill Airgap 4 alarm appeared. It was online checked. All the 3 air-
gap sensor in the same position (No 4, 5, 6) measurement permanent low airgap close to the alarm
limit for 20 seconds long. The measurement was real, not electrical failure.

4.9. Trending data via HMI

Trends for some of the signals monitored below, e.g.:
Ringmotor winding temperatures
Ringmotor Cooling system
Cyclo cooling system
Air gap supervision
Motor power, speed, voltage, current, etc.
Service Date
period dd.mm.yyyy
Ringmotor winding temperatures always ABB ☒ 31-10-2020
Ringmotor Cooling system always ABB ☒ 31-10-2020
Cyclo cooling system always ABB ☒ 31-10-2020
Air gap supervision always ABB ☒ 31-10-2020
Motor power always ABB ☒ 31-10-2020
Motor speed always ABB ☒ 31-10-2020
Motor voltage always ABB ☒ 31-10-2020
Motor current always ABB ☒ 31-10-2020
The cycloconverter cooling system slightly release the pressure. It can be maintained by
Comments: pumping regularly to keep pressure value within the tolerance. In long term recommended
to improve cooling unit to keep pressure.

Result: Cycloconverter cooling unit air pressure slightly decreasing, pressure is maintained 2 times
per month





4.10. Mill functions on request

Creeping and Inching Mode
Control Rollback
Mill brake function
Check the brake control with respect to the controlled apply and release commands. Check it
for “creeping” and “positioning mode”.
Check and record trends for the relevant test.
Result: The functions were not requested to be reviewed.

5. Cycloconverter
5.1. Table of overall activities and tests
Service Date
period dd.mm.yyyy
Preparation and LOTO always ABB ☒ 24-10-2020
Harddrive cleanup (CCT panel), make back-ups always ABB ☒ 31-10-2020
Visual inspection cabinets +CA, CB, CC, +F02 (5.2) always ABB ☒ 24-10-2020
Check cooling water hoses power part (check always ABB ☒
24-10-2020
connections & leakage)
Door switches (function test) (5.2) always ABB ☒ 24-10-2020
Control cables in +F02 (check tightening) (5.3.1) always ABB ☒ 24-10-2020
Cabinet cooling fans in +F02 (5.3.2) always ABB ☒ 24-10-2020
Earth fault protection relay (stator) +F02 (5.3.3) always ABB ☒ 24-10-2020
E-Stop loop & safety relays +F02 (funct.test) always ABB ☒
24-10-2020 Field E-stop 3 is dirty
(5.3.5)
Time synchronization (CCT, PEC, 800xA) (5.3.6) always ABB ☒ 24-10-2020
Check Power Part resistance at input-output (u- always ABB ☒
24-10-2020
ohm meter) (5.4.6)
Thyristor stack (+CA,+CB,+CC) pressure test 12/36m ABB ☒

24-10-2020
(5.4.8)
Power cable connection, tightness & re-torque ( 12/36m Client ☒
5.4.1) 24-10-2020
(supervised by ABB service engineer)
Check tightness of control cable connections 12/36m ABB ☒
and measurement circuits (CT, VT, X100,…) 24-10-2020
(5.4.3)
Input current CTs, check tight connections 12/36m ABB ☒
24-10-2020
(5.4.4)
Check motor voltage VTs (5.4.5) 12/36m ABB ☒ 24-10-2020
Fuse switches of power part (function test) 12/36m ABB ☒ 24-10-2020
Stator overvoltage arrester (function test) (5.4.2) 36m ABB ☐
Stator Ground Fault protection device VME 420 36m ABB ☐
(function test with voltage source) (5.3.4)
Check mill functions (on request) on request ABB ☐

Check MV-breaker interface (on request) on request ABB ☐
Comments:

5.2. Visual inspection

Check the condition of the equipment and note down the results below (dust, water leakage,
damage, signs of overheating, cooling tubes, capacitor leakage, cable trays, cabling, doors,
etc.)
Pls insert photos only in case of any issue or damage.
a) Visual checks of power part bus bar isolators, dust, water leakage, cooling water circuit,
capacitor leakage (snubber circuit, base load capacitor, etc.
b) Check for signs of overheating (e.g. copper flexibles…).
c) Check cooling water hoses power part (check connections & leakage)
d) Check door switches
Result / comments:
a) Visual checks: No visual damage noticed neither in the control panels nor in
the power part main components. Dust was very moderate, it
was cleaned.
b) Signs of over- No sigh for overheating
heating:
c) Cooling water The cooling water hoses were all found in good condition.
hoses:
d) Door switches: At the Back doors some of the Door switches are bypassed, it is
a safety issue. New “long arm” door switches were installed for
the front door, they are functioning properly.
e) other
Result: No visual damage noticed in the control panels neither in the power part main
components.
Some of the Back door’s door switch supervisions are bypassed.

Result: No visual damage noticed in the control panels neither in the power part main
components.
Some of the Back door’s door switch supervisions are bypassed.

Bypassed Door switch at Back door:
New Door switch at Front door:

5.3. Check cycloconverter drive control panel +F02

5.3.1. Check control cables of panel +F02
Result / comments:
Very few dust, cleanness is well maintained.
5.3.2. Check cabinet cooling fans of +F02

Check fan and filter condition of cabinet or rack cooling fans in +F02

Fan: The fans were tested and their functionality are correct.
Filter: Panel +F01 and +F02 rack cooling fans do not use filters.
etc.

5.3.3. Check earth fault protection relay (stator)

Check function of the protection relay, and the correct alarm & trip information on the HMI
and CCT.
Check and note the actual settings of the protection relay in the table below (e.g. Bender
relay):
Result / comments:
The trip function from the stator insulation protection relay is temporary disabled in the
PEC software via parameter setting. The analog output is recorded by the PEC controller
and it is available in HMI.
Settings Description value

1 Leakage capacitance [Ce max]: 10uF
2 Upper cut-off frequency [f max]: 10Hz
3 Lower cut-off frequency [f min]: 0.1Hz
4 #pulse: 02
5 setting alarm 1: 100kOhm

5.3.4. Check Stator Ground Fault Protection Device VME 420

(required only for 36month service)
and CCT.
Verify VME relay settings:
Result / comments:
This function is not tested in a 12 month service, but the settings are recorded in the table
below, they are correct and according the standard.
Menu Submenu Menu Activation Activation Adjustable Parameter

Item VME1 RELAY VME2 RELAY
AL  <U OFF OFF Undervoltage (Alarm
2)
(response >U 6V 6V Overvoltage (Alarm 1)
value) U HYS 5% 5% Hysteresis <U / >U
< Hz OFF OFF Underfrequency
> Hz OFF OFF Overfrequency
Hz Hys ---- ---- Hysteresis, frequency
OUT  M ON ON Fault Memory
(output 1 n.c. n.c. Operating mode K1
control) (n.c.)
2 n.c. n.c. Operating mode K2
(n.c.)
r1 1 Err ON ON Device Error at K1
r1<U OFF OFF Undervoltage K1
r1>U ON ON Overvoltage K1
r1< OFF OFF Underfrequency K1
Hz
r1> OFF OFF Overfrequency K1
Hz
r2 2 Err ON ON Device Error at K2
r2<U OFF OFF Undervoltage K2
r2>U ON ON Overvoltage K2
r2< OFF OFF Underfrequency K2
Hz
r2> OFF OFF Overfrequency K2
Hz
t  t on 1 0.5sec 0.5sec Response delay K1
t on 2 0.3sec 0.3sec Response delay K2
(timing T 0.3sec 0.3sec Starting delay
check) t off 0.5sec 0.5sec Delay on release K1 /
K2

5.3.5. Check safety relay function

Check safety relay function of the whole emergency stop loop of related trip circuits
Check the correct information on the HMI and CCT.
Result / comments
The E-stop buttons from the different panels and locations were tested. The relevant mes-
sage and E-stop relay reacted as expected. Field E-stop no. 3 is very dirty, the first time
that was tested the contact did not acted after pushing as they are very dirty.
item Description tested

1 F01 Panel Emergency Stop ☒
2 MLCP Emergency Stop ☒
3 Pendant Emergency Stop ☒
4 Field Emergency Stop no.1 ☒

5.3.6. Time synchronization

Check the time synchronization between the AC800PEC Controller, MLCP/CCT panels and
the system 800xA.
Result / comments
The AC800 PEC controller is synchronized to 10.42.104.21 IP address. The MLCP/CCT panel
are synchronised to 10.42.100.21.
Panel times, and message event times are matching with the actual time.

5.4. Cycloconverter power part (+CA, +CB, +CC)

5.4.1. Check power cable connections, tightness & torque
(required for 12 & 36month service)
An inspection should be made of the power cables related to torque and tightness.
The following connection type is recommended when connecting a cable lug (4) to a busbar:
Concial spring washer (1) and flat washer (2) on each side of the busbar (3). According DIN
6796.
Other washers can be used, provided they maintain the required contact pressure.
Apply the different torques for power cable connections according below table (specification
of screws: ST-NR A2-70)
Size M10 M12 M16 M20 M24

Torque [Nm] 20.0 40.0 80.0 147.0 153.0
Result / comments:
The torque was checked with torque wrench on all power cables in
the Cycloconverter power part, excitation converter panel, and Off load disconnect-
or switches input side. Some cables were needed to re-apply torque to reach the 40 Nm.

5.4.2. Check tightness of control cable connections and measurement circuits

e.g. terminals X100, X200, X300, VT & CT connections, etc.
Result / comments:
2 loose connection was found, the wire-end-sleeve needed to be replaced to improve con-
nection.
5.4.3. Check input current CTs

(required only for 12 & 36month service)
Check proper and tight cable/wire connections of the CTs secondary side and its earthing.
Result / comments:
No loose connection was found.
5.4.4. Check motor voltage VTs

(required only for 12 & 36month service)
Check of proper & tight connections.

In case of drive control problems, pls check the function of the motor voltage measurement
of all three phases, by injecting voltage (e.g. 400Vac) on the input of the VTs.
(Pls refer to the work instruction 3BHSxxx)
Result / comments:
No loose connection was found. Voltage signals were found in good
shape therefore no need to perform the low voltage test

5.4.5. Check Power Part resistance on input and output of cyclo (µ-ohm meter)
For the Resistance measurement you should use µ-ohm meter, with minimum 1-10A current
injection.
Result / comments:
The measured values were found within the limit.
Cyclo Resistance:
input
Busbars R1-S1 S1-T1 T1-R1 R2-S2 S2-T2 T2-R2 R3-S3 S3-T3 T3-R3
Panel 3.7 mΩ 3.9mΩ 3.8mΩ 3.4mΩ 3.5mΩ 3.5mΩ 3.7mΩ 3.6mΩ 3.7mΩ
+CA
Panel 4.0mΩ 4.0mΩ 3.9mΩ 3.9mΩ 3.9mΩ 3.9mΩ 3.7mΩ 3.6mΩ 3.6mΩ
+CB
Panel 3.7mΩ 3.7mΩ 3.7mΩ 3.7mΩ 3.8mΩ 3.7mΩ 3.5mΩ 3.5mΩ 3.5mΩ
+CC
Cyclo output Resistance:

Busbars U1-V1 V1-W1 W1-U1
Resistance [mΩ]: 33.4 33.6 33.5
5.4.6. Check pressure of thyristor stacks

(Required only for 12 & 36month service)
Check correct pressure (acc. OMM) with the feeler gauge of cyclo tool set.
Result / comments:
The thyristor stack pressure was found lower than usual, it was re-tightened.

5.5. Cycloconverter cooling unit

5.5.1. Table of overall activities and tests
Service Date
period dd.mm.yyyy
Visual inspection (leakage, water hoses, always
ABB ☒ 24-10-2020
pump shaft seals, etc.)
Cooling signal monitoring always ABB ☒ 24-10-2020
Check conductivity trend always ABB ☒ 24-10-2020
Check function of leakage sensors always ABB ☒ 24-10-2020
Check and adjust water level, flow, air pres- always
ABB ☒ 24-10-2020
sure
Clean mechanical filters 12 m ABB ☒ 24-10-2020
Check cooling pump LCS & E-stop function 12/36m ABB ☒ 24-10-2020
The client is pumping air into the Cycloconverter cooling unit approx. twice a month. It is
recommended that the client pump the right amount of water and pump the recommended
Comments:
amount of air to avoid any further problem into the cooling unit. The air must be bleed off
the Cycloconverter cooling unit.
Result / comments:
Visual inspection:
Cooling signal monitoring: Performed via HMI, see chapter 4.9 above. All the
instrumentation inside the cooling unit give coher-
ent information.
Check conductivity trend: The conductivity is stable and oscillate according to
the water temperature. Deionizer bottle was not
require to be replaced.
Check function of leakage sensors: It was tested, the error message came up as ex-
pected.
Check and adjust water level, flow, air pres- Water needed to be refilled, air pressure was
sure: pumped. Pressure needs to be pumped 2 times per
month. No visible sign for leakage. Flows are cor-
rect.
Clean mechanical filters: Was cleaned.
Check cooling pump LCS & E-stop function: Was tested, and working properly

Photo of the condition of the cyclo cooling unit or any findings

Internal inlet pressure:

Water level:
Heat exchanger:

Raw water inlet temperature:

5.6. Excitation Converter (DCS)

5.6.1. Table of overall activities and tests
Service Date
period dd.mm.yyyy
Visual inspection of excitation cabinet +F01 always ABB ☒ 24-10-2020
(grounding, dust, isolators, bus bars, thyris-
tor stack pressure, etc.) (5.6.3)
Fuse switch of surge arrester line-side (5.6.4) always ABB ☒ 24-10-2020
Door switches (function test) (5.6.4) always ABB ☒ 24-10-2020
DCS converter fan & panel fan (5.6.4) always ABB ☒ 24-10-2020
Check Power Part resistance at input-output always ABB ☒ 24-10-2020
(u-ohm meter) (5.6.5)
Earth fault protection relay rotor circuit always ABB ☒ 24-10-2020
(5.6.6)
Power cables, tightness & re-torque (5.6.4) 12/36m ABB ☒ 24-10-2020
DCS parameter backup / update (5.6.7) 12/36m ABB ☒ 24-10-2020
Rotor thermal protection (funct.test) (5.6.8) 36m ABB ☒ 24-10-2020
Rotor overvoltage arrester (funct.test) (5.6.9) 36m ABB ☒ 24-10-2020
Comments:
5.6.2. Photo of the converter rating plate

Photo of the converter rating plate

5.6.3. Visual inspection

Result / comments
No abnormal finding took place in the +F01 panel.

The panel +F01 is in good condition.
5.6.4. Check fuses, door switch and cooling fans, power cables
Result / comments:
Fuses: The input fuses and converter fuses were
checked and measured.
Door switch: The panel door switches were functioning
properly.
Cooling fans: The panel and converter fans were tested
and worked as expected.
Power cable connections, tightness & re- The torque level was adjusted on the power
torque (only for 12/36m): cables.The torque value was 40Nm.

5.6.5. Check Power Part resistance on input and output

For the measurement you should use µ-ohm meter, with minimum 1A current injection.
(During the measurement earthing set must be disconnected and OLDS be closed, brushes
must be installed).
Phase U1 against V1:

Phase V1 against W1:
Phase W1 against U1:
Phase plus + against minus -:
DCS800 Resistance:
AC busbars U1-V1 V1-W1 W1-U1
Resistance: 28.4 mΩ 28.3 mΩ 28.4 mΩ
DC busbars plus - mi-
nus
Resistance 320 mΩ
Result / comments:
No unbalance in resistance value was found the AC side. 1A was injected.
5.6.6. Check function of rotor earth fault protection

and CCT.
1. bridge + and – on the DCS800 and connect via 90 ohm resistance to earth
2. Slow trend of RotorEarthResistance until it trips
3. Record the time until the trip will occur
4. Check OPC events in CCT and HMI
Check and note the actual settings of the protection relay (Bender relay):
Settings Description value

1 Leakage capacitance: 500uF
2 Upper cut-off frequency: 50Hz
3 Lower cut-off frequency: 0.1Hz
4 #pulse: 02
Result / comments
It is recommended to adjust the value of the leakage capacitance to 10µF and check
whether the resistance calculation gets even more stable and reliable.

5.6.7. DCS parameter backup / update

Result / comments:
The parameter backup has been performed. No parameter modification was executed in
the excitation converter from the commissioning time.
5.6.8. Check function of rotor thermal protection

Check trip settings & function
Note actual adjusted setting.
Result / comments:
Setting: 0.52A, as per circuit diagram. The test has been performed and the trip message
came as expected.
5.6.9. Check Rotor over voltage arrester by forcing high voltage from Megger
Disconnect one side of the Rotor over voltage arrester (crow bar) from DC circuit and inject
“high voltage” from megger till the BOD will trigger and activate the arrester. Test arrester in
both directions.
Result / comments:
The overvoltage arrester modules were tested by injecting voltage using the insulation
Resistance tester (Megger). The voltage injected was 1600V. Both rotor overvoltage pro-
tection thyristors were triggered.

6. Cycloconverter Transformers

Service Date
period dd.mm.yyyy
Preparation and LOTO always ABB ☐
Visual check (grounding, dust, leakage, dam- always ABB ☐
age, hot spots, gaskets, oil level, dehydrating
breather,etc.) (6.2)
Buchholz relay & overpressure relief valve test always ABB ☐
incl. hardwired tripping loop test (6.3)
Test oil- & winding temperature and oil level 36m ABB ☐
supervision (6.3)
Check transformer differential protection 36m ABB ☐
relays functionally (6.4)
Check tap changer acc. tansformer OMM 12m Client ☐
Oil analysis 12m Client ☐
Power cable connections HV&LV side 12-36m Client ☐
Comments: No service action was done on transformers due to reduced manpower availability.

Visual inspection should be made for dust, dirt, damage, overheating, and instruments.
General inspection (leakage, damage, hot spots, dust, gaskets, do NOT adjust tap changer).
Result / comments:
Not performed due to the reduced manpower availability and time constraint for the ser-
vice execution.
6.3. Functional checks

Check the functionality of the various protection devices and the related tripping circuit.
Simulate respectively activate supervision, and check that alarm & trip will be activated and
indicated on the CCT.
Result / comments: Not performed due to the reduced manpower availability and time
constraint for the service execution.
Winding temperature:
Buchholz relay:
Overpressure relief valve:
Oil level supervision:
Etc.

6.4. Transformer protection relay

Installed in transformer protection panel +F16 located in E-House.
Functional check of the transformer protection relays (only every 36month):
Pls note relay type installed.
Pls note the type code of the relays (visible on the sticker/label of the relay).
Relay Type Type code
1
2
3
Result / comments:
Not applicable for 12 months service
Test transformer protection relay function (every 36month):

7. Excitation Transformer

Service Date
period dd.mm.yyyy
Preparation and LOTO always ABB ☐
Visual check (grounding, dust, leakage, dam- always ABB ☐
age, hot spots, gaskets, oil level, dehydrating
breather,etc.) (7.2)
Buchholz relay & overpressure relief valve test always ABB ☐
incl. hardwired tripping loop test (7.3)
Test oil- & winding temperature and oil level 36m ABB ☐
supervision (7.3)
Check tap changer acc. tansformer OMM ☐ 12m Client
Oil analysis ☐ 12m Client
Power cable connections HV&LV side ☐ 12-36m Client
No service action was done on excitation transformer due to reduced manpower availabil-
Comments:
ity.

Visual inspection should be made for dust, dirt, damage, overheating, and instruments.
General inspection (leakage, damage, hot spots, dust, gaskets, do NOT adjust tap changer).
Result / comments:
vice execution.
7.3. Functional checks

Check the functionality of the various protection devices and the related tripping circuit.
Simulate respectively activate supervision, and check that alarm & trip will be activated and
indicated on the CCT.
Winding temperature:
Buchholz relay:
Overpressure relief valve:
Oil level supervision:
Etc.

8. Ringmotor

Service Date
period dd.mm.yyyy
Visual inspection (8.2) always ABB ☒ 24-10-2020 Only junction boxes
Ringmotor cooling & overpressure fans (8.3) always ABB ☐
Check rotor excitation cable connection on always ABB ☐
brush gear (bolt torque, cable insula-
tion..)(8.4)
(performed by MSV)
Check rotor grounding cable connection on always ABB ☐
brush holder support (8.4)
(performed by MSV)
Comments: Reduced activities due to reduced manpower.

Check the condition of the equipment and note down the results below (dust, leakage, dam-
age, signs of overheating, damage, cable trays, cabling, doors, etc.).
Result / comments:
A1-A6 junction boxes were visually checked. A2 and A4 electrical connection was checked
as well.
Ringmotor cooling system water and air temperature values were around the alarm lev-
els while the mill was running.


Photo of condition or any findings
8.3. Ringmotor cooling and overpressure fans

Recording and check the consumption of the ringmotor cooling and overpressure fans (be-
fore and after the shutdown). Might be possible via HMI, or by clamp meter at MCC starter
module.
Result / comments:
vice execution.
8.4. Rotor brush gear and mill slipring connections

Check rotor excitation cable connection on brush gear (bolt torque, cable insulation..)
Check rotor grounding cable connection on brush holder support.
This service task should be performed by the MSV (mechanical supervisor) if available.
Brush gear cables connection:
Rotor grounding cable connection:

9. Off load disconnector switches (OLDS for

Stator & Rotor)
9.1. Table of overall activities and checks for Stator OLDS

Service Date
period dd.mm.yyyy
Preparation and LOTO, cyclo grounded at always ABB ☒
24-10-2020
inputs with grounding sets
Visual check general (drive shaft and handle, always ABB ☒
24-10-2020
grounding, etc.) (see 9.3)
Tightening of control cable connections (9.3) always ABB ☒ 24-10-2020
Check condition and alignment of switching always ABB ☒
24-10-2020
blades (9.3)
Check mechanical mechanism for opening & always ABB ☒
24-10-2020
closing and solenoid interlock function (9.3)
Check motor star point, tightness & torque always ABB ☐
of connections (9.4)
Measure resistance of blades and stator always ABB ☒
24-10-2020
winding (u-ohm meter) (see 9.5)
Check tightness & torque of power cable 12/36m Client ☒ Only at the front (in-
24-10-2020
connections periodically (see 9.6) put) side
Comments: Reduced check was performed on OLDS due to reduced manpower.
9.2. Table of overall activities and checks for Rotor OLDS

Service Date
period dd.mm.yyyy
Preparation and LOTO, cyclo grounded at always ABB ☒
24-10-2020
inputs with grounding sets
Visual check general (drive shaft and handle, always ABB ☒
24-10-2020
grounding, etc.) (see 9.3)
Tightening of control cable connections (9.3) always ABB ☒ 24-10-2020
Check condition and alignment of switching always ABB ☒
24-10-2020
blades (9.3)
Check mechanical mechanism for opening & always ABB ☒
24-10-2020
closing and solenoid interlock function (9.3)
Measure resistance of blades and stator always ABB ☒
24-10-2020
winding (u-ohm meter) (see 9.5)
Check tightness & torque of power cable 12/36m Client ☒
24-10-2020
connections periodically (see 9.6)
Comments:

9.3. Visual inspections of Stator & Rotor OLDS (during

shutdown)
Result / comments:
Stator OLDS: Limit switch is bypassed, it is showing all the time “Closed” condition.
Rotor OLDS: No abnormal condition noticed. Operation is very smooth.
Photos of condition and/or any findings
Photos of condition and/or any findings

9.4. Check motor start point connection

Tightness & torque connections, star point cable connection (Stator OLDS)
Stator OLDS: xxx
9.5. Check resistance between input - output

Measure the resistance between the input and output connections with closed blades.
For the measurement you should use µ-ohm meter with min 1-10A injection.
Stator OLDS:
Knife switch stator Resistance in [µΩ]

Blades of phase: U V W
Resistance: 4µΩ 4µΩ 5µΩ
Rotor OLDS:
Knife switch rotor Resistance in [µΩ]

Blades of phase: + (plus): - (minus)
Resistance: 18µΩ 20µΩ
Result / comments:
Stator OLDS: Contact resistance values are optimal.
Rotor OLDS: Contact resistance values are optimal.
Measured with 1A.
9.6. Check power cable connection

Check tightness & torque of power cable connections on Stator & Rotor OLDS.
Apply the different torques for power cable connections according below table (specification
of screws: ST-NR A2-70)
Size M10 M12 M16 M20 M24
Torque [Nm] 20.0 40.0 80.0 147.0 153.0
Result / comments:
Stator OLDS: Only front (input) side were checked, 40Nm was verified with torque wrench.
Rotor OLDS: 40Nm was verified with torque wrench.

10. E-House
Service Date
period dd.mm.yyyy
Visual check (grounding, dust, always ABB ☒
damage, floor entries sealed,
24-10-2020
cable Isolation covers still in
place) (10.2)
Check emergency exit of E- always ABB ☒
24-10-2020
House (10.2)
Seismic sensor:
Check functionality and set- 36m ABB ☐
Not applicable for 12 months
tings of seismic protection
service
(10.3)
Air conditioning system

HVAC (by client):
Visual check always Client ☐
Filter & draining always Client ☐ It was not done as listed as
pending in the first chapters.
Air duct always Client ☐ It was not done as listed as
Overpressure fan (by client):
Check if the filter for the always Client ☒
Overpressure fan is clean (Cli- 24-10-2020
ent)
UPS (by client):
Check batteries 12m Client ☐ It was not done as listed as
Check bypass switch 12m Client ☐ It was not done as listed as
MCC buckets: check torque of 36m Client ☐
power cable connections
service
(10.4)
MCC: Measure resistance of 36m Client ☐
3ph output of all aux. con-
service
sumers (10.4)
Fire Fighting system (by cli-
ent):
Visual check always Client ☐ It was not done as listed as
Check & simulate sensors 12/36m Client ☐ It was not done as listed as
Check battery 12/36m Client ☐ It was not done as listed as
Check bottles 12/36m Client ☐ It was not done as listed as

Check electromagnetic actua- 12/36m Client ☐ It was not done as listed as

tor pending in the first chapters.
Comments: E-house is maintained very clean.

10.2. Visual inspection & general checks

Result / comments:
Visual check of all compo- No damaged components noticed during the visual inspec-
nents: tion.
Emergency exit function: It is working in normal way.
MCC (by client): Pending by client.
UPS (by client): Pending by client.
HVAC (by client): Pending by client.
Overpressure fan (by cli- Was checked, filter was cleaned.
ent):
Fire Fighting system (by Pending by client.
client):

Photos of E-House condition and/or any findings
Message “licenses invalid” on HMI screen

10.3. Seismic Detection

(required only for 36month service)
If the plant is equipped with a seismic detection system delivered by ABB, it needs to be
checked and verified.
Check settings & functionality
Result / comments:
Not scope of 12 month service
10.4. MCC (by client)

Result / comments:
Settings of starter modules: Pending by client.
Torque of the MCC bucket power cables: Pending by client.
Measure resistance of 3ph output of all aux. Consumers: Pending by client.

11. Appendix
No. Description Reference Pages Remarks
Number
12. Revisions
Rev. Page (P) Description Date Dept./Init.
Chapt. (C)
- All pages First issue 28.11.2020 GM/ PI-OE4
13. Disclaimer
The contents of this document should in no event be considered as any acknowledgement of
any liability or obligation (without prejudice). ABB reserves all rights and remedies. This doc-
ument and associated information are privileged and confidential and may not be used or
referred to in any legal or arbitration proceedings. The contents of this document should not
be considered as exclusive or comprehensive. This document contains the opinion of the
author, based on the information currently available to him. It does not represent the opinion
of the company nor necessarily the final opinion of the author.
This work, including all parts thereof, is protected by copyright. Any use of it beyond the nar-
row restrictions of the copyright law without prior approval of ABB Switzerland Ltd. is pro-
hibited and subject to punishment under the applicable law. The above pertains to (in partic-
ular) reproduction, translation, microfilming, and electronic data processing.


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Gearless Mill Drive

PROJECT NAME BASED ON

Cobre Panama Click or tap here to enter text.

PROJECT ID. / REPORT NO. REPORT ID.

First Quantum Minerals SAG Mill 2

2020-11-28 Gabor Meszegeto

2020-12-17 Javier Ossa Approved Confidential

2020-12-22 Guilherme Silva Field Service Report - GMD D00142

OWNING ORGANIZATION DOCUMENT / TEMPLATE ID. REV. LANG. PAGE

IAPI-OE4 3BHS810887_revG2 - en 1/66

2. Service information ....................................................................................................................5

3. Basic technical data of main equipment ................................................................................10

4. Cycloconverter control & mill functions ................................................................................. 12

Cobre Panama FSR_2020-10_CobrePanama_SAG2_Elec 3BHS810887_revG2 - en 2/66

5.4.3. Check input current CTs ........................................................................................ 44

6. Cycloconverter Transformers ................................................................................................ 54

7. Excitation Transformer ........................................................................................................... 56

11. Appendix ................................................................................................................................... 66

12. Revisions ................................................................................................................................... 66

13. Disclaimer ................................................................................................................................. 66

Cobre Panama FSR_2020-10_CobrePanama_SAG2_Elec 3BHS810887_revG2 - en 3/66

1. Customer and site information

1.1. Service basic information

1.2. List of distribution (ABB & customer)

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2.1. Service basic time schedule

2.2. Personnel involved (ABB & customer)

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2.3. Summary & recommendations

Item Summary in general

Item Recommendations Responsible Critical

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2.4. Unscheduled & additional performed service activities

Item Description time

2.5. Non-performed activities / pending items

Item Chapter Description Responsible Critical

2.6. Safety issues and main difficulties

Item Description Responsible Critical

2.7. Spare parts

Item Description / Type pc. pc. identification Location

Cobre Panama FSR_2020-10_CobrePanama_SAG2_Elec 3BHS810887_revG2 - en 7/66

2.8. Actual installed drive control Software version

2.9. Software and parameter changes

Device Type of SW change Description

2.10. Backups & password handling

Task description Done Date Remarks

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3. Basic technical data of main equipment

3.1. Ringmotor data

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3.2. Cycloconverter data

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4. Cycloconverter control & mill functions

4.2. Table of overall activities and tests after shutdown

Mill Creeping and Inching Mode (4.10) on request ABB ☐

Cobre Panama FSR_2020-10_CobrePanama_SAG2_Elec 3BHS810887_revG2 - en 12/66

4.3. Event analysis

Item Result / comments:

Photo of trip events during operation 2019/2020

Trip_runnings during period

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