MINERA PROJECT

Study Report
PYI1701-0000-ADM-BT-0002
Operating Philosophy
November 2015
MINERA Project Definition Phase Study Report October
2015
Table of Contents
1.0 Introduction .............................................................................................................. 5
2.0 Reference Documents.............................................................................................. 5
3.0 Project Description................................................................................................... 5
4.0 General ..................................................................................................................... . 6
5.0 Overview of Control System .................................................................................... 7
5.1 Operation Control Room...........................................................................................................7
5.2 Basic Control and Instrumentation Concepts ........................................................................8
5.3 Control Operation Concepts ....................................................................................................9
5.3.1 Interlocks ................................................................................................................................... .9
5.3.2 Permissive ..................................................................................................................................9
5.3.3 Process Interlock.......................................................................................................................9
5.3.4 Safety Interlock ........................................................................................................................10
5.3.5 Control Loop ............................................................................................................................10
5.3.6 Sequence ..................................................................................................................................10
5.3.7 Operation ..................................................................................................................................10
5.3.8 Event ........................................................................................................................................ .10
5.3.9 Warnings ..................................................................................................................................10
5.3.10 Alarms...................................................................................................................................... .11
5.3.11 Motor Command ......................................................................................................................11
5.3.12 Normal Stop .............................................................................................................................11
5.3.13 Emergency Stop ......................................................................................................................11
5.4 Control Modes..........................................................................................................................11
5.4.1 Manual/Automatic (A/M)..........................................................................................................11
5.4.2 Base/Standby (B/SB) ...............................................................................................................11
5.4.3 Operator/Maintenance (Op/Maint)..........................................................................................12
5.5 Forwards/Reverse (F/R) ..........................................................................................................12
5.6 Functional Test (JOG) .............................................................................................................12
5.7 Local/Remote (L/R) ..................................................................................................................12
6.0 Equipment Control Concept .................................................................................. 12
6.1 Motor Control ...........................................................................................................................12
6.2 Control Operation Scenario....................................................................................................13
6.3 Typical Motor Description ......................................................................................................14
6.3.1 Type M1 ................................................................................................................................... .14
6.3.2 Type M2 ................................................................................................................................... .15
6.3.3 Type M3 ................................................................................................................................... .16
6.3.4 Type M4 ................................................................................................................................... .17

Page 2 of 54
6.3.5 Type M5 ................................................................................................................................... .18
6.3.6 Type M6 ................................................................................................................................... .19
6.4 Valve Control............................................................................................................................19
6.5 Typical Valve Control Description .........................................................................................20
6.5.1 Type V1 .................................................................................................................................... .20
6.5.2 Type V3 .................................................................................................................................... .20
6.5.3 Type V4 .................................................................................................................................... .20
6.5.4 Type V5 .................................................................................................................................... .20
6.5.5 Type V6 .................................................................................................................................... .21
6.5.6 Type V7 .................................................................................................................................... .22
6.5.7 Type V8 .................................................................................................................................... .22
6.5.8 Type V10 .................................................................................................................................. .23
7.0 Process Control Scope .......................................................................................... 24
7.1 Primary Crushing and Coarse Ore Transport Scope...........................................................24
7.2 Reclaim Operation Scope .......................................................................................................25
7.3 Grinding Operation Scope ......................................................................................................27
7.4 Flotation Operation Scope......................................................................................................30
7.5 Pebbles Operation Scope .......................................................................................................37
7.6 Copper-Molybdenum Concentrate Thickener Scope ..........................................................38
7.7 Molybdenum Plant Scope .......................................................................................................38
7.8 Moly Concentrate Thickener Scope ......................................................................................48
7.9 Moly Filtration Plant ................................................................................................................49
7.10 Copper Concentrate Thickener Scope ..................................................................................50
7.11 Copper Concentrate Filter Plant Scope ................................................................................51
7.12 Tailings Thickener Scope .......................................................................................................51
7.13 Water Supply and Distribution Scope ...................................................................................52
7.14 Compressor Air Scope............................................................................................................52
7.14.1 Plant Air ................................................................................................................................... .52
7.14.2 Instrument Air ..........................................................................................................................53
7.14.3 Plant Air for SFR ......................................................................................................................53
7.14.4 Filter Plant Instrument Air ......................................................................................................53
7.15 Conveying and Pumping Water Pipeline ..............................................................................54
Acronyms and Abbreviations
AFD Adjustable Frequency Drive
AMS Asset Management System
CCR Central Control Room
CCTV Closed-Circuit Television
CMS Condition Monitoring System
DCS Distributed Control System
DES Distributed Electrical Subsystem
EWS Engineering Workstations
ESS Electrical Supervisory System
HMI Human Machine Interface
I/O Input/Output
ISA International Society of Automation
LOW Local Operator Workstation
MCC Motor Control Centre
OWS Operator Workstation
PCN Process Control Network
PCS Process Control System
PESS Power Electrical Supervisory System
PID Proportional plus Integral plus Derivative
PIN Process Information Network
PIMS Process Information Management System
PLC Programmable Logic Controller
P&ID Piping and Instrumentation Diagram
RO Reverse Osmosis
MINERA MINERA
1.0 Introduction
This Control Philosophy document provides a functional description of the basis of the process control for the
MINERA Project, Definition Phase Study. This document is supplemental to the P&IDs, which take precedence and
must be used along with this document.

The Control Philosophy describes an overview of the process control strategies established in the P&IDs and the
Operating Philosophy document (November 2015, BHPB NUMBER) with the purpose of guiding the engineering
design that will be developed in the Project. The control strategy and engineering design shall hold safety as the
most important aim of the work, prioritised ahead of production and maintenance considerations.

This Control Philosophy provide a general description of the Process Control System, and also, establishes overall
criteria for PCS design.

3.0 Project Description

The MINERA (MINERA) Project is based on open pit mining and ore processing facilities to produce copper and
molybdenum (moly) concentrates. Transport of packaged molybdenum concentrate would be by truck and copper
concentrate after filtration at the plant site would be by train to the port. Port facilities would be by outsourced
services and are excluded from the concentrator plant scope of work.

The copper concentrator plant shall have a single grinding line, followed by a flotation circuit to process the ground
slurry at a nominal processing rate of 95,000 tonnes per day. All of the supporting facilities are based on this
throughput.

Desalinated sea water from the desalination plant, located near to the port facility, would be pumped to the mine site
for use as process makeup water and to supplement the water recycled from the tailings thickeners and reclaimed
from the tailings impoundment.

The scope of MINERA Project includes the following

facilities:

• Primary crushing and transport coarse ore

 • Coarse ore stockpile and reclaim system

• Grinding

• Bulk flotation plant

• Molybdenum plant

• Copper concentrate filter plant

• Tailing thickeners

• Tailing impoundment and reclaim water system

• Process water distribution system

• Desalinated water pipeline

• Sea water treatment system

• Copper concentrate storage

• Electrical supply and distribution system

• Other minor and supporting facilities

4.0 General
• The Process Control System (PCS) or Distributed Control System (DCS) provides plant operations with the
ability to perform plant process regulatory and discrete control in a safe way. The PCS shall receive
discrete and analog inputs from field devices for control execution, and deliver discrete and analog output
functions to field devices. The PCS performs data handling operations and communicates with external
devices using standardized control algorithms, discrete logic and control languages to perform logic and
control operations.

• The DCS shall be used in its traditional sense to refer a fully integrated collection of hardware and software
and designed specifically for process monitoring and control. In general, all analog, logical and advanced
controls schemes are developed in the DCS.

• PLCs will be used as part of third party packaged equipment supply. In these cases, the PLC provides
plant operations with the ability to perform plant equipment interlocking sequence logic and/or process
regulatory control. PLCs shall be digitally connected to the DCS with the intention to have all HMI functions
displayed at the DCS operator workstations (OWS). The PLC data is obtained through the DCS, and
operators may not notice the difference on which device they are operating the field equipment. This is
called a “transparent interface”.

• For both PLC and DCS, the motor information from MCC will be obtained via digital communication (field
buses). See details on document Control System and Instrument Design Criteria for MINERA Selection
Phase Study.

• All PLCs included on mechanical equipment shall be integrated with DCS. The concentrator comminution
circuit, which include a gyratory crusher, a ~4 kilometre overland conveyor, a 40’ diameter SAG mill
 (28 MW) and two 27’ diameter ball mills (each 20 MW) to grind the ore to the size required to obtain
designed Cu and Mo recoveries.

• All safety interlock shall be developed according to Fatal Risk Controls Standard BHBP GLD 010

5.0 Overview of Control System

5.1 Operation Control Room

All process control for the main plant shall be done from a central control room (CCR). The plant’s CCR shall be
located near existing Spence’s administrative offices. The sea water treatment system, desalinated water pump
stations shall be operated from its own CCR.

Both CCR shall be the focal point of the facility operation. They shall contain all new equipment required to control
process and equipment functionality following the criteria detailed below. Among other equipment, the operator
workstations, associated peripherals, printers and closed circuit television system (CCTV) for process area
supervision shall be installed in each control room. The facilities controlled and monitored from each control room
through the OWS are:

• Plant’s CCR

• Crushing and conveying (Monitoring and control)

• Stockpile and reclaim coarse ore (Monitoring and control)

• Pebbles (Monitoring and control)

• Grinding (Monitoring and control)

• Flotation (Monitoring and control)

• Tailings thickeners (Monitoring and control)

• Concentrate thickeners (Monitoring and control)

• Concentrate pump station and pipeline (Monitoring and control)

• Copper Concentrate Filter plant (Monitoring and control)

• Molybdenum &filter plant (Monitoring and control)

• Reclaim water pump station (Monitoring and control)

• RO plant (Monitoring)

• Water storage and distribution system (Monitoring and control)

• Desalinated water plant’s CCR

• Fresh water conveying system (Monitoring and control)

 • Sea water treatment system, (Monitoring and control)

The degree of automation shall be in accordance with the process and Spence requirements established in the
Operating Philosophy document. The following factors shall be given special consideration:

• Safety of operating personnel, requiring the selection of safe, proven and reliable control system
equipment and instruments.

• Keeping the process and environmental conditions in mind. All instruments and sensing lines shall be
suitably conditioned using heat tracing and/or cleaning system, as required.

• All instruments shall be rugged and reliable and shall require minimal maintenance. This requirement shall
be more rigorous in the case of instruments installed in remote areas.

• Availability of skilled personnel for plant instrument maintenance and the location of vendor service and
parts supply centres.

• Number of operators required to operate the plant shall aim to a minimum.

• High level of flexibility demanded by plant operations and optimum cost per unit of production for fuel,
power, additives and labour.

• Operability and maintainability of control system equipment and instruments, requiring their proper location
and layout.

5.2 Basic Control and Instrumentation Concepts

• The instrumentation and control system will be part of an integrated system, which will allow centralised
and local control operations.

• The control and instrumentation will be shown on the Piping and Instrument Diagrams (P&ID), including the
control strategies performed by PLC and DCS.

• Instruments and control devices to be used in MINERA Selection Phase Study will be designed according
to
Control System and Instrument Design Criteria for MINERA Selection Phase Study.

• The DCS will be arranged as shown on Distributed Control System Block Diagrams, which shows the
structure of the system and its communications. The entire plant can be monitored and controlled from the
operator workstations (OWS). The DCS will provide equipment and process control.

• All OWSs will be identical and interchangeable. They will provide:

— Equipment control stations and status

— Analog process operation

— Analog indications

— Interactive process and equipment graphics

— Alarm and event management and logging

 — Automatic shift, production reports, and special reports

— Real-time trending

— Historical trending

— System diagnostic

— Selection of operational mode

• Heavy duty local control stations (LCS) will be provided for local control cyclone clusters. These stations
may be mainly used for maintenance purposes.

PLCs will be used to control equipment located remotely from the process plant. This applies to coarse ore
conveyors and some mechanical packaged equipment. The PLCs used at the concentrator area will be
linked digitally to the DCS.

5.3 Control Operation Concepts

5.3.1 Interlocks

According to National Fire Protection Association (NFPA), interlock is a device or device groups to detect a limit, a
condition beyond the limits or prevent improper procedures in sequences, in order to avoid a hazardous condition.
Interlocks are useful for:

• Forcing control loops into manual mode under certain conditions or prohibiting the entry into automatic
mode by an operator until certain logical conditions known as permissive are in the correct state.

• Inhibiting unsafe operations.

• Partnering with starting procedures (startup) and ordered sequences of stopping (shut-down).

5.3.2 Permissive

Contacts are similar to the latches, allowing the isolation of processes, equipment, etc., in order to prevent failures
and accidents. In summary, permissive is a series of logical conditions that must be active to permit the completion
of a process. Permissive interlocks are normally connected in series with the starting coil of final elements.

5.3.3 Process Interlock

Process interlock is a condition required for starting and keeping devices in the required state. In the normal state,
the interlock enables the process equipment to be operated by operator actions or logical sequences. Under
abnormal situation (or non-valid state), it causes the equipment to assume the interlock state, disabling running and
shutting devices off or carrying the sequence to the final interlock state.

The process interlocks shall be enabled in automatic and manual operation modes.

An interlock is called hard interlock or wired interlock when some signal is hard wired into the device control circuit.
An interlock is called a soft interlock when the interlock signal is logically connected through a PCS or PLC.

For safety reasons the interlock signal shall be represented by a logical “1” (i.e. normally closed contact) in normal
state allowing fail-safe state with a logical “0”. Interlocks may originate from either a hard or soft source.
 All interlocks in relation to personal safety and catastrophic equipment failure must be connected as hard interlocks.
Operational interlocks are mainly soft interlocks.

Note: Process interlocks shall be disabled in maintenance mode only

5.3.4 Safety Interlock

Safety interlock is a condition that in normal state shall enable the process equipment to be operated, and in
abnormal state shall force the equipment into the interlock state. In all operational modes the safety interlocks shall
be enabled to supervise the operations conditions.

The safety interlock signals may come from protective devices such as emergency stop push buttons, lubrication
systems, etc.

For safety reasons, the interlock signal shall be represented by a logical “1” allowing fail-safe state. All interlocks in
relation to personal safety and catastrophic equipment failure must be connected as hard interlocks. In some cases,
physical locks shall be installed to prevent changes in the authorised operational mode.

The safety interlock should be active at any circumstance, whether the system or equipment is in manual, automatic,
maintenance or any operation mode.

5.3.5 Control Loop

A control loop is a combination of two or more instruments interconnected in an appropriate way to measure or
control a process variable. The components of a control loop will be identified by a group of code letters followed by
a number of the instrument specified by the ISA -5.1-2009 Standard. All components of the control loop will have a
number of common instruments. This common number is called the “loop number”. Each control loop will have a
unique number.

5.3.6 Sequence

An operational sequence is a group of devices which start and/or stop in an established order. The required
interlocks between devices, for a safe and reliable operation, will define the start and stop sequence.

The operator, through the operator workstation, can define whether the sequence will operate automatically or
manually.

5.3.7 Operation

Operation means the plant is up and running.

5.3.8 Event

An event is a detectable occurrence with process significance and it shall be historical logged by DCS. Events may
or may not be associated with a process condition.

5.3.9 Warnings

A condition detected, as occurring prior to a more severe condition that may cause a shutdown, is defined as
warning condition. A warning condition will be displayed at the operator workstation to indicate that a corrective
action shall be taken.
5.3.10 Alarms

An alarm is an abnormal state of a condition which remains active until an operator has acknowledged it. It means a
process deviation, equipment malfunction or any abnormal condition which requires an action.

The project will implement an alarm management system based on recommendations and practices like ASM,
NAMUR, EEMUA and ISA in order to build an effective alarm system. This means a system to notify operators of
abnormal process conditions or equipment malfunction in a rational and effective way

5.3.11 Motor Command

DCS or PLC sends the outputs to command the motor starter. If a warning horn and/or beacon are used for safety
reasons, the motor command will only be activated after the warning signal has completed. A warning horn or
beacon will be ON for at least 15 seconds before starting the device.

5.3.12 Normal Stop

This is the normal way that an operator will stop the process from control room. Devices will be stopped in an
interlocked and timed sequence. Normal stops shall be a normal closed contact that will be opened to stop the
equipment.

DCS or PLC shall normally stop the equipment through the same I/O contact used to start the equipment.

5.3.13 Emergency Stop

An emergency stop will avoid (or stop) the operation (or running) of an equipment or system. For safety reasons and
the emergency stop signal will discontinue the operation immediately, and/or interrupt a sequence if it is part of a
package. Every unit built-in with a motor will be fitted with an emergency stop push/pull button located close to the
motor. The emergency stop push/pull button shall be always in a normally closed contact position at the outer
position for normal operation. In case to be activated the emergency stop at the pushed position the contact shall be
opened and the device shall immediately acquire an emergency stop state.

5.4 Control Modes

5.4.1 Manual/Automatic (A/M)

Automatic mode refers to equipment which is part of a sequence or a configured automatic action and will change
its operational status in accordance to the logics configured in the PCS. The operator selects the auto mode to allow
the PCS take the necessary actions in the equipment operation. The selection of manual operation means that only
the operator can change the operational status of provided equipment.

5.4.2 Base/Standby (B/SB)

When two alternatives equipment are available to perform the same service, one of them shall be selected to
operate (base operation). A configured selector shall allow selection. In this case, the equipment is in auto mode in
the operator workstation. When an equipment or system is selected in base mode, it will be ready to start upon a
command performed by the operator or by an automatic sequence. In case of a failure during the start or in service,
the PCS will automatically select the stand by equipment for operation.
5.4.3 Operator/Maintenance (Op/Maint)

The selection of maintenance or operation modes is done from the PCS operator workstations and allows local
operation of the selected equipment. In maintenance mode only, the process interlocks are ignored and the
maintainer can operate the equipment for maintenance and testing purposes. In maintenance mode, safety
interlocks remain active and do not support the use of automatic mode. Operation mode allows the normal
equipment operation with all safety and process interlocks active. Selection of Automatic mode is possible in this
mode. The Maintenance mode shall be selected first in the PCS operator workstation and then in the field.

5.5 Forwards/Reverse (F/R)

This rotation direction selector will be available in the PCS operator workstations only for equipment that includes
this functionality.

5.6 Functional Test (JOG)

JOG is a local command applied to rotating equipment by means of a pushbutton. With the selector in Maintenance
mode and pushing the JOG button a motor is momentarily energised. Process interlocks will be disabled and safety
interlocks will remain active.

5.7 Local/Remote (L/R)

This mode applies to variable speed motors only, which include its own local panel that allows local motor operation.
Control actions from the PCS will be in normal mode and require the local panel to be in Remote mode.

6.0 Equipment Control Concept

The following points provide the basic equipment control concepts:

6.1 Motor Control

• Control selectors at operator console may include start/stop, operation/maintenance, auto/man,

local/remote (at variable speed driver panel), base/standby and forward/reverse. Specifications of the
motor type, which signals shall be configured for each motor, are given by letters on each side of ISA
symbol YC motor block on the P&IDs. The purpose of this mode of presentation is to reduce diagram
clutter.

• All motors shall have the field push buttons jog/emergency stop. A motor ready to start, for process
operation purposes shall only be enabled when operator/maintenance (Op/Maint) selector is in “OP”. In this
case jog is disabled.
 • A motor ready to start for maintenance purposes from local jog pushbutton shall only be enabled when the
operator at the control room has selected operator/maintenance (Op/Maint) selector in “Maint”. When the
motor is running remotely, any of the selector switches may be switched (independently) at any time to
other positions without any consequence. But if both, the DCS switch and field switch, are placed to
maintenance during motor operation, the motor shall stop.

• The selector on operator position, at the operation console, shall enable remote operation of the system.
When it is set on operation mode, the starting sequence of a system or unit may be accomplished, either
automatic or manually. In both cases all safety and process interlocks are supervising the operational
conditions.

• The field emergency stop button shall be ready to be used under all circumstances.

• The DCS shall be functional for jog function. The jog function shall be configured through the DCS.

• All motor, button or selector states feedback shall be sent to the console operator for information and
historical purposes; additionally, all motor interlock states feedback shall be sent to the console operator
for alarming, troubleshooting and historical purposes.

• Analog motor signals provided via the multifunction motor protection relay to the operator console shall
include at least: Winding temperature for each of the three phases, individual bearing temperatures, motor
average amperage draw, time remaining between starts, numbers of starts, kilowatt draw and in the case
of variable speed drives, speed indication and control set-points and outputs. Some motor vibration signals
are monitored directly by the condition monitoring system (CMS).

• The multifunction motor protection signals shall be sent to the DCS via field communication buses,
exceptionally by direct analog input/outputs or by a combination that may be used on a specific case basis.
The alarm limits for multifunction relay trip points and analog signals shall be provided for each motor for
operator console configurations purposes.

• All motors configured in PLC or DCS shall have runtime hour-meter logic for shift, day and total
accumulation, with an operator-reset option. Where kilowatt is measured, the same frequency of kilowatt-
hour accumulation shall occur.

• All MCC shall be “intelligent” and will communicate digitally with the DCS through a field communication
bus. Additionally, electrical equipment such as variable frequency drives electrical control and protection
devices, electronic relays, etc., shall be intelligent and also communicate digitally with the DCS. See details
in the document Control System and Instrument Design Criteria for MINERA Project (MINERA-SPS-BEC-
0000-J- GD-0001).

6.2 Control Operation Scenario

• When a field operator requires the jog function, the field operator shall communicate with the central
control room (mobile radio communication).The central operator shall place the equipment in maintenance
mode.

• Then, the field operator performs the jog function.

• After local operation, the field operator shall inform the central control room that the equipment is ready.
The central control room operator shall place his switch to Operate.
 • Stop buttons will be red mushroom emergency stop push/pull button (maintained contact). The emergency
stop push/pull button shall be always in a normally closed contact position for normal operation. In case to
be activated, the emergency stop contact shall be opened and the device shall immediately acquire an
emergency stop state. This description shall be applicable for pull-cords and other safety devices. All
interlocks in relation to personal safety and catastrophic equipment failure must be connected as hard
interlock.

6.3 Typical Motor Description

The project has defined the following design criteria details for each typical motor. The motor configuration types are
shown on P&ID Legend Sheet. Following subsections describe only those motor configurations that are used on the
MINERA Project.

6.3.1 Type M1

Low-voltage electric motor (480 Vac), fixed speed, with: start/stop and operation/maintenance functions. Optional
functions: auto/manual, base/standby, forward/reverse at DCS or PLC. Also with safety and process interlocks of the
motor control centre (MCC) and visualisation of status in the control system.

This type of motor shall have the following status and commands in the DCS:

DCS Status:

• Running, stopped, and ready

• Overload status

• Power “ON” status

• Fault

• Control voltage

• Software and hardware interlock status

• Jog status

• Emergency stop status

• Communication loss

• Auto/manual (optional)

• Base/standby (optional)

• Forward/reverse (optional)

DCS Commands:

• Operation/maintenance selector command

• Remote start/stop command

 • Automatic/manual selector command, as applicable

• Base/standby selector command, as applicable

6.3.2 Type M2

Low-voltage electric motor (480 VAC), variable speed, with variable adjustable frequency drive, with: start/stop and
operation/maintenance functions. Optional functions: auto/manual, base/standby, and forward/reverse at DCS or
PLC. Also, with safety and process interlocks of the motor control centre (MCC) and visualisation of states in the
control system.

DCS Status:

• Running, stopped

• Overload status

• Software or hardware interlock status

• Speed (reference and real)

• AFD ready status

• AFD warning alarm status

• AFD powered status

• AFD fault status

• AFD local/remote panel control status

• Jog status

• Emergency stop status

• Communication loss

• Auto/manual (optional)

• Base/standby (optional)

• Forward/reverse (optional)

DCS Commands:

• Operation/maintenance selector command

• Remote start/stop command

• Automatic/manual selector command, as applicable

• Forward/reverse selector command, as applicable

• Velocity set-point adjustment

6.3.3 Type M3

Medium-voltage electric motor (4.16 kV), fixed speed, with: start/stop and operation/maintenance functions. Optional
functions: auto/manual, base/standby, and forward/reverse at DCS or PLC. Also, with safety and process interlocks
of the motor control centre (MCC) and visualisation of status in the control system.

Consider a multifunction motor protection relay with the ability to send variables to control system via digital
communication.

This type of motor shall have the following status and commands in the DCS:

DCS Status:

• Running, stopped, and ready status

• Overload status

• Normal/maintenance local selector status

• Software or hardware interlock status

• Jog status

• Emergency stop status

• Power on status

• Fault

• Communication loss

• Auto/manual (optional)

• Base/standby (optional)

• Forward/reverse (optional)

Additionally, through the protection relay, the following status shall be able to be displayed in the DCS:

• Winding temperature

• Bearing temperature

• Average current

• Average power

• Time between starts

• Number of starts during the last hour

 DCS Commands:

• Operation/maintenance selector command

• Remote start/stop command

• Automatic/manual selector command, as applicable

• Forward/reverse selector command, as applicable

• Base/standby selector command, as applicable

6.3.4 Type M4

Medium-voltage electric motors (4.16 kV Vac), variable speed, with variable adjustable frequency drive, with:
start/stop and operation/maintenance functions. Optional functions: auto/manual, base/standby, and forward/reverse
at DCS or PLC. Also, with safety and process interlocks of the motor control centre (MCC) and visualization of
states in the control system.

Consider a multifunction motor protection relay with ability to send data to control system via digital communication.

This type of motor shall have the following status and commands in the DCS:

DCS Status:

• Running and stopped

• Overload

• Communication loss

• Software and hardware interlock status

• Speed (reference and real)

• AFD ready status

• AFD warning alarm status

• AFD powered status

• AFD fault status

• AFD local/remote panel control status

• Jog status

• Emergency stop status

DCS Commands:

• Operation/maintenance selector command

• Remote star/stop command

 • Automatic/manual selector command, as applicable

• Base/stand by selector command, as applicable

• Forward/reverse selector command, as applicable

• Velocity set-point adjustment

Additionally, through the protection relay or AFD, the following status shall be able to be displayed in the

DCS:

• Winding temperature

• Bearing temperature

• Average current

• Average power

• Time between starts

• Speed (reference and real)

6.3.5 Type M5

Hydraulic motors, variable speed with: start/stop and operation/maintenance functions. Optional functions:
auto/manual, base/standby, and forward/reverse at DCS or PLC. Also optional with safety and process interlocks of
the motor control centre (MCC) and visualisation of states in the control system.

This type of motor shall have the following status and commands in the DCS:

DCS Status:

• Running, stopped and ready status

• Overload

• Local selector status

• Communication loss

• Software and hardware interlock status

• Hydraulic unit local/remote panel control status

• Hydraulic unit warning alarm status

• Hydraulic unit powered status

• Hydraulic unit fault status

• Jog status

• Emergency stop status

 • Speed (reference and real)

DCS Commands:

• Operation/maintenance selector command

• Remote star/stop command

• Automatic/manual selector command, as applicable

• Base/stand by selector command, as applicable

• Forward/reverse selector command, as applicable

• Velocity set-point adjustment

6.3.6 Type M6

Motors monitored through DCS or PLC, external hardwire interlock, logics developed in MCC, local command
start/stop.

This type of motor has the following status in the DCS:

DCS Status:

• Running

• General fault

The above described operations do not affect maintenance or operation procedures, which require MCC “off”
position with personal padlock in locked position on the “on-off” handle of the MCC. The operators, particularly the
field operator, are responsible for any action taken. Selecting “test” position in the Operator Terminal enables this
mode in the MCC.

6.4 Valve Control

Following subsections describe only those valve configurations that are used on the MINERA
Project.

• The control output selectors shall be definable at operator console in general depending on valve size.

• The console shall have operations/maintenance, automatic/manual (optional) selectors and open/close
push buttons. The field open/close push buttons shall be functional only when the console position is in
“maintenance”.

• In general, control output selectors shall be definable at operator console depending on valve size.
Exceptions may be made on an individual basis. For 24 inches valves and larger (hydraulic actuator) the
concept of operation selectors (Automatic/Manual and Operator/Maintenance) shall be similar as for
motors.
6.5 Typical Valve Control Description

The project has defined the following design criteria for each typical valve control block.

6.5.1 Type V1

Manual valve with two-position limit switches open/close (ZSH /ZSL).This type of valve shall have the following
status in the DCS.

• Open/closed status

6.5.2 Type V3

Local operated valve with pneumatic actuator and two-position limit switches open/close (ZSH /ZSL).

This type of valve shall have the following status in the DCS:

• Open/Closed status

6.5.3 Type V4

Single coil solenoid valve with spring return pneumatic actuator and two-position limit switches, remote and local
operation, with the following operating modes: operation/maintenance, auto/manual (optional), from DCS or PLC.
Fail position in these valves depends on the specification for each case (fail open or fail close). This type of valve
shall have the following status and commands in the DCS:

DCS Status:

• Open/closed status

• Fail command

• Fail open

• Fail close

• Valve failure

• Communication failure

• Software permissive

• DCS Commands:

• Operation/maintenance selector command

• Remote open /close command

• Automatic/manual selector command (optional)

6.5.4 Type V5

Two-coil solenoid valve with pneumatic actuator and two-position limit switches remote and local with the following
operating modes: operation/maintenance, auto/manual (optional) from DCS or PLC. Fail position in these valves is
the last position.
 This type of valve shall have the following status and commands in the DCS:

DCS Status:

• Open/closed status

• Fail command

• Fail open

• Fail close

• Valve failure

• Communication failure

• Software permissive

DCS Commands:

• Operation/maintenance selector command

• Remote open/close command

• Automatic/manual selector command (optional)

6.5.5 Type V6

Motorised valve with electric actuator and two-position limit switches open/close, local/off/remote selector and a fail
switch, with open/close and auto/manual (optional) functions from DCS or PLC.

This type of valve shall have the following status and commands in the DCS:

DCS Status:

• Open/closed status

• Fail command

• Fail open

• Fail close

• Communication failure

• Software permissive

• Open/close push button from local panel status

• Local/remote selector from local panel status

• Fail status

• Software interlock status

 DCS Commands:

• Remote open/close command

• Automatic/manual selector command (optional)

6.5.6 Type V7

Single coil solenoid valve with hydraulic actuator and two-position limit switches open/close, with
operation/maintenance, open/close and auto/manual (optional) functions from DCS or PLC. Fail position in these
valves depends of the specification of each case (fail open or fail close).

This type of valve shall have the following status and commands in the DCS:

DCS Status:

• Open/closed status

• Fail command

• Fail open

• Fail close

• General fail

• Communication failure

• Open/close push button from local panel

• Software interlock

DCS Commands:

• Remote open/close command

• Operation/maintenance selector command

• Automatic/manual selector command (optional)

6.5.7 Type V8

Two-coil solenoid valve with hydraulic actuator and two-position limit switches open/close, with
operation/maintenance, open/close and auto/manual (optional) functions from DCS or PLC. In these valves, fail
position is the last position.

This type of valve shall have the following status and commands in the DCS:

DCS Status:

• Open/closed status

• Fail command
 • Fail open

• Fail close

• General fail

• Communication failure

• Open/close push button from local panel

• Software interlock

DCS Commands:

• Remote open/close command

• Operation/maintenance selector command

• Automatic/manual selector command (optional)

6.5.8 Type V10

Electrically actuated valve for modulating control and local or remote operation. In these valve, fail position is the last
position, with local control panel and local indications for open/closed state, local/off/remote selector and open/close
commands. This type of valve shall have the following status and commands in the DCS:

DCS Status:

• Fail status

• Open/closed status

• Manual/auto selector

DCS Commands:

• Valve position (in percentage)

7.0 Process Control Scope
According to project scope and the areas described in Section 3, in the following chapter is described in general
terms the process, detailing the control philosophy that govern each area involved in the MINERA project.
7.1 Grinding Operation Scope

• The purpose of grinding is to process ore from the primary crushing stage and bring it to a final product of
80 percent passing 150 microns (P80 cyclone overflow), which is then sent to flotation circuit.

• The circuit wet grinding will be composed of a gearless motor, adjustable speed, SAG mill, 12.2 m D ×7.92
m (40’ × 26’ EGL) operating in closed circuit. The material feeds the two ball mills 2210-MB-001 @ 002,
(27” × 45” EGL) magnetic trunnion in parallel and also in closed circuit.

• The SAG will discharge material to primary cyclone feed box, 2210-SU-001 and then the slurry is
transported by two pumps: 2210-PP-001 and 2210-PP-002, one per ball mill, to the primary cyclone
cluster. The flow classified as oversize in the trommel is transported to the pebbles plant.

• The undersize material that flows to the primary cyclone feed box, then to the cyclone cluster is transported
to coarse material trap box, 2210-ST-016 and the oversize is transported to respective ball mill.

• The grinding circuit will include:

— SAG mill

— Two balls mills

— Two cyclone batteries

— Ball loading systems

— Two slurry horizontal pumps to batteries cyclones

— Primary cyclone feed box

— Particle size analyser

— X-ray analyser
• The grinding plant will be controlled by the DCS and Vendor dedicated PLCs for some equipment.

• The main control loops or monitoring in this area are:

— Operate and monitor the SAG mill and auxiliary equipment

— Control the addition of water to the SAG mill

— Control the addition of milk lime in the SAG mill

— Operate and monitor ball mills and auxiliary equipment

— Control the addition of milk lime in the ball mills

— Control the density of the slurry feed to cyclones

— Check the pressure in the batteries of cyclones

— Control the level of primary cyclone feed box

— Maximise performance, maintaining a constant supply to the flotation cells

— Monitor the particle size

— Control and monitoring seal water to pumps

— Monitor ore metallurgy

• SAG and ball mills will consist of a gearless mill drive (GMD). All auxiliary drive systems (cooling and cycle-
converter) will be controlled by a PLC provided by the same GMD vendor. The mill and all auxiliary
systems will be controlled from the same PLC provided by the GMD vendor.

• The SAG and ball mills PLCs will communicate bi-directionally with the plant DCS allowing operation of all
systems from the DCS.

The feeders will have the following starting permissive:

Conveyor 2150-CV-003 ready for operation condition. SAG mill ready for operation condition

The process interlocks for the feeders will be the following. Conveyor 2150-CV-003 sttoped

• The SAG mill will have the following starting permissive:

Process water flow greater than N (the number will be determined later) m3/h

At least two feeders in ready for operation condition:

— Conveyor 2150-CV-003 ready for operation condition.

— At least one slurry pump ready for operation condition

— At least one ball mill ready for operation condition

• The process interlocks for the SAG mill will be the following:

— Two slurry horizontal pumps stopped for more than three minutes

— All ball mills stopped

 — 2230-CV-004 stopped

— Ore tonnage to SAG less than N (the number will be determined later) ton/h for more than ten minutes

• SAG mill load weight will be measured indirectly using oil pressure on their bearings.

• Functional specifications for electrical control of SAG and balls mills and auxiliary systems will be prepared
by vendor.

• Control of the addition of water to the SAG Mill is made automatically by a segmented ball type valve with
pneumatic actuator to regulate the water flow according to the measurement of a flow meter. The controller
setpoint will depend of WIC-1+WIC-2

• The controller output of milk lime for SAG and ball mill is using one pinch valve with pulse width modulation
or PWM. The duty cycle time (Tt) for each mill shall be set by programmed logic. If the SAG or ball mills are
stopped, it is required to close all of the milk lime control valves associated to the mills. The controller
setpoint will depend of WIC-1+WIC2

• The main objective for controlling the milk of lime at grinding primary cyclone cluster is to regulate the pH of
the slurry feed to rougher cells, which corresponds to the output of the collecting cyclones overflow and
circulating through metallurgical analyser.

• An ultrasonic level transmitter measures the level of the 2210-SU-001. A level control acts on the variable
speed pumps that feed the battery of cyclones, adjusting its speed to maintain a constant level in the 2210-
SU-001. The low level and high level is indicated on the operator screen, while the low-low level will stop
the pump in operation. The reference level for 2210-SU-001 will be manually set by the operator.

• Addition of dilution water in the 2210-SU-001is made for the purpose of adjusting the density of the pulp. A
nuclear density transmitter is included to the pump discharge as input to the DCS. The density control loop
will govern the reference water addition.

• Mass flow will be calculated in the DCS, and will be based on the measurement of flow and density to the
discharge pumps. One slurry flow meter is included in each line that feeds the cyclones.

• The minimum speed operation of pumps shall be restricted to prevent the siltation in the line. This shall be
configured in the DCS. Pumps will have the following starting permissive:

— At least N (the number will be determined later) valves of battery of cyclones shall be opened

— Suction valve at pump suction shall be opened

— Drainage valves shall be closed

• The process interlocks for pumps will be the following:

— If the pump is operating and more than N (the number will be determined later) valves of battery of
cyclone are closed.

— The condition of low-low flow in the seal water High-high vibration or high - high temperature in the
pumps.

— Low-Low level in 2210-SU-001.

— Suction valve is closed.

 — One drainage valve is opened.

— Drainage valve of 2210-SU-001 is opened.

— The ball mill is stopped for more than 5 minutes.

— Low-low flow of slurry to the battery cyclone.

— All dart valves of distribution box feeds roughers cells are closed.

• The starting sequence for each pump shall be as follows:

— Open washing line valves.

— Close drainage valves.

— Open suction valve.

— Open water valve seal.

— Close washing line valves.

— Start pump.

• The sequence of stopping for each pump shall be as follows:

— Stop pump and the water seal valve shall close 2 minutes after.

— Close suction valve.

— Open drainage valves.

— Open washing line valves for a minute or more (set at field).

— Close washing line valves.

• Mill balls have the following starting permissive:

— As specified by the GMD and mill supplier in its control philosophy

— Battery cyclone pump ready to operate

— As specified by the GMD and mill supplier in its control philosophy

• Battery cyclone pump Mill balls have the following process interlocks:

— is stopped for more than 5 minutes

7.2 Copper-Molybdenum Concentrate Thickener Scope

The copper-molybdenum concentrate thickener is located after the second cleaner stage of the bulk flotation plant
with the objective of achieving high density pulp before the moly plant and at the same time clarified water for re-
circulation. The thickener overflow is send by gravity to the process water pond which will further re-circulate to the
plant. There are two thickener underflow lines, with one of them working and the other stand by. Each line has a
pulp pump to feed the molybdenum rougher feed tank, the following control strategy description is based on P&ID

• The pulp coming from the second cleaner stage goes to the bulk concentrate thickener feed box together
with the thickener recirculation. The dart valve at the bottom of the feed box is manually controlled by the
operator to control the flow to the thickener.
 • At the thickener, there is a level measurement loop and a turbidity measurement loop for monitoring
purpose.

• The drag and lift mechanism are in the scope of the Vendor thickener equipment and identified by him in
the later stages of engineering.

• Each of the underflow lines has a density meter and flow meter, allowing the operator to know the
volumetric flow, mass flow, density and percentage of solids of the underflow pulp. One line is operating
and the other one is stand-by. The density controller shall set the reference speed at the pump VFD to
keep the desired percentage of solids in the underflow and in certain conditions the operator can re-
circulate the pulp. Each of the lines has knife gate control valves that can be manually operated from the
control room to wash and drain the lines. Each pump shall be monitored by the vibration monitoring system

7.3 Moly Concentrate Thickener Scope

The molybdenum concentrate thickener is fed from the fourth cleaning stage through the feed box with the objective
of achieving high density pulp before the molybdenum filtering stage and at the same time clarified water for re-
circulation. The thickener overflow goes by gravity to the molybdenum overflow tank and then the water is pumped
to the copper concentrate thickener overflow tank, there are two thickener underflow lines, with one of them working
stand by, each line conveys by gravity the pulp to the molybdenum concentrate storage tank feed box, the following
control strategy description is based on P&ID MINERA-SPS-BEC-2260-M-PI-0001 to obtain high density in
the underflow to maximise the recovery of water for the plant, the following control strategy description is based on
P&ID

• The pulp to this area is coming by gravity from the fourth cleaning stage in the molybdenum flotation area,
the molybdenum thickener feed box has an ultrasonic level meter, this box feeds the molybdenum
thickener and the molybdenum concentrate storage tanks feeds box when required with a set of dart
valves that allows the operator to manually control either tank.

• At the thickener, there is a level measurement loop for monitoring.

• The drag and lift mechanism are in the scope of the Vendor thickener equipment and identified by him in
the later stages of engineering.

• Each of the underflow lines has a density meter and flow meter, allowing the operator to know the
volumetric flow, mass flow, density and percentage of solids of the underflow tailings. One line is operating
and the other one is stand-by. The density controller shall manipulate the diaphragm pump and convey the
molybdenum concentrate to the molybdenum concentrate storage tank feed box. The molybdenum
concentrate can be recirculated to the molybdenum thickener feed box when required. Each of the lines
has plug control valves that can be manually operated from the control room to wash and drain the lines.
 • After the diaphragm pump there is a valve for recirculation and other valve for conveying, an interlock shall
be to allow one valve open only and if both are closed the diaphragm pump shall be stopped.

7.4 Copper Concentrate Thickener Scope

The copper concentrate thickener is located after the moly plant with the objective of achieving high density pulp
before the copper filtering stage and, at the same time, clarifying water for re-circulation. The thickener overflow
goes by gravity to the process water pond which will further re-circulate to the plant, there are two thickener
underflow lines, with one of them working stand-by, each line has a pulp pump to feed the pipeline feed tank, the
following control strategy description is based on P&IDs

• The pulp coming from the moly plant goes to the thickener feed box together with the thickener
recirculation, the dart valve at the bottom of the feed box is manually controlled by the operator to control
the flow to the thickener.

• There is a pH measuring at the feed box for control at the copper concentrate feed tank 2260-TK-014 in
the moly plant. This is done by two pinch PWM valves with milk lime.

• At the thickener, flocculant should be added to facilitate the siltation. There is a level measurement loop
and a turbidity measurement loop at the thickener that shall be used for the flocculant control strategy. This
shall be developed in detail during the next engineering stage.

• The drag and lift mechanism are in the scope of the thickener Vendor equipment and identified by him in
the later stages of engineering.

• Each of the underflow lines has a density meter and flow meter, allowing the operator to know the
volumetric flow, mass flow, density and percentage of solids of the underflow pulp. One line is operating
and the other one is stand-by. The density controller shall set the reference speed at the pump VFD to
keep 65 percent of solids in the underflow and in certain conditions the operator can re-circulate the pulp.
Each of the lines has knife gate control valves that can be manually operated from the control room to
wash and drain the lines. Each pump shall be monitored by the vibration monitoring system

7.5 Conveying and Pumping Water Pipeline

This system conveys the fresh water from the fresh desalinated water tank, 5230-TK-023 at the desalinated plant
area to the fresh water tank 2831-TK-010 at the concentrator plant. There are three identical pump stations to bring
the water to concentrate plant level. Each pump station shall have a receiver tank and four fixed speed pumps with
a sheared recirculation line to its receiver tank. A control valve to regulate the flow and a second valve to connect to
recirculation shall be installed downstream of each pump.

A cascade control loop shall be in each pumping station to control the water flow, according to the plant
requirements. The principal loop will be the level control of the water tank at the next station, and the secondary loop
will be the flow control from the pumps that feed the tank. The primary controller (level) will drive the set point of the
secondary controller (flow) for all four pumps; this control will reflect the need for water at the level of the last tank,
thus the deficit or surplus of water in the plant is transferred to the upstream tank, successively until the last tank at
the desalination plant.

The recirculation line will be used as a secondary line to fill the main pipe when required, making available the use
of the orifice plates in the recirculation line to allow the pump a higher output pressure when filling the main line.
Thus, when the pressure in the main line reaches a proper value, the output of the pumps can be transferred to
directly feed the main line. The recirculation line it is used as well to keep the operation point of the pumps at an
acceptable level when there are important changes in the required flow.