4 V2 2000 Ic Des 000001 - 0

BHP 4-V2-2000-IC-DES-000001
SGO WP2 Concentrator Project Revision 0, 19Jul2017

Sierra Gorda, Chile Page 2 of 75
Project No: A6YF
Register of Reviews
Rev. No. Date Description
A 22Jun2017 Issued for internal review
B 30Jun2017 Issued for Internal Approval
56
0A 30Jun2017 Issued for Company Approval
0 19Jul2017 Issued for Design
Instrumentation & Control System Design Criteria

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
TABLE OF CONTENTS
1.0 PURPOSE ........................................................................................................................................ 6

2.0 SCOPE ............................................................................................................................................. 6
3.0 STANDARDS AND REFERENCES ................................................................................................ 7
3.1 OCCUPATIONAL SAFETY REGULATIONS .................................................................... 7
3.2 STANDARDS AND CODES ............................................................................................... 7
3.3 APPROVALS .................................................................................................................... 10
3.4 RELATED DOCUMENTS ................................................................................................. 11
3.5 ACRONYMS LIST ............................................................................................................ 11
4.0 DEFINITIONS AND BASE CONDITIONS ..................................................................................... 15
4.1 SITE CONDITION ............................................................................................................. 15
4.1.1 Field Devices........................................................................................................ 15
4.1.2 Control Room ....................................................................................................... 15
4.1.3 Electrical Room .................................................................................................... 15
4.1.4 SEISMIC REQUIREMENT ................................................................................... 15
4.2 UNITS OF MEASUREMENT ............................................................................................ 15
4.3 INSTRUMENT AIR SUPPLY ............................................................................................ 16
4.4 INSTRUMENT IDENTIFICATION ..................................................................................... 17
4.5 CONTROL CABINETS, CABLE AND WIRING IDENTIFICATION ................................. 17
5.0 DESIGN REQUIREMENTS ........................................................................................................... 17
5.1 GENERAL ......................................................................................................................... 17
5.2 CONTROL ROOM ............................................................................................................ 18
5.3 CONTROL SYSTEMS ...................................................................................................... 19
5.3.1 DCS Architecture ................................................................................................. 21
5.3.2 DCS modules ....................................................................................................... 22
5.3.3 Remote IO panels ................................................................................................ 22
5.3.4 Third party Control Systems ................................................................................ 23
5.3.5 Motor Control Modes ........................................................................................... 24
5.3.6 Valves Operating Modes ...................................................................................... 25
5.3.7 Controller operational modes ............................................................................... 26
5.3.8 Motor Control Networks ....................................................................................... 26
5.4 VOIP & DATA NETWORK ............................................................................................... 27
5.5 PROCESS CCTV SYSTEM .............................................................................................. 27
5.6 PAGE/PARTY SYSTEM ................................................................................................... 28
5.7 CONDITION MONITORING SYSTEM.............................................................................. 28
5.8 ELECTRICAL SCADA SYSTEM...................................................................................... 29

BHP 4-V2-2000-IC-DES-000001
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5.9 FIRE DETECTION & ALARM SYSTEM........................................................................... 30

5.10 ANALYZER SYSTEMS .................................................................................................... 30
6.0 INSTRUMENTATION .................................................................................................................... 31
6.1 GENERAL ......................................................................................................................... 31
6.2 FIELDBUS FOUNDATION TRANSMITTERS .................................................................. 33
6.3 FIELDBUS FOUNDATION SEGMENT DESIGN ............................................................. 34
6.3.1 Constraints for segment design ........................................................................... 34
6.4 WIRELESS INSTRUMENTATION ................................................................................... 35
6.5 MACHINERY PROTECTION INSTRUMENTS ................................................................ 36
6.6 INSTRUMENT SELECTION ............................................................................................. 36
6.6.1 Flow Instruments .................................................................................................. 36
6.6.2 Level Instruments ................................................................................................. 38
6.6.3 Pressure Instruments ........................................................................................... 40
6.6.4 Temperature Instruments ..................................................................................... 40
6.6.5 Density Instruments ............................................................................................. 41
6.6.6 pH Analyzers ........................................................................................................ 42
6.6.7 H2S Analyzers ..................................................................................................... 42
6.6.8 Turbidity analyzers ............................................................................................... 42
6.6.9 Belt Conveyor Instruments ................................................................................... 43
6.6.10 On/Off & Regulatory Control Valves (Ball, Globe, Butterfly Valves) .................... 46
6.6.11 Motor Operated Valves ........................................................................................ 50
6.6.12 Hydraulic Operated Valves .................................................................................. 51
6.6.13 Knife Gate Valves ................................................................................................ 51
6.6.14 Pressure regulators .............................................................................................. 51
6.6.15 Flow regulators..................................................................................................... 52
6.6.16 Instrument accessibility ........................................................................................ 52
6.6.17 Process Connections ........................................................................................... 53
6.7 CONTROL CABINETS AND PANELS ............................................................................ 55
6.8 INSTRUMENT AIR AND TUBING FOR CONTROL VALVES ........................................ 57
6.9 JUNCTION BOXES AND INSTRUMENTS SUPPORTS ................................................. 57
6.10 POWER ............................................................................................................................. 57
6.10.1 Uninterruptible Power Supply (UPS).................................................................... 58
6.10.2 UPS design criteria .............................................................................................. 59
6.10.3 Power Distribution Panels .................................................................................... 59
6.11 ELECTRICAL SOCKETS ................................................................................................. 60
6.12 GROUNDING .................................................................................................................... 60
6.12.1 Protection / Safety Grounding (Gnd1) ................................................................. 60
6.12.2 Electronic Grounding (0 Vdc) (Gnd2) .................................................................. 60
6.12.3 Shield Instrumentation Cable Grounding (Gnd3) ................................................. 61

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6.12.4 Cabinet Grounding (TDI) ...................................................................................... 61

6.12.5 Field Instruments Cabinet Grounding .................................................................. 61
6.13 INSTRUMENTATION CABLING, RACEWAY SYSTEMS AND CABLE SEPARATION 61
6.13.1 Instrumentation, Control and Network Cables ..................................................... 61
6.13.2 Instruments Cable Raceway ................................................................................ 62
6.13.3 Cable Separation (Signal Segregation Criteria) ................................................... 63
7.0 LIST OF ATTACHMENTS ............................................................................................................. 66
7.1 ATTACHMENT 1: PREFERRED MANUFACTURER LIST ............................................. 67

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
1.0 PURPOSE
The purpose of this document is to provide a general design criteria and guidance for the Instrumentation
& Control Systems (I&CS) design labors for the execution phase of the SGO Project of BHP. This
document will provide the design criteria for the execution phase of the WP02 EPC contract.
This document establishes and defines the design standards and engineering practices to be used for the
instrumentation and control system discipline in the developing of the project on this stage for all areas of
the process plant. This document will provide tool for selecting types of instrumentation and control
system.
2.0 SCOPE
These design criteria along with specifications, practices, and standards referenced herein provide the
basis for engineering and design of the instrumentation required to monitor and control the Work Package
(WP) 2 of the SPENCE GROWTH OPTION (SGO) Project.
The scope of this document includes the following facilities:
• 2140 Coarse Ore Storage/Stockpile.
• 2280 Coarse Ore Reclaim.
• 2210 Grinding.
• 2220 Copper Flotation and Regrinding.
• 2230 Pebble Crushing.
• 2240 Copper-Moly Concentrate Thickener.
• 2250 Concentrate Pumping & Pipeline.
• 2260 Molybdenum Plant.
• 2265 Copper Concentrate Thickener.
• 2270 Flocculant Plant.
• 2270 Lime Plant.
• 2270 Flotation Reagent Plant.
• 2290 Filter Plant.
• 2291 Compressed Air.
• 2295 Filter Cake Storage and Loadout Facilities.

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• 2610 Tailings Thickener.
• 2831 Water Supply & Distribution.
• 2832 Sewage Treatment Plant (underground pipes).
• 2834 Air Compressors Plant.
• 2850 Project-Wide Systems.
• 2860 Plant Control Systems.
3.0 STANDARDS AND REFERENCES
3.1 OCCUPATIONAL SAFETY REGULATIONS
Occupational Safety and Health Administration (OSHA), including any requirements by Chilean
agencies that have jurisdiction where the equipment will be installed, shall apply.
DS N° 132 Decreto Supremo de 2002 del Ministerio de Minería.

Reglamento de Seguridad Minera (Mining Safety
Regulations), updated 2013. (Note 1)
OSHA 29 CFR 1910 Occupational Safety and Health Standards.
EPA 40 CFR Part 60 Standards of Performance for New Stationary Sources.
EPA 40 CRF Part 63 National Emission Standards for Hazardous Air Pollutants
for Source Categories.
Note 1: an English translation of key articles can be found in document N° 4-V2-2000-EL-DES-

000001, “Electrical Design Criteria”.
3.2 STANDARDS AND CODES
The design, fabrication, testing, installation, and operation of instrumentation and control
equipment and materials must meet or exceed the requirements of the latest edition of the
following standards and codes.
AG-140 Foundation Fieldbus: Wiring and Installation 31.25kbit/s,

voltage mode, wire medium application guide Revision 1.
AG-163 Foundation Fieldbus Application Guide 31,25 kbit/s

Intrinsically Safe Systems 2.0.
AG-181 Foundation Fieldbus System Engineering Guidelines

Revision 3.2.1.

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ANSI / ISA – 5.1. 2009 Instrumentation Symbol and Identification.
ANSI / ISA – 5.3 Graphic Symbols for Distributed Control.
ANSI / ISA – 7.0.01 Quality Standard for Instrument Air.
ANSI / ISA – 12.02.04 Fieldbus intrinsically safe concept (FISCO) and Fieldbus
non-incendive concept (FNICO).
ANSI / ISA – 37.1 Electrical Transducers Nomenclature and Terminology.
ANSI / ISA S50.02 Fieldbus Standards for Use in Industrial Control Systems.
ANSI / ISA – 51.1 Process Instrumentation Terminologies.
ANSI / ISA 75.01.01 Flow Equations for Sizing Control Valves.
ANSI/ISA-95 American National Standards Institute – Enterprise –Control

System Integration.
ISA/IEC-62443 (Formerly ISA99) Security for Industrial Automation and Control Systems.
API 520-part 1 Sizing, Selection and Installation of Pressure-Relieving

Devices.
API 526 Flanged Steel Pressure Relief Valves.
API 670 Machinery Protection Systems.
API 2000 Venting Atmospheric and Low-Pressure Storage Tanks.
ASM Consortium Abnormal Situation Management Consortium.
ASME American Society of Mechanical Engineers.
ASTM American Society for Testing and Materials.
CCHEN Comisión Chilena de Energía Nuclear.
DIN Deutsche Institut für Normung.
EIA Electronic Industry Association.
EEMUA 191 The Engineering Equipment and Materials Users’

Association, Alarm System, A Guide to Design, Management
and Procurement.
EEMUA 201 The Engineering Equipment and Materials Users’

Association, Process Plant Control Desks Utilizing Human-

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Computer Interfaces - A Guide to Design, Operational and

Human Interfaces Issues.
FD-043 Foundation Fieldbus: Technical Overview Rev.3.
ICEA Insulated Cable Engineers Associated.
IEC-6100 Electromagnetic Compatibility.
IEC-61131 Programmable Controller.
IEC-61158 Fieldbus Standard for use in Industrial Control System.
IEEE 518-1982 Guidelines for Electrical Equipment Isolations against RFI.
IEEE 802.1 Bridging & Management specifications.
IEEE 802.3 Carrier sense multiple Access with collision detection

(CSMA/CD) access method and physical layer
specifications.
IEEE 802.11 Wireless LAN Medium Access Control (MAC) and Physical
layer (PHY) specifications.
NCh Elec.4/2003 Instalaciones de consumo en baja tensión (Low voltaje

facilities standard). (Nota 2)
NEC National Electrical Code.
NEMA 250 Enclosure for Electrical Equipment.
NFPA National Fire Protection Association.
PI Order 8.012 Profibus Installation Guideline for Planning.
PI Order 8.021 Profibus Installation Guideline for Assembly.
PIP Process Industry Standards.
PIP PCCGN001 General Instrumentation Design Checklist.
PIP PCCGN002 General Instrument Installation Criteria.
PIP PCEFL001 Flow measurement Guidelines.
PIP PCCFL001 Flow Measurement Criteria.
PIP PCELI001 Level measurement Guidelines.
PIP PCCLI001 Level Measurement Criteria.

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PIP PCCPR001 Pressure Measurement Criteria.
PIP PCCTE001 Temperature Measurement Criteria.
PIP PCETE001 Temperature Measurement Guidelines.
PIP PCCPA001 Process Analyzer System Design Criteria.
PIP PCEPA001 Process Analyzer System Engineering Guidelines.
PIP PCEPA002 Process Analyzer Project Implementation Guidelines.
PIP PCCCV001 Selection of Control Valves.
PIP PCCCR001 Selection Criteria for Control Regulators.
PIP PCCEL001 Instrumentation Electrical Requirements.
PIP PCERE001 Rotating Equipment Monitoring Guidelines.
TIA Telecommunications Industry Association.
UL Underwriters Laboratories.
Note 2: an English translation of key articles can be found in document N° 4-V2-2000-EL-DES-

000001, “Electrical Design Criteria”.
The compliance of these codes and standards shall be considered as integral part of this
document. None deviation will be accepted without approval in writing by Minera Spence S.A. or
their representative.
3.3 APPROVALS
All equipment must have the approval and/or certification of at least one of the following
international organizations:
BS British Standards (Inglaterra)
CSA Canadian Standards Association (Canada)
FM Factory Mutual (USA)
FOC Fire Offices Committee (Canada)
NCE Normas de la Comunidad Europea
UL Underwriters Laboratories (USA)
ULC Underwriters Laboratories (Canada)

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
3.4 RELATED DOCUMENTS
The following documents and drawings complement this document:
GLD.010 (BHP) Fatal Risk Control.
STA.009 (BHP) Environmental.
4-V2-2000-ST-DES-000001 Structural design criteria.
4-V2-2000-PP-DES-000001 Piping design criteria.
4-V2-2000-PP-DES-000003 Fire protection design criteria.
4-V2-2000-EL-DES-000001 Electrical design criteria.
4-V2-2000-ME-SPE-000002 Site conditions technical specification.
4-V2-2000-PP-SPE-000001 Technical specification for piping materials.
4-V2-2000-IC-SPE-000001 Instrumentation and Control System Requirements for

Packaged Equipment.
4-V2-2850-IC-DES-000001 Communications Systems design criteria.
4-V2-2860-IC-SPE-000001 Design requirements for central control room.
4-V2-2000-PR-PID-100005@07 P&ID Instrument Identification.
2000-ME-PRE-0001(BHP) Engineering Tags.
3.5 ACRONYMS LIST
The following acronyms list will be applicable to this document. It corresponds to:
AC Alternate Current.
ADSS All Dielectric Self Supported (for fiber optic cabling).
AWG American Wire Gauge.
CAT Configuration Acceptance Test.
CCR Central Control Room.
CCTV Closed Circuit Television.

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CDEC Centro de Despacho Económico de Cargas (chilean main

interconnected electric system operator: “Economic Load
Dispatch Center”).
CMS Conditions Monitoring Systems.
CN Control Network.
CPU Central Processing Unit.
DC Direct Current.
DCS Distributed Control System.
DES Distributed Electrical Subsystem.
DPDT Double Pole Double Throw.
EAMS Enterprise Asset Management Solutions.
EMI Electromagnetic Interference.
ESS Electrical Supervisory System.
EWS Engineering Work Station.
FAT Factory Acceptance Test.
FDAS Fire Detection and Alarm System.
FF Foundation Fieldbus (or Flat Face Flanged Connection).
FF-H1 Foundation Fieldbus low speed (H1 link).
FF-HSE Foundation Fieldbus High Speed Ethernet.
FHSS Frequency Hopping Spread Spectrum.
FISCO Fieldbus Foundation Intrinsically Safe Concept.
FNPT Female National Pipes Thread.
FRP Fiber Glass Reinforced Plastics.
GbE Gigabit Ethernet.
Gbps Giga bits per second.
HART Highway Addressable Remote Transducer Protocol.

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HIG High Intensity Grinding.
HMI Human Machine Interface.
HIST Host Interoperability Support Test (FF).
HVAC Heating, Ventilating and Air-Conditioning.
IED Intelligent Electrical Device (Smart Starter).
kbps Kilo bits per second.
I/O Input or output point.
LAS Link Active Schedule.
LCD Liquid Crystal Display.
LOWS Local Operator Work Station.
MASL Meters Above Sea Level.
Mbps Mega bits per second.
MCC Motor Control Center.
MNPT Male National Pipes Thread.
NPT National Pipes Thread.
OLE Object Linking Embedding.
OPC OLE for Process Control.
OPGW Optical Ground Wire.
OSAS On Stream Analyzer System.
OSI Open System Interconnection.
OTN Optical Transport Network.
OWS Operator Work Station.
PCN Process Control Network.
PESS Power Electrical Supervisory System.
PF DP Profibus DP.

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PID Proportional, Integrative and Derivative Controller.
PIN Process Information Network.
PLC Programmable Logic Controller.
PIMS Plant Information Management System.
PVC Polyvinyl Chloride.
P&ID Process and Instrumentation Diagram.
RF Raised Face Flanged Connection.
RFI Radio Frequency interference.
RTD Resistance Temperature Detector.
SAT Site Acceptance Test.
SCADA Supervisory Control & Data Acquisition (Electrical).
SFR Staged Flotation Reactor.
SGO Spence Growth Options (the project).
SNMP Simple Network Management Protocol.
SPDT Single Pole Double Throw.
TCP/IP Transmission Control Protocol / Internet Protocol.
UDP User Datagram Protocol.
UHF Ultra High Frequency.
UPS Uninterruptible Power Supply.
UV Ultraviolet Rays.
VAC Volts Alternating Current.
VDC Volts Direct Current.
VCR Virtual Communication Relationship.
VHF Very High Frequency.
VLAN Virtual Local Area Network.

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VPN Virtual Private Network.
VSD Variable Speed Drive.
XLPE Cross linked Polyethylene.
4.0 DEFINITIONS AND BASE CONDITIONS
4.1 SITE CONDITION
In general, I&CS design shall consider environmental conditions for three different zones:
4.1.1 Field Devices
All equipment, instruments installed outdoors shall be designed to meet the environmental
conditions identified in the document 4-V2-2000-ME-SPE-000002, "Site conditions technical
specification”.
Area classification definition established in document 4-V2-2000-EL-DES-000001, “Electrical

Design Criteria”, shall be considered to determine equipment protection to corrosive or hazardous
areas.
4.1.2 Control Room
All equipment installed in control room shall be designed to meet at least the environmental
conditions identified in the document 4-V2-2860-IC-SPE-000001, "Design requirements for
central control room”.
4.1.3 Electrical Room
All equipment installed inside electrical rooms shall be designed to meet at least the
environmental conditions identified in the document 4-V2-2000-EL-DES-000001, “Electrical
Design Criteria”, chapter 13..
4.1.4 SEISMIC REQUIREMENT
Seismic zone 2 as per Chilean code NCh 433 and NCh 2369 shall be used for this Project. Refer
to document N° 4-V2-2000-ST-DES-000001, Structural Design Criteria”, for translation of key
articles.
4.2 UNITS OF MEASUREMENT
The engineering units used in instrument data sheets and specifications will be based on the
International System of Units (SI) of the International Standard Organization (ISO), including the
most frequently used in projects implementation.
In this Project, the following engineering unit shall be used:

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Description Unit Symbol
Process
3
Liquid Flow Rate Meter cubic per hour, liters per minute m /hr, l/min
Mass Flow Rate Ton per hour t/h
3
Gas Flow Rate Normal Cubic Meter per hour Nm /h (*)
(*) At standard conditions of 0°C and 101.325kPa
3
Kilogram per cubic meter kg/m
Density 3
Tons per cubic meter t/m
Level Percentage (%), Meters, millimeter %, m, mm.
Pressure (gauge) Kilopascal gauge kPa
Pressure (absolute) Kilopascal absolute kPa(a)
Pressure (differential) Kilopascal kPa
Pressure (Vacuum) Millimeter of Mercury mmHg
Temperature Celsius Degrees °C
Vibration (displacement) millimeter mm
Vibration (speed) Millimeter per second mm/s
2
Vibration (acceleration) Millimeter per square second mm/s
Weight Kilogram, metric ton kg, mt
Electrical
Current Ampere A
Voltage Volt V
Energy Joule, kilowatt per hour J, kWhr
Electrical Power Watts W
Apparent power Volt Ampere VA
Frequency Hertz Hz
Analytical
Acidity/Alkaline No dimensional pH
Concentration Gram per liter, parts per million, gr/l, ppm,
Conductivity Micro Siemens per centimeter uS/cm
Specific Heat Kilo joule per kilogram Kelvin degree kJ/kg °K
Viscosity Centipoises cP
Basic
Distance Meters, millimeters m, mm
Angular speed Revolution per minute rpm
Linear speed Meters per second m/s
Pipeline Diameters Inch, millimeters in, ”, mm
Others
Sound Level Decibel dB
Time Hour, Minute, Second Hr, min, s
4.3 INSTRUMENT AIR SUPPLY
Instrument air shall be free of corrosive contaminants and hazardous gasses, which could be
contained in the instrument air supply. The air system intake shall be located in a zone free of
contaminants.

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Instrument air supply will be provided at the following conditions in pipe rack headers and sub-
headers
Minimum operating pressure 550 kPag
Maximum operating pressure 690 kPag
Dew Point -40°C at 690 kPag
Maximum 40 micrometer particle size is defined in the instrument air system (ANSI/ISA– 7.0.01–
1996). Pneumatic devices that require instrument air with less than 40 micrometer particle sizes
shall have additional filtration to meet the particulate size limit for the device.
The lubricant content should be as close to zero as possible, and under no circumstances it shall
exceed one (1) ppm w/w or v/v (ANSI/ISA– 7.0.01– 1996).
See section 6.8 for design criteria about tubing and manifolds.
4.4 INSTRUMENT IDENTIFICATION
Instrument symbols on Piping and Instrument Diagrams shall be according to P&ID Instrument
Identification 4-V2-2000-PR-PID-100005 /100006/100007.
The document “Engineering Tags” 2000-ME-PRE-0001 from BHP establishes the instrument
tagging structure and procedure.
4.5 CONTROL CABINETS, CABLE AND WIRING IDENTIFICATION
Control cabinets, cable and wiring Instrument shall also be according to the document
“Engineering Tags” 2000-ME-PRE-0001 from BHP.
5.0 DESIGN REQUIREMENTS
5.1 GENERAL
Instrumentation and control systems will be designed having a centralized operation from a
central control room CCR. Local operation of equipment only can be authorized from the control
room based on field operators’ requests or in special cases.
All instruments and control systems will be manufactured as a standard. The brands of
instruments and associated equipment shall be represented in Chile and its representative must
provide service at site.
Instrumentation and control systems supplied with mechanical packages shall be specified trying
to keep as much as possible the vendor’s standard design.
All instrumentation and equipment installed in the field shall be designed to operate properly in
the environmental and seismic conditions described in point 4.1 “Site Condition.

BHP 4-V2-2000-IC-DES-000001
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In particular cases, additional protection to that specified in data sheets should be considered for
instruments installed in dusty areas with strong sunlight and/or high humidity, risk of spillage of
water or other liquids, gasses and sulfur environments (acid mixtures).
Equipment will be installed as much as possible outside of classified areas. Nevertheless, if an

equipment must be installed within a classified area, the design shall be based on ISA 12.01.01,
“Definition and Information Pertaining to Electrical Apparatus in Hazardous (Classified) Locations”
for non-Foundation Fieldbus Instrumentation, and FISCO for Foundation Fieldbus
Instrumentation.
Instrumentation installed in classified areas must be rated intrinsically safe and rated for the
specific gas group and temperature rating. All conventional instruments located in classified areas
shall have intrinsically safety barriers. Intrinsically safe requirement for apparatus and electrical
system shall be according to ISA 12.02.01 (IEC 60079-11 mod).
5.2 CONTROL ROOM
The SGO project will include a control room located adjacent to the existing administration
building of Minera Spence and it will be called “central control room” CCR tag number 2915-ER-
001. The existing administration building is located at an approximate distance of 3.5 kilometers
from the concentrator plant. The communication between both facilities will be by means of a
Multi-services Telecommunication System. The Multi-services Telecommunication System will be
integrated with an optical transport network as a transport layer network and Ethernet switches as
a services layer network.
In addition, local Human Machine Interfaces (HMI) will be used for monitoring and controlling
processes which require local operation (such as filter presses).
Central control room will host operation workstations and equipment from separate contractors to
control and monitor different process areas as follows:
• Primary Crusher (by separate contractor).
• Sacrificial and Overland Conveyors (by separate contractor).
• Stock Pile and Ore Reclaim.
• Grinding Plant.
• Pebbles Crushing and Conveying Plant.
• Flotation Plant.
• Regrind.
• Moly Plant.
• Reagents Plant.

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
• Cu and Moly Thickening.
• Filter Plant & Concentrate Handling.
• Tailings Thickeners.
• Tailings distribution (by separate contractor).
• Reclaim water system (by separate contractor).
• Desalination plant and water supply system (by separate contractor).
There will not be a segregated control room to manage the primary crusher and overland
conveyor and all equipment upstream of the stockpile. Also, there will not be a segregated control
room to manage the tailings distribution and reclaim water system.
Filter plant will be able to be locally controlled from local control panels.
Desalination plant and water supply system will provide its own control room to manage the
desalination process and the three pumping stations.; However, certain signals from these
facilities will be monitored from CCR,.
Additionally, concentrate plant process analyzer systems and advanced/expert engineering

workstations will be installed within the engineering room nearby CCR. Mine dispatch operation
workstations (by Company) are projected to be installed within the CCR.
Electrical SCADA operation workstations (by separate contractor) will be installed in the SCADA
engineering room near CCR.
Control room building and its services facilities engineering and construction tasks are out of
Fluor-Salfa scope of work.
5.3 CONTROL SYSTEMS
The control system DCS hardware and software will be of last generation available in the market
and already tested and working in other similar plants.
SGO Project’s DCS concept shall be based on DCS technology, which will be used for controlling
process areas and mechanical packages supplied without control system. Third party PLCs and
dedicated proprietary controllers shall be considered for specific mechanical equipment packages
of the plant and they shall be communicated to the DCS. In general, the following mechanical
equipment shall be controlled directly from the DCS:
• In Plant conveyors.
• Belt feeders.
• SFR Flotation cells.

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
• Reagent plants.
• Flocculant plant.
• Lime plant.
• Dust collector system.
• Dust suppression system.
• Pumps (slurry, water, etc.).
• Moly plant.
On the other hand, the following mechanical equipment shall be controlled by its own PLC or
proprietary controller:
• SAG Mill.
• Ball Mills.
• Regrind HIG mills.
• Filter plant.
• Maxibag packaging equipment.
• Compressed air.
• Concentrate & tailings thickeners.
Main process areas and mechanical packages supplied without a control system will be
controlled by the DCS using FF H1 segment cards for connecting intelligent FF instrumentation
and control valves; and remote Input/Output (I/O) panels compatible with Profibus DP v0/ v1
protocol, for connecting discrete and conventional analog instrumentation.
The following paragraphs describe the main requirements and characteristics considered for
DCS, remote I/O and third party PLCs.
The DCS’s modules shall be removable and plugged-in under power conditions (“RIUP” type),
including controllers. DCS cabinets shall include all accessories and electrical hardware such
power supplies, terminals, cable trays, etc.
The DCS shall provide self-diagnostic capabilities. DCS shall allow a real online configuration
while the process is running. Tag database shall be unique and global, so that control tags can be
invoked from any workstation and/or controller just writing the tag number in the configuration
tool. DCS shall be configured using functional blocks, high level language, etc. Both, online and
off line configuration processes of the control application shall be allowed.

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
DCS shall consider 20% spare installed capacity of I/Os points, slots, power supplies, terminals
blocks, and space in cabinets and panels at the moment the system is tested at factory (FAT).
Deviation to this criterion shall be analyzed and approved case by case by Fluor-Salfa.
Processors shall be sized so each one provides 50% spare capacity in memory and processing
cycle after developing the configuration and site acceptance test.
Resulting spare capacity shall be informed to Fluor-Salfa, in order to define, whether the
processor shall be divided in two, or whether it shall be kept as final spare capacity.
5.3.1 DCS Architecture
The DCS will be the base of the hierarchy structure of the automation platform as stated in ISA
95. The DCS shall consist of a control network (CN) which runs throughout the plant. The DCS
controllers and the operation consoles shall be connected to the CN. DCS can be based on
either, client/server or peer to peer architecture.
DCS controllers shall be redundant type regarding CPU controllers; communication modules;
communication channels and power supplies.
CN shall provide high availability, achieved through redundancy. CN shall be redundant Ethernet
network based on single mode fiber optic backbone encompassing the entire plant, which will be
able to share information among different type of workstations and process controllers.
CN shall only support network services related with control systems (DCS); therefore, it could not
share its infrastructure with CCTV, CMS, among others.
The CN will meet the following requirements
• At least two different communication paths between nodes to tolerate all single faults
and some multiple faults.
• Tolerate a variety of multiple failures in cables and electronics.
• Rapid (~1 sec) detection and recovery (switch over)
• Transparent to PC applications.
• Allow normal non Fault Tolerance Ethernet (non-FTE) nodes.
• Online addition/removal of nodes.
• No proprietary hardware.
• Minimal overhead — no duplicate messages.
• Fully distributed — no “master” node.
• Fast 100/1000 Mbps performance.

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5.3.2 DCS modules
DCS cabinets shall consider FF H1 and Profibus DP DPM1/DPM2 communication modules for
connecting the remote I/O panels in the field.
DCS shall be fully compatible with Foundation Fieldbus technology, including control-in-the-field
feature. DCS shall allow to configure any Fieldbus Foundation instrument directly, without using
external equipment or software (third party equipment), for developing this task.
Fieldbus Foundation H1 modules will not be redundant. However, power supply and conditioners
used for feeding the segments shall be redundant.
In general, since field conventional instrumentation will be connected using remote IO panels, no
conventional I/O modules shall be considered or installed in DCS Cabinets, unless it is required
for special cases.
Profibus DP communication modules shall be segregated by remote IO panels; mechanical

package’s PLC; MCC smart starters; and VSDs independently.
5.3.3 Remote IO panels
Remote I/O panels shall be installed in the field and they shall collect signals from instrumentation
and field devices. These panels will transfer the data to/from the DCS cabinet (installed inside the
electrical rooms) by means of communication buses. Conventional instruments, such as on /off
valves; switches; and 4-20mA analog instruments will be connected to remote I/O panels
communicated to DCS cabinets through Profibus DP v1 links. Foundation Fieldbus instruments
and throttling valves will be connected to remote I/O panels communicated to DCS cabinets by
Foundation Fieldbus H1.
Remote IO panels shall provide NEMA4 or NEMA 4X enclosure protection depending area
classification, including free maintenance terminals for electrical feeding circuitry and Profibus DP
v0/v1 communication port. Remote IO panels shall be connected to the DCS, using a Profibus
DPv0/ v1 communication links in a redundant topology.
Profibus DP segments shall be designed considering the amount of remote IO panels to be

communicated, the amount of data to be transferred and the communication link speed required
for each application.
Remote IO Profibus DP segments shall consider a maximum of six (6) nodes per segment, with a
segment length shorter than or equal to 400 m in order to set bus baud rate at least at 500 kbps.
Deviation to this criterion shall be analyzed and approved case by case by Fluor-Salfa.
Remote IO panel shall consider the following Input/Output modules:
• DI - Discrete Input modules, 120 Vac, isolated channel type.
• DO - Discrete Output modules, 120 Vac, relay type, isolated channel type.
• AI - Analog Input modules, 4-20mA, conventional input (no HART), isolated channel
type.

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• AO - Analog Output modules, 4-20mA, conventional output (no HART), isolated

channel type.
• Pulse counter for encoders (exceptionally).
Instrumentation connected to the same remote IO panel shall belong to the same sub-process
area, and as much as possible a single Profibus DP network of remote IO panels shall not share
different process areas.
Discrete instruments such as switches (DI or DO signals) shall be connected to the remote IO
panel. In general, electrical power for each input/output point will be provided by the remote IO
panel. Deviation to this criterion shall be reviewed and approved case by case by Fluor-Salfa.
Remote IO shall be designed such as when the system is tested at factory (FAT) there shall be
20% spare installed capacity of I/Os points, racks, power supplies, terminals, etc. Deviation to this
criterion shall be discussed and approved case by case by Fluor-Salfa.
Instruments belonging to common areas such as air system, emergency showers, etc. shall be
connected to the closest remote IO panel disregarding the process area.
5.3.4 Third party Control Systems
Some mechanical and electrical packages will be controlled directly by the DCS and some other
equipment will include control systems for managing themselves according to the standard
definition of the vendor.
There will be different types of vendor control systems available within this project. Equipment
with vendor control systems may require a local control in the field or remote control from the
DCS workstations in the control room.
For remote control cases, the operating displays in the DCS shall reflect the vendor HMI displays
and the link between DCS and vendor PLC will transfer several variables, statuses, alarms, etc.
These cases are Gearless mill drives, pebble crusher, HIG mills, etc.
For local cases, the amount of data transferred between DCS and vendor PLC is less than
previous case. A few statuses and alarms may be enough (definition will be done case by case).
The vendor HMI displays are not required to be duplicated in the DCS. Filter press; bag
packaging equipment; etc. are examples of these cases, in the same way that there is no need to
duplicate HMI from desalination plant or water supply system.
The packaged equipment PLC may be connected by either redundant or non-redundant

communication link to the DCS upon the critical nature of the equipment and its importance within
the process. For equipment remotely controlled from the DCS, the link shall be redundant. For
local control, a non-redundant link is enough.
Equipment with proprietary controller will be used for special equipment where Vendor has a
proprietary development (example compressors control system, X-Ray Analyzer System, particle
size analyzer, cartridge filter jet pulse, etc.).

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If a PLC controller for equipment packages is used, this shall be communicated to DCS through
Modbus TCP/IP or Ethernet/IP when high quantity of transferred data is required (HMI) and
Profibus DP, for low quantity of transferred data.
The communication link between vendor control system and DCS shall be exclusive and it shall
not be shared with HMI or printer or any other device within the vendor package.
As much as possible, the vendor will provide RTDs or Thermocouples with 4-20mA temperature
transmitters embedded into the same enclosure. Vendor’s exception to this requirement must be
approved by Fluor-Salfa.
Vendor shall supply all the configuration software, licenses and accessories such as special
cables and adapters required for configuring the PLC, HMI and any other equipment considered
within its supply.
5.3.5 Motor Control Modes
Typically, all process equipment will be operated in three (3) main control modes, “Operation
Mode”, “Maintenance Mode” and “Out of Service Mode”. For all equipment, these control modes
are selected from DCS workstations in the control room; no local physical selector shall be
installed at field.
A. Operation Mode
Typical motor in Operation mode has all safety/process interlocks and start permissive inputs
enabled, so that all of them shall be in logical state 1 for the equipment becomes “Ready to start”.
Once started, all permissive inputs are disregarded in the logic control, however as soon as any
safety or process interlock is activated (changes down to logical state 0) the equipment must stop
immediately.
Operation mode will comprise two (2) sub modes Manual and Automatic:
• In manual mode, motor will start/stop based on start/stop commands given by the
operator through the DCS workstations in the control room.
• In automatic mode, motor will start/stop based on start/stop commands generated by

sequences and/or algorithms included in logic control application configured into the
DCS.
In both modes, manual stop commands from DCS workstations shall always stop the equipment.
This description of the Operation mode is valid for all kind of motors, low and medium voltage
with fixed and variable speed.
B. Maintenance Mode
Low voltage
In Maintenance mode, low voltage motors (both fixed and variable speed) are operated by
commands from the local control station (push button station located at the field), and process

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interlocks and permissive inputs are disregarded by the control logic, and only safety interlocks
are considered. The functionality of the push buttons located at the local control station is
described below.
• Jog pushbutton: As long as the jog pushbutton is pushed, the equipment will be
operating. The jog operation can only be initiated if the equipment has its selector
switch in the “Maintenance” mode position.
• Emergency stop pushbutton: This mushroom pushbutton (latched) will immediately

stop the equipment, regardless the operation mode selected.
Medium voltage
In Maintenance mode, medium voltage motors (both fixed and variable speed) are operated from
the DCS workstation as requested by the local operator in the field, who takes over the
equipment during maintenance procedures. JOG pushbutton is not provided in local station. And
the emergency stop pushbutton will immediately stop the equipment, regardless the operation
mode selected.
Similar to the low voltage motors, in this mode process interlocks and permissive inputs are
disregarded by the control logic, and only safety interlocks are considered.
C. Variable Speed Drive Motor Control
In Operation and Maintenance modes, variable speed drivers (VSD) will normally operate in
remote mode selected from the VSD local control panel, so that the start/stop commands will
come from DCS workstations or from the local control station in the field (jog and emergency stop
pushbuttons) according to the description above.
Only for troubleshooting or commissioning purposes, the local mode may be selected from the
VSD local panel, so that the VSD may be commanded locally through it.
D. Out of Service Mode
In “Out of Service Mode”, all motors shall have its control logic completely deactivated, and no
alarm of any abnormal condition shall be reported to the operator HMI.
A depicted description for all motor types considered within the Project is shown in “P&ID Typical
Motor Control Description” A4-V2-2000-PR-PID-100009.
5.3.6 Valves Operating Modes
On/Off valves will operate in two (2) main control modes, Operation mode and Out of Service
(OOS) mode, both modes can only be selected from the DCS operation workstations in the
central control room. Maintenance mode is not available for valves, and consequently local
control station is not provided either.

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A. Operation Mode
Unlike motors, on/off valves will have separate interlocks to open and interlocks to close. So that,
the functionality of a particular valve shall be as follow:
In operation mode, the valve will open when: it receives an open command and all opening
interlocks are in logic status 1. Likewise, the valve will close when: it receives a close command
and all closing interlocks are in logic status 1.
In addition, operation mode shall consider two (2) sub modes: Manual and Auto. In manual sub
mode, Valves will open/close according to the open/close commands given by the operator
(open/close soft buttons in DCS-HMI). In Auto sub mode, On/Off valves shall open/close
according to the open/close commands generated by the automatic algorithms such as
sequences configured at the DCS.
In Out-of-Service mode, the valve will be out of service so that it will remain in its normal or last
position, depending on its setting and there will be no way to open or close it.
B. Motorized Control Valves Operational Modes
The motorized on/off valves shall have the same functionality as on/off valves as described
above. However and only for troubleshooting or commissioning purposes, the local mode may be
selected from the local panel of the electrical actuator, so that the valve can be commanded
locally through it. Therefore, the status of the local panel of the electrical actuator shall be in
remote mode normally.
C. Out of Service Mode
In “Out of Service Mode”, all valves shall have its control logic completely deactivated, and no
alarm of any abnormal condition shall be reported to the operator HMI.
A depicted description for all valve types considered within the Project is shown in P&ID “Typical
Valve Control Description” 4-V2-2000-PR-PID-100008.
5.3.7 Controller operational modes
All process controllers shall consider at least the standard control modes defined for this kind of
elements Local, Remote, Auto, Manual.
5.3.8 Motor Control Networks
Motor starters and variable speed drivers (VSD) will be used for commanding and controlling
motors in the process. Motor commands shall be done using Profibus DP communication links
between smart starters/VSDs and DCS or control systems of vendor package.
Where motor starters or VSD cannot be controlled by Profibus DP links, and only in justified
cases, Project will accept commanding the starters/VDSs using hardwired signals. These
schemes shall be reserved for special equipment, such as compressors, or critical equipment,
that for safety reasons, requires this kind of command.

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Profibus DP networks shall be preferably designed in a segregated way, considering type of

voltage (Low or Medium Voltage), and type of equipment (motor starters, VSDs). More than one
Profibus DP network can be included within a single MCC.
Maximum amount of Profibus nodes in a motor control network shall be based on the type of
devices and operation voltage, such as indicated below.
Type of Device Node Quantity
Low Voltage motor starters 20
Medium Voltage motor starters 10
Low Voltage VSDs 20
Medium Voltage VSDs 10
In networks with 3 or less nodes, the criterion described in the table above should be flexible and
type combination may be permitted. Preferable, duty and stand by motors shall not share the
same Profibus segment.
Vendor packages that include control system (except for GMDs), the motor starters will be
provided by the Project, and the vendor’s control system shall manage its motors via Profibus DP
v0/v1 (preferred) or directly hardwired.
5.4 VOIP & DATA NETWORK
The scope of the discipline includes the VoIP & Data Network for providing communication to the
facilities throughout the plant such as administration buildings, workshops, warehouse, offices
and control room. For a detailed description of this system, please refer to Communications
Systems design criteria 4-V2-2850-IC-DES-000001, and the Communications Systems technical
specification 4-V2-2851-IC-SPE-000001.
5.5 PROCESS CCTV SYSTEM
A single Central Control Room CCR for monitoring and controlling all processes within the Project
will be provided. In order to allow this remote approach for the operation of the entire plant, a
Closed Circuit TV system shall be provided, which shall capture images from critical points
throughout the plant by video cameras and it shall show these images to operators in the CCR.
CCTV video cameras shall provide pan/tilt/zoom features controlled by the operators in the CCR.
Cameras shall provide embedded IP connections that shall integrate digital video and
pan/tilt/zoom signals for controlling the setting of the camera and any alarm or status. Signals
over Ethernet from cameras will be concentrated and arranged in a VLAN in the high availability
backbone switches located in the electrical rooms, and finally they shall arrive to a CCTV digital
video server (DVS) for historical records and to a workstation for displaying the images on High
Definition LCD LED monitors in the CCR for operators, who may select images camera to be
displayed and adjust pan/tilt/zoom function for each camera.

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All camera control shall be done through Ethernet from Windows application and no additional
desktop controller shall be necessary.
CCTV video manager system shall be Honeywell Digital Video Manager (DVM), nevertheless,
CCTV cameras could be of any brand compatible with Honeywell DMV R600 or comply with
ONVIF standards supporting H.264 encoding format.
For more information related to Process CCTV cameras integration and high availability
backbone network, refer to Communications Systems Design Criteria 4-V2-2850-IC-DES-000001.
Surveillance CCTV system is out of scope of Fluor-Salfa.
5.6 PAGE/PARTY SYSTEM
The SGO project does not consider using a page/party system. For paging communications of
personnel within the plant facilities and for whole or zoned messaging delivery, trunking radio
system existing in Minera Spence will be used.
Radiating cables will be installed (by other) to provide RF coverage in structures which are
otherwise difficult to cover (for example: ore reclaim tunnel).
5.7 CONDITION MONITORING SYSTEM
For predictive maintenance purposes on certain equipment in the plant, a condition monitoring
system CMS shall be provided, which comprises the following sensors:
• Displacement vibration.
• Speed vibration.
• Accelerometer.
• Axial thrust position.
• Bearing metal temperature.
• Bearing oil temperature.
These sensors shall be installed in the following equipment:
• SAG mill feed conveyor.
• SAG mill motor & trunnion.
• Ball mills motor & trunnion.
• Pebble crusher.
• Primary cyclone feed pumps.

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• HIG regrind mills.
• First cleaner feed pumps.
• Second cleaner SFR concentrate pumps.
• Second cleaner SFR feed pumps.
• Flotation cells blowers.
• Regrind cyclone pumps.
• Process water distribution pumps.
The system shall be capable for future integration of signals from primary crusher, overland
conveyor and tailing pumps.
The mounting type for transducers must be drilled hole mounting. The Process connection of
transducers must be according to accelerometer application considerations showed in Annex C of
API Standard 670.
The quantity and types of sensors must be according to the typical system arrangement plans
showed in Annex H of API Standard 670. For special equipment like a conveyor, process
connections for CMS sensors must be provided for all pulleys, at both sides of belt.
The signals from all sensors shall be collected and concentrated in field junction boxes and then
connected to field monitoring units which will integrated with CMS server or engineering
workstation in the Central Control Room CCR, for recording, analysis, trending and predicting
maintenance.
The communication between all field monitoring units, servers and engineering workstations of
the system shall be through a VLAN in the high availability backbone switches which connect all
plant facilities.
For more information related to CMS components integration and the high availability backbone
network, refer to Communications Systems Design Criteria 4-V2-2000-IC-DES-000002.
5.8 ELECTRICAL SCADA SYSTEM
For monitoring electrical variables and execute certain actions such as operate disconnect
switches, an electrical SCADA system shall be provided for the Project by separate contractor.
The electrical SCADA shall consider switches installed inside each electrical room, which will
collect and concentrate IEC-61850 protocol signals with electrical variables from certain IED, and
PQM (power quality monitoring) devices and RTUs.
All switches from electrical rooms shall be concentrated and connected to a SCADA server in the
Central Control Room CCR through IEC-60870-5-104 protocol to send telecontrol and
teleprotection messages. Also a SCADA workstation shall be provided to allow the SCADA
operator to monitor and control.

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The functional requirement of this system shall be provided by the electrical discipline, including
the definition of IED, PQM and RTU to read (typically, 23kV & 4.16kV switchgears). The SCADA
system will report to the CDEC/SING.
The communication between all switches and components of the system shall be based on the
fiber optic backbone which connects all plant facilities.
The scope of work, supply and services, of all the electrical SCADA system is by separate
contractor.
5.9 FIRE DETECTION & ALARM SYSTEM
For detecting and alarm any fire condition at certain equipment and facilities, a fire detection and
alarm system FDAS shall be provided for the Project. The FDAS shall comprises flame and heat
smart detectors and wires; very early smoke detectors; fire alarm stations; abort stations; horn
and beacons; fire panels and FM-200 bottles and flooding devices.
FM-200 gas shall only be considered for cycloconverter electrical houses of SAG and Ball Mills.
Several smart devices, stations and horn-beacons shall be connected in a loop, which
encompasses certain area or zone, and each loop shall be terminated in and input of the fire
panel. A fire panel is installed in an electrical room, and it will take care of the loop(s) inside the
electrical room, and the loops outside covering hydraulic units, and conveyors.
Fire detection and alarm panels located in electrical rooms shall consider alarms contact to
connect to DCS cabinets
Each fire panel of the electrical room shall be communicated to the Plant Master Fire Alarm Panel
installed on the Central Control Room CCR for reporting any fire condition event identifying the
affected area or device.
The communication between all fire panels shall be based on the fiber optic backbone which
connects all plant facilities.
For standardization purposes, the brand and model of the fire panels is Notifier NFS-320-SP.
5.10 ANALYZER SYSTEMS
Some process or metallurgical variables will be measured using specialized and dedicated
systems which shall be integrated to the DCS through OPC over Ethernet. The following analyzer
systems shall be considered:
• Ore Size Analyzer.
• In-Stream Analyzer.
• Particle Size Analyzer (PSI).
• Particle Size Tracking Analyzer (PST).

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• Roping Analyzer (Oversized Monitoring System – OSM).
• Froth Analyzer.
• Mill Impactmeter Analyzer.
Each analyzer shall be autonomous to perform its function. Electrical, water and compressed air
supply will be delivered according its requirements.
Ethernet networks of every analyzer system will be assigned to different VLANs over the high
availability backbone network. For more information related to analyzer systems integration and
the high availability backbone network, refer to Communications Systems Design Criteria 4-V2-
2850-IC-DES-000001.
Ore Size analyzers and froth analyzers shall use image processing techniques to determine ore
size distribution.
Two different types of In-Stream analyzer shall be considered, one for process control purpose
and other for metallurgical analysis. Both kinds of analyzers shall use X-Ray fluorescence (XFR)
measurement principle, but metallurgical analyzers shall be integrated with metallurgical sampler
according to Process Discipline study developed in DPS.
In-Stream analyzer for bulk flotation shall be capable to measure %Cu, %Fe, %Mo and %Solid,
while In-Stream analyzer for selective flotation, only %Cu and %Mo.
For grinding cyclones cluster, particle size tracking and roping system measurement technology
shall be based on acoustic impact principle.
Particle size analyzers shall use laser diffraction measurement principle to determine particle size
of the regrinding cyclone cluster sample.
Froth analyzer shall use image processing techniques to determine bubbles size and velocity, in
bulk flotation and Moly flotation plants
Impactmeter analyzer system shall use acoustic sensors to determine if the charge of a mill falls
on its lining. Only SAG Mill shall use this kind of analyzer.
6.0 INSTRUMENTATION
6.1 GENERAL
Analog instrumentation selection shall be mainly based on Foundation Fieldbus. 4-20 mA

instrumentation will be accepted only in special cases, where Fieldbus Foundation features is not
available for certain kinds of instruments, or in cases where the instrumentation will be connected
to vendor packages’ PLC.
Discrete instruments and on/off valves shall be suitable for operating with 120 Vac, 50 Hz.
Discrete signal to Fieldbus Foundation converter shall not be used.

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Discrete and conventional analog instruments (4-20 mA signals) will be connected to the DCS
using I/O modules, installed in remote I/O panels, as indicated in point 5.3.3 “Remote IO Panels”.
Instruments must be state-of-the-art technology and must have proven applications operating in
similar installations. Instrumentation shall be provided for operations for 24 hours a day, 365 days
a year, in a dusty and harsh environment with electromagnetic interference (EMI) and radio signal
interference (RFI). Transmitters must be immune to EMI/RFI interference. Each transmitter shall
be capable of functioning with the operation of VHF/UHF equipment, rated at 5 watts located one
meter away.
All instruments will be manufactured as a standard. The brands of instruments and associated
equipment shall be represented in Chile and its representative must provide service at site. The
project must attempt to ensure standardization of instruments and components, to minimize the
amount of spare parts in warehouse and simplify the service and maintenance activities.
All instruments must be factory calibrated according to the information included in the
corresponding data sheet. Any special device required to perform the instrument calibration must
be identified and included in the scope of supply.
Instruments must be supplied with the necessary accessories required for complying with the
mounting arrangement described in the data sheets and/or indicated on the installation detail.
All electrical conduit connections to instruments shall be ½” NPT. Deviations to this requirement
may be analyzed if there is no ½” NPT available.
The instruments that are connected to high-pressure systems (> 1031 kPag) shall include block
valves to isolate the instrument from the pressure source and bleed valves to relieve the pressure
in the process line to the floor.
Instruments shall be connected so that they can be removed from service without shutting down
or disrupting the process.
All interlock contacts shall be failsafe. All digital contacts shall be wired into the DCS inputs or
hardware circuits such that contacts in the normal (non-shutdown, non-alarm) are closed and
open when abnormal condition is reached.
Switches type instruments must provide two (2) SPDT type output contacts, rated for a minimum
of 2 Amperes at 120 Vac and 50 Hz. Contacts shall be hermetically sealed.
Electronic transmitters shall be 2-wire or 4-wire type, with linear output, and accuracy of 0.5% of
span or better.
Transmitters shall have an integral indicator display in engineering units defined on the
instrument data sheet. Blind transmitters may be used, but the design shall include a local gauge
or local Foundation Fieldbus indicator within line of sight to indicate the process variable being
transmitted.
Instruments with remote transmitters shall include cables within the vendor’s scope.

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6.2 FIELDBUS FOUNDATION TRANSMITTERS
The instrument transmitters and control devices shall be intelligent devices based on
microprocessors and H1 Fieldbus Foundation communication protocol according to IEC 61158
standard. Only devices properly registered in the Fieldbus Foundation organization shall be
allowed.
The Fieldbus Foundation circuits shall be connected in a tree configuration. A main home run or
trunk cable shall be installed between the H1 port at the DCS module and a junction box located
at the field close to the local fieldbus devices. The local devices shall be connected to the junction
box in a chicken-foot arrangement.
The junction box shall contain one 10 port fieldbus hub (megablock), Relcom, Turck or other
according to preferred manufacturer list. The Foundation Fieldbus megablock shall include a
selectable line terminator. Fieldbus hub shall be made with plug-in type connector with locking
screws.
Intelligent devices must allow changes in their configuration without having to unload the process
control system segment.
Intelligent instruments and control valves shall keep its configuration using non-volatile memory
so they can retain it.
All 2-wire Fieldbus instruments will be powered through the H1 segment.
Fieldbus Foundation transmitter and control valves shall provide, at least, the following features
• LAS capability.
• Online Firmware update/download.
• Execution of standard function blocks.
• IEC 61804 compliant.
• Polarity Insensitive terminals
• Configuration Method.
• Quiescent Current lower than 20 mA
• All devices shall consider the last version of ITK tests.
• All devices shall guarantee faultless communication between the transmitter and Project’s
DCS, via Fieldbus Foundation H1 communication protocol.
• Available Function Blocks.

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For cases where no instrument accomplishes all the requested features, deviations shall be
analyzed case by case and presented to Fluor-Salfa.
All FF instruments and control devices shall be provided with all required drivers for its proper
operation (DD, CFF, etc., files). FF drivers shall be fully compatible with the Project DCS.
6.3 FIELDBUS FOUNDATION SEGMENT DESIGN
FF segment design shall consider the maximum allowed amount of FF devices per segment,
VCR and links constrains, execution time, critical instruments from control requirements and
current consumption. The use of active repeaters and active couplers will not be permitted.
The location of the terminators will be evaluated for each segment. By default, it will be located at
FF hub. Terminators shall be installed at each end of the trunk cable.
Multivariable transmitters input shall be used in one control loop only. All other variables from the
transmitter can be used only for monitoring applications. Multi-input transmitters using function
block(s) shall be used only monitoring applications.
Open or short circuit conditions in FF segment or power supply failures shall set spring loaded
valves to their designated failure position, regardless of the device hosting the PID algorithm.
The transmitter and the primary process variable shall be on the same segment with its
associated valve. This requirement is mandatory. No exceptions are allowed.
Multiple process measurements used to provide a calculated differential shall be assigned to a

common segment.
Field device assignment shall assure that a segment failure does not affect more than one of the
parallel (redundant/spare) process equipment.
Devices which require a large data transfer between them shall share the same segment in order
to minimize communications among networks.
Each fieldbus segment shall have at least one fieldbus instrument designed as a backup Link
Active Scheduler (LAS). This parameter shall be specified and required on the instrument data
sheets.
Power supplies and power conditioners will be redundant. Short-circuit protection will be
considered on each FF hub.
The instrument transmitters and control devices shall be intelligent devices based on
microprocessors
6.3.1 Constraints for segment design
General segment (non-intrinsically safe) shall require the following considerations
• Maximum 7 devices per segment.

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• Design for a maximum of 10 powered devices per fieldbus segment.
• 2 to 4 mA power supply consumption for each FF terminal blocks
• 10 mA for possible spur short circuit protection at the FF hub.
• 12 mA for eventual connection of field bus test devices/configuration devices.
• Design shall consider the following recommendations for the macrocycles times
indicated, which shall be confirmed / validated with the DCS’s Vendor, before issuing
segment drawings for construction.
• For loops requiring 1 s macrocycle time, limit segment to 10 devices including 3

valves maximum
• For loops requiring 0.5 s macrocycle time, limit segment to 6 devices including 2
valves maximum
• For loops requiring 0.25 s macrocycle time, limit segment to 3 devices including 1
valve maximum.
• Design fieldbus power conditioner supply voltage at 32 Vdc.
• Design for a minimum voltage of 15 volts at any fieldbus device on the segment
• Segment length shall be less than electrical limits.
• Spur lengths shall be kept as short as possible, considering a maximum of 120 m.

Longer distances are not acceptable.
Intrinsically safe segments shall require the following considerations
• Design for a maximum of 4 to 6 devices per fieldbus segment.
• Design for a maximum of 1 to 2 control loops per segment.
• Design fieldbus power conditioner supply voltage at 18.4Vdc.
• Design for a minimum voltage of 10 volts at any fieldbus device on the segment
For all segments, macrocycle time shall be determined the DCS’s vendor and verified by the
developer engineer.
6.4 WIRELESS INSTRUMENTATION
Wireless instrumentation will not be used as standard for this project; however, for particular
cases when field devices at remote areas must be monitored, wireless connection may be a
solution.

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Wireless applications shall comprise wireless instruments, access point devices, a transport
equipment layer, and communication gateways connected to the DCS, at the final point.
Once the 4-20 mA signal is converted to wireless format, data is transported to the DCS through
access point devices, connected to a communication transport layer used for linking the origin
point (field instruments) and the destination point (DCS).
Wireless instruments, 4-20 mA/Wireless converter and access point systems shall be based on
the industrial automation wireless communications standard ISA 100.11a.
Transport layer shall be based on IEEE 802.11 standard (origin and destination points).
Final gateway used for transferring the information to the DCS, shall be compatible in one end to
IEEE 802.11, and shall have a Profibus DP v1 port for integrating the information in the DCS.
Wireless instruments shall be powered using an internal battery, or using external power supplied
using a solar cell system.
Antennas used in the transport layer shall be located based on coverage study; to minimize the
number.
6.5 MACHINERY PROTECTION INSTRUMENTS
All machines with a medium AC induction motor must include a dual vibration and temperature
monitor, with dual output 4-20 mA, one for vibration a the other for temperature. These signals
will be wired to the DCS for alarm and trip.
This instrumentation is complementary to vibration switches that medium voltage motors over
1000 HP are required to have according to “Electrical Design Criteria”, N° 4-V2-2000-EL-DES-
000001, which are directly connected to their drives.
The quantity and types of sensors must be according to the typical system arrangement plans
showed in Annex H of API Standard 670. For specialty equipment like conveyor dual vibration
and temperature monitor must be provided for all pulleys, at both sides of belt.
The mounting type for transducers must be flush mounting, allowing the accelerometer base to
fully contact the mounting surface. The Process connection of transducers must be according to
accelerometer application considerations showed in Annex C of API Standard 670.
6.6 INSTRUMENT SELECTION
Project shall consider the following technical requirements for providing instruments for the SGO
Project.
6.6.1 Flow Instruments
Design shall consider the flow transmitter’s technology upon the application as follow:

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FLUID / MATERIAL TECHNOLOGY
Fresh water and process Magnetic flowmeter

water
Air / O2 Vortex or averaging Pitot tube flowmeter
Slurry in pipes Sonar, ultrasonic Doppler type or magnetic
flowmeter
Slurry on launders velocity/area flowmeter
Frother Coriolis flowmeter
Collector Coriolis flowmeter
Milk of Lime Magnetic flowmeter
Diesel Coriolis flowmeter
Flocculant Magnetic flowmeter
Cooling or gland water Thermal dispersion (Switch)
All flowmeters shall be installed accomplishing the installation requirements indicated in vendor
documentation (upstream/downstream pipes diameters).
A. Magnetic
Magnetic flow meters shall be used for measuring fresh/process water, flocculant and milk of lime
lines.
Magnetic flowmeter with direct current pulses shall be specified for avoiding external magnetic
field effects.
Magnetic Flowmeters shall keep, preferably, the same size of the process line, unless the fluid
speed is lower than the minimum value recommended by manufacturer.
In general, magnetic flowmeters shall be sized for velocities between 0.5 and 3 m/s, unless
vendor recommends a different range for a specific application.
The electrode materials’ specification shall address the chemical, ionic and galvanic corrosion
produced by the circulating currents. Grounding rings must be supplied when the meter is
installed in plastic pipes or pipes with plastic liners.
The damage produced by the circulating currents must be prevented by the proper use of
grounding brackets so that the electrodes and the fluid remain at approximately the same
electrical potential. The ionic corrosion damage shall be prevented by using special electrodes
(platinum or tantalum).
B. Flow Switches
Flow switches shall be used mostly for determining low flow condition of gland seal water of
process pumps and cooling water circuits. They will be of thermal dispersion technology, without
movable parts for horizontal and vertical assembly. Their body and the wet parts shall be made of
stainless steel, unless otherwise specified.

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C. Vortex Flowmeter
Vortex flowmeters will be adequate to measure air flow in pipes (diameter< 6”) of non-conductive
fluids (< 5 μS/cm).
D. Coriolis Flowmeter
This type of instrument will be used to measure the flow rate of non-conductive liquids. Also
Coriolis flowmeter shall be used to measure the flow rate of clean liquids in pipes with low
velocity.
Coriolis flowmeter shall be manufactured to eliminate effects caused for pipe vibration and
pressure pulse induced stress. Temperature effect compensation shall be provided, so that
temperature effect is less than 0.1% of calibrated span for the entire normal ambient temperature
range of the installation.
Coriolis flowmeter tubes shall be preferably straight tube type for reducing pressure drops across
it, and it shall not be affected by the pressure changes providing an automatic mechanism to
compensate the pressure changes.
In spite of built-in Coriolis immunity mechanism considered against vibration, instrument mounted
in vendor skid shall consider vibration reducing elements for reducing its effects.
E. Other Flowmeters
For highly abrasive fluids such as ore slurry, ultrasonic Doppler type flowmeters or sonar based
sensors must be used in pipes. For ore slurries in launders, velocity/area flowmeters will be used.
For ore slurry pipes and those cases in which it is very difficult to comply with the installation
requirements of the sonar based flow meters, magnetic flow meters can be used, with the prior
approval of the company.
Also, for clean water service in large pipes, transit time ultrasonic flowmeters may be used.
6.6.2 Level Instruments
Design shall consider the following level transmitters according to the application and fluid or
material to sense:
APPLICATION / MATERIAL TECHNOLOGY
Flooding collector sumps, froth of flotation cells, Ultrasonic

slurries and water.
Thickener interface, depth of bottom of a pond Sonar
Crushed ore, pebbles and solid minerals Radar
Thickener bed (inventory), pond Level Hydrostatic
Crushed ore level (switch) Nuclear
Oil tanks truck shop, fuel or toxic reagent tanks Magnetostrictive

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A. Ultrasonic and radar level transmitter
Ultrasonic and radar level transmitters shall be specified according to the vessel or tank
characteristic.
For radar transmitters, when choosing the frequency type and range, the desired measurement
scope, any disruptions in the liquid surface, foam, etc shall be taken into account. The type of
tank and the installation assembly type must be considered. The installation design must
eliminate any interference between the transmitting microwave antenna and the liquid’s surface
caused by echoes.
The ultrasonic level instrument housing and acoustical face shall be manufactured of materials
suitable for the intended service and shall be self-cleaning and maintenance free. The ultrasonic
transmitter shall include automatic temperature compensation for variations in the speed of
ultrasonic wave due to ambient temperature changes.
B. Sonar
Thickener interface shall be measured using a sonar level transmitter, based on a high powered
acoustic pulsed beam, which will be reflected in the interface with selected density. Level
transmitters shall include a software algorithm that shall be able to eliminate effects of lighter
density zones and stratified layer to allow measurement of bed levels.
C. Radiometric
Radiometric level switches shall be considered for detecting low feed level at the entrance of
stockpile feeders.
Design shall take special care in the instrument size; container source; sensor dimension; chute
wall thickness; liner thickness, chute dimensions and geometry; etc. for assuring proper
operation.
Radiometric level instrument requirements are completed described at point 6.6.5 “Density
Instruments”. For safety reasons, the radiation source will have a proximity switch to indicate the
position of the shutter to the operator.
For safety reasons, the radiation source will have a proximity switch to indicate the position of the
shutter to the operator.
D. Magnetostrictive Level Gauge
The magnetostrictive transmitter may be utilized as a direct insertion transmitter or externally

mounted to a magnetic level indicator for non-invasive level control.
In direct insertion service, the sensor probe with magnetic float(s) is inserted into a tank and as
the float rises or falls with the fluid, the transmitter provides level output. For externally mounted
service, the probe senses the float(s) inside the magnetic level indicator.

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6.6.3 Pressure Instruments
All pressure instruments shall be provided with a chemical seal suitable for the application. The
only exception to this will be those instruments used in clean services as air, oil, water and
equivalents. Pressure instruments including chemical seal must be provided with SS 316 armored
capillary with PVC coating. The whole system must be all welded type.
When process considerations require that an instrument be protected, a diaphragm seal with
capillary line or equivalent shall be furnished. The process conditions listed below require sealing:
DIAPHARGM SEAL
APPLICATION / STREAM
REQUIRED
Slurry Yes
Water with more than 0.1% of solids Yes
Fresh water No
Air No
Seals shall comprise a diaphragm material compatible with the process fluid and a suitable fill
fluid between the diaphragm and the pressure element in the instrument. A capillary may be
included when remote reading is required. The pressure indicators where pulsation or shock may
occur shall be oil filled and provided pulsation damper.
Pressure gauge shall have a 4 ½” diameter, bourdon type, stainless steel mechanism, filled with
a proper fluid and connected to process with a ½” pipe with male NPT thread. The preferred
material for cases of pressures gauges is black fiberglass-reinforced thermoplastic.
All instrument dials, scales, etc., shall be based on the International System using metric units.
However, Vendor shall provide dual scales (kPa/Psi) for all for pressure gages supplied.
In locations subject to vibration, pressure gauges shall be oil filled.
Gauge siphons shall be provided for steam applications.
Each blind pressure transmitters, switch, regulator, or blind controller shall be installed with a
pressure gauge.
When the use of pressure switches cannot be avoided, pressure switches elements shall be
bourdon or diaphragm type.
6.6.4 Temperature Instruments
Temperature gauges shall be bi-metal type (5" diameter minimum). Switches or local indicators
may be liquid or gas filled type. Mercury filled instruments are not acceptable. Fill liquid shall be
suitable for storage and operating conditions.
All gauges dials scales shall be based on the International System using metric units.

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RTDs shall be used for temperatures up to 600°C; above this temperature, K type thermocouples
shall be used. RTDs shall be 3 wires, 100 ohm at 0°C and comply with DIN43762 class A, B, and
1. Any RTD or thermocouple shall be supplied with its own temperature transmitter.
Thermocouples with temperature transmitters will be used for temperatures above 600°C. The
thermocouple types will be provided for the following temperature ranges
• Type K: 300°C to 1000°C
• Type R: >1000°C
All process temperature-sensing instruments shall be furnished with thermowells. Thermowells

shall be 304 or 316 stainless steel unless other materials are required due to corrosive service
applications. Thermowells shall be constructed from solid bar stock, not “built-up” from piping or
tubing. Lengths must be selected from standard U-dimensions listed in the vendor's literature.
Element probes inserted into thermowells shall be spring-loaded.
Remote heads shall be provided for process temperature 400°C and above.
Temperature element heads shall be suitable for the hazardous locations in which they are
installed.
When the use of temperature switches cannot be avoided, temperature switches elements shall
be bimetallic type.
6.6.5 Density Instruments
The radiometric density instruments shall consist of a radioactive source and its holder, a
detector/transmitter (scintillation counter type) and a remote display and operating unit.
The radiometric source shall be Cesium 137 and shall be double encapsulated in lead. Suitable
shielding shall be provided in conformance with standard practices. Cobalt 60 sources shall only
be considered in special cases, where the application requires a radioactive source of higher
power than Cs137.
The source and enclosure assembly shall comply with Chilean law and regulations.
The Seller shall certify that the surface radiation intensity of the gage assembly, including source,
detector and adjacent process equipment shall not exceed a specified maximum value. In no
case, should radiation intensity exceed 5mR/hour at 30cm from the surface of the source
assembly.
Calibration instructions and all data necessary for standardization and recalibration of the
radiation density instruments shall be provided by the vendor, including standardization blocks
and check plates. For maintenance purpose the density instruments shall be provided with check
plates for 100%, 75%, 50% and 25% within the specified range.
The density instruments shall be provided with a hand or pneumatic operated shutter mechanism
for isolating the radiation source. Open limit switch for shutter position feedback shall be

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provided. The shutter shall provide locking mechanism in the closed position by means of a key
and padlock.
6.6.6 pH Analyzers
The probe shall be glass type, based on digital technology, with quick connection. Two electrodes
shall be provided, one electrode for process potential measurement, and the other for reference.
The probe shall have a ceramic diaphragm membrane for the reference electrode and shall have
no-glass interface for the process electrode.
Probes shall work immersed in a solution mounted from the top of a tank or in pipe insertion with
retractable valve for maintenance without stopping the process. Mounting accessories / insertion
with retractable valve shall be provided by vendor.
For tank application, the probe mounting accessories shall allow easy access and retrieval of the
probe for frequent service, cleaning and calibration tasks.
An RTD for performing temperature compensation shall be required.
6.6.7 H2S Analyzers
H2S analyzer shall include externally mounted sensor, so they can be easily replaced by
unscrewing the sensor.
Analyzer shall provide indications or alarms for informing that sensors are near to end-of-life, so
they can be replaced.
Analyzer shall include all required accessories such as cable between sensor and transmitter,
strobe light (beacon), horn, etc.
6.6.8 Turbidity analyzers
Turbidity measurement shall be done using a light beam sent through the medium, which is
diverted from its original direction by optically denser particles (suspended particles).
The affected scattered light beam is measured using a dual sensor instrument, which includes
two light receivers, located at different angles (90° and 135°), for detecting turbidity in the media.
Smaller angles give information about fluid with few particles, while the bigger angles are more
affected when the fluid has more particles.
Turbidity instruments shall process information from any light receivers automatically, upon the
current status of the fluid.

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6.6.9 Belt Conveyor Instruments
A. Pull cord
Pull cord will be used as emergency stop and it is latched once operated. Unlatching process
must be carried out locally. These switches shall be installed where people have access to the
conveyor.
All conveyors shall consider at least two pull cords at head and two at the tail. All pull cords shall
be double except those located at the head and tail. All double pull cords shall be installed each
30m preferable, but it should not exceed 60m.
The force required to operate the pull cord applied over the activation pull wire shall not exceed
70 N at midway between supports and at right angle to the axis of a pull wire with less than 300
mm of wire displacement. When the force us applied along the axis of the pull wire it shall not
exceed 230 N.
A visual indicator (pilot light on the device) shall be provided to indicate which switch has been
activated.
Pull cord shall be considered an emergency stop, and it shall provide two (2) SPDT contacts. One
contact shall be hardwired to the motor starter, and the other one shall be connected to the
control system for alarming purposes and for determining the precise location of the hazard
condition.
B. Belt misalignment detector
All belt feeders and belt conveyor shall consider at least two belt misalignments devices at head,
and two at the tail on opposite sides.
For a typical conveyor with a drive at the head pulley and a gravity take-up unit close to the head
or tail ends, belt misalignment switches shall be located in the following locations:
• Tail on the carrying belt side, preferably clear of skirts, skirt and pulley guards for
purposes of resetting and maintenance.
• Head on the carrying belt side, again clear of guards for purposes of resetting and
maintenance.
• Feed area, just beyond the skirt on the carrying belt side and outside skirt guards and
clear of over belt sprays.
• Additional belt misalignment switches may be located on conveyors in the following

locations:
• Drives remote from the head and tail ends on the return belt side.
• Gravity take-up unit remote from head and tail ends on the return belt side (except
when near a remote drive).

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• Tripper on carrying belt side, adjacent to tripper head pulley.
• Upstream to a belt weight scale on the carrying belt side.
All misalignment switches shall provide two position of activation, each position provide SPDT
contacts associated respectively. The first position of activation detects first level misalignment of
the belt for alarming; the second position of the switch detects a greater level of misalignment of
the belt for shutting down of the conveyor. Both ones shall be connected to the control system
segregated to identified each condition.
C. Plug chute detector
Plugged chute switches shall be located in the transfer chute away from the normal ore stream
protected from impact, but properly located for detecting a plugging chute condition. A good initial
approach may be right underneath the head pulley.
Plug chute detection shall be done using microwave plug chute detector or tilt type.
D. Zero speed detector
The zero speed switch shall be located on a non-driven pulley, typically the tail pulley. There shall
be only one switch per conveyor. Zero speed switches shall be magnetic or optical coupling type
based on counter encoder.
E. Slipping detector
This slipping detector will be installed in long belt conveyors (over 500 m). This detector will
consider two pulse transducer and a speed monitor.
The detector will include two magnetic or optic coupling type heavy duty pulse generator on the
drive and non-drive pulleys of each conveyor. The pulse generators shall be connected to a
monitor device or the control system of the plant, where the difference between all speed values
will be calculated and an alarm will be triggered as the difference is above certain preset value.
F. Mechanical rip detector
These switches shall be installed in conveyors underneath each feed chute. Rip switches shall be
rope type, mounted in pairs, located on either side of the belt.
G. Electronic rip detector
These instruments will be installed in critical belt conveyors for early detection of longitudinal belt
rip events. For the SGO project, only the SAG mill feed conveyor will have an electronic rip
detector which antennas shall be inserted in the belt every at most at 50 meters.
The instrument comprises several coils embedded in the belt every certain distance; and sensors
placed at high potential damage points such as incoming chutes.
The coils are arranged so that any rip of the belt will affect their galvanic continuity. The sensors
detect when the embedded coils are electrically open, arising an alarm.

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H. Take-up limit switches
These switches shall be installed at gravitational conveyor take-ups for detecting when the
conveyor is stretched. Each gravitational take-up typically provides two position limit switches on
each movement extreme; one for alarming and one for shutdown. Switches will be heavy duty
lever wheel type.
I. Metal Detector
The metal detector shall be based on a manufacturer’s standard design. The detection system
operates by measuring the change in received electromagnetic signal of material being conveyed
through the sensor area. Since the magnetic properties of materials are completely independent
of conductivity, both magnetic and non-magnetic tramp metals shall be consistently detected.
A sensitivity setting mechanism shall be supplied to allow field adjustment of the minimum
detectable size. The metal detector shall be capable of identifying belt clips without alarming,
avoiding nuisance alarms and shutdown.
The metal detector will be able to detect ferrous and nonferrous metals alloys of 13-15 mm size.
The metal detector shall be suitable for operation outdoors and in an environment having high
concentrations of fine Copper ore particles and dust.
The metal detector shall be capable of detecting several pieces of metal such as drill roads, tools,
shovel teeth, liner plates, angle iron, flat bar, mill balls, nuts and bolts when conveyed with ferrous
or nonferrous ores, as well as ores of different electrical conductivities.
The system shall not be affected by normal equipment vibration or movement of personnel.
Isolation materials shall be supplied.
J. Belt scale
Some belt conveyors may include weight scales according to the following precision criteria:
• General conveyors: 0.5%
• Final product conveyors: 0.25%
The belt scale shall be supplied with Profibus DP v1 communication interface and calibration
chains installed on the conveyor structure including winch for positioning and removal.
K. Horn and beacon
Horn and beacons for announcing the start of the belt or any hazardous condition shall be
installed each 120 meters. Horns shall operate at a minimum of 100 dB @ 1m. Both devices shall
be powered by 120Vac, 50Hz, single phase.

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6.6.10 On/Off & Regulatory Control Valves (Ball, Globe, Butterfly Valves)
A. General
Pneumatic actuators shall be diaphragm or piston type. Electrical type actuators will be for special
circumstances when instrument air supply is not available.
All pneumatic on/off valves shall be furnished with open/close limit switches and solenoids (single
or dual depending on the application). The limit switches shall be inductive proximity (non-
contacting) type.
All pneumatic control valves (on/off and throttling) shall be supplied with a filter and pressure
regulator set, including outlet pressure gauge. All tubing interconnecting, filters, regulators,
positioners, etc. must be stainless steel tube with NPT stainless steel fittings double ferrule type.
Pneumatic valve actuator shall be designed to operate with 6 to 140 psig instrument air signal.
All accessories with the exception of pressure gauges shall be firmly mounted to the control valve
actuator by means of bracket designed for it.
All valves bodies shall be flanged.
Control valves (on/off and throttling) shall have body material matching the line material and will
follow the 4-V2-2000-PP-SPE-000001 Technical specification for piping materials. Exceptions
require approval from the Company.
Trim shall be stainless steel or alloy steel as a minimum. Severe service conditions may dictate
consideration of hardened stainless steel. All guiding surfaces shall be of non-galling hardened
materials.
Control valve odd sizes such as 1-1/4", 2-1/2", and 5" shall not be used.
Control valve bodies size shall be 1" minimum, 150# ANSI minimum. Special applications with
body sizes smaller than 1" require written authorization from the Company.
Control valves provided with reduced capacity trim shall be designed for conversion to full
capacity by replacement of a minimum of parts. Valve stem, packing box and actuator shall be
designed for full capacity requirements.
Butterfly valves shall be lug type, suitable for mounting between ASME B16.5 flanges.
B. Valve Sizing
Cv calculations shall be based on ISA 75.01.01, “Flow Equations for Sizing Control Valves”.
Corrections shall be applied for piping geometry (valves mounted between pipe reducers) and
low Reynolds numbers (below 10000, viscosity / non turbulent flow conditions).
ISA 75.01.01 and ISA RP75.23, together with manufacturer cavitation index data shall be used
for determining the severity of cavitation, choked flow or flashing conditions. Cavitation shall be
avoided under all operating conditions. Choked flow together with excessive noise shall be

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avoided since it will physically damage the control valve. Where noise, cavitation and flashing can
occur, special valve trim shall be provided.
The maximum vibration levels of the control valve shall be less than 12.5 mm/sec root mean
square (0.5 mm/sec RMS).
Outlet fluid speeds at trim and body must be verified in order to reduce control valve vibrations
and trim erosion. For single phase liquids, the trim outlet fluid speed shall be lower than 30m/sec
and lower than 23m/s for cavitating, flashing and/or erosive service.
The operational range of the control valve shall meet all flow conditions specified. The specified
minimum flow condition shall be fully controllable.
Valve’s vendor will be responsible for the noise calculation. This level will be below 85 dBA+/-
5dBA, measured at 3 feet from the output flange of the valve in any direction. If this level is
exceeded, additional accessories (diffusers, silencers) shall be provided.
Vendor shall verify the preliminary sizing of throttling control valves according to the following
criteria
• (Calculated CV for Minimum Flow)/(CV Valve Maximum Rated) >0.1
• (Calculated CV for Normal Flow)/(CV Valve Maximum Rated) <0.7
• (Calculated CV for Maximum Flow)/(CV Valve Maximum Rated) <0.9
Vendor data sheets shall indicate the percentage of valve stroke for each flow (minimum, normal
and maximum) and shall submit CV values to client for comparison.
Vendor shall consider the following valve opening range in the sizing of throttling valves:
Globe/Ball/Segmented
• %Opening for minimum flow : 20%
• %Opening for normal flow : 40-70%
• %Opening for maximum flow : 80%
Butterfly valves
• %Opening for minimum flow: 20%
• %Opening for maximum flow: 40%

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C. Block and Bypasses
In general, control valves mounted in skids (except three-way valves) shall be provided with
isolating block valves and a bypass valve for hand control. Bypass and block valves shall not be
used when they cannot be safely operated manually.
Bypass valves shall have a capacity at least equal to the calculated CV of the control valve, but
not greater than twice the selected CV of the control valve. Globe valves will be used as bypass
valves up to 4” size. However, if the capacity requirement dictates larger than a 4" globe valve,
butterfly valves may be used.
In special applications such as high pressure drops, flashing service, faster filling and emptying
requirements, size of block and bypass valves shall be of the same type as the main control
valve.
In cases where the predicted noise level in the control valve is a problem, the noise level in the
bypass valve shall also be considered and/or insulated.
D. Handwheels
All control valves (on/off and throttling) shall be supplied with handwheels or manual override
mechanism based on the following criteria
• Handwheels: For valves with diameters <= 10”
• Manual override : For valves with diameters > 10”
For hydraulic actuators, the control valves shall be locally operated through local control panels
pushbuttons provided at the hydraulic power units.
E. Gear box
Valves supplied with handwheels shall consider gear boxes for manually opening the valve,
following the criterion below:
• Without Gear Box: For valves with diameters <= 10”
• With Gear Box: For valves with diameters > 10”
Any deviation to this criterion will be analyzed case by case.
F. End Connections
Control valves flanges shall be in accordance with ANSI B16.1, B16.5 or B16.42. Material shall
be according to line material which shall follow the Technical Specification for Piping Materials 4-
V2-2000-PP-SPE-000001.
Valve rating shall be in accordance with line class. Integral flanges shall be used; slip-on flanges
are not permitted.

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G. Face-to-Face Dimensions
Control valves shall have face-to-face dimensions in accordance with ISA (Globe, Ball) or MSS
(Butterfly) standards.
H. Actuators
Actuators shall provide adequate torque to stroke the valve completely under the maximum
differential shut-off pressure condition. However, the vendor shall estimate dynamic forces the
actuator shall be fight against with, as the valve is partially or completely open. Some additional
torque should be considered due to hysteresis and other phenomena, so that this safety factor
may be 30%.
Actuators shall be pneumatic or hydraulic upon the following criteria:
• Valves with diameters <= 24”: Pneumatic Actuator
• Valves with diameters > 24: Valve’s manufacturer shall be consulted whether to verify
if it is necessary to use actuators with hydraulic piston,
Electrically powered actuators are described in point 6.6.11, “Motor Operated Valves”.
Spring and diaphragm actuators shall be fully enclosed. The actuator cases shall be of steel
construction and provided with suitable corrosion protection for mining atmosphere.
Springs shall be corrosion resistant, adjustable, readily accessible and shall have a linear
characteristic
Diaphragm and O-Ring seals shall be of molded, age resistant material suitable to withstand
maximum pressure and designed for reliable operation over the full range of ambient conditions
as specified.
Pneumatic piston actuators shall be fully enclosed. The cylinder and the valve positioner shall be
suitable for operations from an air supply with minimum and maximum pressures as specified.
Actuators will be sized considering maximum (rating) and minimum (operation) instrument air
pressure supply indicated in the data sheets.
The flow direction (to close/open) will coincide with the valve safe position. If not, the spring will
be designed with double the safety factor.
I. Failure Position
Open/close fail position mechanisms in both on/off and throttling control valves shall follow the
criteria below:
• Spring: for valves with diameters <= 10”
• Compressed air vessel: for valves with diameters > 10” and <= 24”

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• Compressed Nitrogen vessel: for valves with diameters > 24”
J. Positioners
Positioners shall be supplied with adjustable valve travel.
Each positioner will include a built-in position transmitter. The position signal shall be transmitted
via Foundation Fieldbus.
In case of control system supplied by vendor (PLC), control valves position signal shall be
transmitted via 4-20 mA.
K. Limit Switches & Solenoids
On/off valves shall be supplied with solenoids powered by 120Vac, 50Hz, single phase for
guiding the pneumatic power to one or other side of the piston inside the cylinder and thus to
open or close the valve.
Enclosed position switches and terminal box mounted on the valve shall be supplied with the
actuator. All these signals (position switches and solenoid commands) shall be prewired by the
valve vendor to the terminal box. These switches shall be inductive-proximity type with SDPT
contact rated at 120Vac, 2A minimum.
Lever arm or plunger limit switches are not allowed.
L. Pressure Test
Control valve shall be requested considering the ISA-S75-19 and ANSI/FCI 70-2 test for leakage
classification.
6.6.11 Motor Operated Valves
A. Electrically Powered Actuator
Electrically powered actuator shall be powered from a single and dedicated 480Vac, 50Hz, three
phase circuit breaker installed at power distribution panel, designed by I&CS discipline.
Operational control modes for motorized valves shall be selected locally in a local control panel
integrated to the actuator.
Motorized valves actuators shall be heavy duty and solid state type. Also the actuator shall
provide a high torque alarm.
Motorized on/off control valves shall be supplied with manual control, so that local commands
such as open, close, local/remote selector can be executed over the valve without the DCS
connection, when the local operational mode is selected.
When the actuator is in remote mode (selected in its local panel), the motorized valve will receive
commands through remote discrete commands/inputs (DO/DI) received from the control system
(remote I/O panel located at field). Discrete signals (DI/DO) shall be un-powered type.

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In the case of Motorized Throttling Control Valves, these shall be Foundation Fieldbus type.
B. Fail Position
Motorized valves only consider Fail Last (FL) failure position by default. Therefore, when a
different fail position is required, the Project may study the following alternatives:
• Local small UPS for powering the actuator for a stroke.
• Change the actuator to hydraulic type.
6.6.12 Hydraulic Operated Valves
Hydraulic power unit shall be considered for providing hydraulic power to each valve or group of
valves located in the neighborhood.
Hydraulic units shall be powered with 480 Vac, including a single hydraulic pump and shall be
designed typically to feed four (4) hydraulic valves at the time. Finally the amount of valves will be
determined upon location of valves and unit.
Special cases where hydraulic valves are located alone, or away from any hydraulic power unit,
shall consider individual power units or change its actuator type to a motorized one.
Hydraulic units shall have local and remote mode. In local mode, hydraulic valves will be
commanded through local pushbuttons integrated in the hydraulic power unit local panel. In
remote mode, hydraulic valves will be commanded remotely from the DCS through Profibus DP
v1 link to send commands to the valve and hydraulic unit.
6.6.13 Knife Gate Valves
Knife gate valves will be used in slurry fluid applications such as slurry pumps isolation, water
flushing and purge.
Isolation knife gate valves in contact with slurry for both sides shall be flanged type (reference
Clarkson KGA). Flushing and purge knife valves shall be wafer type (reference Clarkson KGD).
Except for the pressure test requirements described below, all other selection criteria remain the
same as mentioned above for control and on/off valves.
For throttling knife valves, characterized type should be used (reference SlurryFlo).
A. A. Pressure Test
Knife gate valve shall require the MSS SP-61-2009 test for leakage classification.
6.6.14 Pressure regulators
Pressure regulators will be used only in clean services as air, oil, water and equivalents.
All pressure regulators shall be flanged.

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Pressure regulators shall have body material matching the line material and will follow the 4-V2-
2000-PP-SPE-000001 Technical specification for piping materials. Pressure regulators with cast
iron body are not allowed. Exceptions require approval from the Company.
For pilot operated pressure regulators, all tubing interconnecting must be stainless steel tube with
NPT stainless steel fittings double ferrule type.
Trim shall be stainless steel or alloy steel as a minimum. Severe service conditions may dictate
consideration of hardened stainless steel. All guiding surfaces shall be of non-galling hardened
materials.
Control valve odd sizes such as 1-1/4", 2-1/2", and 5" shall not be used.
Control valve bodies size shall be 1" minimum, 150# ANSI minimum. Special applications with
body sizes smaller than 1" require written authorization from the Company.
Pressure regulators will be supplied with upstream and downstream pressure gages.
6.6.15 Flow regulators
Flow regulators will be used only for gland seal water applications up to 3” (Reference American
Grandy).
6.6.16 Instrument accessibility
Special care shall be taken to design the instrument location and installation regarding their
accessibility. Aspects as described below shall be considered:
• Safe access aspect such as avoiding exposure to nuclear sources, etc.
• The location shall guarantee a good and representative measurement of the process
variable.
• Frequency of access required.
• Type access (for removal, cleaning, configuring or just reading). Limited access is
acceptable for indicating instruments, as long as they can be properly read from an
accessible location. Space shall be provided for properly removing bolts, nuts,
gaskets, covers, doors, etc.
• Conditions of access (preferable access to any instrument should not require shutting
down the process).
• Required space for accessories or equipment such as special tools, calibration laptop
or bench.
• On-line instruments are to be mounted directly on or at short distance from the

instrument process connection(s).

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• Excessive vibration conditions such as on suction or discharge lines of pumps or

compressors.
• Mechanical stresses.
• High temperatures which may affect the measurement
• Access for equipment such as mobile hoists shall be considered for installation of
heavy instruments such as control valves and inline flowmeters, densimeter, etc.
• Special protection fences shall be included to restrict access to instruments such as

nuclear.
6.6.17 Process Connections
Instrument connections to vessels shall be in accordance with the Instrument Installation Details.
Any horizontal runs will be run with a gradient of at least 151 to prevent condensation being
trapped.
The size, type and material of the instrument connection to process and utility piping shall be
defined by the associated Piping Material specifications and the following tables:
LEVEL INSTRUMENTS
Ultrasonic or Radar closed tanks - liquids: 4" RF Flange ASME B16.5
Ultrasonic or Radar open tanks - liquids: 1-1/2” NPT Male
Radar - Solids: 8" RF Flange ASME B16.5
Hydrostatic 2" RF Flange ASME B16.5
Closed Tank Level Transmitter (DP Cell) 2” RF Flange ASME B16.5
Magnetic Level Gauges 2" RF Flange ASME B16.5
Other level instruments (switches) 2" RF Flange ASME B16.5
PRESSURE INSTRUMENTS
Clean services
No diaphragm seal is required. 1/2" NPT Female
Pressure gauges, pressure switches,
pressure transmitters and differential
pressure transmitters
Dirty services (No slurries) and
sulphuric acid 1” RF Flange ASME B16.5 without
Diaphragm seal is required. flushing port
Pressure gauges, pressure switches,
pressure transmitters and differential

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PRESSURE INSTRUMENTS
Slurries (including milk of lime)
Diaphragm seal is required.
Pressure gauges, pressure switches, 3” RF Flange ASME B16.5
pressure transmitters and differential w/extension or inline wafer
TEMPERATURE INSTRUMENTS
Thermowells on pipes ¾” NPT or 1-1/2" RF Flange ASME
B16.5, depending on piping material
specification
Thermowells on tanks 2" RF Flange ASME B16.5
ANALYSIS INSTRUMENTS
pH/redox and conductivity probes on Inline holder fitting should be provided
pipes up to 1-1/2 in. with RF Flanges ASME B16.5
pH/redox and conductivity probes on 2" RF Flange ASME B16.5 (with

pipes larger than 1-1/2 in. retractable assembly, provided by
vendor)
pH/redox and conductivity probes on 2" RF Flange ASME B16.5 (with
tanks retractable assembly, provided by
vendor)
Option: Submersible assembly
Density meters (radiometric type) Without process connection (non-
invasive, clamp-on type)
Turbidity meter Without process connection (use
tubing to process)
FLOW INSTRUMENTS
Magnetic flowmeters RF Flange ASME B16.5 (Flange size
according to manufacturer sizing
sheet)
Coriolis flowmeters RF Flange ASME B16.5 (Flange size
sheet)
Vortex flowmeters RF Flange ASME B16.5 (Flange size
sheet)
Sonar Flowmeter Without process connection (non-

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FLOW INSTRUMENTS
Thermal mass flowmeters (up to 4”) RF Flange ASME B16.5 (Flange size
sheet)
Thermal mass flowmeters (larger than 1” NPT male
4”)
Pitot tube flowmeters 1” NPT male
Ultrasonic Flowmeter Without process connection (non-
Thermal dispersion flow switch 3/4” NPT male
Rotameters RF Flange ASME B16.5 (Flange size
sheet)
VALVES
Throttling control valves RF Flange ASME B16.5 (Flange size
sheet)
Open/Close automatic valves RF Flange ASME B16.5 (Flange size
Solenoid valves same to pipe size)
Relief devices RF Flange ASME B16.5 (Flange size
sheet)
Pressure Regulators RF Flange ASME B16.5 (Flange size
sheet)
Flow regulators Inline wafer (Size according to
manufacturer sizing sheet)
6.7 CONTROL CABINETS AND PANELS
DCS controllers, third party’s control systems or communications cabinets will be installed in
electrical rooms where environmental conditions are controlled and free of dust and corrosive
agents.
The enclosure protection class for field mounted instruments, devices, panels, cabinets, junction
boxes shall be weatherproof, conforming to NEMA 4 or IP 66 requirements as a minimum, and
NEMA 4X for corrosive areas.
Equipment, cabinets and panels located inside electrical rooms shall have NEMA 12 or IP 55
enclosure rating. However, inside control, engineering and server rooms will not require any
protection rating currently identified in NEMA or IP standards.

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Enclosures and instruments shall be in accordance with ambient conditions and the electrical
classification of the area where they will be located at, in accordance with NFPA 70 (NEC) or IEC
equivalent.
Control cabinets and local panel’s enclosures shall be manufactured with steel plates with at least
1.9 mm of thickness and standard hinged doors. All hinges, quick-release latches, clamps and
hasp for padlocking shall be 316L SS.
Enclosures shall be preferably floor mounted type, right – left opening, door latch, base plate with
adjustable depth, injected foam joint, protective back panel, bottom (floor) with cable sealing
system (reference Roxtec) for cable insertion and folding door handle with lock and key. It shall
include too, lifting eyes for easy handling. When the length of the cabinet exceeds 750 mm, it
shall have 2 doors and 3-point latch with heavy-duty handle. Each panel shall have a door
mounted data pocket.
Different enclosure mounting types (wall mounting) can be accepted for the project depending on
the application.
Cabinet and control panel design shall consider opening(s) and designated internal spaces for
wiring external cables from the field. Installation at field shall not require cutting holes or installing
hardware inside the panel to secure owner-installed wire.
All control cabinets shall be designed considering the thermal load installed inside of it and the
environmental conditions defined for the area where it will be installed.
Cabinet shall consider electrical heaters, cooling system, etc., so that adequate temperature shall
be assured inside it. Using instrumentation air for field cabinet cooling system is not allowed.
Wiring will be routed inside the cabinet through fire retardant plastic cable trays, with sufficient
wide and space. Whenever is possible, the cable will come into the cabinet through the bottom
windows.
Terminal blocks will be mounted horizontally in columns, about 200 mm from the bottom of the
cabinet. Terminals with more than one wire from field are not allowed.
Bridges among terminals can be used as necessary; however, they shall be done using insertion
bridges.
Terminals shall be free maintenance type.
All electrical circuit breakers shall use a lock out device to comply with the lock out and tag out
procedure of the project (internal and external breakers).
In general, surface preparation and paint shall be in accordance with the manufacturer's standard
paint specification. Enclosures shall be primed with manufacturer's standard primer and finished
with a minimum of two coats of semi gloss lacquer or enamel.
All control cabinets and panels shall be provided with nameplates in Spanish, showing the control
panel tag and the service.

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Control system supplied with vendor packages shall be fully integrated into control cabinets,
which shall protect all the electronics devices part of the control system (PLC cards, power
supply, communication switches, etc.).
Vendor packages supplied with IEDs/VSDs shall include a separate cabinet for control system
and electrical devices. Control system cabinet will have a base plate for its components, and no
electrical motor starter will be installed on it.
6.8 INSTRUMENT AIR AND TUBING FOR CONTROL VALVES
All Instrument tubing shall be stainless steel 1/2” external diameter (1/2” OD), with 0.049 inch wall
thickness.
Instruments requiring constant pressure must be provided with a filter-pressure regulator set
complete with output pressure gauge.
Air supply circuits to control valves or equipment shall be arranged in star topology from air
bottles (preferred) or loop topology.
Tubing laid down from air bottles to each field device shall be protected using metallic trays in
most of its extension.
As much as possible, field devices requiring air supply shall be assigned air bottles considering
FF segments and process assignment, such as failure in a bottle will only affect a single FF
segment.
6.9 JUNCTION BOXES AND INSTRUMENTS SUPPORTS
Instruments shall be specified for being installed in 2” Mounting Pipes (Yoke mounting
instruments). 2” mounting pipes shall be single or double type; single types shall support one
instrument, while double types shall support two instruments.
FF junction boxes, wall mounted instruments, etc., shall be installed in instrument panels, singles
or doubles, depending on its installation requirements.
6.10 POWER
Electrical power for instruments and control equipment shall be the following:
• Foundation Fieldbus Instruments: Two (2) wires Powered from FF H1 segment (power
conditioner); Four (4) wires Powered with 120Vac ± 10%, 50 Hz, ± 1%, single phase
grounded, from UPS.
• Foundation Fieldbus Control Devices: Pneumatic Regulatory Control Valves Electronic

powered from FF H1 segment (power conditioner);
• Analog Instruments (4-20 mA): Two (2) wires 24 Vdc loop powered from remote I/O panel or
vendor PLC. Four (4) wires 120Vac ± 10%, 50 Hz, ± 1%, single phase grounded (power
distributor panels JP from UPS or Vendor PLC).

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• Analog Control Devices: Pneumatic Regulatory Control Valves 24 Vdc loop powered from
remote I/O panel or vendor PLC.
• Digital Instruments and Valves: Process switches and on/off valves 120Vac, 50Hz, single
phase from remote I/O panel or vendor PLC.
• Electrical Actuators: 480Vac, 3Ø (4wires), 50 Hz from dedicated panels in the electrical rooms
provided by I&CS discipline.
• Hydraulic Power Unit: Motors powered from starters in the MCC located in the respective
electrical room of the project; local control panel powered by 120Vac, single phase 50Hz from
power distributor instrumentation panels JP from UPS.
• Control system panels or cabinets: Including vendor panels (if applicable) powered by
120Vac, single phase 50Hz from power distributor instrumentation panels JP from UPS.
The power distribution design for instruments considers that 120 Vac panels and cabinets will be
powered from the UPS unit in the electrical or control/communication room. By other hand, 480
Vac distribution panels will be directly powered from a 480 Vac feeder in the MCC located in the
respective electrical room.
The main 120 Vac power distribution panel will feed the following equipment within the same
electrical room:
• DCS, PLC cabinets
• Telecomm cabinets
• SCADA cabinets
Analyzers cabinetsThe main power distribution panel will also feed field power distribution panels
JP, which will feed field cabinets, panels and 4-wire instrumentation, as required.
The UPS will power the control panels and instruments from vendor packaged equipment, but if
the vendor power requirement cannot be complied, the Project should request to the vendor to
provide a UPS for feeding their equipment.
Finally, equipment located at CCR will be powered by 220 VAC from UPS. The following
equipment will be located at CCR:
• Server and workstations cabinets.
• Communication equipment cabinets.
• Fire panels.
6.10.1 Uninterruptible Power Supply (UPS)
UPS units considered in the SGO’s project shall be used to accomplish the following objectives

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• Provide power back up for Instrumentation and equipment as described above.
• Provide filtered and conditioned electrical power supply
• Enable an adequate computer and server shutdown when power outage occurs.
6.10.2 UPS design criteria
UPS for electrical rooms supplied by the Project shall consider the following technical
requirements:
• UPS power shall be standardized for:
• Input voltage of 480V phase-to-phase;
• Output voltage of 120Vac phase-to-neutral
• UPS shall be True Double On-Line type, VFI-SS-111, rated to operate at 1750
m.a.s.l. and designed for backing up loads up to 1 hour.
• UPS shall have main and bypass electrical inputs, powered from 480 V motor control
centers (MCC). The ability to perform automatic synchronization, automatic and
manual by-pass is mandatory.
• The design factor will be 20%.
• The UPS will be de-rated at least according to the factor indicated at IEC 62040-3.
• Alarms contacts: Dry, SPST, 120 Vac, 2A.
• 480 VAC Three phases input / 120 VAC single phase output UPS for electrical rooms.
• 380 VAC Three phases input / 220 VAC three phases output UPS for CCR
The final power of the UPS will be chosen from available commercial option just upper than the
calculated demand.
UPS for OT/IT equipment rooms shall consider the design criteria indicated in document number
V2-2000-IC-DES-0001, Communication Design Criteria.
6.10.3 Power Distribution Panels
Electrical room 120 Vac main power distribution panels and 120 Vac field power distribution
panels powered from UPS, shall be single phase type
Field distribution panels shall be distributed in the field by process lines, such as a failure in the
panel will not affect other process lines.

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Both main and field distribution panels shall consider voltage indicators (lights), per phase,
located in the front of the panel. And also, circuit breakers for load isolation during repair and
maintenance procedures.
Both main and field distribution panels shall consider 10% spare in installed power and 10%
spare in space for future expansion.
6.11 ELECTRICAL SOCKETS
Equipment and cabinets requiring electrical sockets or plugs for services shall consider IEC Type
L. Theses sockets or plugs shall support 120 Vac, 10 A, 50 Hz.
Requirements for 220 Vac sockets and plugs are indicated on document “Communications
Systems Design Criteria”, N° 4-V2-2850-IC-DES-000001.
6.12 GROUNDING
Three grounding systems shall be considered for Instrumentation & Control Systems design. The
first one is the grounding system to Protect people, named Gnd1. The second one is the
reference ground system, named Gnd2, used for referencing electronic devices to 0 volt. Finally,
Gnd3 is the ground connection for cable shielding.
For adequate performance, a unique grounding for instrumentation shall be provided by the
reference ground (Gnd2). However, the grounding system of the DC power, instrumentation
cable, the grounding system of cabinets and AC power shall be isolated from each other until
they connect to the plant grounding system.
Each cabinet and local panel shall include grounding for its body. It will have a copper bar for
grounding. The enclosure of the panel and any other metallic elements shall be connected to this
ground bus. These connections and also the door connection must be installed with flexible
wiring. Each connection must be independent. Copper bar shall provide hole connections to a
Copper cable (N° 2/0 AWG) to the ground grid.
6.12.1 Protection / Safety Grounding (Gnd1)
The protection / safety grounding shall be connected to the overall power ground bar located in
electrical room which is connected to the ground mesh. The wire should be green / yellow Class
600 V.
6.12.2 Electronic Grounding (0 Vdc) (Gnd2)
The Electronic grounding is a sub system of plant grounding, which is dedicated to connect
electronic grounding systems bar.
This ground bar located inside each cabinet containing electronic equipment is isolated and
connected directly to the grounding mesh, not through the electrical room ground bar.
The electronic grounding shall be available in process control systems enclosures (DCS, PLC).
The wire shall be green. The ground bar is the same of transformer secondary of UPS.

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6.12.3 Shield Instrumentation Cable Grounding (Gnd3)
The shield cable of individual and multi-pair shall be grounded at one point (Gnd3). Grounding
shall be done in the marshalling cabinet of process control system (DCS). Grounding bar shall be
isolated from the cabinet.
In local panels, the shield of each signal pair cable shall be connected to the Instrument Ground
Bus (IGB) provided inside the panel.
6.12.4 Cabinet Grounding (TDI)
All hardware boxes, supporting network cable, such as ladder racks, cable trays, racks, cabinets
and conduits, shall be grounded connecting to protection /safety ground (Gnd1).
6.12.5 Field Instruments Cabinet Grounding
The local instruments shall be grounded through process lines or structure.
6.13 INSTRUMENTATION CABLING, RACEWAY SYSTEMS AND CABLE SEPARATION
6.13.1 Instrumentation, Control and Network Cables
The standard cable types to be used in the Project are described below:
• Foundation Fieldbus trunks and drops: Belden 3076F or equivalent according to

preferred manufacturer list – 18AWG - 7x26 stranded tinned Copper; Beldfoil®100%
shield coverage; Tinned Copper drain wire; Orange outside jacket color. Recognized
by Fieldbus Foundation.
• Profibus DP; Belden 3079A or equivalent according to preferred manufacturer list -

22AWG, Solid 0.6mm bare Copper; Beldfoil®; 65% Tinned Copper braid; purple
outside jacket color. Recognized by Profibus International Organization.
• Ethernet: UTP or FTP, Cat 5e or Cat 6 depending on location (see 4-V2-2850-IC-

DES-000001).
• 4-20mA Analog signal pair cables & RTD 3 wires/Pt100 signal triad cables: 18 AWG,
7 strands, 300 Volt, individually shielded, concentric bare copper wires with XLPE
overall jacket shall be used for single pair and single triad conductors. Shielding shall
be 100% coverage by an Aluminum-Mylar tape shield and drain wire. Drain wire shall
be 20AWG. The aluminum-Mylar tape shall be in contact with the drain wire along the
cable. The following instrumentation cables will be considered in the design process
• 1 x 1 p ; # 18 AWG
• 1 x 2 p ; # 18 AWG
• 1 x 8 p ; # 18 AWG

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• 1 x 1 t ; # 18 AWG
• 1 x 8 t ; # 18 AWG
• Thermocouple signals: Thermocouple extension wire shall be in accordance with

ANSI Standard C96.1. Extension wire shall be twisted pairs with aluminized shield
tape and Copper drain wire. Conductors shall be 18 AWG, 600 V, PLTC, single
twisted pair of Chromel-Alumel conductor.
• Discrete signals 120Vac/24Vdc: Control cable shall be stranded 16@18 AWG, 600 V
XLPE insulation and black overall LSZH jacket. The following control cables will be
considered in the design process:
• 1 x 3 c ; # 16@18 AWG
• 1 x 5 c ; # 16@18 AWG
• 1 x 9 c ; # 16@18 AWG
• 1 x 12 c ; # 16@18 AWG
• 1 x 19 c ; # 16@18 AWG
I&CS design shall consider independent cables for connecting discrete input signals and discrete
output signals.
• Instrument power cables shall be stranded 3c, 14@16 AWG, XLPE insulation type,
600 Volt with Black LSZH overall jacket.
• Electrical Valves Power Cables: Typical power cable used for feeding electrical
actuators shall be stranded 3c+G, 12 AWG, XLPE insulation type, 600 Volt with Black
LSZH overall jacket. However, each electrical power cable for electrical actuators
shall be based on the electrical actuator power requirement.
• Multi-pair triad or thermocouple extension cables shall have each pair or triad
shielded, insulated and with a drain wire. An overall shield and drain wire shall be
provided.
• All cables shall have UV resistant (sunlight) and flame retardant outer jacket.
• Cables used in intrinsically safe designs (intrinsically safe areas or FISCO design)
shall be supplied with a blue color jacket for identifying intrinsically safe circuits from
general purpose circuits.
6.13.2 Instruments Cable Raceway
Fiber Optic cables shall be laid down considering independent routes such as design provides an
effective redundancy. Deviation to this criterion shall be informed and approved by Fluor-Salfa.

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A. Conduits
All conduits shall be galvanized steel conduits for non-corrosive areas; galvanized steel conduits
PVC coated or PVC conduits type UV resistant (sunlight) for corrosive areas.
Minimum conduit size shall be ¾ inch. All conduits supports, clamps, and struts shall be selected
according to the area to be installed.
A meter long, liquid-tight, sunlight resistant PVC coated flexible conduit shall be installed at each
cable entrance to an instrument or equipment. Flexible conduit usage is recommended for
vibration isolation purpose.
All instruments and junction boxes shall consider plastic cable gland at cable entrance, to avoid
water entry.
Instrument and control cables shall be installed within rigid conduit when routed outside of the
cable tray.
Conduit coupling fitting and junction boxes shall be provided as required to facilitate replacement
of instrument.
Delicate communication cables may be installed in galvanized steel PVC coated or galvanized
steel conduit above ground.
B. Cable trays
All cable trays shall be galvanized steel for non-corrosive areas; and fiberglass (FRP) for
corrosive areas.
Electrical rooms shall provide metallic ventilated cable tray for laying down all communication
cables. Ventilated cable trays shall be installed above equipment requiring this service.
6.13.3 Cable Separation (Signal Segregation Criteria)
The instrumentation and electrical cable raceways shall be separated according to the different
kinds of signals and voltages/power levels in order to minimize the EMI/RFI interferences present
in the area. Cables with the same signal level shall be permitted to share the same raceway (tray,
conduit or duct). Cables with different signal level shall be located in different raceways.
The definition of distance between different types of raceways is based on IEEE 518-1982 (PIP-
EL001).
The separation distance will be defined according to the cable raceway and voltage in the cables
within it. Cable trays are based on metal, solidly grounded, with good ground continuity.
Cables trays were divided in levels as follow:
• Level 1: Low-low power (communication & analog)
• Fieldbus Foundation

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• Profibus DP
• Ethernet
• Analog 4-20 mA + HART
• Analog RTD
• Analog Thermocouple
• Any other proprietary signal from sensor to transmitter
• Intrinsically safe signals same level, but routed separately, i.e., using a different
conduit or raceway (IEC 60079-14).
• Level 2: Low power (analog signals)
• 24 VDC Digital signals
• 24 VDC Power Supply
• Analog tachometers signals
• Proximities signals
• Level 3 Medium-low power (control signals - single phase)
• 120 Vac Digital signals
• 120 Vac Instrumentation Power Supply
• 125 VDC Digital signals
• 220 Vac Lighting feeders
• In general AC feeders up to 20 A
• Level 4 Medium-high power (power signals – three phases)
• 460 Vac 3ph motor power supply (20A-80A)
• 460 Vac 3ph feeders power supply (20A-80A)
• 460 Vac 3ph Transformers circuits above 5 kVA
• In general AC and DC buses of 0 – 1000 V and 20 - 800 A
• Level 5 High power (medium & high voltage)

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• Circuits of 4.16 kV and 23 kV
• Circuits above 800 A
The design shall include the following criteria for the minimum distance between any pair of levels
as shown below:
Steel-Conduit-to-Steel-Conduit Spacing (inches)

Wiring Levels 1 2 3 4 5
1 0 1 3 12 12
2 1 0 3 9 12
3 3 3 0 0 0
4 12 9 0 0 0
5 12 12 0 0 0
Steel Tray-to-Steel Tray Spacing or Steel Tray-to-Steel Conduit Spacing
(inches)
1 0 1 6 26 26
2 1 0 6 18 26
3 6 6 0 6 12
4 26 18 6 0 0
5 26 26 12 0 0
Cable-to-Steel Conduit or Steel Cable Tray Spacing (inches)
1 0 2 4 20 48
2 2 0 6 20 48
3 4 6 0 12 18
4 20 20 12 0 0
5 48 48 18 0 0
Cable-to-Cable Spacing (inches) without Armed Cable
1 0 2 6 28 84
2 2 0 6 28 84
3 6 6 0 20 29
4 28 28 20 0 0
5 84 84 29 0 0
Cable tray spacing is defined as the minimum distance (in inches) between the top of one tray
and the bottom of the tray above or between the sides of adjacent trays. This spacing also
applies to the distance between trays and power equipment less than 100 KVA.

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Conduit spacing is defined as the minimum distance (in inches) between the outside surfaces of
conduits. This spacing also applies to the distance between conduits and power equipment less
than 100 KVA.
As a basic concept, only cables having the same voltage class may be run together. However,
levels 3 and 4 may be run in the same cable tray if separated by a barrier. Additionally, levels 1
and 2 may be combined in the same cable tray, with a grounded metal barrier for separating
levels.
Trays and conduits containing Levels 1 and 2 shall not be routed parallel to high-power
equipment enclosures of 100 KVA and larger at a spacing of less than 1.5 m (5 feet) for trays and
0.8 m (2-1/2 feet) for conduit.
Where the spacing listed in the table is difficult to maintain, parallel runs should be minimized and
in no case be run parallel to each other for a distance greater than 1.5 m (5 feet).
For non-metallic trays or conduits, consider the separation indicated in Cable-to-Cable Spacing
table.
7.0 LIST OF ATTACHMENTS
The following can be found in the “Attachments” section at the end of the document:
Attachment 1 Preferred manufacturer list

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7.1 ATTACHMENT 1: PREFERRED MANUFACTURER LIST
The following preferred manufacturer list is based on “Subcontractors and Suppliers List”
indicated in section 7, Form H, of Fluor-Salfa BAFO Technical proposal and is complemented in
some cases with additional manufacturers.
Valves
Control valves (butterfly, globe and Emerson – Fisher Controls
ball) Metso – Neles Jamesbury
Flowserve
Masoneilan
Samsom
Bray Control
Tyco Flow
Somas
Severn Glocon
Advance Valves
L&T
High pressure ball valves Valve Technologies
Mogas
Process solenoid valves Emerson – Asco
STCvalve
Burkert
Danfoss
Noshok
Rotex
Parker
Knife gate valves Pentair - Clarkson
Krebs Technequip
Weir Minerals Chile – Isogate
DeZurik
FNV (Ferguson)
Red Valve
Larox
Lockwood
MC Junkin Red
Tyco
ValyVal
Modulating knife gate valves Slurryflo

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Valves
Pinch valves Flowrox (Larox)
Clarkson (Muscle)
Red Valve
Fastpack
RF (Ferguson)
Inter
Lockwood
MC Junkin Red
Onyx (Zurich)
Rhinoflex
Plug valves Flowserve
Dezurik
Xomox
Bray Control
Ferguson
Tyco Flow Control
Pressure regulating valves Bermad
(Waterworks and fire protection) OCV
Singer
Tyco
Tecval
Flow Valve
Pressure regulating valves (Other Emerson – Fisher Controls
services) Spirax Sarco
Samson
JordanValve
Pneumatic valve Metso – Neles
Actuator/Positioner Dresser
Fisher
Flowserve
Foxboro
Pentair
Samson
Siemens
Topworx
Yokowaga
Motorized valve actuators Rotork
Auma
Limitorque
Biffi
Emerson – EL-O
Flowserve

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Relief Valves
Relief valves (Waterworks and fire Bermad
protection) OCV
Singer
ASCO
Relief valves (Other services) Farris
Dresser Consolidated
Pentair
Crosby
Lesser
ASCO
Flow
Sonar flow meter Cidra (Sonartrac)
Magnetic flow meter Endress + Hauser

Emerson-Rosemount
Yokogawa
ABB
Krohne
Foxboro
Honeywell
Coriolis mass flowmeter Endress + Hauser
Emerson-Rosemount
Yokogawa
ABB
Krohne
Foxoboro
Honeywell
Vortex flowmeter Endress + Hauser
Emerson – Rosemount
Yokogawa
ABB
Krohne
Foxboro
Honeywell
Siemens
Thermal dispersion flowmeter Endress + Hauser
ABB
Magnetrol

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Flow
Differential pressure flowmeter Endress + Hauser
Yokogawa
ABB
Honeywell
Flow switch UFM
Yokogawa
FCI
Brooks Instruments
Magnetrol
Greyline
Hach
Area-Velocity
Micronics
DNK Water
Temperature
Smart transmitter Emerson – Rosemount
Endress + Hauser
ABB
Yokogawa
Foxboro
Honeywell
Gauges/thermometers Ashcroft
Wika
Ametek
Versa
Switches Ashcroft
Wika
Dwyer
SOR
Pressure
Smart transmitter Emerson – Rosemount
Endress + Hauser
Foxboro
Yokogawa
ABB
Honeywell

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Pressure
Gauges/manometers Ashcroft
Wika
Ametek
Versa
Switches Ashcroft
Wika
SOR
Ametek
Level Transmitters
Ultrasonic Emerson – Rosemount
Endress + Hauser
Vega
Hawk
ABB
Yokowaga
Magnetostrictive MTS
Emerson – Magtech
Magnetrol
ABB
Yokowaga (K-TEK)
Endress + Hauser
Capacitance Endress + Hauser
Vega
Radar Emerson – Rosemount
Endress + Hauser
Vega
Hawk
ABB
Yokowaga
Honeywell
Foxboro
Siemens
Vega
Endress + Hauser
Hydrostatic Vega
ABB
Siemens

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Level Switches
Conductance type B/W Controls
Warrick
Drexelbrook
Endress & Hauser
Emerson
Capacitance type B/W Controls
Magnetrol
Endress + Hauser
Emerson
Drexelbrook
Nuclear type Endress + Hauser
Ronan Engineering
Berthold Technologies
Ohmart Vega
Liquid Analysis
Density Endress + Hauser
Ohmart Vega
Ronan Engineering
Berthold Technologies
pH and ORP analyzer Emerson- Rosemount Analytical
Endress + Hauser
ABB
Foxboro
Mettler Toledo
Yokowaga
Honeywell
Conductivity analyzer Emerson- Rosemount Analytical
Endress + Hauser
ABB
Foxboro
Mettler Toledo
Honeywell
Yokowaga

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Others instruments & equipment

Process display Emerson
Endress + Hauser
Yokogawa
ABB
Honeywell
Foxboro
Instrument Fittings Swagelock
Parker
Proximity switch Emerson - GO
Allen Bradley
Pepperl fuchs
Topworx
Stonel
Vibration switch/transmitter Honeywell
PCB
PMC/Beta
Load cells Dynisco
BLH Electronics
Mettler Toledo
Conveyor Instruments
Pull cord Switch Conveyor Components
Thermo Ramsey
Crouse-Hinds
Misalignment switch Conveyor Components
Thermo Ramsey
Rip detector (Mechanical) Conveyor Components
Thermo Ramsey
Rip detector (Electronics) Goodyear
Becker
Bridgestone
Contitech
Zero speed switch Conveyor Components
Siemens - Miltronics
Thermo Ramsey
Speed transmitter Siemens - Miltronics
Thermo Ramsey

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Conveyor Instruments
Tilt switch Conveyor Components
Thermo Ramsey
Microwave level switch Hawk
Thermo Ramsey
Belt scales Thermo Ramsey
Siemens Milltronics
Shenck
Merrick
Metal detector Ramsey
Techtron
Eriez
Federal Signal
Beacon & Horns Legrand
Rockwell
Systems
CCTV Honeywell – DVM R620
Fire system Honeywell - Notifier
Programmable logic controller Siemens - S7
(PLC) Allen-Bradley – ControlLogix
Distributed control system (DCS) Honeywell
Condition Monitoring Systems and GE
Sensors SKF
Emerson
Rockwell
Ore Size Analyzer System Split Engineering, LLC
Metso Minerals (Chile) S.A.
Outotec Chile LTDA
Woodgrove Technologies Inc. (Portage
Technologies)
Particle Size Tracking Analyzer Cidra
System Woodgrove Technologies Inc. (Portage
Technologies)
Roping Analyzer System (Over Cidra
Size Monitoring) Woodgrove Technologies Inc. (Portage
Technologies)
Particle Size Analyzer System Outotec
Thermo-fisher
In-stream Analyzer Outotec
Thermo-fisher
Heath & Sherwood

BHP 4-V2-2000-IC-DES-000001
Project No: A6YF
Systems
Industrial Ethernet switches Hirschmann
Cisco
Moxa
Ruggedcom
Rittal
Schneider Electric
Cabinets Pentair – Hoffman
Honeywell
Legrand
Terminal blocks Phoenix Contact
Weidmuller
Wago
Legrand
Foundation Fieldbus Components Relcom
MTL
Turck
Pepperl & Fuchs
Phoenix Contact
Foundation Fieldbus Cable Belden
Dekoron
Eaton
KEI
Lapp
Leoni Kerpen
Marlew
MESC
Northwire
Phoenix Contact
ShawFlex
Tekab
Profibus DP Components ABB
Belden
Eaton
Harting
Phoenix Contact
Turck
Siemens
Profibus DP Cable Belden
Eaton
Harting
Phoenix Contact
Siemens
End of Criteria

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BHP 4-V2-2000-IC-DES-000001

SGO WP2 Concentrator Project Revision 0, 19Jul2017

Rev. No. Date Description

A 22Jun2017 Issued for internal review

B 30Jun2017 Issued for Internal Approval

0 19Jul2017 Issued for Design

Instrumentation & Control System Design Criteria

1.0 PURPOSE ........................................................................................................................................ 6

Instrumentation & Control System Design Criteria

5.9 FIRE DETECTION & ALARM SYSTEM........................................................................... 30

Instrumentation & Control System Design Criteria

6.12.4 Cabinet Grounding (TDI) ...................................................................................... 61

Instrumentation & Control System Design Criteria

The scope of this document includes the following facilities:

• 2140 Coarse Ore Storage/Stockpile.

• 2280 Coarse Ore Reclaim.

• 2220 Copper Flotation and Regrinding.

• 2230 Pebble Crushing.

• 2240 Copper-Moly Concentrate Thickener.

• 2250 Concentrate Pumping & Pipeline.

• 2260 Molybdenum Plant.

• 2265 Copper Concentrate Thickener.

• 2270 Flocculant Plant.

• 2270 Lime Plant.

• 2270 Flotation Reagent Plant.

• 2290 Filter Plant.

• 2291 Compressed Air.

• 2295 Filter Cake Storage and Loadout Facilities.

Instrumentation & Control System Design Criteria

• 2610 Tailings Thickener.

• 2831 Water Supply & Distribution.

• 2832 Sewage Treatment Plant (underground pipes).

• 2834 Air Compressors Plant.

• 2850 Project-Wide Systems.

• 2860 Plant Control Systems.

3.0 STANDARDS AND REFERENCES

3.1 OCCUPATIONAL SAFETY REGULATIONS

DS N° 132 Decreto Supremo de 2002 del Ministerio de Minería.

OSHA 29 CFR 1910 Occupational Safety and Health Standards.

EPA 40 CFR Part 60 Standards of Performance for New Stationary Sources.

Note 1: an English translation of key articles can be found in document N° 4-V2-2000-EL-DES-

3.2 STANDARDS AND CODES

AG-140 Foundation Fieldbus: Wiring and Installation 31.25kbit/s,

AG-163 Foundation Fieldbus Application Guide 31,25 kbit/s

AG-181 Foundation Fieldbus System Engineering Guidelines

Instrumentation & Control System Design Criteria

ANSI / ISA – 5.1. 2009 Instrumentation Symbol and Identification.

ANSI / ISA – 5.3 Graphic Symbols for Distributed Control.

ANSI / ISA – 7.0.01 Quality Standard for Instrument Air.

ANSI / ISA – 37.1 Electrical Transducers Nomenclature and Terminology.

ANSI / ISA – 51.1 Process Instrumentation Terminologies.

ANSI / ISA 75.01.01 Flow Equations for Sizing Control Valves.

ANSI/ISA-95 American National Standards Institute – Enterprise –Control

API 520-part 1 Sizing, Selection and Installation of Pressure-Relieving

API 526 Flanged Steel Pressure Relief Valves.

API 670 Machinery Protection Systems.

API 2000 Venting Atmospheric and Low-Pressure Storage Tanks.

ASM Consortium Abnormal Situation Management Consortium.

ASME American Society of Mechanical Engineers.

ASTM American Society for Testing and Materials.

CCHEN Comisión Chilena de Energía Nuclear.

DIN Deutsche Institut für Normung.

EIA Electronic Industry Association.