GERENCIA DE PROYECTOS

INGENIERÍA DE DETALLE

MEJORAMIENTO FUNDICION HORNO FLASH

POTENCIADO

DQ-170137 / DP-170013

0 JOOKAL 23.3.2018 AKUJAA 23.3.2018 KRITUL 23.3.2018 APPROVED FOR FURTHER ENGINEERING
B JOOKAL 8.2.2018 AKUJAA 8.2.2018 KRITUL 8.2.2018 FOR INFORMATION
Name Date Name Date Name Date Revision Text
Rev
Prepared Checked Released
Status: Original Size:
APPROVED FOR FURTHER ENGINEERING
Customer: Project Lifecycle Phase: Site No.:
CODELCO CHILE DIV. CHUQUICAMATA IMPLEMENTATION 01 S-00262
Project Name: Customer Document ID:
CHUQUICAMATA FSF 17EP11-ID-5220-ME-SP-008
Replaced by: Replaces: Language:
EN
Document Title:
DUTY SPECIFICATION
SMELTING PLANT
FLASH SMELTING
HEAT EXCHANGERS
INTERCAMBIADORES DE CALOR - AREA BOMBAS
Equipment No: Item No:

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 1 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339
 CHUQUICAMATA FSF
DUTY SPECIFICATION
SMELTING PLANT

TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................................ 3
2. SCOPE ............................................................................................................................... 3
2.1. Engineering and documentation ................................................................................. 3
2.2. Spare parts and wearing Parts ................................................................................... 3
2.3. Work excluded ........................................................................................................... 4
2.4. Battery limits............................................................................................................... 4
3. OPERATION AND DESIGN CONDITIONS......................................................................... 4
3.1. General desing Conditions ......................................................................................... 4
3.2. Codes and standards ................................................................................................. 4
3.3. Duty description ......................................................................................................... 5
Cooling water heat exchangers 5226-INC-004 and 5226-INC-005...................................... 5
3.4. Design characteristics ................................................................................................ 5
4. EQUIPMENT DESCRIPTION ............................................................................................. 6
4.1. Mechanical ................................................................................................................. 6
4.2. Materials and welding ................................................................................................. 6
4.3. Surface treatment and painting .................................................................................. 7
4.4. Instrumentation and automation ................................................................................. 7
5. ASSEMBLY ........................................................................................................................ 8
5.1. Shop assembly........................................................................................................... 8
6. COMMISSIONING AND TESTING ..................................................................................... 8
6.1. Shop tests .................................................................................................................. 8
6.2. Tests after Installation ................................................................................................ 8
7. ATTACHMENTS ................................................................................................................. 8

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 2 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339
 CHUQUICAMATA FSF
DUTY SPECIFICATION
SMELTING PLANT

1. INTRODUCTION
This specification covers the minimum requirements of heat exchangers to be used
for the Primary Cooling Water System area in the Flash Smelting process.
The equipment shall be supplied as a complete functional and operational unit
incorporating all necessary auxiliary materials except as specifically excluded in
section
Note 1: If the supply deviates from this specification, complete technical and
economic arguments for the alternative solutions are to be stated.
Note 2: All SI-units of volume stated in this specification refer to the temperature
of 0C and the pressure of 101,325 kPa (NTP).
Note 3: All document references included in this specification refer to the latest
revision of the document in question.

2. SCOPE
The equipment shall consist of but not be limited to the following items:

EQ code Qty Description

5226-INC-004 1 Cooling water heat exchanger
5226-INC-005 1 Cooling water heat exchanger

The equipment shall include at least, but not be limited to the following:
- Plate type heat exchangers
- Flanged inlets and outlet for primary water circuit
- Flanged inlets and outlet for secondary water circuit
- Local temperature gauges for inlet and outlet water circuit
- Local pressure gauges for inlet and outlet water circuit

The above listed equipment is to be furnished as a complete package, which shall

include at least material for design, fabrication, testing and delivery.

2.1. Engineering and documentation

The Heat Exchangers to be dimensioned by the supplier.
Supplier shall provide Engineering and documentation that includes at least: design
drawings, Data Sheets, Technical sheets, Part and Component list, erection
instructions, IOM-manuals, diagram of statistical and dynamic loads, electrical and
instrumention plans and other requested information.

2.2. Spare parts and wearing Parts

The supply shall include a list for recommended spare and wearing parts for:
 Commissioning and start –up
Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 3 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339
 CHUQUICAMATA FSF
DUTY SPECIFICATION
SMELTING PLANT

 2 year operation (minimum)

2.3. Work excluded

All work and equipment required for a complete operating unit shall be included
except as specifically excluded below:
 Foundation anchor bolts
 Field erection and installation
 Access platforms, handrails and stairs not mounted on the unit
 Piping unless an integral part of the equipment assemblies or of this
specification
 Anchor bolts

2.4. Battery limits

 Fastening on foundation/supporting steels
 Outlet / inlet connections to cooling water system piping

3. OPERATION AND DESIGN CONDITIONS

3.1. General desing Conditions
Design criteria for utilities and site conditions are presented in attached document
“Design Criteria”.
The seismic design should be done according to response spectrum.
The equipment will be installed indoors.
The design of the equipment shall be suitable for continuous heavy-duty service of
8672 hours per year.
Special consideration shall be given to the industrial atmospheric corrosive
conditions of the site.
The equipment noise shall not exceed the design levels of 85 dBA, based on 8
hours time-weighted average exposures.
Please see more detailed noise levels requirement in Criteria for Mechanical
Design_Codelco_SGP-GI-ME-CDI-001r0, chapter 27 Noise levels.

3.2. Codes and standards

The following standards shall apply for the engineering and equipment delivery:
Pressurized parts:
- Pressure bearing parts will be designed, manufactured and inspected according
to the Pressure Vessel Code ASME.

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 4 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339
 CHUQUICAMATA FSF
DUTY SPECIFICATION
SMELTING PLANT

Drawings:
 All design and drawings shall be done in Spanish language, using metric system
and SI-units and projection shall be according to first angle projection.

3.3. Duty description

Cooling water heat exchangers 5226-INC-004 and 5226-INC-005

Cooling water heat exchangers are for cooling the furnace jacket cooling water
circuit. Jacket (primary) cooling water is cooled with secondary cooling water
circulation.
The heat exchangers shall be of plate type heat exchangers.
Heat exchanger 5226-INC-004 are in operation and 5226-INC-005 is stand-by.

3.4. Design characteristics

Heat Exchangers 5226-INC-004 and 5226-INC-005 Capacity:

Capacity 10 MW (each)

Water Flow: Primary side Secondary side

JCW Cooling water
3
1050 m /h 1050 m3/h

Water Temperature: Primary side Secondary side

JCW Cooling water

- Inlet temperature 43 °C 30 °C
- Outlet temperature 35 °C 38 °C
- Inlet pressure, max 650 kPa(g) TBC kPa(g)
- Pressure loss, max 100 kPa

Water Analysis: Primary side Secondary side

JCW Cooling water,
requirements by vendor
- pH 8-8,5
- Total hardness <4 °dH
- Ca hardness
- Mg hardness
- Carbon hardness
- Other hardness
- KMnO4 consumption < 25 mg/l
- Chloride < 20 mg/l
Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 5 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339
 CHUQUICAMATA FSF
DUTY SPECIFICATION
SMELTING PLANT

- Free chloride < 0.05 mg/l

- Sulphate < 200 mg/l
- Phosphate
- Nitrate < 20 mg/l
- Iron+Manganese < 0.3 mg/l
- Ammonia < 0.1 mg/l
- Silica content as SiO2 < 20 mg/l
- Suspended solids < 10 mg/l
- Total residue < 300 mg/l
- Fixed residue < 250 mg/l
- Free CO2 no signs
- Oil no signs

Secondary side is to be defined by Supplier.

Max. pressure loss allowed < 100 kPa

4. EQUIPMENT DESCRIPTIONEquipment shall be a complete unit including all

the equipment with necessary accessories listed earlier in section 1.2, ready to be
erected on supporting steels supplied by others.
Equipment shall be manufacturer's standard type ("heavy duty type"), modern and
reliable.
Equipment shall have lifting lugs for handling of subassemblies.
The equipment and structures included in the supply must be of proven design,
modern and reliable.

4.1. Mechanical
The heat exchangers shall be of plate and frame type.
The frame shall be sized to provide space for 25-50 % additional plates.
There shall be manual tightening of clamping bolts.
The construction must allow for easy opening, cleaning and inspection of the plate
pack.
The frame must be constructed so that it is stable enough to carry the weight of the
heat exchanger without being attached to the foundation.

4.2. Materials and welding

The Supplier shall recommend suitable materials of construction compatible with the
material being handled.
Plate: AISI 316
Frame: Carbon Steel
Sealing: NBR
Connections: AISI 316

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 6 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339
 CHUQUICAMATA FSF
DUTY SPECIFICATION
SMELTING PLANT

The abrasive and corrosive conditions must be taken in consideration when

selecting materials for construction of the equipment.

Welding shall be done either by metal-arc welding or corresponding welding

method.

The properties of filler metal have to correspond to the values of the basic material.

4.3. Surface treatment and painting

All cleaning, painting or finishing will be done in full accordance with the latest
edition of SSPC standard and in accordance with standard practices of the supplier.
Supplier shall recommend if other painting options are their standard in use.
Insulated steel structures shall have transport protection.
Surface treatment and painting of standard components shall be according to
manufacturer’s standard practice.
Surface treatment for stainless steel parts.
Corrosion protection work in the work shop:
All defects and contaminations of Stainless Steel parts surfaces such as welding
oxide, heat tint or scale shall be cleaned with stainless steel brush or acid pickled
and passivated.

4.4. Instrumentation and automation

All controls and instrumentation equipment (field instruments) necessary for opera-
tion and control of the equipment shall be furnished.

All instrumentation and related items according to Specification Instrumentation

and controls for the mechanical equipment
302205_PSP01_PS01_EEC01_00002_EN_OU100048300.

Heavy conditions must be taken in consideration when selecting instrument

components.

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 7 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339
 CHUQUICAMATA FSF
DUTY SPECIFICATION
SMELTING PLANT

5. ASSEMBLY
5.1. Shop assembly
Components and installation shall be shop assembled to the maximum extent
regarding the fabrication, transportation and installation. Seller is responsible to
consult with the Client about the extent of the shop assembly.

6. COMMISSIONING AND TESTING

6.1. Shop tests
Seller shall provide a description of tests normally provided in the shop. These tests
shall be performed before the shipment.
Standard testing by the manufacturer or Seller shall include, but not be limited to the
following equipment:
- Pressure test of the heat exchangers is the minimum requirement
- Construction materials
- Welded structures

6.2. Tests after Installation

All preliminary performance tests required by the Seller for the purposes of
ascertaining the optimum operation of the equipment shall be carried out by the
Seller at his own expense. The Client will supply necessary non-skilled labor and
utilities.

Seller shall provide a description of the tests recommended to be done after

installation.

7. ATTACHMENTS

1. Criteria for Mechanical Design_Codelco_SGP-GI-ME-CDI-001r0

2. Process Design Criteria
302205_PSP01_PS01_PEC02_00001_OU100049388
3. Process Flow Diagram Cooling Water System
302205_PSP01_PS01_PFB01_00001-R0
4. Specification_Instrumentation and controls for the mechanical equipment
302205_PSP01_PS01_EEC01_00002_EN_OU100048300_R0A

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 PEC10 00004 0 8 (8)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054339