Molino Sag Anillo

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DOCUMENTS PACKAGE TRANSMITTALFACTIBILIDAD PROYECTO TRANSICION UJINA-ROSARIO

COMPAIA MINERA DOA INES DE COLLAHAUSI

KVAERNER METALS

C00423 PAGE 1

KMS-18/01/2001-10:58:26

TO: CIA. MINERA DOA INES DE COLLAHUASI

AV. ANDRES BELLO N 2687, PISO 11

LAS CONDES - SANTIAGO

ATTN: R.DELUCCHI

FROM: KVAERNER METALS

AV. NUEVA TAJAMAR N 481, PISO 19

LAS CONDES

SANTIAGO

PACKAGE ID: KX0-045 Documento aprobado

DOCUMENT ID DESCRIPTION REV. AND DATETYPE

DATE: January 18, 2001

COPIES

141E-TS001 GEARLESS DRIVES FOR SAG AND BALL MILLS P 18/01/2001SPECIFICATION ELECTRONICA

Please sign and return: Sincerely,

Received By

DateALEX FALCK

DISTRIBUTION LIST:

ALEX FALCK

FRANCISCO CAICHAC

VICTOR VALDES


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Kvaerner

PROJECT N C-423

COMPAIA MINERA DOA INES DE COLLAHUASI SCM

UJINA - ROSARIO TRANSITION PROJECTFEASIBILITY STUDY / BASIC ENGINEERING

Specification N 141E- TS001

Gearless Drives for SAG and Ball Mills

Kvaerner MetalsAv. Nueva Tajamar 481, Piso 19 CLIENT APPROVAL:Las Condes, Santiago DATE:

REV. DATE BY CHK. APPROV. DESCRIPTION

A 18/12/00 VVE VVE / JA FMC / AF Issued for internal coordination

M 03/01/01 VVE VVE / JA FMC / AF Issued for Client approval

P 18/01/01 VVE VVE / JA FMC / AF Issued for Feasibility Study


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Kvaerner Project NC-423Specification N141E-TS001

Gearless Drives for SAG and Ball MillsRev A

INDEX

Page

1.0 SCOPE 3

2.0 CODES AND STANDARDS 4

3.0 OPERATING AND DESIGN CONDITIONS 5

4.0 DESIGN REQUIREMENTS 7

5.0 PAINTING 24

6.0 QUALITY ASSURANCE, INSPECTION, AND TESTING 25

7.0 LIST OF ATTACHMENTS 26


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1.0 SCOPE

1.1 Equipment Identification

The Vendor shall furnish gearless drive systems for SAG and Ball mills, completewith motor, cycloconverter controllers, associated transformers and relatedequipment in the quantity indicated for the Ujina Rosario Transition Project,property of Compaa Minera Doa Ins de Collahuasi SCM, Chile.

Item Qty Equip. No. Description

1 1 141ML001A SAG mill motor 20,500 kW, synchronous motor.(Mill Size:40 ft diam x 20 ft long)

2 2 141ML002A

141ML003A

Ball mill motor 14,000 kW, synchronous motor.(Mill Size:26 ft diam x 40 ft long)

3 1 141VY901 Cycloconverter Cubicles for SAG mill drive

4 2 141VY902

141VY903

Cycloconverter Cubicles for Ball mill drives

5 1 141CO901 Drive Control Panels for SAG mill

6 2 141CO902

141CO903

Drive Control Panels for Ball mills

7 3 141XF901

141XF902

141XF903

24 kV transformers 3-phase, 50 Hz, primary andappropriate secondary voltage suitable for the SAG milldrive system.


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3 phase, 50 Hz, ahead of the SAG mill motors terminals.

12 2 141SG905

141SG906

Switchgear indoor type, with 600 A discconnect swi tch,3 phase, 50 Hz, ahead of the Ball mill motors terminals.

13 1 141EX901 Synchronous rotor exciter system panel for SAG millcicloconverters

14 2 141EX902

141EX903

Synchronous rotor exciter system panel for Ball millcicloconverters

15 1 141ER901 Prepackaged, containerized electrical building to houseitems 3, 5, 9, 13 and other panels and componentsnecessary for operation of the gearless SAG mill drivesystem.

16 2 141ER902

141ER903

Prepackaged, containerized electrical building to houseitems 4, 6, 10, 14 and other panels and components

necessary for operation of the gearless Ball mill drivessystem.

17 1 141HF901 Harmonic filter. 24 kV, four stages of filtering, 20 MVAand studies.

18 Lot Special tools and equipment

19 Lot HOLD Replacement spare parts recommended for one yearoperation. Spare parts shall be itemized and individuallypriced.


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The equipment shall be designed, fabricated, assembled and tested in accordance

with the following standards:

NEC - National Electrical CodeANSI - American National Standards InstituteIEEE - Institute of Electrical and Electronics EngineersIEC - International Electrotechnical CommissionNEMA - National Electrical Manufacturers AssociationASTM - American Society for Testing and MaterialsASME - American Society of Mechanical Engineers

UBC - Uniform Building CodeUL - Underwriter's LaboratoriesNFPA - National Fire Protection AssociationNESC - National Electrical Safety CodeNOSA - National Occupational Safety Association, CMDIC

All applicable country state and local codes.

If the equipment does not comply with these standards, the Vendor shall so state,fully describe each exception taken, and indicate the standards that the equipmentwill meet.

Where conflict exists between referenced standards, the most stringent standardshall be used.

Equipment, materials, components, and functions designed, built, rated, tested andperforming in accordance with other standards such as JIS, DIN, and IEC areacceptable provided that they meet supplemental requirements which will makethem equivalent to those specified in 3.1 above. Such supplemental requirementsshall be explicitly stated in Sellers proposal and they are subject to mutualagreement between the Purchaser and Seller.


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- Power will be available to supply the drive systems at 24 kV. The power system will

be 3 phase, 50 Hz, wye connected, low resistance grounded.

- The available symmetrical short circuit capacity of the 24 kV system will be 700MVA.

- The available short circuit current of the 380/220 V system will be 60 kA.

- The total WK2 of the SAG and Ball mills are to be obtained from the mills Vendor,including structural analysis and foundations.

- In order to obtain the Sellers most accurate drive system efficiency, the Purchaserintends to assess a penalty of US$ 5,000/kW on the purchase price of the drive forany reduction in actual efficiency from the Sellers stated efficiency. Seller shallprovide the detailed kW losses for the entire drive system including motor,cycloconverter, power transformers and auxiliary equipment. The kW losses shallbe furnished for 75% and 100% torque at rated speed.

3.2 Environmental Conditions

Plantsite conditions are specified in Appendix A attached.

All equipment supplied herein shall be suitable for service at the plantsite conditions.Switchgear will be installed in a ventilated, air conditioned switchgear room (E-house). The room will be pressurized to prevent entrance of dust.

3.3 Seismic Design

The seismic analysis for electrical equipment, its parts, and foundations, shall bemade based in two horizontal directions, perpendicular to each other, and onevertical, acting simultaneously, being the magnitude of vertical force equal to + of


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Duty [kV] Rated [kV] Sec [kV] Ear th ing Serv ice

220 Main incoming Voltage

23 24 24 Resistance grounded Site Primary Distribution Voltage

7.2 7.5 7.2 High Resistance Mine Equipment

3.3 3.45 3.45 Resistance grounded Process Medium Voltage Motors

0.38 0.40 0.40 Solidly grounded Low voltage motors and loads

0.22 0.231 0.231 Solidly grounded Lighting loads

0.115 0.12 0.12 Solidly grounded Control Voltage

0.125 0.125 DC Control voltage

0.115 0.12 AC Control Voltage

Vendor shall be entirely and solely responsible for the design, procurement ofmaterials and components, fabrication, assembly, quality inspection, testing andguarantee of the equipment performance.

4.0 DESIGN REQUIREMENTS

4.1 General Requirements

4.1.1 The mill drives and auxiliary equipment shall be Sellers latest design, proven inservice to meet the requirements and intent of this Specification, and theattachments.

4.1.2 All components and materials shall be new, unused, and of current Manufacture bygenerally recognized well established firms in the industry. Replacement parts


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4.2 Drive Rating and Mill Data

SAG mill

Drive concept Gearless SAG Mill Drive(Cycloconverter-fedsynchronous motor)

Rated power, kW 20,500

Service Factor 1.0

Mill speed, RPM Variable

Mill Rated critical design speed 78 % HOLD

Mill critical speed operating range 60 80 % HOLD

Mill speed, constant torque 60 78 % HOLD

Mill speed, constant power 78 80 % HOLD

Speed Range (normal) 0 80 % HOLD

Inching speed 1.3 RPM

Creeping speed 0.3 RPM

Operation In both directions

Start-up torque 130 % for 30 sec


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Mill speed, constant power 78 80 % HOLD

Speed Range (normal) 0 80 % HOLD

Inching speed 1.3 RPM

Creeping speed 0.3 RPM

Operation In both directions

Start-up torque 130 % for 30 sec.

Creeping 130 %

4.3 SAG Mill Synchronous Ringmotor

4.3.1 Stator Sections:

a. The wrap-around motor design shall be based on the mill design, taking intoconsideration the following:

Torque transmission directly to the mill shell, not through torque tubes. Stability of the mill as a result of mill (including bearings) stiffness and

motor stator stiffness. Reference of thermal expansion of mill and stator at the same level. Axial shifting capability of stator for maintenance and inspection

purposes. Minimum floor-space requirements

b. The stator assembly shall be fabricated and shipped in as few pieces aspractical, considering the available transport facilities from Manufacturerslocation to the jobsite, and the facilities at the site installation. Bidder shallstate the number and location of proposed shipping splits in their proposal


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adjustments. Air filters of the replaceable type shall be installed in anaccessible location.

f. The high-voltage three-phase stator winding system shall use class Finsulation materials and shall be vacuum-pressure impregnated (VPI) beforeinsertion into the stator slots. During normal operation, the temperature riseof the winding shall be limited to that of class B materials, i.e. 80C at site.Class F temperature rises are permissible for short overload periods only.The insulation system used shall be totally insensitive to moisture.

g. Field-splices at shipping splits shall be kept to an absolute minimum. Theproposed method of splicing shall result in joints that exhibit equal electricaland mechanical properties as the windings themselves and shall beexplained in Bidders proposal. Connections to the supply cables shall notinterfere with the possible axial movement of the stator assembly.

h. Mechanical stresses on the windings encountered during normal and faultconditions shall not lead to fracture, deformation, or loosening of thewindings. Field repairs to the VPI insulation system shall be possible.

i. Service voltages for stator and rotor windings shall be determined byManufacturer during his optimization process for the entire drive system.The selected voltages and resulting currents shall be indicated in Bidder'sproposal.

j. The air gap of the motor shall be monitored prior to and during mill operationby suitable sensors. Excessive static deviations from the nominal airgapshall prevent the mill from being started, and shall lead to an immediate shut-

down if detected during operation.

k. Two sets of temperature detectors RTD's, 100 ohm platinum in stator slotsconnected to the auxiliary termination box for external wiring, whereby one

t h ld b i ti d h ld b i t d b Th b f


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design and required performance data into account. Design shall minimizethe installation time and labor.

b. The mill Vendor will make available a suitable mounting flange, or othersuperstructure, to accept the field poles or pole-segments. The mountingflange or superstructure will be machined to the required tolerances by themill manufacturer according to the data given by the motor Manufacturer.Bidder shall state their required machining tolerances for radial and axialrunout, and the number of bores required. Design of rotor elements shallminimize the number of bores and bolts. Installation procedures also shall bestated in Bidders proposal.

c. If all or part of the cross section of iron required to carry the magnetic fieldflux is part of the mill body, Bidder shall indicate this required cross-sectionin his proposal. Field poles may be laminated or solid iron at the discretionof the motor Vendor, however laminated poles are preferred.

d. The electrical connections between field poles shall be bolted.

e. Rotor windings shall be executed with class F insulation materials suitable formaximum temperature rises. However, during normal service, thetemperature rise values of class B materials, i.e. 80C shall be utilized. ClassF temperature rises are permissible for short overload periods only.

f. All components of the field circuit shall be sized to continuously satisfy themaximum flux demand of the synchronous motor that corresponds to themaximum torque required by the drive.

g. The excitation power to the field winding shall be transmitted via a rotormounted slip ring assembly. Access via an oversized inspection door shall beprovided for inspection and maintenance of the excitation ring brushes. Themotor field circuit shall be separately excited from a static power supply. Thecycloconverter shall shut down on loss of field supply


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4.3.4 Air Gap Monitoring System

a. The motor air gap shall be monitored by two independent measuringsystems. One system shall use proximity limit switches and the other shall bebased on a Hall effect measuring system.

b. Two sets of proximity switches shall be located at 90C intervals around themotor circumference. One set shall be used for warning and the other set formotor tripping purposes. The switches shall also be operational while themotor is at stand still.

c. The second air gap monitoring system shall be capable of continuouslymeasuring the motor air gap while the motor is running. A set of Hall crystalsshall be positioned at 90, so that each pair is capable of measuring the airgap in the horizontal and vertical direction. The output of the measuringnetwork shall be calibrated for Video Maintenance Display. In addition,deviation limits shall be programmed into the motor controller, so thatautomatic alarm and shutdowns are initiated as soon as set limits areexceeded.

4.3.5 Anti-Condensation

a. Heating elements shall be provided, and shall be metal-clad with terminalenclosure to prevent exposure to live parts, and with full protection againstfire risk by inadvertent contact with heated parts.

b. Heating elements up to 2000 watt maximum shall be rated for a single phase

operation. Higher wattage heaters shall be suitable for 3 - phase operation.

c. Heaters shall be sized to raise the temperature approximately 5C above thedew point temperature for the specified ambient conditions when the motor


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- rated horsepower required at mill shell

- rated speed range and torque - speed curve of mill

- nominal mill diameter and minimum hole - pitch circle of field - polemounting flange.

- bearing geometry and type of lubrication

- maximum wear of bearings and maximum permanent deformation of mill

cylinder at motor location

- thermal growth data of mill

- maximum dynamic eccentricities of mill during operation.

The motor Manufacturer shall supply to the mill manufacturer the following data:

- maximum one - sided magnetic pull at standstill and rated speed of mill

- maximum static & dynamic eccentricity of rotor at field-pole mountingflange

- field - pole mounting hole geometry & tolerances

The mill Manufacturer shall run a system stiffness study using finite element models.The input data for that study shall be determined in close cooperation with themotors Manufacturer, a system stiffness of mill / motor / bearing / foundation, etc. is

of essential importance for a successful operation.

The necessary coordination shall be the mutual responsibility of the mill and motormanufacturers.


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34.5 kV class Circuit Breakerfor operation at 24 kV. 1,200 A circuit breaker,

vacuum type, a switch disconnector and all the necessary disconnecting / protectingequipment shall be provided ahead of the primary of the converter transformersinside the E - House. The battery limit of the supply shall be 24 kV. The BIL of thebreaker and disconnector at sea level shall be 200 kV. Breaker control voltage shallbe 125 V DC supplied from a battery provided by the Seller. Breaker shall conformto applicable ANSI standards for application at the site elevation.

4.6 Cycloconverter Transformers

4.6.1 Transformation from the incoming line voltage down to the cycloconverter inputvoltage, and thereby isolation of the two systems, shall be done via three-phase, oil-filled, self cooled outdoor transformers. Within the constraints stated else-where inthis specification, ratio, impedance voltages, and number of transformers andwindings shall be chosen by the Manufacturer to obtain optimized systemperformance and efficiency, and to keep disturbances of the incoming line to aminimum. The quoted design shall take shipping size limitations and the effects ofearthquakes into account. The additional harmonic loads and the increaseddynamic stresses typical for thyristor-equipment loads shall be duly considered inthe design. Tolerance for impedance voltages and electrical displacement ofparallel windings shall be kept smaller than in regular power transformers tominimize the creation of harmonic.

4.6.2 Standard off load taps shall be furnished on 24 kV primary windings. BIL at 24 kVshall be 200 kV at sea level. Lightning arresters shall be provided at the primaryterminals within the primary terminal box. Primary terminal box shall be side-mounted with high voltage bushings, lightning arresters and terminal connectors for

cable entry from the bottom. Terminal chamber shall be provided with spaceheaters with thermostat control, for connection by others into 220 VAC powersource.

4 6 3 Transformer secondary voltage shall be Manufacturers standard as required for


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e. One pressure/vacuum gauge (63).

f. One mechanical oil pressure relief device with mechanical indication ofoperation.

g. A bolted manhole cover on the top of the tank.

h. One stainless steel or brass diagrammatic nameplate to state the following:

Connection diagram (terminal markings)

Rate kVA at the various temperature ratingsVoltage ratings at no load, all tapsPolarities of windingsImpedance percentagesWeightsInsulating liquid type and contents in litersSecondary current at full load

In addition, the following information shall be given on the nameplates or on

the diagram plate:

Year of manufacture Type of cooling Pressure in mm Hg.

i. Protection relays with the appropriate ANSI functions shall be recommendedby Bidder and located in the Electrical Room.

4.7Thyristor Cycloconverter

The cycloconverters shall be designed as a twelve pulse system to minimize


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4.7.6 A ground bus running the full length of each converter shall be provided. Eachground bus shall be drilled for 13 mm ( inch) bolts on 44 mm (1- inch) centers to

accommodate two hole lugs for Purchasers ground cables at each end.

4.7.7 The cycloconverters shall be fully self-protected for all internal and external faultand surge conditions, including loss of utility supply voltage to the plant.

4.7.8 Solid state components shall be burned in to eliminate the components subject toinfant mortality. Seller shall certify that all solid state components have been burnedin.

4.7.9 Auxiliary power for each cycloconverter shall be 380 V, 3 phase, 3 wire, 50 Hz fromthe local low voltage MCC, supplied by Vendor in the Electrical Room.

4.7.10 Each cycloconverter shall have automatic shutdown and alarms or self-diagnosticsfor at least the following:

a. Open phase or missing gateb. Commutation failurec. Shorted thyristor leg

d. Loss of gate power e. Over voltage protection line side and variable frequency sidef. Voltage supervisiong. Loss of thyristor h. Current limitation

4.7.11 All access to the interior of the cycloconverter which is required for installation ormaintenance shall be through hinged doors.

4.8 Excitation System

The excitation supply and control shall provide sufficient power for the field of the


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Loss of thyristor Current flow supervision

Voltage supervision Loss of synchronizing voltage Over voltage protection AC and DC side.

5.9 Drive Control Panel

A panel shall be furnished to provide integrated control on each drive system withprovision for remote control and monitoring from the SAG and Ball mill locations or acontrol room via a serial data communication link.

The panel shall have a IP42 (NEMA 1) enclosure.

The drive control cubicle shall include Vendors Programmable Logic Controller(PLC) system which shall be used to perform all logic and computational functions.The PLC system shall be capable of interfacing with the Purchasers DCS system.The PLC system shall consist of but not be limited to the following:

a. CPUb. AC/DC isolated input modulesc. AC/DC isolated power contact output modulesd. 4-20 mA isolated analog input modulese. 4-20 mA isolated analog output modulesf. Serial communication processor cardg. I/O racks and power supplies with at least 100 percent spare

capacity

h. Interface equipment with the Purchasers DCS. The panel shall include the following control power system:

A l k bl di t it h f 220 V AC i l h i i


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Structural Loading: Containerized Electrical Building shall be engineered to UBCseismic zone requirements identified in Appendix A attached. E houses for mills

shall be installed indoors to protect from wind blown dust. Doors, walls and roofpanels shall be reinforced by braces, stiffeners and/or structural members toprovide rigid structure. Base shall be constructed using welded I-beams, channelsand angle supports and shall be sized to withstand the loads required duringshipping, installation and normal operation. Skid beams shall be incorporated intothe base where required. Lifting lugs shall be provided with a flat surface forjacking. These lugs shall be removable to eliminate a tripping hazard. When theElectrical Building is shipped in separate sections, each section shall have its ownlifting lugs.

Floor: The floor shall be constructed of 6 mm (1/4 in.) thick, ASTM-A36 levelgalvanized steel plate welded to the base framework with an ASA #61 skid resistantepoxy finish. Insulating floor mats shall be provided in front of all electricalequipment. Computer-type false floors with removable panels shall be provided.Floor space shall be used for internal wiring and piping.

Wall: Wall panels shall be galvanized steel 16 GA minimum, formed in aninterlocking design and meet the structural requirements listed herein. All electrical

equipment mounted on the building walls will have reinforcement channels providedto support the subject equipment adequately.

Roof: Roof panels shall be 18 GA galvanized steel in a standing rib designeliminating the possibility of water entry in addition to withstanding winter loadingconditions discussed in Appendix A. The roof shall be designed to withstanddamage during lifting, installation, and maintenance.

Doors: Two personnel doors (W 1m x H2.25m) shall be provided. Doors shall be

ANSI/SDI-100, Grade III extra heavy duty, model 4, with 16 gage galvanized facesheets, gasketed using neoprene gasket material, complete with stainless steelpanic bar, hardware and door closers. Doors shall be keyed alike using tamper-proof locks. Door frames shall be ANSI/SDI-100, 14 gage extra heavy duty. The


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energize an external revolving alarm beacon. The fire suppression system shall useFM-200.

Two portable type fire extinguishers suitable for electrical fires shall be locatedinside the electrical building beside each exit doors. Fire extinguishers shall beportable type, UL classification 10-B:C, 20 lbs., in accordance with NFPA 10.

The outside width of the electrical building shall not exceed 11 meters. For shippingpurposes, dimensions of the each piece shall not exceed 5.5 meter wide, 4 meterhigh and 12 meter long.

4.12 Control System

Seller shall provide a closed loop control system, PLC sequence control, faultmessage system, diagnostics, interfaces and special control features as required. Itis the intent of the Buyer to get the state-of-the-art equipment with an utmost ofhandling and operating comfort. Maintenance and trouble shooting shall besimplified by means of diagnostic functions. Seller shall describe in detail the offeredfunctions and demonstrate the successful use in the mining industry.

The Manufacturer shall provide a completely integrated system of control,regulation, protection, monitoring, alarming and diagnostic equipment for the entiremill drive system and its auxiliary equipment. The control system shall compriseexclusively of modular, standardized solid-state components on plug-in printed orpreassembled circuit boards of industrially Manufactured grade. Control systemsshall be mounted in free standing steel-cubicles, using standardized equipmentframes with easily accessible front and rear sides. If wall mounting is required,swivel-frames shall be installed to allow access to the wiring side of the equipment.Assembled cubicles shall be factory wired to terminal strips in the bottom or rear of

the cubicles and shall be functionally tested before installation into theContainerized Electrical Building.

Close Loop Control: The closed loop control system shall be fully digital


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The control shall have a high dynamic performance and accuracy to limitdisturbances to the network and to the mill shell. Speed control accuracy shall be

1% or better.

Seller shall indicate in his proposal the amount and frequency of torque harmonicsintroduced to the mill.

Programmable Logic Control: Programmable Logic Controllers (PLC) shall beassembled from standardized, modular components of a design proven in processplant applications. Programs shall be stored on read-only memory chips thatcannot be erased accidentally but can be reprogrammed in the field by means of

portable programming devices.

PLCs shall be used to control the complete SAG and Ball mill drive systems andshall include but not be limited to the following:

Automatic sequence control Start of auxiliaries and main drive Stop of main drive and auxiliaries

Operation supervision Status Interlock Emergency off Interface control with others Measuring value collection Fault indication collection

4.13 Fault Message System

The Fault Message System shall be an integral part of the PLC control. Theminimum requirements shall be:


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- plant status identification- alarm group messages

Vendor shall state in the bid, number and kind of flow charts, bar diagrams andcurves.

Vendors PLC shall provide a serial link to Buyers central control room automationsystem and shall guarantee the compatibility of his controller and Owners DCS.

4.15 Diagnostic and Information System

The Diagnostic and Information System shall be PC based suitable for the oreprocessing industry to reduce downtime. Besides the diagnostic part, the systemshall provide information to the process personnel, enabling them to control theprocess. The performance of such a diagnostic and information system shallincorporate, but not be limited to, the following functions:

Measured value acquisition Measured value curve displays Fault and operating message acquisition Tracing of transient control values Archiving Maintenance list Maintenance instructions Spare part list

Seller in his proposal shall describe in detail his approach to use such an

information system.4.16 Special Control Features

F Ch P t ti S ll h ll id F B k d h


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The potential transformers shall be of the indoor dry or compound-filled type with aminimum insulation class and full-wave basic impulse level as indicated in ANSI

Standard C57.13.

The potential transformers shall have high and low voltage fuses and shall bemounted on drawout carriages in separate compartments. The high-voltageterminals shall be disconnected and grounded and the secondary shall bedisconnected when the carriage is withdrawn to permit safe replacement of fuses.High-voltage fuses shall be of the current-limiting type.

The potential transformers shall conform to ANSI Standard C57.13, 0.3X, 0.3Y and

1.2Z for the applicable voltage class.

4.19 Wiring

All outgoing wires from the apparatus and all unused contacts shall be terminated inpermanently identified 600 V terminal blocks for Buyers external connections.Shorting type terminals shall be provided for current transformer circuits.

Sellers wiring shall be restricted to one side of the terminal blocks.

Fifteen percent of spare control and instrumentation terminals shall be provided.

The terminals for each low level signal or instrument circuit shall be grouped with adedicated terminal for the cable shield of the circuit.

Soldered connection shall be used only on printed circuit boards. All externalconnections to printed circuit boards shall be plug-in type.

All control and instrumentation wires shall be marked at each termination with wiremarkers.

4.20 Nameplates


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The equipment shall be cleaned, primed and finish painted in accordance withSellers standard specification suitable for the service conditions listed in this

specification.

6.0 QUALITY ASSURANCE, INSPECTION, AND TESTING

6.1 Quality Assurance Program

Bidder shall furnish details of the quality assurance program to be applied during

the preparation and fabrication of the equipment.

Program shall describe the measures to be used to control activities affecting thequality of equipment to be supplied in compliance with this Specification. Qualitylevel and minimum quality requirements shall be in accordance with the attachedVendor Quality Plan (VQP).

Written certificates shall be furnished by Bidder indicating that the equipment hasbeen manufactured in compliance with the quality assurance program and the

requirements of the procurement documents Quality Surveillance Instructions AB-04 W, and Quality Program Requirements AB-04 Y. These certificates will be thebasis of Purchaser's final payment of Purchase Order.

6.2 Inspection and Testing

Equipment furnished will be subject to expediting and shop inspection by theauthorized representatives of the Buyer.

It is the intent of this specification to have the drive systems fully tested at thecomponent level, subassembly level and system level. Bidder shall submit in hisproposal a complete list of tests and test methods to achieve this intent to the fullestextent possible.


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operating and tripping currents and voltages at the secondary terminals of theinstrument transformers. Buyer shall be notified before this test is performed.

Transformers:

a. ANSI C57.12.00Routine tests (tests and certification required on the transformer furnished).Manufacturer's design tests performed on identical or similar transformersshall also be furnished.

b. ANSI C57.12.90Standard Tests Code for Distribution, Power and Regulating Transformers,and Shunt Reactors.

c. Transformer shall be tested for polarity, ratio, resistance, impedance, coreloss, excitation current, efficiency, regulation and insulation.

d. The transformer shall meet the short-circuit qualification requirements givenin Short-Circuit Test Code prepared by IEEE and withstand the effects of

through fault current.

Motor:Motor test according to ANSI

7.0 LIST OF ATTACHMENTS

The following documents are attached and shall be considered a part of this specification:

Appendix A Standard Technical and Site Data

000E-DW101 Electrical Single Line DiagramEquipment Data Sheets (to be filled by Vendor)VQP-141E-TS001 Vendor Quality PlanForm ENG 44 Drawing and Data Requirements


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EQUIPMENT DATA SHEETS(Vendor shall complete these data sheets and submit to Purchaserwith the proposal)

Page 1 of 6

Equipment Name: Cyclo-converter Equipment No.:

1. Outline drawings of equipment showingdimensions of the converter, connections andaccessories.

2. Complete equipment descriptions and design data, catalogs, brochures, etc. as required, todescribe the construction and operation of equipment offered.

3. Assembled Converter Lineup:

Length, mm.

Depth, mm.

Height, mm.

Weight, kg.

Earthquake withstand rating UBC Zone

Minimum to gnd clearance, mm.

Minimum to clearance, mm.

4. Converter Ratings:

Rated maximum voltage

Operating voltage range

Operating frequency range/speed rangeInput power

Output power


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EQUIPMENT DATA SHEETSPage 3 of 6

Equipment Name: Transformers (Contd) Equipment No.:j) Efficiency at:

0.5 load

0.75 load

1.00 load

k) Continuous rating for 55/65Ctemperature rise at the plant elevation

l) Insulation class of winding-

H. V. side

L. V. side

6 Transportation weight of transformer

7. Weight of core and coils

8. Weight of tank and accessories9. Weight of oil

10. Weight of complete transformer

11A. Bushing 50 Hz wet flashover voltage at 1000meter elevation

11B. Bushing 50 Hz wet flashover voltage at 4400meter elevation

12A. Bushing/Winding BIL at 1000 metersa) HV side

b) LV side


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EQUIPMENT DATA SHEET

Page 4 of 6Equipment Name: Synchronous Motor

1. Outline drawing of equipment showingdimensions of the motor2.Complete equipment descriptions and design data, catalogs, brochures, etc. as required todescribe the construction of the equipment offered.3. The bidder shall furnish as part of bid documents the following information:

Weights and Dimensions:Total weight of the statorTotal weight of the rotor(poles)Motor kW (Horsepower)Motor voltage at rated outputCurrent at rated outputStarting inrushFrequency at rated outputRated speedNumber of poles

Power factor at rated outputReactances: Xd, Xd, Xd in PUEfficiency at full loadEfficiency at loadEfficiency at loadFull load current

Exciter Panel dimensions :Length, mm.Depth, mm.Height, mm.Exciter field currentat rated outputExciter field voltage at rated output


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EQUIPMENT DATA SHEETPage 5 of 6

Equipment Name: Synchronous Motor

Synchronous Motor (Contd)

Name and Address of Principal Manufacturer:

Name and Address of Suppliers of majorComponents:

Guaranteed Losses:a) Motor kWb) Cooling fans kWc) Cycloconverter kWd) Transformers kW

e) Excitation System kWf) Total Losses (PV) kWg) Overall System Efficiency=

PM/(PM + PV) %Where PM = Rated power output of themotor.

Motor Construction:

Stator:Number of piecesShipping dimension of pieces


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EQUIPMENT DATA SHEET

Page 6 of 6Equipment Name: Containerized ElectricalBuilding

Dimensions:Overall Width in metersOverall Length in metersOverall Height in metersWeight: Total assembly w/ equipment, kgsMax. Shipping dimensions Length m

Width m Height m

Number of shipping sectionsShipping weighteach section in kgs

HVAC System

- Capacity- Manufacturer- Air filter units- Horsepower


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ENGINEERING DRAWINGS AND DATA REQUIRED WITH THIS INQUIRY/ORDERThe following data constitute a part of the Inquiry and Purchase Order and are to be supplied as indicated. Specific exceptions must benoted on this form and returned with the Bidder's Proposal.

Legend: "P" - Designates manufacturer's standard print - Maximum "E" size (34" x 44")"T" - Designates a full size transparency from which legible prints may be made - Maximum "E" size"C" - Designates a photocopy - Either 8-1/2" x 11" or 11" x 17" is acceptable"D" - Designates a 3-1/2" computer diskette - CAD files in Intergraph or DXF format.E Designates a CD ROM multimedia file.

Time Limits: Bidder shall submit a drawing list submittal schedule with his Proposal. This schedule will form the basis for theagreed schedule which will be incorporated into the Purchase Order. This schedule shall accommodate the following engineering

requirements:

A) Approval drawings and data required no later than 4 weeks after orderB) Final certified drawings and data required no later than 8 weeks after order C) Manuals required for approval no later than 12 weeks after order D) Final certified manuals required no later than 16 weeks after order

Vendor's drawings and data will be reviewed and approved only as to arrangement and conformance to the specification and relateddrawings, and approval shall not be construed to relieve or mitigate the Bidder's responsibility for accuracy or adequacy and suitability ofmaterials and/or equipment represented thereon.

A) PROPOSAL DRAWINGS AND DATA shall be manufacturer's standard drawings and data in sufficient detail to lay out equipment,drives, access for maintenance/operation, and design of foundations/supports.

B) APPROVAL DRAWINGS AND DATA shall be complete with equipment number(s) and Purchase Order number. Initial drawingsand data must show all information necessary for Purchaser's design of foundations and any connections to other equipment.

C) FINAL DRAWINGS AND DATA shall be complete with equipment number(s) and Purchase Order number, marked "CERTIFIEDFOR CONSTRUCTION," and SIGNED by an authorized person. Certification warrants equipment shall conform to the final drawings,specifications, and data. Should equipment fail to conform, Bidder shall furnish all materials, labor, and equipment required to correct all

deficiencies to the satisfaction of Kvaerner Metals and/or Owner.

D) MANUALS shall include the following information as a minimum, published in Spanish. Instructions for Installation Instructions for Operation


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Form Eng-44 Drawings and Data Requirements Project N C-423

Equipment :

Gearless Drives for SAG and Ball Mills

Specification N 141E-TS001 Rev A


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Item Description Number and Form Required

With each

Proposal

Issued After Receipt

of Purchase OrderApproval Final

GENERAL

1 Brochures 3C

2 Preliminary Drawing List with Schedule for Submittal 3C

3 Outline Dimensions & Foundation/Mounting Req. 3P 1D + 3P 1D + 5P

4 Anchorage and Loading Diagram (Static and Dynamic) 1D + 3P 1D + 5P

5 Cross Section with Parts Description 3P

6 Shop Detail Drawings 1D + 3P 1D + 5P

7 Erection Drawings 1D + 3P 1D + 5P

8 Instructions for Erection 3C 5C

9 Completed Kvaerner Metals Equipment Data Sheets 3C 3C 5C

10 Certified Performance Data 3C 5C

11 Installation, Operation, and Maintenance Manuals 3C + 3E 5C + 5E

12 Complete Parts List Including Vendor's and OriginalManufacturer's Part Number

3C 5C

13 List of Recommended Spare Parts for One Year of Operationwith Prices

3C

14 List of Spare Parts Recommended During Commissioning withPrices

3C 3C 5C

15 List of Special Tools Recommended for Erection, Testing, andMaintenance

3C 3C 5C

16 Lubrication Schedule

17 Code Certificates 5C

18 Bill of Materials 1D + 3P 1D + 5P

19 Calculations 3C 5C

ELECTRICAL/INSTRUMENTATION

21 Catalog Cut Sheets22 Wiring Diagrams

23 Completed Kvaerner Metals Motor Data Sheet

24 Motor Name Plate and/or Calculations

Kvaerner Project NC-423


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Kvaerner Project N C-423Specification N141E-TS001


P:\C423\ELE\docs\archivo\espec\141E-TS001\141E-TS001 Gearless drive for sag and ball mill-p.doc 2

VAERNER V E N D OR Q U A L I T Y P L A N (VQP) Quality Requirements for Manufacturers

DOCUMENT NO.: VQP-141E-TS001 PROJECT: UJINA ROSARIO TRANSITION PROJECT REQ. NO.:

QUALITY SYSTEM STANDARD: EQUIPMENT DESCRIPTION: DRIVES FOR SAG AND BALL MILLSKvaerner QA. STD. (If required): CHECKED & APPROVED BY: VV DATE:

ITEMNO. ITEM

* HOLDPOINT

WIT-NESS INSP. VERIFY

CERTREQ'D

FINALDOCS

INSP. INIT.DATE ACCEPT. REMARKS SPECIAL REQUIREMENTS

1. Approved Drawings X

2. Material Test Reports X

3. Test Pieces X

4. Heat Treatment

5. Weld Procedures

6. Prototype Tests X

7. Trial Assemb. Match Marking8. Functional Test X

9. Performance Test

10. Running Test

11. Balancing

12. Continuity/Megger Test

13. Certificate of Compliance

14. M & TE Calibrations

15. Paint Thickness Test X REV. DATE PREPARED BY CHECKED /APPR. BY

16. Visual Inspection X A Dec/00 VV JA

17. Drawing Dimensions X M Jan/01 VV JA

18. Packing X

19. Tagging/Marking X

20. Release for Shipment X

21.

22. BY KVAERNER:

KVAERNER ENGINEER TO WITNESS TEST NOS.: ______________ *CONTACT KVAERNER PRIOR TO PROCEEDING ALL PROCEDURES WITH QUALITY PLANS AND ASSOCIATED DOCUMENTATIONMUST BE SUBMITTED FOR REVIEW.

Kvaerner Project NC-423


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Kvaerner Project N C 423Specification N141E-TS001


P \C423\ELE\d \ hi \ \141E TS001\141E TS001 G l d i f d b ll ill d 3

Molino Sag Anillo

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