Page 1. GENERAL................................................................................................................................3 1.1 1.2 1.3 Introduction...................................................................................................................3 Scope........................................................................Error: Reference source not found References................................................................

Error: Reference source not found 1.3.1 Outside Organizations...................................Error: Reference source not found 1.3.2 Other Project Design Criteria.........................Error: Reference source not found 1.3.3 Other Documents..............................................................................................3 Units..........................................................................Error: Reference source not found Working Language........................................................................................................3 Symbols and Standards............................................Error: Reference source not found

1.4 1.5 1.6 2.1 2.2

2. Design Method/Philosophy...........................................Error: Reference source not found General.....................................................................Error: Reference source not found Engineering and Design............................................Error: Reference source not found 2.2.1 P&IDs............................................................Error: Reference source not found 2.2.2 Loop and Motor Narratives............................Error: Reference source not found 2.2.3 Instrument Specifications / Data Sheets........Error: Reference source not found 2.2.4 Plant Wide Integration...................................Error: Reference source not found 3. Control System...............................................................Error: Reference source not found 3.1 3.2 3.3 3.4 3.5 3.6 System Architecture..................................................Error: Reference source not found Fault Tolerance.........................................................Error: Reference source not found Control Philosophy....................................................Error: Reference source not found Operator Interfaces...................................................Error: Reference source not found Motor Control and Interlocks.....................................Error: Reference source not found UPS Systems............................................................Error: Reference source not found

4. Control Room Layouts...................................................Error: Reference source not found 5. Packaged Equipment.............................................................................................................7 6. SECURITY...............................................................................................................................7 6.1 7.1 8.1 8.2 UPS Systems............................................................Error: Reference source not found General.....................................................................Error: Reference source not found Instrument and Control Signals.................................Error: Reference source not found Instrument Power Supplies, Cabling and Grounding. Error: Reference source not found 8.2.1 Power Supplies.............................................Error: Reference source not found 8.2.2 Field Cabling, Junction Boxes and Grounding.........Error: Reference source not found Instrument Identification............................................Error: Reference source not found Instrument Selection Guidelines................................Error: Reference source not found 8.4.1 General.........................................................Error: Reference source not found 8.4.2 Flow...............................................................Error: Reference source not found 8.4.3 Level..............................................................Error: Reference source not found 8.4.4 Pressure........................................................Error: Reference source not found 8.4.5 Temperature..................................................Error: Reference source not found 8.4.6 Density..........................................................Error: Reference source not found 8.4.7 Belt Scales....................................................Error: Reference source not found 7. EQUIPMENT CONTROL PACKAGES............................Error: Reference source not found 8. Field Instrumentation And Controls.............................Error: Reference source not found

8.3 8.4

8.4.8 Control Valves...............................................Error: Reference source not found 8.4.9 Material Selection..........................................Error: Reference source not found 9. System Architecture preliminary block diagram.........Error: Reference source not found

1. 1.1

GENERAL Introduction The criteria will govern the development of the process control systems related to the project. This includes field instrumentation and process control hardware and software.

1.2

Scope This document describes the level of automation proposed for the project. The scope also includes the general guidelines for the design and selection of the process control system and of the field instrumentation.

1.3 1.3.1

References Outside Organizations Unless specifically stated otherwise, the instrumentation and controls will be based on the applicable parts of the latest revision of the following codes, specifications, standards, regulations and other documents. In addition, the layouts will comply with any laws or regulations of local authorities. In the event of conflicting requirements, the most stringent will apply: ISA ANSI NEC OSHA UL CSA Instrumentation, Systems and Automation - Standards and Practices for Instrumentation American National Standards Institute National Electrical Code Occupational Safety and Health Administration Underwriters Laboratory Canadian Standards Association

Local laws and codes 1.3.2 Other Project Design Criteria This criteria should be read in conjunction with the following additional design criteria: 1.3.3 1.4 Units All units shall be in accordance with the International System of Units (SI units) using the "Metric Practice Guide.Where a piece of equipment is manufactured to Imperial units then the Imperial units should be shown as the primary dimensions with the metric equivalent shown in brackets. 1.5 Working Language 1.6 For the Engineering phase of the project, drawings will be in English translation Other Documents

Symbols and Standards

Piping and Instrumentation Diagram (P&ID) symbols will be in conformance with ISA Standard S5.1. The Symbol and Legend P&ID defines the symbols in detail.

2. 1.7

DESIGN METHOD/PHILOSOPHY General The objective is to build a plant, which will require a minimum number of operating personnel using essential instrumentation only. The control system to be provided will be capable of fully automatic start and stop sequences and interlocks using PLC or DCS based (hold on pending decision) control systems and high speed communication networks. The design of the control system will be based on an hierarchical breakdown of the plant into areas, systems and sub-systems representing logical groupings of related equipment, which can be controlled and operated as a unit.

1.8 1.8.1

Engineering and Design P&IDs The P&IDs will be developed in conjunction with the piping department based on approved Process Flowsheets and will include the following minimum information: Primary instrumentation Motors and variable frequency drives (VFDs) Connections to the control system Control loops and critical interlocks and alarms Air supply requirements Valves and piping specialty items Valve failure positions Notes and descriptions

1.8.2

Loop and Motor Narratives In conjunction with the P&IDs, loop and motor narratives will be written for each loop and motor controlled or monitored through the process control system. The narratives will describe and establish the following: Degree of automation Operating philosophy Control and operation system breakdown Process control loop description Start/Stop sequence description Interlocks

1.8.3

Instrument Specifications / Data Sheets Based on approved P&IDs, instrument specifications and data sheets will be prepared in order to purchase instruments and related equipment.

1.8.4

Plant Wide Integration The control system for the entire plant will be tightly integrated and transparent. This integration also applies to vendor supplied packaged equipment.

3. 1.9

CONTROL SYSTEM System Architecture A preliminary block diagram of the system is included at the end of this document. The diagram will be superseded by a System Architecture Block Diagram drawing as locations and I/O quantities become available. PLCs supplied with vendor equipment packages will repeat status and alarms as required to the main plant control system via a communications protocol to be determined at a later date. Extreme care will be taken when buying equipment so that the systems supplied are fully capable of integration with the overall plant process control system. During the development of the system architecture, other aspects such as communication with smart devices and instruments will be considered in consultation with the Client.

1.10

Fault Tolerance Essential equipment requiring redundancy will have a hot back-up meaning that the stand-by equipment will start automatically whenever a trip condition is detected. Non-essential equipment back up will be started on operator requests. Redundant controllers will be installed for continuous operation. The number of control room human-machine interfaces (HMIs) will be sufficient to allow operation of the entire plant whenever one of the HMIs fails.

1.11

Control Philosophy A Programmable Logic Controller (PLC) or a Distributed Control System (DCS) based plant control system will be used to control the main processes. Both process and motor control logic will be incorporated into the control system. The process and motors will be capable of being controlled manually as well as by the control system. Local start/stop stations will be provided for all pieces of equipment. Interlocks between equipment will be incorporated in the control system. Personnel safety interlocks will be hardwired. Control system controllers will be will be linked via a redundant network, allowing overall plant monitoring and control from any control room. Access to other areas would require password access. Where possible PLCs or Remote I/Os will be located in Electrical Rooms or Control Rooms. The status of the whole plant will be monitored from the main plant control room located in the process plant building. All historian, data logging and reports will be from the main plant control

room. Local HMI workstations will be provided in remote areas of the plant. Refer to preliminary block system diagram (section 9) Operator video workstations will be provided in the process plant control room, primary crusher control room, secondary crusher control room and load out and ARD plant control room. A Data Historian system will gather data from the plant control system and other analytical equipment. The plant control system will be capable of interfacing with a future advanced control system or expert system. Separate controllers will be provided for the following areas: The process plant operator will be able to monitor, and if necessary, control the **** plant. PLC or DCS based (hold on pending decision) process control system will be used to control plant operations. Both process and motor control logic will be incorporated into the control system. Interlocks between equipment will be incorporated in the control system. Personnel safety interlocks will be hardwired. 1.12 Operator Interfaces The HMI workstations located in the main control room will provide: Process indication and control interface Motor start/stop capability and status Process and motor failure alarms Interlocks and sequence monitoring Trending Reports and logs (process plant only) Maintenance diagnostic screens Selected Motor runtime data The HMIs, located in the local control rooms, will display local process status and control the plant locally. Printers (colour and black and white) will be located in the main control room for alarms, trends, graphics and reports. HMIs will have 21 brand name colour monitors, with keyboards and trackballs/mice for operator actions. The operating platform will be latest version Microsoft Windows 2000 PRO. 1.13 Motor Control and Interlocks The control system will indicate motor status, overload trip alarm and availability to start. Motor temperature, and starts per hour will also be monitored on larger motors. Pop-up faceplates for motor control will be provided. They will appear when a pick is made on the equipment symbol on the process graphic.

1.14

UPS Systems The control system, including operator and engineering workstations, will be powered from a dedicated UPS source, which will keep the system operational for at least 30 minutes in the event of a power failure. The UPS units will be located in the electrical room(s). UPS health will be monitored and alarmed in the control system. Color printers, field instruments, and panels requiring 110 VAC power will not be powered from a UPS source unless thought to be critical to operations in the event of a power failure.

4.

CONTROL ROOM LAYOUTS Operator workstations will be desktop type and mounted on customised modular furniture. Control rooms will be pressurized and be equipped with HVAC as described in, Building Services Design Criteria.

5.

PACKAGED EQUIPMENT Packaged equipment will be supplied with primary instrumentation. The controls required for these packages will normally be performed by PLC. Allen-Bradley PLC (type and model to be determined) will be used for packaged equipment supplied with a control system. PLCs supplied with vendor equipment packages will repeat, status and alarms to the PLC or DCS based (hold on pending decision) control system via hardwired I/O signals or interface links.

6.

SECURITY The security system and CCTV will be supplied as a package system.

1.15

UPS Systems The security system will be powered from a dedicated UPS source, which will keep the system operational for at least 30 minutes in the event of a power failure. The UPS units will be located in the electrical room(s). UPS health will be monitored and alarmed in the control system.

7. 1.16

EQUIPMENT CONTROL PACKAGES General A number of pieces of equipment will be supplied with instrumentation and control packages, typically:

Important alarms, status and analogue values from these local panels will be wired to the control system for display on the operator stations. Some of these packages will use PLCs for control. It is intended to standardize with one PLC manufacturer, refer to section 5 for packaged equipment. All equipment supplied PLCs will be capable of communicating with the plant control system using a protocol as yet to be determined. 8. 1.17 FIELD INSTRUMENTATION AND CONTROLS Instrument and Control Signals Electronic analogue signals will be isolated 24 V, 4 to 20 mA DC. Pneumatic signals will be 20-100 kPa. Signals from field switches/contacts and control signals to solenoid valves will be 24 VDC. Control voltage for motor starters and the control system I/Os used for motor control will be 120 VAC, 60 Hz. 1.18 1.18.1 Instrument Power Supplies, Cabling and Grounding Power Supplies Two wire transmitters will be 24 VDC powered from the control system I/O card or control panel instrument as applicable. Four wire transmitters and switches will be powered by 120 VAC, 60 Hz from instrument power distribution panels. A breaker will be supplied for each instrument or a related group of instruments. Disconnect type terminal blocks will be used to provide isolation between instruments powered through the same breaker. The control system will be 120 VAC, 60 Hz powered from a UPS or conditioning transformer. 1.18.2 Field Cabling, Junction Boxes and Grounding Separate junction boxes will be used for 24 VDC and 120 VAC wiring. Individual cables shall generally be used for cabling from instruments to junction boxes or panels. Multiconductor cables will be run from field junction boxes to the control system I/O or panels. Cables carrying 4-20 mA signals will have individual twisted pairs with an overall shield or drain wire. Shields on all cables will be terminated at the control system I/O rack or panel as applicable and these will serve as the single ground point for signal wiring. Normally, separate trays will be used for instrument cables. However, instrument signal cables

( 4-20 mA ) may be run in cable trays carrying electrical cables with voltages up to 600 Volts. In this case a magnetic barrier and separate portion of the tray must be used. Fiber optic cable will be considered for long distance and/or outdoor signal transmission. 1.19 Instrument Identification All instruments will be tagged with permanent tag numbers assigned as follows: Example: 210-PSL-0201 Area 210 Instrument type per P&ID legend PSL P&ID sequential number (last 2 numbers) 02 Instrument sequential number on P&ID 01 Area numbers are required on a P&ID only if instruments from more than one area are shown on the P&ID. Example: 210 230

1.20 1.20.1

Instrument Selection Guidelines General Wherever possible, transmitters will be smart type and HART compatible.

1.20.2

Flow Magnetic flowmeters will be used for flow measurement of conductive liquids and slurries and for fluids with corrosive properties or particulates. For local indication, line-mounted rotameters will be used for clear liquids. Vortex meters will be used for gases in small lines, or otherwise a pitot tube type primary element, such as an annubars, will be used with direct connected differential pressure transmitters. Positive displacement meters will be used for local flow totalization.

1.20.3

Level Ultrasonic level transmitters will be used for pump box level measurement, bin levels, water storage tanks and some reagent mix and storage tanks. Where warranted by the application, radar level instruments will be considered. Sump level switches will be conductivity type switches complete with 3 probes (ground, low and high). For lined vessels, transfer chute, feeder chutes etc., nuclear type transmitters or switches will be used.

Microwave or Tilt level switches will be used for plugged chute applications. 1.20.4 Pressure Direct mounted pressure transmitters will be used except where slurry, temperature or vibration dictate the use of remote diaphragm seals. For local pressure indication bourdon tube type gauges with a minimum dial diameter of 115 mm will be used. 1.20.5 Temperature Sensing elements will be 100 ohm, platinum, 3 wire RTDs or thermocouples c/w temperature transmitters. For local temperature indication, every angle bi-metallic temperature gauges with a 125 mm diameter dial. 1.20.6 Density Nuclear Gamma Ray dispersion method will be used for measurement of slurry density. 1.20.7 Belt Scales Belt scales will be of the load cell type. 1.20.8 Control Valves For control valves on lines greater than or equal to 4 inches in diameter handling corrosive fluids, lined butterfly valves will be used. For control valves on lines less than 4 inches in diameter handling clear fluids, globe valves or partial ball valves will be used. Solenoid operated ball valves will be used for on-off applications on clear liquids or non-abrasive reagents. Solenoid operated pinch valves will be used for lime addition. Shut-off valves for low pressure slurry lines will be knife gate type. 1.20.9 Material Selection Materials in direct contact with the process will be selected on the basis of the Piping Specification.

9.

SYSTEM ARCHITECTURE PRELIMINARY BLOCK DIAGRAM END OF DOCUMENT