M40035 5 CRIT 001 (Mechanical Design Criteria)

7/21/2019 M40035 5 CRIT 001 (Mechanical Design Criteria)

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ESCONDIDA BIOLEACH PAD EXPANSION III (EBPEIII)

EC-001

AMEC International Ingeniería y Contr!""i#n Lt$a%

EXEC&'ION PHASE

MECHANICAL DESIN CI'EIA

M*00+,-,-CI'-001

(AMEC POEC' N. M*00+,)

E/ISION 0



BHP Billiton – Base Metals / Project Development

Escondida Bioleach Pad Expansion III – Execution Phase

Mechanical Design Criteria

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!erm"nSu"re#

RonaldParedes

!uillermo$or%uera

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)'*A+ Este documento &ue desarrollado a nivel de detalles en la ,(ase deDe&inici-n. del Proyecto E/PE III0 con el )1 E/PEIII23456272CRI*2884






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ÍNDICE

•

49 SC'PE9999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999999:

39 C'DES A)D S*A)DARDS999999999999999999999999999999999999999999999999999999999999999999999999999999999999:

;9 !E)ERAL RE<=IREME)*S9999999999999999999999999999999999999999999999999999999999999999999999999999999997

3.1 GENERAL..............................................................................................................5

3.2 EQUIPMENT SELECTION AND DESIGN..............................................................6

3.3 EQUIPMENT LAYOUT...........................................................................................8

3.4 SAFETY AND PERSONAL PROTECTION............................................................9

3.5 ENVIRONMENTAL CONTROL............................................................................10

3.6 SEISMIC CONDITIONS FOR MECANICAL EQUIPMENT DESIGN..................10

3.! TRANSPORT RESTRICTIONS............................................................................10

:9 DRA>I)!S A)D D'C=ME)* DE(I)I*I')999999999999999999999999999999999999999999999999999999948

4.1 GENERAL ARRANGEMENT DRA"INGS #G.A.$................................................10

4.2 DESIGN DRA"INGS............................................................................................11

4.3 TECNICAL SPECIFICATIONS...........................................................................11

4.4 CALCULATION....................................................................................................11

4.5 MATERIAL REQUISITIONS.................................................................................11

79 MEC?A)ICAL E<=IPME)*9999999999999999999999999999999999999999999999999999999999999999999999999999999944

5.1 OISTS................................................................................................................115.2 TAN%S..................................................................................................................11

5.3 PUMPS.................................................................................................................12

5.4 FA&RICATED PLATE"OR%...............................................................................12

5.5 AERATION OF EAP PADS................................................................................12

5.6 EATING' VENTILATING' AND AIR CONDITIONING SYSTEMS #VAC$..........13

@9 MAI)*E)A)CE RE<=IREME)*S99999999999999999999999999999999999999999999999999999999999999999999994;

49

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49 SC'PE

*he Mechanical Design Criteria estalishes the engineering standards and practices toe &olloed in the execution o& mechanical design &or e%uipment and installations o& theproject ,Escondida /ioleach Pad Expansion III 2 Estudio de De&inici-n. o& MineraEscondida Ltda9

*his Design Criteria covers the &olloing items+

• !eneral Re%uirements &or e%uipment selection and design

• Sa&ety and Personnel Protection

• Environmental Control

• Seismic Conditions &or Mechanical E%uipment Design

• Draings and Documents De&inition

• Maintenance Re%uirements

*he Mechanical Design Criteria ill govern the production and contents o& the &olloingdocuments+

• *echnical speci&ications

• Duty speci&ications

• !eneral arrangement draings

• Mechanical arrangement draings

• Mechanical design D>!

• Material and e%uipment re%uisitions

*his Mechanical Design Criteria is complemented y the /?P /illiton document /M2CR*2M284 ,Criterios !enerales de DiseBo Mec"nica.

39 C'DES A)D S*A)DARDS

All mechanical e%uipment shall e designed0 manu&actured and tested in accordanceith the latest applicale sections o& the Chilean '&&icial Standards )orma Chilena'&icial2)Ch as ell as aspects related to sa&ety0 health or local municipal las or decrees that are listed at the end o& this section9 In cases that sujects are not coveredy these codes and standards they shall e designed0 manu&actured and testedcon&orming to the regulations codes0 standards or speci&ications listed in /?P /illitondocument /M2CR*2M284 ,Criterios !enerales de DiseBo Mec"nica.0 chapter :

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,)ormas y C-digos.9 E%uipment speci&ications shall include re&erences to speci&icsections o& those listed codes and standards here re%uired9

Chilean decrees related ith sa&ety0 health or environment+

• Decreto Supremo )1 4;3 ,Reglamento de Seguridad Minera.9

• Resoluci-n Exenta )1 84;@F388; de la Comisi-n Regional del Medio Amiente de

la II Regi-n de Anto&agasta9

E%uipment design0 manu&acture and test shall taGe into account aspect o& risG0 in the&olloing standard that as developed y /?P /illiton+

• S*A9837 ,(atal RisG Control Standard.9

;9 !E)ERAL RE<=IREME)*S

;94 !eneral

*he project includes the &olloing main process areas and &acilities+

• Area 8888 !eneral

• Area ;488 Leach Pads

• Area ;;88 /ooster Pumps and Ponds

• Area :@88 Poer Supply

• Area :588 Poer Distriution

• Area :688 Communication and Control

• Area 7488 Miscellaneous Site Development

• Area 7388 Site Access Road De&initive and *emporary

• Area @:88 Shut don and *ie2in

• Area @788 Rhyolite Crushing Plant Rehailitation

'ther areas related to indirect costs are+

• Area 5888 !eneral Indirect Cost

• Area 5488 *emporary (acilities

• Area 5388 Service Contracts

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• Area 5;88 (reight

• Area 5:88 Duties

• Hrea 5788 EP

• Area 5@88 Pre2Commissioning

• Area 5588 endors Reps

• Area 5688 Spare Parts

'nerJs cost area+

• Area 6888 'nerJs Cost

'ther areas+

• Area K888 Contingency

• Area K488 Escalation

• Area K388 (oreign Exchange

• Area K;88 RisG Provision

(acilities shall e designed to operate ;@7 days per year0 3: hours per day9 *he totalproject li&e expectancy is :8 years9 (or &urther in&ormation and site conditions0 re&er tothe &olloing Process Design CriteriaJs+

M:88;72P2CRI*2884 Criterio de DiseBo Pilas /iolixiviaci-n

M:88;72P2CRI*2883 Condiciones del Sitio F Site Conditions

;93 E%uipment Selection and Design

E%uipment selection shall e primarily ased on process considerations0 speci&ically0the capaility o& each piece o& e%uipment to achieve the design ojectives o& oththroughput and %uality9 'ther considerations shall include the &olloing+

• Sa&ety

• Lo capital and maintenance costs• Lo li&e cycle cost

• Lo operating cost

• ?igh reliaility

• Readily availale spare parts

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• Standardi#ation o& components to minimi#e inventory

• Proven history o& operation in similar applications

• Surge capacity

• Spare parts availaility in e%uipment destination place

In general0 unless otherise speci&ied0 e%uipment design shall e the responsiility o& the Supplier9 Supplier shall provide certi&icates0 issued y independent organi#ations0hich state that the e%uipment &ul&ills the codes and standards detailed on its technicalspeci&ications9 *he &olloing general design criteria shall also e incorporated inspeci&ications i& applicale+

• E%uipment shall e designed using conservative capacity ratings and operation

speeds to ensure a high degree o& reliaility9

• E%uipment shall e designed to &acilitate oth e%uipment operation and accessiility

&or maintenance9

• E%uipment shall e designed to operate ithin the site environment9 Special

attention shall e given to the site altitude conditions during the e%uipmentselection0 particularly &or electric motors and other e%uipment ith convective air cooling9 I& the electric motor is over2si#ed0 the driven mechanical componentsmust e checGed &or their aility to ithstand high starting tor%ue9

• E%uipment shall e shop assemled and tested to design capacity9

• Sel& contained uniti#ed e%uipment and ancillaries shall e supplied &ull &actory

assemled on sGid mounts complete ith integral piping and electrical systems9

• Stand y units shall e provided &or critical e%uipment to assure continued plant

operation9

• All motors shall e supplied and integrally assemled ith e%uipment y the

Supplier according to the /uyers speci&ications and pre&erred supplier9

• *he /uyer must approve all sustitutions o& speci&ied materials or components9

• In vie o& the limited %uantity o& ater availale at the mine site0 cooling o& hydraulic

oil andFor luricating oil shall e y direct oil to air exchanger or y using closed

circuit ater cooling system9• Emergency poer supply is re%uired &or critical process e%uipment here

e%uipment stoppage could result in shutdon0 and conse%uent di&&iculties torestart9

• >here rotating machinery is mounted on structural steel support instead o& a

concrete &oundation0 consideration shall e given to isolate e%uipment viration

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&rom piping0 ducting or other resonating steel structure9 iration isolation mountsshall e used to minimi#e the e&&ects o& viration herever possile9

• E%uipment0 suassemlies and components shall e provided ith li&ting lugs as

appropriate to &acilitate installation and maintenance9 Any one li&ting lugs shallhave the strength to support the entire unit to e li&ted9

• )o prototypes shall e acceptale9 All e%uipment shall e success&ully tested in

similar conditions o& operation9

• All components o& same capacity shall e identical0 ith all the parts that complete

the same &unction interchangeale9

(or &urther re%uirements re&er to /?P /illiton document /M2CR*2M284 ,Criterios!enerales de DiseBo Mec"nica.0 chapter 7 ,Re%uerimiento de los E%uipos9

Electrical e%uipment supplied along ith mechanical e%uipment shall comply ith thetechnical speci&ication M:88;7252SPEC28;@ ,Electrical Re%uirements &or MechanicalE%uipment PacGages.

;9; E%uipment Layout

In general0 e%uipment layout shall e dictated primarily y process &lo considerations9 Also o& primary importance is accessiility in and around the e%uipment &or operationand maintenance9 *he &olloing speci&ic criteria shall e incorporated into e%uipmentlayout design+

• >alGays and plat&orms shall e designed to allo normal operation andmaintenance tra&&ic &lo to proceed expediently &rom one plant area to adjacentareas ithout the retracing o& paths9

• )ormal alGay idth shall e K88 mm and minimum 568 mm9

• Stairays shall e used to accommodate travel eteen &loor and plat&orm levels

herever possile9 *he use o& ladders is not alloed9

• >herever possile0 e%uipment shall e located on pedestals to &acilitate

maintenance and ashing9

• Moile or overhead crane access shall e provided to all major e%uipment9

• Monorail access shall e provided to all other heavy e%uipment and component

hich do not have &orGli&t access9

• Any e%uipment provided ith alGing or orGing sur&aces either &or operator or

maintenance personnel use shall have its stairays0 handrails0 alGays andplat&orms designed in con&ormance ith part 4K480 su2part I0 >alGing2>orGingSur&aces o& the aove re&erenced 'S?A standards0 or /?P /illiton document

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/M2CR*2M284 ,Criterios generales de diseBo2 Mec"nica.0 chapter @0,Consideraciones generales para la mantenci-n.0 the most restrictive o& oth

• Design shall include concrete &loors and drains on elevated &loors here there are

possiilities o& ore and solution spillage9 (or acid handling areas0 all elevated&loors and plat&orms shall e made ith an ade%uate material &or the intendeduse0 ith structural steel supports0 suitale acid proo&ed9

• Curs shall e used around all &loor openings9

• (loors shall e sloped and e%uipment &oundations shall e countered &or easy

ashing9

• *he steel supports &or sGid mounted e%uipment ill e designed to &acilitate

maintenance and ashing9

;9: Sa&ety and Personal Protection

Consideration to sa&ety and personnel protection shall e given to all aspects o& designand engineering o& the plant9 Re%uirements o& 'S?A standards0 ,SER)A!E'MI).and ,Decreto Supremo )15:7. shall e &ully complied9 In those cases herediscrepancies appear0 the priority shall e the Chilean la9

*he design o& installations and speci&ication o& mechanical e%uipment shall comply iththe directives in /?P /illiton ?ealth0 Sa&ety0 Environment and Community ?SEC

Assurance and Sel&2Assessment Procedure0 PRO.0239

All places here orG is per&ormed shall have sa&e access and exits9

Plant personnel shall e shielded &rom high temperature sources9

(loors shall e sloped and drainsFsumps provided here there are possiilities o& solution spillage9

)oise levels shall not exceed 67 d/A at 4 m &rom e%uipment9

Mechanical viration o& e%uipment shall e Gept ithin acceptale levels9 IS' 3@;4,Evaluation o& ?uman Exposure to >hole /ody iration. recommendations shall e&olloed9

E%uipment and rotary components mechanical viration shall e measured andevaluated in accordance to IS' 4864@9

Recommendations on alance %uality o& rotating rigid odies as per IS' 4K:8 shall eadhered to9

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Isolation o& piping and services &or maintenance andFor entry shall e incorporated inthe design and layout o& e%uipment9

Sources o& ignition shall e eliminated or controlled in the presence o& a &lammale

atmosphere9

Emergency eye ash stations and emergency shoers shall e provided at theconcentrated or diluted sul&uric acid pumping and consumption areas0 such as ooster pump station9 >ater shall e potale9

All places that have &loor openings0 such as+ elevated plat&orms0 sha&ts or similar shallhave handrails around and arning title9

;97 Environmental Control

Special care must e given to reduce any harm&ul environmental e&&ects or other undesirale conse%uences9 All mechanical design shall meet project environmentalimpact study re%uirements9

Disposal method &or e&&luents and clean2up must e considered as an integral part o& the design9

;9@ Seismic Conditions &or Mechanical E%uipment Design

Seismic loads o& mechanical e%uipment shall e calculated according to )ormaChilena )Ch 3;@K o&9 388;0 ,DiseBo SNsmico de Estructuras e InstalacionesIndustriales.0 Oona 39 =ni&orm /uilding Code =/C 4KK50 Oone I0 may e used instead9

;95 *ransport Restrictions

*he terrestrial transport restrictions are+

• >idthF?eightFLength 397 F 397 F 43 Qm )ormal Load

• >idthF?eightFLength 5 F :93 F :8 Qm 'ver2dimensioned Load0 height measured

&rom &loor9

:9 DRA>I)!S A)D D'C=ME)* DE(I)I*I')

:94 !eneral Arrangement Draings !9A9

In these draings all the project installations shall e dimensioned and located ithcoordinates0 elevation and ey Plan9

Project installations shall e located 788 meter aay &rom &re%uent explosion places9

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All e%uipment shall e located ith respect to columns lines9

*hese draings shall include main piping0 electrical trays0 drains and ducts9 Also all themain details &or design shall e shon9 In general these draings shall include all

necessary in&ormation to design and supply e%uipment9

:93 Design Draings

*hese draings shall include all the necessary in&ormation to develop &arication anderection draings0 ithout additional de&initions9

:9; *echnical Speci&ications

*hese documents shall include minimal re%uirements &or design0 manu&acture andsupply o& e%uipment as+ design re%uirements0 capacities0 environmental conditions0operating conditions0 and all the in&ormation re%uired &or preparation &or shipment0 and

inspection and testing o& each piece o& e%uipment9

:9: Calculation

*hese documents shall include all the calculation to determine capacity0 dimensionsand operating range &or e%uipment and could e reali#ed in computational so&tare9 Allcalculations shall have all acG up in&ormation re%uired to support e%uipment selectionor si#ing9

:97 Material Re%uisitions

*hese documents shall include the complete speci&ication pacGage re%uired to supply

the e%uipment and all the endor Suppliers that shall e %uoted9

79 MEC?A)ICAL E<=IPME)*

794 ?oists

?oists shall con&orm to standards o& the ?oist Manu&acturers Institute ?MI9

793 *anGs

(RP tanGs shall con&orm to AS*M D;3KK as a minimum standard9

Cathodic protection shall &ollo the recommendation expounded on A)SIFAPI RP @74,Cathodic Protection.9

*anG vents &or enclosed tanGs shall e si#ed &or the orst conditions9

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All tanGs shall e provided ith drains0 over&lo pipes and no##les &or instruments andsensors unless speci&ied y the oner9

*he minimum capacity o& ater tanGs or ater ponds that elong to a &ire protection

system shall e calculated according ith procedures stated on /?P /illiton document/M2CR*2(P2884 ,!eneral Design Criteria &or (ire Protection.0 section 793 .(ireater Supply Systems. and Appendix 4 ,Speci&ic Design Criteria &or SprinGlersFSprayProtection o& Particular Areas.9

79; Pumps

(or pump design re%uirements re&er to /?P /illiton document /M2CR*2M284 ,Criterios!enerales de DiseBo Mec"nica.0 section 4896 ,/omas9

79: (aricated PlateorG

(aricated items shall e designed and &aricated in accordance ith the AISC Manualo& Steel Construction9

Materials o& construction+

• Caron steel plates and shapes AS*M A;@ F CAP A :3235 ES

• Caron steel olts AS*M A;370 *ype 4

• Caron steel nuts AS*M A7@;0 *ype D

• Caron steel ashers AS*M (2:;@

• Stainless steel plates and shapes AISI ;4@LF37: SM'• PLSFRe&&inate spools 37: SM'FDuplex SA( 3785

• Stainless steel olts AS*M A4K;2/6M

• Stainless steel nuts AS*M A4K:26M

Materials shall e ne0 straight and &ree &rom tists and ends9 All exposed sharpedges shall e ground9

(arications shall e shop2assemled as much as practical &or shipping and

installation9 All &arications shall e assemled e&ore shipment to the extent re%uired&or ensuring satis&actory &ield erection9 All dimensions shall e veri&ied and matingassemlies must e match2marGed to &acilitate &ield erection9

797 Aeration o& ?eap Pads

Centri&ugal air &ans shall e sGid2mounted type0 ith %uicG type connections &or electrical poer and air piping9

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*he centri&ugal &ans ill e moved regularly &or aeration o& di&&erent strips in the R'Mheap9

79@ ?eating0 entilating0 and Air Conditioning Systems ?AC

?AC design &or electric rooms shall agree to /?P /illiton document /M2CR*2M284,Criterios !enerales de DiseBo Mec"nica.0 chapter 4; ,Cale&acci-n0 entilaci-n y

Aire Acondicionado.9

@9 MAI)*E)A)CE RE<=IREME)*S

All e%uipment shall have plat&orms and stairs to easy access &or maintenance9 *heseshall e located to avoid ostruction maintenance laors9

Access and li&ting device re%uirements are settled in /?P /illiton document /M2CR*2M284 ,Criterios !enerales de DiseBo Mec"nica.0 chapter @ ,Consideraciones

!enerales para la Mantenci-n.9

>herever &easile lurication points shall e routed to a common area adjacent to theservice alGay and rigidly mounted on steel plate9

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