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Minera Antamina S.A.Electrical System for 1600 TPH Shiploader for Puerto Huarmey, Peru

Date: September, 2000Author: Harry DoughtySynergy team: Russ Carder, Wanda Stefanska, Harry Doughty

Glen Wise, Kim Welchman, Hernan Alvarez

2829 Murray StreetPort Moody, BC V3H 1X3Canada

Tel: 604.469.6040Fax: 604.469.4944

E-mail: office@synergy-eng.comWeb: www.synergy-eng.com

E N G I N E E R E D S O L U T I O N S F O R M A T E R I A L H A N D L I N G

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Executive Summary

HEN THE NEW Antamina copper minewas constructed high in the AndesMountains of Peru, a new port facilitywas needed at Puerto Huarmey to

process the concentrate and transfer it to deep seavessels. For this purpose, a slewing/shuttling/luffingshiploader was specified. MAN TAKRAF of Leipzig,Germany was awarded the contract for the supply ofthis 1600 TPH machine and contracted the supply ofthe complete electrical system to Synergy EngineeringLtd. Synergy’s engineering team worked closely withthe MAN TAKRAF mechanical and electrical engineersto co-ordinate the design of the equipment.

Project Scope

The major components in Synergy’s supply included theprefabricated electrical room, hydraulic room, andoperator cab. In addition, all lighting, fire suppression,field instrumentation and construction materials weresupplied by Synergy including a large flexible powertrack to feed power to the electrical loads on theshuttle boom. Synergy did all the HMI and PLCprogramming which included support right through tothe startup and commissioning phases. In addition,Synergy was awarded a separate contract to designand supply 7 unit substations to feed electrical powerto the shiploader and other areas of the port facility.

Table of Contents

Executive Summary . . . . . . . . . . . . . . . . . . . . 2

Project Scope . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical Room . . . . . . . . . . . . . . . . . . . . . . . 3

Control System . . . . . . . . . . . . . . . . . . . . . . . . 3

Environment & Safety . . . . . . . . . . . . . . . . . . 3

Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . 4

Power Distribution . . . . . . . . . . . . . . . . . . . . 5

Construction, Commissioning & Startup . . . 5

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Minera Antamina S.A: Electrical System for 1600 TPH Shiploader for Puerto Huarmey, Peru, continued

Electrical Room

The electrical room was designed in conjunction with anintegral hydraulic room. The 2 rooms share a common

air conditioner and fire protection system. The roomswhich are installed on the rear of the slew platform hadto be designed to accommodate tight space restrictions.An extra pitch on the roof of the hydraulic room wasrequired to clear the rear section of the boom whenluffed to the highest angle. The electrical room housesthe PLC cabinet, motor control centre and theadjustable frequency drives for the slewing andshuttling motions.

Control System

The operator cab is housed on the main boom and ahydraulic system using feedback from an inclinometerautomatically keeps the cab level as the boom luffingangle changes. The operator controls the reclaimconveyor and shiploader operation from an HMI screenin conjunction with devices located in the consolesattached to the operator’s chair arms. The HMIapplication was developed using Wonderware InTouchand runs on a Compaq Desk Pro EN computer. The HMIcommunicates to the PLC over 2 independent networks,Ethernet and Data Highway Plus. The HMI is configuredto use Ethernet as the default network with anautomatic switch over to DH+ on failure. WonderwareAB-TCP and AB-KTX I/O servers are used to access thetwo networks. A radio controller was also provided so

that control can be switched over to an operator on theship’s deck.

Environment and Safety

To protect the pristine tropical waters, stringentenvironmental requirements were adhered to. In orderto prevent leakage of copper concentrate, the entireboom area is sealed and dust is controlled by a dust

collection system. All cables entering the boom had tobe sealed to prevent leakage. The high-humidity salt airis highly corrosive therefore special finishes wereapplied to all metal parts including junction boxes, cable

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Minera Antamina S.A: Electrical System for 1600 TPH Shiploader for Puerto Huarmey, Peru, continued

trays and electrical buildings. Due to the lack of anatural shelter, consideration had to be given to therequirement of retracting the boom and spout clear ofthe ship to allow for a hasty departure to deep water ifa sudden storm should arise. The client supplied anemergency shore power feed and Synergy included aload shedding function in the control logic to drop allnon-essential loads. Critical motions were designed sothat they could still operate at reduced capacity in theevent of the failure of a single motor.

Fire Protection

The electrical and hydraulic rooms and operator cabwere provided with automatic FM200 fire protectionsystems. The FM200 systems and a customer supplied

water sprinklersystem in theboom area arecontrolled by afire protectionpanel in theoperator’s cab.Standard smokeand heatdetectors andmanual pullstations completethe package.

Power Distribution

Synergy designedand manufactured 6 oil-filled unitsubstations and onedry type unit forpower distributionthroughout the portfacility. 4160 V fusedload break switches

feed the transformers which have 480-volt secondaries.Special consideration was given to selecting fuses to co-ordinate with the customer’s upstream protection.

Construction, Commissioning and Startup

Synergy personnel were on site at Puerto Huarmey toprovide technical assistance to the construction crewsand commissioning and start up services. The Synergystartup crew stayed on after the initial startup phase toprovide training to operators and maintenanceelectricians and technical support during the loading ofthe first ships. ■

Synergy Field Service RepresentativeGlen Wise.

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