Synergy Antamina 4212 - Synergy Engineering Ltd

ENGINEERED SOLUTIONS FOR MATERIAL HANDLING
Minera Antamina S.A.
Electrical System for 1600 TPH Shiploader for Puerto Huarmey, Peru
2829 Murray Street
Port Moody, BC V3H 1X3
Canada
Date:
September, 2000
Author:
Harry Doughty
Synergy team: Russ Carder, Wanda Stefanska, Harry Doughty
Glen Wise, Kim Welchman, Hernan Alvarez
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Tel: 604.469.6040
Fax: 604.469.4944
E-mail: [email protected]
Web: www.synergy-eng.com
Table of Contents
Executive Summary . . . . . . . . . . . . . . . . . . . . 2
Environment & Safety . . . . . . . . . . . . . . . . . . 3
Project Scope . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical Room . . . . . . . . . . . . . . . . . . . . . . . 3
Power Distribution . . . . . . . . . . . . . . . . . . . . 5
Control System . . . . . . . . . . . . . . . . . . . . . . . . 3
Construction, Commissioning & Startup . . . 5
Executive Summary
W
HEN THE NEW Antamina copper mine
was constructed high in the Andes
Mountains of Peru, a new port facility
was needed at Puerto Huarmey to
process the concentrate and transfer it to deep sea
vessels. For this purpose, a slewing/shuttling/luffing
shiploader was specified. MAN TAKRAF of Leipzig,
Germany was awarded the contract for the supply of
this 1600 TPH machine and contracted the supply of
the complete electrical system to Synergy Engineering
Ltd. Synergy’s engineering team worked closely with
the MAN TAKRAF mechanical and electrical engineers
to co-ordinate the design of the equipment.
Project Scope
The major components in Synergy’s supply included the
prefabricated electrical room, hydraulic room, and
operator cab. In addition, all lighting, fire suppression,
field instrumentation and construction materials were
supplied by Synergy including a large flexible power
track to feed power to the electrical loads on the
shuttle boom. Synergy did all the HMI and PLC
programming which included support right through to
the startup and commissioning phases. In addition,
Synergy was awarded a separate contract to design
and supply 7 unit substations to feed electrical power
to the shiploader and other areas of the port facility.
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Minera Antamina S.A: Electrical System for 1600 TPH Shiploader for Puerto Huarmey, Peru, continued
that control can be switched over to an operator on the
ship’s deck.
Electrical Room
The electrical room was designed in conjunction with an
integral hydraulic room. The 2 rooms share a common
air conditioner and fire protection system. The rooms
which are installed on the rear of the slew platform had
to be designed to accommodate tight space restrictions.
An extra pitch on the roof of the hydraulic room was
required to clear the rear section of the boom when
luffed to the highest angle. The electrical room houses
the PLC cabinet, motor control centre and the
adjustable frequency drives for the slewing and
shuttling motions.
Environment and Safety
To protect the pristine tropical waters, stringent
environmental requirements were adhered to. In order
to prevent leakage of copper concentrate, the entire
boom area is sealed and dust is controlled by a dust
Control System
The operator cab is housed on the main boom and a
hydraulic system using feedback from an inclinometer
automatically keeps the cab level as the boom luffing
angle changes. The operator controls the reclaim
conveyor and shiploader operation from an HMI screen
in conjunction with devices located in the consoles
attached to the operator’s chair arms. The HMI
application was developed using Wonderware InTouch
and runs on a Compaq Desk Pro EN computer. The HMI
communicates to the PLC over 2 independent networks,
Ethernet and Data Highway Plus. The HMI is configured
to use Ethernet as the default network with an
automatic switch over to DH+ on failure. Wonderware
AB-TCP and AB-KTX I/O servers are used to access the
two networks. A radio controller was also provided so
collection system. All cables entering the boom had to
be sealed to prevent leakage. The high-humidity salt air
is highly corrosive therefore special finishes were
applied 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
feed the transformers which have 480-volt secondaries.
Special consideration was given to selecting fuses to coordinate with the customer’s upstream protection.
trays and electrical buildings. Due to the lack of a
natural shelter, consideration had to be given to the
requirement of retracting the boom and spout clear of
the ship to allow for a hasty departure to deep water if
a sudden storm should arise. The client supplied an
emergency shore power feed and Synergy included a
load shedding function in the control logic to drop all
non-essential loads. Critical motions were designed so
that they could still operate at reduced capacity in the
event of the failure of a single motor.
Construction, Commissioning and Startup
Synergy personnel were on site at Puerto Huarmey to
provide technical assistance to the construction crews
and commissioning and start up services. The Synergy
startup crew stayed on after the initial startup phase to
provide training to operators and maintenance
electricians and technical support during the loading of
the first ships. ■
Fire Protection
The electrical and hydraulic rooms and operator cab
were provided with automatic FM200 fire protection
systems. The FM200 systems and a customer supplied
water sprinkler
system in the
boom area are
controlled by a
fire protection
panel in the
operator’s cab.
Standard smoke
and heat
detectors and
manual pull
stations complete
the package.
Synergy Field Service Representative
Glen Wise.
Power Distribution
Synergy designed
and manufactured
6 oil-filled unit
substations and one
dry type unit for
power distribution
throughout the port
facility. 4160 V fused
load break switches
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