Page

1. GENERAL ................................................................................................................................ 3
ntroduction 3
Scope 3
3 References 3
3 Outside Organizations 3
3 Other Project Design Criteria 3
33 Other Documents 3
Units 3
Working Language
Symbols and Standards
. Design Method/PhiIosophy .................................................................................................... 4
General
Engineering and Design
P&Ds
Loop and Motor Narratives
3 nstrument Specifications / Data Sheets
Plant Wide ntegration
3. ControI System ....................................................................................................................... 5
3 System Architecture
3 Fault Tolerance
33 Control Philosophy
3 Operator nterfaces
3 Motor Control and nterlocks 7
3 UPS Systems 7
4. ControI Room Layouts............................................................................................................ 7
5. Packaged Equipment.............................................................................................................. 7
6. SECURITY ................................................................................................................................ 8
UPS Systems 8
7. EQUIPMENT CONTROL PACKAGES ..................................................................................... 8
7 General 8
8. FieId Instrumentation And ControIs ....................................................................................... 8
8 nstrument and Control Signals 9
8 nstrument Power Supplies, Cabling and Grounding 9
8 Power Supplies 9
8 Field Cabling, Junction Boxes and Grounding 9
83 nstrument dentification 9
8 nstrument Selection Guidelines

8 General
8 Flow
83 Level
8 Pressure
8 Temperature
8 Density
87 Belt Scales
88 Control Valves
89 Material Selection
. System Architecture preIiminary bIock diagram ................................................................ 1

1.1 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. 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 References
1.3.1 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 n addition, the layouts will comply with any laws or
regulations of local authorities n the event of conflicting requirements, the most stringent will
apply:

SA nstrumentation, Systems and Automation - Standards and Practices for
nstrumentation
ANS American National Standards nstitute
NEC National Electrical Code
OSHA Occupational Safety and Health Administration
UL Underwriters Laboratory
CSA Canadian Standards Association
Local laws and codes

1.3. Other Project Design Criteria

This criteria should be read in conjunction with the following additional design criteria:

1.3.3 Other Documents

1.4 Units
1. GENERAL

All units shall be in accordance with the nternational System of Units (S units) using the "Metric
Practice GuideWhere a piece of equipment is manufactured to mperial units then the mperial
units should be shown as the primary dimensions with the metric equivalent shown in brackets

1.5 Working Language
O For the Engineering phase of the project, drawings will be in English translation

1.6 SymboIs and Standards
Piping and nstrumentation Diagram (P&D) symbols will be in conformance with SA Standard
S The Symbol and Legend P&D defines the symbols in detail






.1 GeneraI
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


. Engineering and Design
..1 P&IDs
The P&Ds 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
. DESIGN METHOD/PHILOSOPHY

.. Loop and Motor Narratives

n conjunction with the P&Ds, 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
nterlocks

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

..4 PIant 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 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 /O
quantities become available

PLC's 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

3. FauIt ToIerance
3. CONTROL SYSTEM

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 (HMs) will be sufficient to allow operation of the entire plant
whenever one of the HMs fails

3.3 ControI PhiIosophy
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 nterlocks 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 PLC's or Remote /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 HM 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:

O
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
nterlocks between equipment will be incorporated in the control system Personnel safety
interlocks will be hardwired

3.4 Operator Interfaces

The HM 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
nterlocks and sequence monitoring
Trending
Reports and logs (process plant only)
Maintenance diagnostic screens
Selected Motor runtime data
The HMs, 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

HMs will have brand name colour monitors, with keyboards and trackballs/mice for operator
actions The operating platform will be latest version Microsoft Windows PRO

3.5 Motor ControI and InterIocks
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


3.6 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 3 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 VAC power will not be powered from
a UPS source unless thought to be critical to operations in the event of a power failure





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


4. CONTROL ROOM LAYOUTS
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

PLC's supplied with vendor equipment packages will repeat, status and alarms to the PLC or
DCS based (hold on pending decision) control system via hardwired /O signals or interface
links






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

6.1 UPS Systems
The security system will be powered from a dedicated UPS source, which will keep the system
operational for at least 3 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 GeneraI
A number of pieces of equipment will be supplied with instrumentation and control packages,
typically:
O

mportant 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 PLC's for control t is intended to standardize with one PLC
manufacturer, refer to section for packaged equipment All equipment supplied PLC's will be
capable of communicating with the plant control system using a protocol as yet to be determined





6. SECURITY
7. EQUIPMENT CONTROL PACKAGES
8. FIELD INSTRUMENTATION AND CONTROLS

8.1 Instrument and ControI SignaIs
Electronic analogue signals will be isolated V, to mA DC

Pneumatic signals will be - kPa

Signals from field switches/contacts and control signals to solenoid valves will be VDC

Control voltage for motor starters and the control system /Os used for motor control will be
VAC, Hz

8. Instrument Power SuppIies, CabIing and Grounding

8..1 Power SuppIies

Two wire transmitters will be VDC powered from the control system /O card or control panel
instrument as applicable

Four wire transmitters and switches will be powered by VAC, 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 VAC, Hz powered from a UPS or conditioning transformer


8.. FieId CabIing, Junction Boxes and Grounding

Separate junction boxes will be used for VDC and VAC wiring

ndividual 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 /O or panels
Cables carrying - 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 /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
( - mA ) may be run in cable trays carrying electrical cables with voltages up to Volts n
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

8.3 Instrument Identification

All instruments will be tagged with permanent tag numbers assigned as follows:
Example: -PSL-
Area
nstrument type per P&D legend PSL
P&D sequential number (last numbers)
nstrument sequential number on P&D


Area numbers are required on a P&D only if instruments from more than one area are shown
on the P&D

Example: 3




8.4 Instrument SeIection GuideIines
8.4.1 GeneraI
Wherever possible, transmitters will be smart type and HART compatible

8.4. FIow
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




8.4.3 LeveI

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

8.4.4 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 mm
will be used

8.4.5 Temperature
Sensing elements will be ohm, platinum, 3 wire RTDs or thermocouples c/w temperature
transmitters

For local temperature indication, every angle bi-metallic temperature gauges with a mm
diameter dial

8.4.6 Density
Nuclear Gamma Ray dispersion method will be used for measurement of slurry density

8.4.7 BeIt ScaIes
Belt scales will be of the load cell type

8.4.8 ControI VaIves
For control valves on lines greater than or equal to inches in diameter handling corrosive
fluids, lined butterfly valves will be used

For control valves on lines less than 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

8.4. MateriaI SeIection
Materials in direct contact with the process will be selected on the basis of the Piping
Specification

END OF DOCUMENT
. SYSTEM ARCHITECTURE PRELIMINARY BLOCK DIAGRAM