t11m408-i1-takraf-03763-vdcel02-p1me01-009

This document is CODELCO CHILE’s property. Its reproduction and publication without CODELCO CHILE’s previous consent is forbidden. Once this document has been printed is considered a NON CONTROLLED copy and may be obsolete. Ask for last issue in the Project’s Library. Codelco Doc.No. of 49

CORPORACIÓN NACIONAL DEL COBRE DE CHILE

VICEPRESIDENCIA DE PROYECTOS

PROYECTO NNM EL TENIENTE

CONTRACT N° 4501303343

EQUIPMENT MANUAL CONSTRUCTION (CTR-11 & CTR-05)

TMM_DocNumber_3rdParty

ABB REFERENCE N°: 9940-63-2-1002

0 28.08.13 ISSUE FOR CONSTRUCTION RU.BUD GU.ZER

C 14.08.13 APPROVAL RU.BUD

B 31.05.13 APPROVAL RU.BUD

A 09.05.13 INTERNAL REVIEW RU.BUD

REV N° DATE ISSUED FOR BY REVIEWED APPROVED BY APPROVED BY

TAKRAF CODELCO

SKM Doc.No.: TMM_DocNumber_Customer Page. 1 of 4

TAKRAF REFERENCE N°: 49047234 Rev. 0

DEU102750

TAKRAF-ABB

EQUIPMENT MANUAL

CONSTRUCTION (CTR-11&CTR-05)Codelco Chile, Vicepresidencia de Proyectos N° Proyecto: 4501303343Proyecto El Teniente Rev. 0

Este Documento es propiedad de CODELCO CHILE Fecha de impresión Se prohibe su reproducción y exhibición, sin el consentimiento de CODELCO CHILE 28-08-2013 13:57:00 El Documento, una vez impreso, se considera una copia NO CONTROLADA y puede estar obsoleta Consulte la revisión actual en: Biblioteca de Proyectos o en el Escritorio de la VCP NO.DOCUMENTO Página 2 de 49

EQUIPMENT MANUAL CONSTRUCTION (CTR-11 & CTR-05)

Codelco Doc.No.

APPROVALS

TAKRAF SIGNATURE DATE

PREPARED BY RU.BUD 29-04-13

REVIEWED BY GU.ZER

APPROVED BY

VICEPRESIDENCIA DE PROYECTOS SIGNATURE DATE

REVIEWED BY

REVIEWED BY

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EQUIPMENT MANUAL



0 Table of contents 1 Introduction into the project 1.1 General explanations 1.2 Interfaces 1.2.1 Electrical system 1.2.2 Control Equipment 1.2.3 Communication Equipment 1.2.3.1 Redundant Ethernet MMS protocol for control network (controller to controller communication) 1.2.3.2 Redundant Ethernet Modbus TCP protocol for controller to DCS communication (CCR) 1.2.3.3 Local Ethernet Modbus TCP protocol for CCM/CDC/AUX to controller communication 1.2.3.4 Local Ethernet Modbus TCP protocol for fire detection system 1.2.3.5 IEC61850 network 1.2.3.6 Ethernet MMS protocol for client server network 1.2.3.7 Profibus DP fieldbus network 1.2.3.8 Modbus RTU network 1.2.3.9 Dupline network 1.2.4 Foundations 1.2.5 Grounding 2 Occupational health and safety, fire protection, accident prevention regulations 3 Storage of electrical and installation material 3.1 Inspection of incoming shipments 3.2 Storage of electrical material 3.3 Storage of installation material 3.4 Storage of sectional steels 3.5 Storage of small materials 4 Specification of labor and tools 4.1 Specification of employment of labor / Job descriptions 4.1.1 Foreman 4.1.2 Fitter 4.1.3 Auxiliary and transport worker 4.1.4 Electrician 4.1.5 Specialist for wiring and PLC 4.2 General tools 4.2.1 List of equipment for one electrician 4.2.2 List of equipment for one electrical fitter in the electrical industry 4.2.3 List of equipment for the employment of 10 – 15 workers 5 Containers 5.1 General 5.2 Structure of the containers (cooling containers and e-containers) 5.3 Installation of the containers 5.3.1 Lighting and socket installation 5.3.2 Internal cable connections

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5.3.3 Fire detection and fire-extinguishing system 5.3.4 Positive pressure ventilator 5.3.5 Air-conditioners 5.4 Cable trays in the range of the container 5.5 Cable entry into the e-container/switchgears 5.6 Connections in the switchgears 5.7 Water cooling 5.7.1 Pipe installation in the cooling system 5.8 Grounding/equipotential bonding of the e-container 6 Construction of cable ways and cable laying 6.1 Installation of cable trays 6.1.1 Separation 6.1.2 Fastening 6.1.3 Type of cable laying 6.1.4 Coverings 6.1.5 Corrosion protection 6.1.6 Grounding 6.2 Installation of conduits and flexible tubes 6.2.1 Separation 6.2.2 Fastening 6.2.3 Fastening distances 6.2.4 Corrosion protection 6.2.5 Grounding 6.3 Cable laying 6.3.1 General 6.3.2 Smallest permissible bending radii 6.3.3 Cable laying in conduits 6.3.4 Cable laying in cable trays 7 Installation of the electrical equipment 7.1 Installation of transformers 7.1.1 Transport 7.1.2 Installation and fastening 7.1.3 Grounding 7.2 Installation of motors 7.2.1 Transport 7.2.2 Installation and fastening 7.2.3 Grounding

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7.3 Installation of boxes 7.3.1 General 7.3.2 Distributed boxes and terminal boxes 7.3.3 Local control boxes 7.3.4 Junction boxes, transmitter boxes 7.3.5 Grounding 7.4 Installation of push buttons, transmitters, limit switches and signaling devices 7.4.1 General 7.4.2 Push buttons and switches 7.4.3 Pull-rope switches 7.4.4 Misalignment switches 7.4.5 Limit switches 7.4.6 Tachogenerators, incremental transmitters, absolute value transmitters 7.4.7 Overflow probes 7.4.8 Belt damage detectors 7.4.9 Photoelectric switch 7.4.10 Start-up warning 7.4.11 Grounding 7.5 Installation of sockets 7.5.1 General 7.5.2 Outdoor sockets 7.5.3 Indoor sockets 7.5.4 Grounding 7.6 Installation of lighting fittings in the range of the e-containers 7.6.1 General 7.6.2 General lighting 7.6.3 Safety lighting 7.6.4 Grounding 8 Installation technology 8.1 Cable entry/Cable bushing 8.1.1 Cable glands 8.1.2 ROXTEC cable bushing 8.2 Sealing ends 8.2.1 Medium-voltage sealing ends (1 - 33kV) 8.2.1.1 MV sealing ends in switchgear systems and boxes 8.2.1.2 MV sealing ends in motors 8.2.2 Low-voltage sealing ends (> 1kV) 8.2.2.1 LV sealing ends in switchgear systems 8.2.2.2 LV sealing ends in motors 8.2.2.3 LV sealing ends in boxes, switches and sockets

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8.3 Connections 8.3.1 Compression-type cable lugs 8.3.2 Crimping cable lugs 8.3.3 Core end sleeves 8.4 Shield connection 8.5 Grounding / Equipotential bonding 8.6 Lettering and labeling 8.6.1 Cables 8.6.2 Cores 8.6.3 Electrical equipment 8.6.4 Electrical operating areas 8.7 Connection techniques 8.7.1 Screwed connection 8.7.1.1 General 8.7.1.2 Non-conductive electrical connection 8.7.1.3 Conductive electrical connection 8.7.2 Welded connection 8.7.3 Riveting 8.7.3.1 General 8.7.3.2 Blind rivet connection 8.7.3.3 Blind rivet nut connection 8.8 Corrosion protection 9 Measurements to be carried out by the erection company 9.1 Insulation measurement for cables 9.2 Measurement of loop impedance for socket and lighting system 10 List of companies Annex

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1 Introduction into the project 1.1 General explanations The erection manual includes regulations about working safety, implementation of transport, handling and storage processes, documentations about mounting material, mounting variants and stipulations for the implementation of the erection that aim at a high quality and professional erection of the electrical equipment delivered by ABB. The ABB supervisors shall be responsible for the technical instruction and supervision of the implementation of the erection which is based on the technological documents of the electrical project, the cable tray drawings and the erection manual. The technical documentation of the manufacturers of the electrical equipment shall be observed as well. For that reason the erection staff shall be informed widely about the technological part of the electrical project, the documentation and the appropriate erection guidelines. Deviations from the erection guidelines shall only be allowed if - there are no violations of the present rules and standards (DIN or IEC) - there are objective reasons, but only with due regard to the first bullet. In general all deviations shall be confirmed by the ABB site manager. 1.2 Interfaces 1.2.1 Electrical system The scope of deliveries includes 4 containers with the electrical equipment (03713-SEL-01; 03723-SEL-01, 03733-SEL-01, 03763-SEL-01). Each e-container is equipped with a gas-insulated 33 kV power distribution switchgear with 2 main incoming supplies each. The socket contacts of these main incoming supplies are the interfaces of the scope of deliveries. All power, control and data cables laid outside the e-containers are not included in ABB's scope of deliveries. In each e-container there is a space reserved for the electrical systems that will be installed by the Customer. This space also includes the interfaces for the data cables that provide the transfer point to the higher-level control system. Power supplies to auxiliary and secondary consumers of CODELCO have been taken into consideration as agreed. The power terminals in the respective switchgears provide the interfaces. 1.2.2 Control equipment Each e-container is equipped with a redundant ABB PLC AC800M PM864 controller. The controller serves as the processing unit for the belt conveyor main drives, auxiliary drives and field devices. They are installed in PLC cabinets. At the drive station local remote I/O cabinets are provided. They are equipped with S800 remote I/Os and marshaling terminals. Both the controller and the S800 remote I/Os are prefabricated and preinstalled and do not need any installation work. The controller-to-controller communication and the remote I/O-to-controller communication are described in the chapter “Communication equipment”.

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1.2.3 Communication equipment The following communication equipment is installed: 1.2.3.1 Redundant Ethernet MMS protocol for control network (controller to controller communication) The network is based on Codelco's switched Ethernet backbone with redundant single mode fiber optic cable connection from e-container to e-container. There is only a connection from the local PLC and communication panel to the Codelco backbone switch which is a prefabricated CAT6 cable. For details see the Ethernet Block diagram “9940-63-3-1002” (Annex 13). 1.2.3.2 Redundant Ethernet Modbus TCP protocol for controller to DCS communication (CCR) The network is based on Codelco's switched Ethernet backbone with redundant single mode fiber optic cable connection from e-container to e-container. There is only a connection from the local PLC and communication panel to the Codelco backbone switch which is a prefabricated CAT6 cable. For details see the Ethernet Block diagram “9940-63-3-1002” (Annex 13). 1.2.3.3 Local Ethernet Modbus TCP protocol for CCM/CDC/AUX to controller communication The network connects all local Modbus TCP slaves which are:

PQM (EPM7000) in low voltage CCM and CDC Battery unit Uninterruptible power supply

The switch is connected directly to the AC800M controller and all CAT6 cables are prefabricated. For details see the Ethernet Block diagram “9940-63-3-1002” (Annex 13).. 1.2.3.4 Local Ethernet Modbus TCP protocol for fire detection system The network connects all local fire detection panels (Modbus TCP slave) with an Ethernet switch supplied by Codelco. The CAT6 cables are prefabricated. For details see the Ethernet Block diagram “9940-63-3-1002” (Annex 13).. 1.2.3.5 IEC 61850 network The network connects all protection relays and PQMs (EPM7000) in the medium voltage CCM to Codelco's SCADA system. The switch is supplied by Codelco. The CAT6 cables are prefabricated. For details see the Ethernet Block diagram “9940-63-3-1002” (Annex 13).. 1.2.3.6 Ethernet MMS protocol for client Server Network The network is based on Codelco's switched Ethernet backbone with single mode fiber optic cable connection from e-container to e-container. There is only a connection from the local PLC and communication panel to the Codelco backbone switch which is a prefabricated CAT6 cable. For details see the Ethernet Block diagram “9940-63-3-1002” (Annex 13).

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1.2.3.7 Profibus DP fieldbus network The network connects the Profibus master (connected to the PLC) to the Pofibus slaves as they are:

S800 remote I/O Dupline channel generator Belt monitoring devices CCM smart starter and VFDs Cooling unit for VFD and motor Belt scales SOBO brake controller

Some of the equipment mentioned above is already prewired in the electrical room. Everything outside the electrical room will be installed at side. For details see the Profibus Block diagram “9940-x3-3-1003” (Annex 14). Most of the connections are made by multimode fiber optic cable with ST connector. Short distances are connected via Profibus DP copper cable. Take care that at each extreme end of a copper cable connection the termination resistor must be switched “ON”. The cable connection to a Profibus plug must be performed as indicated on page 1 in the above mentioned document. The incoming cable must always be connected to A1 and B1, the outgoing cable to A2 and B2. Please take care of the wire colors. 1.2.3.8 Modbus RTU network The network connects the Main Circuit Breaker of the low voltage CCM to the controller. The connection is prefabricated (twisted pair cable). For details see the Modbus RTU Block diagram “9940-x3-3-1004” (Annex 15). 1.2.3.9 Dupline network The Dupline network connects the safety switches along the conveyor with the channel generator. A two wire cable must be used. The connection is wire sensitive. Take care that wire one is always connected to terminal A and wire two always to terminal B. For details see the related circuit diagram. 1.2.4 Foundations The concrete supports and their appropriate devices for fastening the substructure of the e-containers provide the interface for the erection of the containers whilst the steel sections on the oil sump constitute the interfaces for the installation and fastening of the transformers. 1.2.5 Grounding The grounding diagram (Annexes 4 and 10 – 13) provide the basis for grounding and equipotential bonding. The interfaces for grounding and equipotential bonding are the connections of the foundation ground connectors to the respective substructures of the e-containers, the transformers and the structure of the transfer point CTR 05 and CTR 11.

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2 Occupational health and safety, fire protection, accident prevention regulations In general the erection company assumes the independent responsibility for observing the occupational health and safety and fire protection regulations.

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3 Storage of electrical and installation material 3.1 Inspection of incoming shipments The incoming material shall be checked for completeness and intactness. Damages of the packing and the content shall be photographed and recorded, and the project manager and the responsible insurance company shall be informed immediately. 3.2 Storage of electrical material The checked material shall be unpacked and stored on shelves in dry and locked rooms. The storage shall be classified into devices or components. A record must be kept about the receiving and issuing materials. Cables shall to be stored on cable drums, standing or lying in ring form on plane surfaces. All cables shall be protected against mechanical damages. The cable ends must be accessible. A cable record book must be kept. Before the cables are laid, an insulation test must be carried out and recorded in the cable book. 3.3 Storage of installation material The checked material shall be stored under a weather-proof roof in a fenced area. The material shall be stored on racks, classified into devices or components, on stable and plane surfaces. The receiving and issuing materials shall be recorded 3.4 Storage of sectional steels The checked material shall be stored under a weather-proof roof in a fenced area. The material shall be stored on racks, classified into devices or components, on stable and plane surfaces. The receiving and issuing materials shall be recorded 3.5 Storage of small materials These materials shall be assigned to the various erection sites, stored in locked rooms, and the consumption shall be recorded

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4 Specification of labor and tools 4.1 Specification of employment of labor / Job descriptions The workers bound by contract must fulfill the following qualification requirements: 4.1.1 Foreman Training - Electrician Qualification - Special knowledge in the erection of complete electrical installations - Many years of professional experience, technician's examination, if possible - Ability of leading small erection teams Working tasks In addition to the working tasks of the electrician the following is required: - Leading a team in own responsibility - Enforcement of measures to guarantee the safety - Coordination of working progress - Solving of technical questions in the erection documentation handed over - Enforcement of an efficient use of materials - Enforcement and observation of written instructions in his range of responsibilities 4.1.2 Fitter Training - Fitter for electrical installations Qualification - Handicraft skills - Welding test for EB 1 M and GR 1 M in accordance with DIN 8560, (for material quality up to ST 52) and EN 2871 or equivalent welding test of the Customer's country. - Working of metals, plastics, wood - Separating, drilling, grinding, straitening, filing, bending, welding, cutting Working tasks - Independent implementation of difficult works acc. to sketches, drawings, dimension drawings and other specifications - Implementation of difficult cutting and welding works at non-accessible places - Implementation of complicated busbars works (transformer, switchgear system) under observation of the existing regulations - Erection of switchgear systems, panels and transformers acc. to a layout plan - Implementation of routing works acc. to specification and under observation of the given welding points and fastening elements

- Installation of lighting and heating systems, sockets, operating and transmitter elements acc. to installation diagrams - Manufacturing of difficult supporting and fastening elements and installation of the parts of the electrical plant

EQUIPMENT MANUAL



- Erection of boxes, structures, cubicles, poles and brackets - Erection of supporting pipe installations using steel pipes 4.1.3 Auxiliary and transport worker Training - Basic skills in the auxiliary processes of plant erection Qualification - Training in manual skills Working tasks - Laying of cables and lines - Mounting of fastening materials and supporting elements - Mounting of simple devices and parts of the plant - Transport works on the construction site - Stripping of cables up to 1 kV - Erection and alignment of parts of the plant - Simple fitter works - Installation of cable trays, supports and bushings - Implementation of general auxiliary works on the construction side 4.1.4 Electrician Training - Electrician for electrical power installations Qualification - Special knowledge in the erection of complete electrical installations - Independent erection of complex LV, MV and HV switchgear systems and control systems - Reading of electrical drawings, survey diagrams and logic diagrams Working tasks - Commissioning of plants with a medium degree of difficulty - Cable laying - Installation of devices and lighting fittings, fittings - Installation of cable channels - Implementation of simple fitter and welding works - Mounting of branching and terminal materials - Wiring acc. to connection and circuit diagrams - Installation of busbars and strainings in HV systems - Installation of switching frames, distributions, panels, capacitor panels, PLC stations etc. - Installation of cable accessories up to 30 kV - Installation of enclosed distributions - Installation of current transformers, voltage transformers, electrical machines and switching devices of all voltage levels - Revision of drawings - Implementation of functional tests, trial runs and load runs

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4.1.5 Specialist for wiring and PLC Training - Electrician for electrical power installations Qualification - Excellent skills in the field of programmable logic controllers - Special knowledge in the erection of complete electrical installations - Independent erection of complex LV, MV and HV switchgear systems and complicated control systems - Reading of electrical drawings, survey diagrams and logic diagrams Working tasks - Commissioning of plants with a medium degree of difficulty - Cable laying - Installation of devices and lighting fittings, fittings - Mounting of branching and terminal materials - Wiring acc. to connection and circuit diagrams - Installation of switching frames, distributions, panels, PLC stations etc. - Installation of enclosed distributions - Installation of current transformers, voltage transformers, electrical machines and switching devices of all voltage levels - Revision of drawings - Implementation of functional tests, trial runs and load runs

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4.2 General tools 4.2.1 List of equipment for one electrician Pos. Pc. Designation Size/Quality (Length x Depth x Height) 1 1 Tool bag 440 x 180 x 310mm 2 1 hammer 300g 3 1 water pump pliers 4 1 cutting pliers up to 200 kp/mm² 5 1 flat-nose pliers 140mm 6 1 round-nose pliers 140mm 7 1 hand cable cutter 85mm 8 1 flat-round radio pliers 160mm 9 1 wire stripper 10 1 crimping pliers 11 1 crimping pliers 12 1 electrician's knife for round cable 13 1 electrician’s pocket knife 14 9 double open-end wrench 5,5-7; 7-9; 8-10; 12-14;13-17; 17-19; 19-22; 22-24; 24-27mm 15 1 jaw spanner (set) 7/16“; 1/2“; 9/16“; 3/4“; 7/8“; 15/16“; 1 1/8“; 1 5/16“ 16 7 box wrench, cranked 5,5-7; 8-9; 10-11; 12-13; 14-15; 16-17; 18-19mm 17 1 box wrench (set) 7/16“; 1/2“; 9/16“; 3/4“; 7/8“; 15/16“; 1 1/8“; 1 5/16“ 18 9 twist drill 3.2 / 4.0 / 4.2 / 4.8 / 5.2 / 6.4 / 8.0 / 8.5 / 10.5 mm 19 9 socket wrench 5,5-7; 7-9; 8-10; 12-14;13-17; 19; 22; 24; 27mm 20 1 socket wrench (set) 7/16“; 1/2“; 9/16“; 3/4“; 7/8“; 15/16“; 1 1/8“; 1 5/16“ 21 8 screwdriver with flat blade blade width 1.5; 2.5; 3; 4; 5; 6; 8 10mm 22 7 cross-point screwdriver size 01; 02; 0; 1; 2; 3; 4 23 1 soldering iron 60 W 24 1 continuity tester (Prüffix or the like) 25 1 voltage tester 6 - 380V 26 1 scriber 27 1 centre punch 28 6 punch/arbor 3; 4; 5; 6; 8; 10 mm 29 1 spirit level 400mm long 30 1 steel tape measure 3,000mm long 31 1 folding rule 2,000 mm long 32 1 wire stripper

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4.2.2 List of equipment for one electrical fitter in the electrical industry Pos. Pcs. Designation Size/Quality (Length x Depth x Height) 1 2 tool box 430 x 200 x 200mm 2 1 metal back square 300 x 200mm 3 3 flat file, cut 1 300; 250; 150mm 4 3 flat file, cut 2 300; 250; 150mm 5 1 flat file, cut 3 250mm 6 3 half-round file, cut 1 300; 250; 150mm 7 2 half-round file, cut 2 300; 150 mm 8 2 round file, cut 1 300; 150 mm 9 3 round file, cut 2 300; 250; 150mm 10 1 round file, cut 3 250mm 11 1 triangular file, cut 2 250mm 12 1 square file, cut 2 250mm 13 1 universal file 250mm 14 1 file brush 15 1 flat chisel 200mm 16 1 cross-cut chisel 200mm 17 3 machinist's hammer 300; 500; 800 g 18 1 hand saw blade with chucking capacity 300mm 19 10 hand saw blades HSS 300/12 20 2 gripping tongs with port mouth 21 1 water pump pliers 22 1 combination cutting pliers 23 6 punch/arbor 3; 4; 5; 6; 8; 10 mm 24 3 screwdriver with flat blade blade width 6; 8; 10 mm 25 4 screwdriver with cross blade size 1; 2; 3; 4 26 9 double open-end wrench 5,5-7; 7-9; 8-10; 12-14;13-17; 17-19; 19-22; 22-24; 24-27mm 27 1 jaw spanner (set) 7/16“; 1/2“; 9/16“; 3/4“; 7/8“; 15/16“; 1 1/8“; 1 5/16“ 28 7 box wrench, cranked 5,5-7; 8-9; 10-11; 12-13; 14-15; 16-17; 18-19mm 29 1 box wrench (set) 7/16“; 1/2“; 9/16“; 3/4“; 7/8“; 15/16“; 1 1/8“; 1 5/16“ 30 1 dividers 175mm 31 1 centre punch 125mm 32 1 scriber 200mm 33 10 twist drill 3.2; 4.0; 4.2; 4.8; 5.2; 6.4; 8.0; 8.5; 10.5; 12.5mm 35 1 screw tap (set) 1/4“; 5/16“; 3/8“; 1/2“; 9/16“; 5/8“; 3/4“; 7/8“; 36 1 folding rule 2,000 mm long 37 1 slag hammer 38 1 welder’s shield

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4.2.3 List of equipment for the employment of 10 – 15 workers List of equipment that must be available at each erection site for a staff of 10 to 15 persons: Pos. Pcs. Designation Size/Quality (Length x Depth x Height) 1 1 torque wrench 2 1 step cutter up to M50 3 1 cable cutter up to 95mm 4 1 hydraulic hand pressing device for hexagon pressing 5 1 box-column drilling machine incl. up to 16mm drilling machine jaw vice 6 3 hand drill (480 W) up to 13 mm 7 1 static cutting device 8 2 hand-held angle grinder wheel 230mm 9 3 hand-held angle grinder wheel 125mm 10 1 grinding pedestal wheel 200mm 11 2 welding rectifier up to 200A 12 1 welding rectifier up to 140A 13 2 parallel vices width of jaws 120 mm 14 1 guillotine cutting capacity up to 6 mm 15 2 workbench width 2,000 mm 16 2 lockable tool cabinet 1,000 x 500 x 1,000mm 17 1 welding place with dust extractor 18 1 hand-operated flat bar bender for flat steel up to 40 x 8 19 1 ladder with 5, 7, 9 steps 20 2 storage box for small materials 1,000 x 500 x 500 mm 21 2 tarpaulins 4000 x 5,000mm 22 1 electrical hand lamp 23 1 steel tape measure 30m 24 4 screw clamp 800mm 25 1 complete hand screw driver set with changeable inserts 26 5 extension cable, a 50 m 28 2 extension cable for welding, a 100 m 29 2 pliers for tightening of cable ties with a width of 4.8 and 7.6 mm 30 2 mechanical cable reel winch up to 8.0t 31 2 blind rivet pliers up to 5.0mm 32 2 blind rivet nut pliers up to 10.0mm 33 1 welding and burner box 34 2 cordless drill/screwdriver incl. charger 35 2 turbo milling drill 6.4mm 36 1 hot-air device 37 6 walkie-talkies 38 1 hoisting device up to 5 Mp

EQUIPMENT MANUAL



5 Containers 5.1 General E-houses in container construction are provided for the El Teniente project. The e-containers are built on concrete pillars. The e-containers are accessible via staircases and platforms. A lighting installation for general and safety lighting shall be installed on the platforms (see item 7.6). 5.2 Structure of the containers (cooling containers and e-containers) The erection and assembly is carried out in accordance with the specifications and documents of the container manufacturer (Annex 21). At first the shipping packaging shall be removed from the container segments. Then the girders (I-beams) shall be mounted on the concrete pillars in which four M20 threaded bolts each have been flash-mounted by the customer and they shall be aligned. Afterwards the containers shall be erected and assembled on the girders. When the four individual container segments are assembled, it shall be ensured that the sealing between the individual segments is carried out in accordance with the manufacturer's specifications. After the containers have been assembled the walkways and platforms for accessing the containers shall be set up. All means necessary for making the connections and sealing shall be included in the scope of delivery. 5.3 Installation of the containers As the container segments have been partly preinstalled by the manufacturer they only need to be completed at the place of installation. 5.3.1 Lighting and socket installation The lighting and socket system has been preinstalled by the container manufacturer. After the container segments have been assembled the lighting and socket installation shall be completed according to the installation drawings of the container manufacturer (Annex 21: Installation of e-container.pdf). 5.3.2 Internal cable connections The cables for the switchgears that were preinstalled by the container manufacturer, then disconnected again and placed down in a ring for the transport shall be laid in the appropriate cubicles again and connected according to the cable list. The cable trays in the cable floor of the e-containers shall be used for laying the cable. These works should mainly be carried out using the documents of the first installation by the manufacturer. 5.3.3 Fire detection and fire-extinguishing system The fire detection and fire-extinguishing system will be completed by the company INGETROL. 5.3.4 Positive pressure ventilator The positive pressure ventilators will be installed in accordance with the manufacturer's specifications (Annex 35).

EQUIPMENT MANUAL



5.3.5 Air-conditioners The outdoor devices of the air-conditioners shall be installed on girders in the range of the upper containers in accordance with the installation diagram (Annex 8). The connection between the outdoor devices of the air-conditioners and the AC cabinets in the e-containers (pipes and cables) shall be carried out in accordance with the specifications of the AC manufacturer (Annex 32) or the cable list. The specifications of the AC manufacturer shall be ensured when making the connection between the outdoor and indoor devices of the air-conditioner in the cooling container (Annex 33). The manufacturer's specifications shall also be ensured when filling the pipes of the air-conditioners. 5.4 Cable trays in the range of the container The trays below the e-container and those to the container for the cooling devices installed on top of the e-container shall be carried out on the basis of the Cable Trays drawing (Annex 5) and the respective Installation Details of the Cable Trays (Annex 3). The local conditions shall be observed for that work. 5.5 Cable entry into the e-container/switchgears ROXTEC cable entries shall be used for entering the cables from the outdoor installation into the cable floor of the e-container. The ROXTEC cable entries consist of the ROXTEC frame installed in the container floor, the modules for the cables and the ROXTEC wedge. The ROXTEC modules and wedges shall be installed in accordance with the Instructions attached to the packaging (Annex 41). The allocation of the cables in the ROXTEC cable bushings is given in Annex 16. The cables shall be entered in the switchgear from below from the cable floor. The holes necessary for the cable entry in the bottom sheets shall be made using a screw hole punch. Cable glands (e.g. Hensel STM 25, STM 40 or KST 70) shall be pressed into these holes. The cable glands shall then be opened depending on the cable diameter with the hole just being big enough to ensure the degree of protection of the switchgear. Then the cables shall be entered in the cubicle where they are distributed accordingly. 5.6 Connections in the switchgears The manuals of the switchgear manufacturers (Annexes 26 – 32) and the connection lists shall be used for connecting the cable in the switchgears. The medium-voltage cables in the 33-kV switchgears shall be connected to the switchgear via plugs. The medium-voltage sealing ends must only be installed by certified professionals. The plugs for the medium-voltage sealing ends are included in the scope of deliveries of the erection company. Medium-voltage sealing ends in the plugs shall be made in accordance with the instructions delivered in the packaging for the sealing ends and plugs. The MV shrinking sealing ends in the medium-voltage converter systems for the belt drives shall be carried out and connected according to the instructions provided in the packaging. 5.7 Water cooling The cooling units of the cooling system for the converter system shall be set up in accordance with the Installation Drawing (Annex 8) and the specifications given by the container manufacturer (Annex 21) and the manufacturer of the cooling systems (Annex 23).

EQUIPMENT MANUAL



5.7.1 Pipe installation in the cooling system The installation of the cooling pipes between the cooling container and the converter system, chiller and belt drive motor shall be carried out in accordance with the specifications given by the manufacturer of the cooling system (Annex 23). These specifications shall also be observed for rinsing and filling the cooling pipes. 5.8 Grounding/equipotential bonding of the e-container The equipotential bonding within the e-container and between the individual container segments shall be based on the Cable List and the Grounding Layout (Annex 4). The containers, platforms and staircases shall be included into the grounding concept of the entire plant on the basis of the Grounding Layout.

EQUIPMENT MANUAL



6 Construction of cable ways and cable laying 6.1 Installation of cable trays Cable tray systems consisting of cable ladders or wide-span cable ladders are used for supporting the cables on the main routes. The installation shall be carried out on the basis of the Cable Trays drawings (Annex 5) taking the local conditions and minimum bending radii into consideration. 6.1.1 Separation The cable trays shall be separated using a non-thermal process (sawing or cutting). The cutting sites shall be deburred after the separation and provided with the corrosion protection specified by the customer. 6.1.2 Fastening The cable trays shall be fastened on a substructure which will be chosen depending on the kind of the supporting system to be installed, the specifications of the cable tray manufacturer and the constructive conditions of the cable tray route. The Installation Details for the Cable Trays (Annex 3) provide the technical specifications for each cable tray (kind of fastening, covering and use of separation sheets) as well as the constructional conditions. The cable trays shall be linked among each other by means of fittings, joint connectors, hinge connectors or angle connectors depending on the course of the cable tray route. Welding connections between the trays are not permissible. The cable trays shall be fastened to the substructure using round-head screws. Welding connections or other fastening types can only be used if requested or approved by the customer. Power and control cables shall be laid separately in separate cable tray systems or, if only one cable tray system is used, a separation sheet shall be used. The separation sheets shall be overlapping and be riveted with each other at the ends. Round-head screws shall be used for fastening the separation sheets in the cable trays. The fastening distances for the trays are specified by the manufacturers. The cable weight and weight of the tray shall be taken into consideration. 6.1.3 Type of cable laying The cables shall be installed as a closed system, meaning there are no spatial interruptions in the cable tray route. Horizontal or vertical changes of direction shall be carried out using curved sections, whereas molded parts shall be used for crossings, intersections or branches. If the cable tray route cannot be carried out using prefabricated molded parts or curved sections, changes of direction, crossings and branches can also be made using angle connectors or hinge connectors.

EQUIPMENT MANUAL



6.1.4 Coverings Cable tray coverings can be designed as flat roof coverings with or without a turning bolt lock. After cable laying, bundling and fastening the respective sections of the cable trays shall be provided with the coverings. If coverings without a turning bolt lock are used, the covering sheet shall be arrested at both sides of the ends and, if longer coverings are used (> 1m), also in the middle on both sides using Parker screws. 6.1.5 Corrosion protection The prefabricated steel parts and sectional steels to be used are made of galvanized material. The corrosion protection shall be restored in accordance with the specifications of the Customer where damages occur on the surface and at welded joints. The welded joints shall be cleaned (removal of welding remainders and rust) after welding and before the corrosion protection coating is applied. The corrosion protection works shall be finished before the cable trays are installed on the girders. 6.1.6 Grounding In general all trays of a cable tray route and the appropriate end saddles and intermediate saddles shall be galvanically connected with each other and be included in the equipotential bonding or protective grounding. The galvanic connection shall be provided using toothed lock washers or grounding jumpers. The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding. 6.2 Installation of conduits and flexible tubes Transmitters, limit switches, motors, loads etc. shall be connected to the main cable tray route as a closed system using conduits and flexible tubes. The conduits and flexible tubes shall be selected in accordance with the number and diameter of the cables to be laid Steel pipes and flexible metal tubes shall be used for that. The installation shall be carried out in accordance with the local conditions and in due consideration of the minimum bending radii. 6.2.1 Separation Conduits shall be separated by means of a hand saw, angle grinder or power saw. After separation the cutting sites shall be deburred. 6.2.2 Fastening The conduits shall be fastened on mounts by means of clips. These mounts shall be clamped or screwed to the main structure and can be welded to auxiliary structures. The connection between the conduits and the field devices shall be made by a flexible tube. Tube couplers shall be used as adapter pieces. In order to fasten the conduits to sheet walls 5 mm thick distance pieces shall be used. These distance pieces can be made of flat steel.

EQUIPMENT MANUAL



6.2.3 Fastening distances The fastening distances for the conduits are listed in the following table:

Conduit diameter / Inches Maximum fastening distance

Feet m (approx.)

1/2 and 3/4 6.5 2

1 and 1 1/2 8 2.5

2 10 3

3 and 4 12 3.5

EQUIPMENT MANUAL



6.2.4 Corrosion protection The prefabricated steel parts and steel pipes to be used are made of galvanized material. The corrosion protection shall be restored in accordance with the specifications of the Customer where damages occur on the surface and at welded joints. The welded joints shall be cleaned (removal of welding remainders and rust) after welding and before the corrosion protection coating is applied. 6.2.5 Grounding In general all conduits shall be included in the equipotential bonding or protective grounding. The galvanic connection shall be provided using toothed lock washers or grounding jumpers. The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding.

EQUIPMENT MANUAL



6.3 Cable laying 6.3.1 General When the cables are laid it must be ensured that the cables are laid without any twist. If the cables are laid by a machine, the permissible mechanical load (as specified by the cable manufacturer) must not be exceeded. It must always be ensured that the transmitter cables are laid separately from the power cables. Before the cables of the same cross-section are laid, the person responsible for cable laying has to select the cable drums and determine the cable lengths that are taken from the appropriate drums. This should avoid a waste of cables or that rest pieces of various drums have to be joined together to become one cable length. The following auxiliary devices shall be used for cable laying:

- cable drum winches - cable reel cars - cable coilers

The cables shall be reeled off from the cable drum from above. for which the drum shall be positioned in such a way that the arrow showing the reeling direction indicates in the direction opposite to the direction of rotation. The cable drum shall be jacked up using a shaft with cable drum winches and, when heavy cable drums are used, on hydraulic cable supports or cable reel cars. The cable drum winches must have a safe base. It must be possible to brake the cable drum at any time in order to prevent a further reeling-off and by that a breaking of the cables when the drum is stopped immediately. A simple plank can be used as a brake, if necessary. Smaller cable rings can be rolled out for laying. Larger cable rings shall be reeled off from a cable coiler or from a rotating disk on which they lie. 6.3.2 Smallest permissible bending radii The minimum bending radii specified by the cable manufacturers shall be observed. 6.3.3 Cable laying in conduits Cables must not be bent, compressed or pulled over sharp edges when being laid in conduits. 6.3.4 Cable laying in cable trays As for cable laying in trays, bending, compressing and pulling over sharp edges shall be avoided. The cables shall be laid in such a manner that the cables with the largest diameter are laid first. The cables shall be fastened in the cable trays by means of cable clips or similar fasteners. Cable ties are not permissible for fastening (only bundling is permissible). When the cables are laid horizontally and up to an inclination of 10% within the cable tray, the cables shall be bundled using UV-resistant cable ties and to be fastened at the cable tray ends, offsets or intersections in cable loops using cable clips or similar fasteners. When the cable trays run vertically or with an inclination of >10%, cable clips or similar fasteners shall always be used.

EQUIPMENT MANUAL



The fastening distances are defined in the following table:

Type of laying Fastening distance

horizontal to inclined = 10% 10m

inclined >10% 5m

vertical 1m

EQUIPMENT MANUAL



7 Installation of the electrical equipment 7.1 Installation of transformers 7.1.1 Transport The transport and placing of the transformers in the transformer boxes shall be carried out in accordance with the transport technology specified by the manufacturer (Annexes 24 and 25). The transformers shall be set up using a mobile crane. The following criteria shall be taken into consideration for the selection of the appropriate lifting accessories:

- permissible load - last check

7.1.2 Installation and fastening of the 6 MVA transformers The transformers have to be completed after the transport packaging has been removed. The completion of the transformers and the implementation of all the necessary tests shall be carried out by a company listed under item 10 – List of companies. The transformers shall be installed on the respective substructure on the oil sump for which the specifications given in the User's Manual Synchronous Machine AMZ 1250WW12 LAB in Annex 22 shall be met. They have to be arrested in such a way that a horizontal and vertical shift is impossible. Cable racks or the like shall be installed for the connection of primary and secondary cables. After the installation of the transformers the DD covers at the cable connection boxes shall be replaced by covers with ROXTEC bushings (Annex 12 Sheet 3 to 4). 7.1.3 Installation and fastening of the 2 MVA transformers After the transport packaging has been removed the terminal boxes delivered separately shall be installed on the primary and secondary sides. The transformers shall be installed on the respective substructure on the oil sump. They have to be arrested with M12 anchor bolts using the eight mounts provided by the manufacturer. (The anchor bolts are delivered by the erection company.) Cable racks or the like shall be installed for the connection of primary and secondary cables. After the installation of the transformers the DD covers at the cable connection boxes shall be replaced by covers with ROXTEC bushings (Annex 12 Sheet 1 to 2). 7.1.4 Grounding The transformers shall be included visually into the grounding system using a grounding jumper. The grounding cables shall be laid in accordance with the Cable List and Grounding Layout (Annex 4). The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding.

EQUIPMENT MANUAL



7.2 Installation of motors 7.2.1 Transport The transport of the motors shall be carried out in accordance with the transport technology specified by the manufacturer (Annex 22). The motors shall be transported by mobile cranes. The following criteria shall be taken into consideration for the selection of the appropriate lifting accessories:

- permissible load - last check

7.2.2 Installation and fastening of the 2.5 MW motors The motors have to be completed after delivery. The completion of the motors and the implementation of all the necessary tests shall be carried out by a company listed under item 10 – List of companies. The motors are delivered with half a coupling which is mounted on the motor shaft before the motors are installed on a motor stand. The motors shall be placed on a construction provided for that reason. Aligning and fastening shall be carried out in accordance with the manufacturer's specifications (Annex 22). After the installation of the motors the DD covers at the cable connection boxes shall be replaced by covers with ROXTEC bushings (Annex 12 Sheet 5). 7.2.3 Installation and fastening of the 500 kW motor The motor is delivered with half a coupling which is mounted on the motor shaft before the motor is installed on a motor stand. The motor shall be placed on a construction provided for that reason. Aligning and fastening shall be carried out in accordance with the manufacturer's specifications (Annex 34). . 7.2.4 Grounding The motors shall be included visually into the grounding system using a grounding jumper. The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding.

EQUIPMENT MANUAL



7.3 Installation of boxes 7.3.1 General The distributed boxes, terminal boxes, local control boxes and sockets shall be selected in accordance with the relevant list of equipment. 7.3.2 Distributed boxes and terminal boxes The boxes shall be installed in accordance with the Installation Diagram (Annex 2, 6, 7 and TAKRAF-drawing 42016971) at the places of installation agreed upon with the Customer. The boxes shall be set up on supports made of U-steel. These supports shall be installed on girders fastened below the walkway (Annex 17). The distributed RIO boxes shall be installed on a bracket provided by the machine-building contractor. In order to prevent the boxes from vibrating their upper parts shall be fixed at the structure. If during the installation the handrails of the guardrails are opened, they shall be properly closed and fastened again after the installation of the boxes . Smaller terminal boxes can also be installed at mounts between the hand and knee rails. Below the boxes a possible strain relief for the cables using cable clips or the like (cable ties are not allowed) shall be provided. 7.3.3 Local control boxes The local control boxes shall be installed in accordance with the Installation Diagram (Annex 2, 6, 7 and TAKRAF-drawing 42016971) at the places of installation agreed upon with the Customer. The boxes shall be installed on mounting sheets fastened to a bracket that has been provided by the machine-building contractor. These supports shall be installed on girders fastened below the walkway. In order to prevent a vibration of the boxes, their upper parts shall be fixed at the structure. Below the boxes a possible strain relief for the cables using cable clips or the like (cable ties are not allowed) shall be provided. 7.3.4 Junction boxes, transmitter boxes Junction boxes and transmitter boxes shall be screwed on mounting sheets. Depending on the structural conditions the mounting sheet shall be screwed on at the angular side and in accordance with the Installation Diagram (Annexes 2, 6, 7 and TAKRAF-drawing 42016971). The box should possibly be installed in a horizontal position. In case of a vertical installation the screw joints shall be arranged downwards or to the side. 7.3.5 Grounding Junction boxes and terminal boxes in metal design shall generally be included in the equipotential bonding. In addition to that the protective conductor carried along shall be led over the terminal to the enclosure. The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding.

EQUIPMENT MANUAL



7.4 Installation of push buttons, transmitters, limit switches and signaling devices 7.4.1 General Push buttons, transmitters, limit switches and signaling devices shall be installed in accordance with the Installation Diagram (Annexes 2, 6, 7 and TAKRAF-drawing 42016971) and depending on the local conditions. The push buttons, transmitters, limit switches and signaling devices shall be selected in accordance with the relevant list of equipment 7.4.2 Push buttons and switches Outdoor push buttons and switches shall be screwed on mounting sheets and fastened at the guardrail post or at a wall using the mount provided by the machine-building contractor. Indoor push buttons and switches can be fastened directly at the wall. If blind rivet nuts are used, it must be ensured that this rivet connection does not provide an equipotential bonding. 7.4.3 Pull-rope switches The pull-rope switches shall be installed in a distance of 30m in the range of the driving station and return station and in a distance of 50m on brackets provided by the machine-building contractor on both sides along the conveyor roads. In the range of the cable trays the boxes containing Dupline modules for the pull-rope switches shall be installed on mounting sheets. The connection between the box with the Dupline modules and the pull-rope switches shall be made through pipes laid in the ground and conduits and flexible tubes. The end points for the pull-rope shall be installed in the middle between the pull-rope switches. The pull-rope is led through pull-rope eyelets. It shall be installed as specified in the documentation of the manufacturer. 7.4.4 Misalignment switches The misalignment switches shall be installed on brackets provided by the machine-building contractor on both sides along the conveyor roads. In the range of the cable trays the boxes containing Dupline modules for the misalignment switches shall be installed on mounting sheets. The connection between the box with the Dupline modules and the misalignment switches shall be made through pipes laid in the ground and conduits and flexible tubes. The bypass switches for misalignment shall also be installed on the mounting sheets provided for the boxes with the Dupline modules. 7.4.5 Limit switches Limit switches and the appropriate rulers shall be installed on brackets by the machine-building contractor. 7.4.6 Tachogenerators, incremental transmitters, absolute value transmitters These transmitters shall be installed by the machine building contractor depending on the purpose of use . 7.4.7 Overflow probes The overflow probes shall be installed by the machine building contractor at brackets in the transfer area of belt conveyors.

EQUIPMENT MANUAL



7.4.8 Belt damage detectors These detectors shall be installed by the machine building contractor on mounts depending on the purpose of use. 7.4.9 Photoelectric switch The photoelectric switch shall be installed at an appropriate place on a mounting sheet. The four cardinal directions and the possible incidence of light from an artificial light source shall be taken into consideration for this. 7.4.10 Start-up warning In the range of the drives these signaling devices shall be installed on every other mounting sheet for the boxes containing the Dupline modules for the pull-rope switches. In the tunnel the signaling devices shall be installed at the cable tray above every other box with Dupline modules for the pull-rope switches. A good visibility shall be ensured (Annex 2). 7.4.11 Grounding Push buttons, transmitters, limit switches and signaling devices in metal design shall always be included in the equipotential bonding. In addition to that the protective conductor carried along shall be led over the terminal to the enclosure. The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding.

EQUIPMENT MANUAL



7.5 Installation of sockets 7.5.1 General The sockets shall be installed in accordance with the Installation Diagram (Annex 2, 6 and 7), the type, and the local conditions. The places of installation of special sockets (vulcanization sockets) have to be agreed upon with the Customer. The sockets shall be selected in accordance with the relevant list of equipment. 7.5.2 Outdoor sockets The sockets shall be installed on mounting sheets. The mounting sheets shall be installed on mounts at the guardrail or at auxiliary structures at the walkway depending on their size and the purpose of use (Annex 1). 7.5.3 Indoor sockets Indoor sockets can be fastened directly at the wall. If blind rivet nuts are used, it must be ensured that this rivet connection does not provide an equipotential bonding. 7.5.4 Grounding Sockets in metal design shall always be included in the equipotential bonding. In addition to that the protective conductor carried along shall be led over the terminal to the enclosure. The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding.

EQUIPMENT MANUAL



7.6 Installation of lighting fittings in the range of the e-containers 7.6.1 General The lighting fittings shall be installed in accordance with the Installation Diagram (Annex 8), the specified type and the local conditions. The lighting fittings shall be arranged in such a way that a uniform illumination and the locally required illumination level are ensured and the specifications of the manufacturer are observed. The lighting fittings shall be selected in accordance with the relevant list of equipment. 7.6.2 General lighting Side-mounted pole luminaires shall be used for the general illumination of walkways and staircases in the range of the containers. These luminaires shall be installed at 2m long 1 1/2 inch steel pipes. The steel pipes shall be fixed by mounts preferably at the guardrail (Annex 1). 7.6.3 Safety lighting LED safety luminaires shall be used for the safety lighting in the range outside the containers. The safety luminaires shall be installed on mounting sheets at the guardrail posts (Annex 1). 7.6.4 Grounding Lighting fittings in metal design shall always be included in the equipotential bonding. In addition to that the protective conductor carried along shall be led over the terminal to the enclosure.

EQUIPMENT MANUAL



8 Installation technology 8.1 Cable entry/Cable bushing 8.1.1 Cable glands Tube cable glands shall be used as cable entries into boxes and electrical devices. The cable glands shall be selected in accordance with the cable diameter and the bore hole in the box or the electrical device. If the bore hole or the thread in the casing are too small, extension glands shall be used. If the bore hole or thread are too big, reducers/adapters shall be used. If metric threads are provided in the casings, adapter pieces for the treads shall be inserted on the inch cable glands. 8.1.2 ROXTEC cable bushing ROXTEC cable bushings shall be used for the entry of MV- and power cables into transformers and belt drive motors. ROXTEC frames are provided in the cable connection casing or have to be exchanged by replacing DD covers with sheets provided with ROXTEC frames. The ROXTEC frames shall be filled with ROXTEC-RM modules. It has to be ensured that the stay plates are fitted in between each layer of modules. ROXTEC wedges shall be fitted in and tightened in order to ensure the tightness and proper fastening. The instructions for the installation of the ROXTEC cable entries (Annex 41), which are attached to the packaging, shall be observed.

EQUIPMENT MANUAL



8.2 Sealing ends 8.2.1 Medium-voltage sealing ends (1 - 33kV) Shrinking sealing ends are mainly used as sealing ends for MV cables. The sealing ends shall be selected from the list of equipment for the electrical engineering. The sealing ends shall be carried out in accordance with the installation instructions attached to the packaging. After the MV sealing ends have been made, the individual cores shall be marked by color coding in accordance with the specifications of the Customer. 8.2.1.1 MV sealing ends in switchgear systems and boxes After the sealing end has been made, it shall be provided with a strain relief in the cable connection compartment. Attention must be paid to the clearance between the individual cores when the cables are bent and connected. 8.2.1.2 MV sealing ends in motors After the sealing end has been made, it shall be fastened with the strain relief of the terminal box. Attention must be paid to the clearance and the bending radius of the individual cores when the cables are bent and connected. 8.2.2 Low-voltage sealing ends (>1 kV) 8.2.2.1 LV sealing ends in switchgear systems Starting from the cable floor in the cubicle the cables are led to the height of the respective connection point, then placed and fastened to the C-bars using cable clips. The active cores shall be connected to screw terminals using cable lugs or to terminal blocks using core end sleeves. The N-conductor and the PE-conductor shall be connected to the respective busbar using cable lugs. When parallel cables are connected, the individual active cores shall be marked by color coding in accordance with the specifications of the Customer. 8.2.2.2 LV sealing ends in motors The cable entry into the terminal box of the motor shall be carried out by a cable gland or a cable entry gland. The end isolation of the cable shall be stripped about 1 cm above the cable entry. The cables shall be bent and adjusted before the cable lugs are pressed on the cable. It has to be ensured that the minimum bending radius is kept and touching the terminal studs of other active cores is prevented when the cores are connected in the terminal box. 8.2.2.3 LV sealing ends in boxes, switches and sockets The cable entry into boxes, switches or sockets shall be carried out by a cable gland or cable sleeve. If a cable sleeve is used for the cable entry, the cable shall be provided with a strain relief either in front of the sleeve or in the enclosure. The end isolation of the cable shall be stripped about 1 cm above the cable entry. The cables shall be bent and adjusted before the cable lugs are pressed on the cable. It has to be ensured that the minimum bending radius is kept and touching the clamping points of other active cores is prevented when the cores are connected.

EQUIPMENT MANUAL



8.3 Connections 8.3.1 Compression-type cable lugs The cores shall be bared depending on the cable lug used. The bared range of the cores has to be clean and without any residuals of the insulating covering. The core has to be inserted properly and placed with the correct depth. Cutting off single cores and thus reducing the cross-section is not allowed. The compression tool specified by the manufacturer of the cable lugs shall always be used for pressing the cable lugs. The compression shall be carried out at the respectively marked position of the compression-type cable lug or in accordance with the specification in the respective instructions for use of the compression tool manufacturer. If several compression actions are necessary, the compression shall always be carried out from the connection flange to the end of the sleeve. If hydraulic compression tools are used, the compression shall continue until the compression parts touch each other. If manual compression tools are used, the built-in forced blocking ensures a continuous optimum compression depth. It must be ensured that the surface of the connection points in the range of the cable lugs is even and the tightening torques are kept in accordance with the following table.

Screw-type thread

Marking DIN 267

Steel High-strength copper alloy yield stress >|52 da N/mm²

Tightening torque Tightening torque

for cable tapping

blocks and cable connectors

for cable lugs

for cable tapping


for cable lugs

da Nm 1) da Nm 1) da Nm 1) da Nm 1)

M 5 8.8 0.5 0.5

0.44 0.44 10.9 0.75 0.75

M 6 8.8 0.9 0.9

0.74 0.74 10.9 1.25 1.25

M 7 8.8 1.5 1.5

1.25 1.25 10.9 2.1 2.1

M 8 8.8 2.2 2.2

1.8 1.8 10.9 3.1 3.1

M10 8.8 3.1 4.4

3.1 3.7 10.9 3.1 6.2

EQUIPMENT MANUAL



Screw-type thread

Marking DIN 267

Steel High-strength copper alloy yield stress >|52 da N/mm²

Tightening torque Tightening torque

for cable tapping


for cable lugs

for cable tapping


for cable lugs

da Nm 1) da Nm 1) da Nm 1) da Nm 1)

M 12

5.6 3.3

6.4 8.8 7.5

10.9 10.5

1) .. 1 da N = 10N ≈ 1kp The specified tightening torques apply to bright, galvanized, cadmium-plated and refined screws. 8.3.2 Crimping cable lugs The cores shall be bared depending on the cable lug used. The bared range of the cores has to be clean and without any residuals of the insulating covering. The core has to be inserted properly and placed with the correct depth so that the insulating sheath encloses the insulation of the core. Cutting off single cores and thus reducing the cross-section is not allowed. Crimping shall be carried out in accordance with the specification in the respective instructions for use of the compression tool manufacturer. If manual compression tools are used, the built-in forced blocking ensures a continuous optimum compression depth. It must be ensured that the surface of the connection points in the range of the cable lugs is even and the tightening torques are kept in accordance with the table under 8.3.1. 8.3.3 Core end sleeves The cores shall be bared depending on the core end sleeve used. The bared range of the cores has to be clean and without any residuals of the insulating covering. The core has to be inserted properly so that the insulating sheath encloses the insulation of the core. Cutting off single cores and thus reducing the cross-section is not allowed. Crimping shall be carried out in accordance with the specification in the respective instructions for use of the compression tool manufacturer. If manual compression tools are used, the built-in forced blocking ensures a continuous optimum compression depth.

EQUIPMENT MANUAL



8.4 Shield connection Basically the shield shall be connected in accordance with the specifications of the Customer and the installation instructions of the manufacturer of the device. The shields of shielded power cables (cables to converter drives) shall be connected on both sides in the casing of the respective device or cubicle in accordance with the specifications of the manufacturer. The shields of shielded control cables shall only be connected on one side on the shield bus in the higher-level control system.

EQUIPMENT MANUAL



8.5 Grounding / Equipotential bonding All parts of the plant shall be conductively connected with each other in the grounding and equipotential bonding system. The Grounding Layout (Annexes 4, 9, 10 and 11) provides the basis for grounding and equipotential bonding. The e-container and its substructure shall be connected to the foundation ground connector in accordance with the Grounding Layout. In general all cable trays shall be galvanically connected among each other and the appropriate intermediate saddles with each other and be included in the grounding and equipotential bonding. The galvanic connection shall be provided using toothed lock washers or grounding jumpers. All electrical devices, motors, thrustors and cabins installed outdoors as well as the necessary piping installations shall be included in the grounding and equipotential bonding which can be achieved by the protective conductor of the connection cable, toothed lock washers or grounding jumpers. Grounding jumpers shall be used for bearings, spherical revolving joints etc. on structures with relative movements in order to establish the same potential.

EQUIPMENT MANUAL



8.6 Lettering and labeling 8.6.1 Cables Basically both cable ends shall be provided with the cable number given in the cable list. UV-resistant and abrasion-proof cable labels shall be used throughout the project. The clearly visible cable labels shall be fixed beneath the cable entry of outdoor devices and directly on the cables within the switchgear. 8.6.2 Cores The cores shall be marked using an abrasion-proof labeling system. All control cores coming from outside shall be marked in the switchgears. This also applies to intermediate terminal boxes and boxes with distributed devices. The single core shall be marked with the complete designation that is visible on the terminal using cable marking sleeves. 8.6.3 Electrical equipment All transmitters, field devices, motors, thrustors and loads shall be provided with their equipment identifiers. Type and size of the delivered designation labels are given in the enclosed order list. Labeling shall be carried out on Resopal signs with alphanumerical lettering which shall be fastened preferably above or on the right of the electrical device to be lettered. For drive groups (motors, thrustors, gears with electrical transmitters) all lettering signs can be installed together on one mounting sheet for lettering signs and fastened at a central place in immediate vicinity to the drive group. Fastening on the electrical devices is not allowed. The Resopal signs shall be fixed using 3 mm self-tapping screws on the places provided for that reason on mounting sheets and supports. 8.6.4 Electrical operating areas The electrical operating areas shall be designated and labeled in accordance with the Chilean standard.

EQUIPMENT MANUAL



8.7 Connection techniques 8.7.1 Screwed connection 8.7.1.1 General The screwed connection shall be used to fasten mounting parts and devices at steel structures where welding is not allowed or where welding works would increase danger. Basically screwed connections shall be secured by means of spring lock washers or toothed lock washers in order to prevent the connection from loosening. When the structures are subject to severe shocks or vibrations, they can be additionally secured using a counter nut. It has to be ensured that the nuts are at least fully filled or the thread of the nut projects maximal 3 turns of the thread. 3 Gewindegänge übersteht. 8.7.1.2 Non-conductive electrical connection If screw connections are used to fasten mounting part (e.g. mounts for plastic pipes, plastic enclosures etc.), they shall always be provided with a washer and a spring ring with the spring ring securing the screwed connection. Order of the fastening elements: screw head – washer – mounting part – mount – washer – spring ring – nut 8.7.1.3 Conductive electrical connection To establish galvanic connections between pieces of the electrical equipment with metal enclosures and mounts as well as cable-bearing systems (trays, conduits) and structures, the screwed connection for high quality surface protection parts (galvanized) shall be established by washer, and for painted surfaces by a toothed lock washer. Order of the fastening elements – mounting part (painted) and mount (painted): screw head – toothed lock washer – mounting part – mount – toothed lock washer – nut Order of the fastening elements – mounting part (galvanized) and mount (color): screw head – washer – mounting part – mount – toothed lock washer – nut Order of the fastening elements – mounting part (color) and mount (galvanized): screw head – toothed lock washer – mounting part – mount – washer – spring ring – nut 8.7.2 Welded connection Welded connections are rigid and permanent connections used to fasten supports, brackets and frames at auxiliary structures. In general welded connections must only be performed by qualified persons who have a valid welding certificate. Before the welding works can start the persons performing the work have to get informed about the applicable safety and fire regulations and obtain a written approval (welding permit) from the responsible authority for this working area. The safety measures specified on the welding permit (extinguishing agents, fireguard, and alarm indication devices) shall be taken before the welding starts.

EQUIPMENT MANUAL



For electric welding the return conductor shall always be connected with the work piece to be welded. Steel or other parts of the structure shall not be used for that. Before welding works are carried out at steel mounting parts or galvanized steel sections, the zinc coating in the high-temperature area of the weld shall be removed. Welding works at galvanized or corrosion-protected steel pipes or open hollow sections are only permitted at such places where the quality can be re-established entirely, e.g. at the pipe ends (head half clip at steel conduit must only be tack welded punctually from outside). Coats of paint in the welding range shall be removed before the welding. If no welding specifications are given in the drawings, the weld shall always be carried out as a closed circumferential weld. If welding works are necessary at parts of the supporting structure or hollow s sections, welding shall be approved by the responsible construction manager for the mechanical work. 8.7.3 Riveting 8.7.3.1 General Riveting is used in particular for the installation of electric rooms and recreation rooms as well as for fastening lettering signs. Two variants are used for this fastening method:

- Fastening or connection by means of blind rivets - Fastening by means of blind rivet nuts

Both variants are used when during the installation of the electrical equipment and cable supporting systems access is only possible from one side, e.g. at insulated sheet walls, in double floors or when other fastening modes are not permissible. When electrical devices are fastened by rivets, it must be ensured that the electrical device is included in the equipotential bonding through the protective conductor of the cable or grounding jumpers. The riveted joint is not regarded as equipotential bonding.

EQUIPMENT MANUAL



8.7.3.2 Blind rivet connection This riveted joint is implemented in one cycle using the NTX type blind rivet pliers The blind rivets must always be selected depending on the material strength to be riveted

Rivet diameter x length of rivet shank / mm

Material strength to be riveted / mm

Bore hole diameter / mm

3 x 5 1.5 – 2.5

3,1

3 x 6 2,5 – 3.5

3 x 7 3.5 – 4.5

3 x 8 4.5 – 5.5

3 x 10 5.5 – 7.0

4 x 6 1.5 – 3.0

4.1

4 x 8 4.0 – 5.0

4 x 10 5.0 – 6.5

4 x 12 6.5 – 8.5

4 x 16 10.5 – 12.5

4 x 20 14.5 – 16.5

5 x 8 3.0 – 4.5

5.1

5 x 10 4.5 – 6.0

5 x 12 6.0 – 8.0

5 x 16 10.0 – 12.0

5 x 20 14.0 – 16.0

EQUIPMENT MANUAL



8.7.3.3 Blind rivet nut connection The connection are carried out using the hand riveter GBM 10 or GBM 30. The hand riveter GBM 10 is used for the blind rivet nuts M 4 to M 6 whilst the hand riveter GBM 30 is used for the blind rivet nuts M 5 to M 10. The blind rivet nuts shall always be selected in accordance with the material strength to be riveted

Dimension Material strength to be riveted / mm

Hand riveter Bore hole

diameter / mm GBM 10 GBM 30

M 4 x 6 x 10 0.25 – 1.0 X X

6.1 M 4 x 6 x 11 1.0 – 2.0 X X

M 4 x 6 x 12 2.0 – 3.0 X X

M 4 x 6 x 13 3.0 – 4.0 X X

M 5 x 7 x 10.5 0.25 – 1.0 X X

7.1 M 5 x 7 x 11.5 1.0 – 2.0 X X

M 5 x 7 x 12.5 2.0 – 3.0 X X

M 5 x 7 x 13.5 3.0 – 4.0 X X

M 6 x 9 x 14 0.25 – 1.5 X X

9.1 M 6 x 9 x 15.5 1.5 – 3.0 X X

M 6 x 9 x 17 3.0 – 4.5 X X

M 8 x 11 x 15.5 0.25 – 1.5 X

11.1 M 8 x 11 x 17 1.5 – 3.0 X

M 8 x 11 x 18.5 3.0 – 4.5 X

M 10 x 12 x 16 0.25 – 1.5 X

12.1 M 10 x 12 x 17.5 1.5 – 3.0 X

M 10 x 12 x 19 3.0 – 4.5 X

EQUIPMENT MANUAL



8.8 Corrosion protection The prefabricated steel parts and sectional steels to be used are made of galvanized material. The corrosion protection shall be restored in accordance with the specifications of the Customer where damages occur on the surface and at welded joints. The welded joints shall be cleaned (removal of welding remainders and rust) after welding and before the corrosion protection coating is applied. The corrosion protection works shall be finished before the cable trays are installed on the girders.

EQUIPMENT MANUAL



9. Measurements to be carried out by the erection company 9.1 Insulation measurement Required measurements An insulation measurement is a measurement of insulation resistance of electrical equipment, e.g. cables, for assessing their functionality and safety. Insulation measurements are required for new systems, refurbishments, modifications, repairs and in cases of trouble. Furthermore repeated tests are specified on a regular basis for commercial plants because insulation values can get worse by aging, the influence of weather and humidity, damages and for other reasons. Measuring process The insulation resistance shall be measured between each active conductor and the protective conductor or the ground conductor. As the insulation resistance is getting smaller and smaller with the length of the cables the rule of thumb is that only that part of the plant after the last upstream fuse shall be used for an assessment. That means for installations that each individual circuit must keep the minimum insulation resistance; the entire plant, however, can have a lower value. Measuring procedure The measuring shall be implemented by individual steps in the following order: protective conductor (PE) against neutral (N), and then protective conductor against all L-conductors (L1, L2, L3). The measurement shall be carried out by feeding a high measuring voltage at a low capacity of the power source for a short time in order to avoid a fire. The breaking down of the measuring voltage is then an evidence for an insulation fault or a flashover. Qualified measuring procedures are specified in national and international standards (EN, VDE, ÖVE). Measuring voltage Direct voltage shall be used for the measurement to exclude capacitive effects. The measuring voltage shall at least be as high as the operating voltage of the plants. Common values are 100 V for telecommunication and extra-low-voltage plants, and 1000 V for low-voltage motors. In accordance with VDE 0100 T 600 the test voltage can be reduced to 250 V if an overvoltage arrester/protection is provided. Measuring instruments Measuring instruments to be used for insulation measurement are, for example, magneto generators that generate the necessary high measuring voltage by a small generator driven via a gearbox and a hand crank. There are also measuring devices with integrated electronic oscillators that transform the battery voltage via a transformer and then rectify and smooth it again. The measuring results are indicated by pointer instruments or digitally.

EQUIPMENT MANUAL



9.2 Measurement of loop impedance for socket and lighting system The loop impedance is the sum of all impedances in a closed conducting path through which a fault current flows in case of an insulation fault in an electrical equipment (short circuit to exposed conductive part). After a low-voltage plant has been erected, a measurement of the loop impedance shall be carried out using the mains frequency, amongst other things, to check the compliance with the shutdown conditions. This measurement is particularly required when the protection for direct contact is provided by automatic shutdown using overcurrent protection devices. The measuring results shall be recorded in the test reports. The measurements for the loop impedance must only be implemented using the measuring instruments provided for them.

EQUIPMENT MANUAL



10 List of companies The following is a list of works to be carried out by special companies. Company Transport and installation of e-container at the site Connection and commissioning of air-conditioners in the e-container Connection and commissioning of fire distinguishing plant in the e-container Construction and commissioning of coolant pipes to the converter systems and motors Construction and commissioning of overpressure devices at the e-container Provision and testing of MV sealing ends (incl. reports) Provision and testing of fibre-optic sealing ends (incl. reports) Completion and testing of oil-insulated transformers (incl. reports) Placing and adjusting of motors (incl. reports) Specialist required for

Equipment Construction Commissioning Recommended Company ACS 6000 No Yes ABB Swizerland Sychronous motors No Yes ABB Finnland Fire extinguishing system Yes Yes Integrol S.A.

Av. Galvarino N° 7641, Quilicura Santiago, Chile

liquid cooling system No

Yes Drechsler Germany

general Electrical and Instrumentation system

Yes Yes ABB Cottbus

MV SGR No Yes

Yes ABB Ratingen

LV SGR No No LV MCC No No UPS No No Battery (DC-unit) No No E-house & auxiliaries No No Transformers Yes Yes Motors Yes Yes

EQUIPMENT MANUAL



Annex Drawing-No. Document Annex 1 9940-00-2-1051 Installations Details Electrical Equipment Annex 2 9940-00-2-1052 Installations Details Instrument Field devices Annex 3 9940-00-2-1053 Installation Details Cable Trays Annex 4 9940-63-2-1153 Interior Grounding Layout 03763-SEL-01 Annex 5 9940-63-2-1154 Cable Trays Layout CTR-05/CTR-11 Annex 6 9940-63-2-1158 Equipment & Instrument Location CTR-11 Annex 7 9940-63-2-1159 Equipment & Instrument Location CTR-05 Annex 8 9940-63-2-1160 Equipment & Instrument Location 03763-SEL-01 Annex 9 9940-00-2-1173 Grounding Details General Annex 10 YX00052-03762-EEE-DG-D3-D004 Conveyor Grounding CTR-11 Annex 10 YX00052-03911-EEE-DG-D3-D001 Conveyor Grounding CTR-11 Annex 11 YX00052-03762-EEE-DG-D3-D003 Conveyor Grounding CTR-05 Annex 12 9940-00-2-1054 Prefabricated Construction Material Annex 13 9940-63-3-1002 Ethernet Block Diagramm Annex 14 9940-63-3-1003 Profibus Block Diagram Annex 15 9940-63-3-1004 Modbus RTU Block Diagram Annex 16 9940-63-2-1180 ROXTEC-Cable entrys Annex 17 9940-63-3-1012 Layout RIO Annex 18 Not Applicable Annex 19 Not Applicable Annex 20 Not Applicable Annex 21 Manual for Container Annex 22 Manual for 2,5MW-Motor Annex 23 Overview Cooling System Annex 24 Manual for Transformer 2MVA Annex 25 Manual for Transformer 6MVA Annex 26 Manual for MV-Switchgear Annex 27 Manual for VFD-Switchgear Annex 28 Manual for 600V-CDC-Switchgear Annex 29 Manual for 400V/600V-CCM-Switchgear Annex 30 Manual for ACS 800-Switchgear Annex 31 Manual for Battery/UPS Annex 32 Manual for Air Condition 23kW Annex 33 Manual for Air Condition 7kW Annex 34 Manual for Motor Baldor 500kW Annex 35 Manual for Overpressure Unit Annex 36 Not Applicable Annex 37 Not Applicable Annex 38 Not Applicable Annex 39 Not Applicable Annex 40 Not Applicable Annex 41 Instruction ROXTEC-Module

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