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MQ13-02-DC-1120-IN0001
Proyecto Quellaveco Fecha 26-Nov-2021
Contrato Q1CO Página 1 de 104
Rev. 2
Este Documento ha sido revisado como se indica abajo, y describe en el registro de revisiones en la
página siguiente. Por favor destruir todas las revisiones previas.
Gerente de Área
Registro de Revisiones
Revisión
Fecha Descripción
N°
0 13/Abr/2020 Construcción
1 04/Jun/2021 Construcción
2 26/Nov/2021 Construcción
Tabla de Contenido
1 ALCANCE ..................................................................................................................................................... 9
1 ALCANCE
El presente documento tiene por alcance, describir las lógicas de control discreto y regulatorio
consideradas para la captación de agua del río Titire, Estación de Bombeo de Titire, Cerro Pelluta y
Poza Caracoles durante la fase de operación normal de estos.
2.1 General
La infraestructura que permite el suministro de agua fresca al Proyecto se encuentra ubicada en
el área llamada Alta Montaña (área 1000 del WBS) que incluye: dos fuentes independientes de
agua (río Titire y río Vizcachas), un sistema de transporte de agua y tres pozas de almacenamiento
que, en conjunto, puede proveer por más de 30 días agua fresca a la planta de Papujune.
Para impulsar el agua desde las fuentes a la planta, se consideran estaciones de bombeos
independientes.
La fuente primaria de agua será el río Titire, del que se extraerá agua en forma permanente
(mientras su caudal así lo permita). La fuente secundaria de agua viene de la presa del río
Vizcachas, que se usará en los períodos en los que del río Titire no se pueda extraer el agua total
requerida (temporada seca).
El sistema de transporte de agua (“pipeline”) opera como un sistema presurizado con fuentes
independientes desde dos estaciones de bombeos, uniéndose en la cabecera común en la estación
de bombeo de Vizcachas y fluye hasta el punto más alto del trazado en el Cerro Pelluta (4820
msnm) que está aproximadamente a 21 km desde la toma de agua del río Titire. Desde el Cerro
Pelluta, el agua fluye en forma gravitacional, parte de este flujo (tubería 8”) entra al tanque 2910-
TK-001, el resto (tubería 24”) se almacena en las pozas de Caracoles. Una estación de choque es
requerida para mantener el gradiente hidráulico y evitar flujo irregular (slack flow).
El sistema de transporte de agua está diseñado para operar con una capacidad de 770 l/s y tiene
una extensión aproximada de 86.5 km
1
La tubería principal (pipeline) tiene una capacidad de diseño general de 2772 m3/h y tiene dos
fuentes de agua fresca, una correspondiente al río Titire donde el agua se capta y se desvía a un
sumidero ubicado en una estación de bombeo. El agua es llevada a la tubería por medio de cinco
bombas verticales en el sumidero.
La otra fuente de agua es de los ríos Vizcachas, donde el agua es recolectada por una presa con
una capacidad de almacenamiento de 60Mm3, y se canaliza a la estación de bombeo de Vizcachas
y luego a la tubería principal.
Dependiendo de los Modos de Operación (Húmedo/ Seco) y la razón de flujo general del pipeline
establecida por el Operador, el pipeline de agua fresca se puede operar solo con el funcionamiento
de la estación de bombeo de Titire, o con el funcionamiento tanto de las estaciones de bombeo
de Titire como de Vizcachas.
A continuación, se entrega una descripción de los diferentes componentes que componen este
sistema:
Las operaciones y el control de la captación del río se realizan a través de las compuertas
y los sensores de flujo en las secciones Presa móvil, sección bocatoma, compuertas
desarenadoras y de purga.
El agua del río Titire que ingresa a la estación de bombeo Titire fluye por gravedad hacia
el sumidero de agua dulce Titire (1120-SU-001). El nivel de líquido se mantiene mediante
la compuerta motorizada 1120-GA-013. La compuerta está configurada para mantener un
nivel suficiente en el sumidero de agua fresca Titire. El agua acumulada en el sumidero
es luego transferida por cinco bombas verticales de etapas múltiples (1120-PU-
001/002/003/004/005) a la tubería.
1
La estación de bombeo Titire funcionará en dos modos, Modo húmedo y Modo seco.
El Pipeline también requiere de la estación choke diseñada para evitar “slack flow”. A
continuación se entrega una descripción de los diferentes componentes que componen este
sistema:
La presión en Cerro Pelluta es monitoreada por el PCS. Hay dos transmisores de presión
1140-PIT-011 y 1140-PIT-008, conectados a los PCS Vizcachas 1130-PC-101 y Titire
1120-PC-101, respectivamente a través de enlaces FO entre las CFUs en Cerro Pelluta y
Vizcachas, y Cerro Pelluta y Titire, los cuales permiten seguir monitoreando la presión si
el PCS de Vizcachas o Titire están inactivos. Los transmisores de presión son instalados
en el punto de elevación más alta en el cerro Pelluta, entre el “pig receiver” de tubería de
24“y el “pig launcher” de tubería de 28”, tal de monitorear la presión ya sea para
indicación de “slack flow” o indicación de bloqueo aguas abajo.
La estación choke realizará pequeños ajustes cuando la presión en Cerro Pelluta esté en el
rango normal de entre 90 a 210 kPag.
Una alarma alta alta (1140-PAHH-010A) activará la detención de las bombas Titire y
Vizcachas cuando la presión sea superior a 480 kPag. La estación choke regulará la altura
requerida para evitar una condición de “slack flow” aguas abajo de Cerro Pelluta.
3 REFERENCIAS
3.1 Diagramas de Flujo
Listado Diagramas de Flujo
N° Documento Descripción
No aplica
3.3 Listados
Listado
N° Documento Descripción
MQ13-02-LI-1120-IN0005 Instrument I/O List
MQ13-02-LI-1140-IN0005 Instrument I/O List
3.6 Terminología
Abreviatura - Término Descripción
“!” Not/Negación
AA Anglo American
CL Cerrado / Closed
Debounce Tiempo que una condición de enclavamiento se debe mantener para que desenergice un
dispositivo (2 a 3 segundos)
Debounce Extendido Tiempo que una condición de enclavamiento se debe mantener para que desenergice un
dispositivo (5 a 10 segundos)
IL Enclavaniento / Interlock
1
Sin perjuicio de la funcionalidad configurada, el operador deberá cumplir el Estándar de aplicación de By Passes definido por AA
OP Abierto/Open
OPN Abriendo/Openning
2
P (Process By Pass) Corresponde a la acción de “By Passear” un interlock a petición del personal de procesos de
la planta.
Este tipo de By Pass no expira automáticamente, y puede ser activado mientras el equipo está
energizado.
Este tipo de By Pass puede ser sólo activado por el personal de procesos que cuente con los
debidos privilegios configurados en el Sistema de Control.
PERMIT (Permisivo) Corresponde a una condición que impedirá la enegización del equipo mientras éste esté
detenido. Este tipo de condición previene que un equipo se energice, pero no tiene efecto sobre
él una vez que éste se encuentra energizado.
En las tablas de Interlock, corresponde a la condición que de estar presente, o permite partir.
PROTECT (Enclavamiento) Corresponde a un enclavamiento que desenergizará el equipo. Este tipo de enclavamiento no
se liberará después que la condición de enclavamiento se ha superado. La liberación de éste
sólo será posible una vez que la condición se ha superado y la condición reconocida
(reseteada). Una vez superada y reconocida la condición, el equipo permanece desenergizado
hasta que un nuevo comando de arranque es dado.
Este tipo de enclavamiento es utilizado para proteger la seguridad de las personas y los equipos
(Ej. Alta temperatura de descansos, enclavamientos de seguridad, etc.). Este tipo de
enclavamientos, por defecto, no podrán ser habilitados para ser By Paseados.
En las tablas de Interlock, corresponde a la condición que de estar presente, enclava al equipo
de proceso.
2
Sin perjuicio de la funcionalidad configurada, el operador deberá cumplir el Estándar de aplicación de By Passes definido por AA.
RDY Listo/Ready
SEQRDY Equipo Listo para Partir en Secuencia /Equipment Ready to Start in Sequence
SP Set Point
WATCHDOG Tren de pulsos simétrico de periodo constante (Ej: 3 segundos con estado "1" lógico, y 3
segundos con estado "0" lógico), enviado por PCS a equipo externo con el cual se tiene
enlace de comunicaciones (transferencia de información).
PCS monitorea retorno del tren de pulsos vía enlace de comunicaciones, declarando falla de
comunicaciones (alarma Watchdog), en caso de detectarse que pulso no varió por un periodo
de tiempo.
CH Chute
CY Ciclones / Cyclones
CV Faja / Conveyor
FA Ventilador / Fan
FE Alimentador / Feeder
HE Calefactor / Heater
MO Motor
PU Bomba / Pump
TK Estanque / Tank
4 DESCRIPCION DE CONTROL
La Figura 2 y Figura 3 - Esquema de Control General Sistema de Impulsión Agua Fresca
, muestran los esquemas de control general considerados para la Estación de Bombeo Titire, la línea
de impulsión de Agua Fresca (Estación Chocke, llegada Pozas Caracoles), y la entrega de agua fresca
a la planta Papujune.
1200 m3/hr
SP hacia SP By Pass
SP: 180 kPa
PIC
013B
<
LOOKUP TABLE FIC FY
FLOW PIPELINE SET POINT 014 014
InletPre = f(PipelineFlow)
FIT
014
1140FV014
PIC 800 m3/hr
010A +
M LIT LIT
Note 2 102A
SP: 200 kPa 102B
FIC
PIT PIT 141
010A 010B 1140LV102
FIT
141
1oo3
PIC
018
1140FV141
PIC 800 m3/hr
013A C2
LIT LIT
SP: 130 kPa 101A 101B
M FIC
ESTACION BOMBAS PIC
143
PIT PIT PIT
VIZCACHA 018 011
014
014 FIT
1140LV101 143
M
M M
FIT LIC
1140LV104
1140PV015 268 018
M
PIC
016
1140FV268
M LIT
018
C4
1140PV016 Notes:
1. Pond Discharge can work in the following schema: C1 and C4, or C2 and C4. PLANTA DE
2. Controller 1140‐PIC‐010 will consider a ‐300 kPa and 300 kPa MV span for adjusting will PIC‐018 controller 3930TK002 PROCESOS
PIC
017
3. Controller 1140PIC013A will untruck when 1140FIC014 has taken control of override.
M
3930TK001
1140PV017
Las unidades asociadas a los procesos Bocatoma del Río Titire, Estación de Bombeo Titire, Estación
Reductora de Presión/Choke, Pozas Caracoles C1/C2/C4, y Estanque Alimentación Mina Quellaveco
serán controladas mediante el Controlador 1120-PC-101, mientras que las Unidades Presa Vizcacha y
Estación de Bombeo Vizcachas serán controladas mediante el controlador 1130-PC-101. El presente
documento, describe la lógica de control considerada para el controlador 1120-PC-101, mientas que
la lógica correspondiente al controlador 1130-PC-101, será descrita en el documento Filosofía de
Control – Controlador 1130-PC-101, documento N° MQ13-02-DC-1130-IN0001.
Para mayor información respecto a la Jerarquía de Planta considerada para esta área/controlador, ver
documento:
6 UNIDAD AF_BOCRIOTIT
La unidad AF_BocRioTit está destinada a albergar los equipos que componen la Bocatoma del Río
Titire, considerando sus compuertas principales de desvío (1120-GA-011/12), la compuerta de
regulación del caudal de entrada a la bocatoma (1120-GA-013), y las compuertas utilizadas en la
sección del desarenador (1120-GA-014 @ 017). Considera además, las mediciones de caudal del río
antes y después de la bocatoma, las cuales se utilizan para accionar las compuertas de desvío en caso
de una crecida.
La unidad AF_BocRioTit está compuesta por Siete (7) módulos de equipos, tags 1120GA011,
1120GA012, 1120GA013, 1120GA014, 1120GA015, 1120GA016, 1120GA017, los cuales se
describen a continuación.
PURGE DAMPER
1120-GA-017
Los módulos de Equipos 1120GA011, 1120GA012 tienen por función operar las Compuertas Radiales
localizadas en el río, de forma de desviar el agua hacia la bocatoma. 1
El módulo de Equipos 1130GA013, está destinado operar la válvula de ingreso de agua a la bocatoma,
mientas que los Módulos de Equipos 1120GA014, 1120GA015, 1120GA016, 1120GA017, están
destinados a operar las válvulas motorizadas asociadas al desarenador de la bocatoma.
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
No Aplican Interlocks
Nota
1. El lazo es tipo On/Off. En modo Automático, si el valor del caudal de entrada del río
es mayor al punto de operación por más de 5 minutos, se abre completamente la
1
compuerta 1120-GA-011 (Tracking a 100%). Si el valor del caudal de entrada del río
es menor a punto de operación por más de 5 minutos, el controlador cerrará la
compuerta (tracking a 0%). El punto de operación es de 362.2 m3/s corresponde a la
máxima venida del río.
Cerrará, cuando la medición de caudal del río, medida por el del instrumento
1120-FT-508, esté por debajo de los 362.2 m3/s por 5 min.
solo en casos de aumento significativo del río debido a una crecida, o o para efectuar la limpieza
de sedimentos acumulados en el área del embalse.
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
No Aplican Interlocks
Nota
1. El lazo es tipo On/Off. En modo Automático, si el valor del caudal de entrada del río
es mayor al punto de operación por más de 5 minutos, se abre completamente la
compuerta 1120-GA-012 (Tracking a 100%). Si el valor del caudal de entrada del río
es menor a punto de operación por más de 5 minutos, el controlador cerrará la
compuerta (tracking a 0%). El punto de operación es de 362.2 m3/s corresponde a la
máxima venida del rio.
Cerrará, cuando la medición de caudal del río, medida por el del instrumento
1120-FT-508, esté por debajo de los 362.2 m3/s por 5 min.
Notas:
Nota:
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
No Aplican Interlocks
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
No Aplican Interlocks
Notas:
7 UNIDAD AF_ESTACBBEOTIT
La unidad AF_EstacBbeoTit está destinada a albergar los equipos que componen la estación de
bombeo Titire.
La unidad cuenta con cinco (5) líneas de impulsión, cada una compuesta por bomba de impulsión, un
flujómetro y una válvula de control. Considera además, una línea de recirculación, la cual está
destinada evitar, que el caudal proporcionado por la Estación de Bombeo, exceda el caudal máximo
que permite la línea de transporte principal.
La operación de la Estación de Bombeo Titire considera dos (2) modos de operación: Modo Seco,
Modo Húmedo, los cuales son seleccionados por el operador en función de la información de caudales
obtenidas de la bocatoma, así como el mes del año en que encuentra. Cuando el Sistema de Transporte
de Agua esté trabajando en Modo Seco, el caudal de impulsión requerido es complementado/suplido
1
por el caudal bombeado por la Estación Vizcacha. En modo húmedo por su parte, se considera que
debido a los caudales que presenta el río, no será necesario el aporte de la Estación de Bombeo
Vizcachas.
El PCS se configurará de modo de priorizar el arranque de las bombas con menor cantidad
de horas de operación, por sobre aquellas que presentan mayor cantidad de horas
operando. Las horas de operación de cada bomba deberán estar disponibles para el
1
operador, de forma que él pueda realizar un seguimiento de éstas.
Para tal objetivo, este módulo de equipos trabajará en conjunto con el controlador
Interventor 1120-FICQ-100_INT, el cual definirá el Set Point de la cantidad de bombas
que deben estar funcionando, en función del modo de operación del Sistema de Agua
Fresca, el error ´(%Error) y la acción de control (MV), generado por el Controlador 1120-
FQIC-100. Para mayores detalles de bloque Interventor 1120-FQIC-100, ver la sección
7.7.4, “Lazos de Control Regulatorio”, de la Unidad AF_EstacBbeoTit.
Permisivos
Enclavamientos
Todas las bombas de la Estación de Bombeo Titire, tags 1120-PU-001 @ 005 están
en falla. 1
Todas las pozas de destino (C1, C2 y C4) están con nivel alto-alto.
DESDE
1120FQIC100 1120LV
M
018
FIT
018
VT VT VT
013X 013Y 013Z
M
M
VT VT VT
014X 014Y 014Z
VT VT VT TT
011X 011Y 011Z 011
1120PU001
T1 Control Modules
UN AF_EstacBbeoTit EM1120PU001_005 Sub EM 1120PU001
Tag Service
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE -
1120-VT-014Y
TRANSMISOR VIBRACION Y LADO DE
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE -
1120-VT-014Z
TRANSMISOR VIBRACION Z LADO DE
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
T2 Interlock
Tag Servicio MOTOR ELECTRICO BOMBA IMPULSION AGUA 1
1120-PU-001-MO1
FRE
UN AF_EstacBbeoTit EM 1120PU001_005 SEM 1120PU001
Tipo
Tipico Motor M23 Intlck_1120BB_01
Interlock
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
Notas:
1. Corresponden a los estados de nivel bajo y bajo/bajo obtenidos a partir del Esquema
de Transmisores de Nivel 1120-LIT-001 y 1120-LIT-002 operando en condición
redundante (1oo2), considerando el modo de operación, Menor Nivel.
Nota:
1. Las alarmas de bajo/bajo y bajo flujo, deberán estar inhibidas durante la partida de
la bomba.
ésta abrirá en rampa hasta alcanzar un valor de 30%, a una razón de cambio de 0.5%/s
(valor a ser confirmado durante la Puesta en Servicio). Una vez que la válvula de salida
alcance este valor, ésta considerará la salida de control entregada por el Controlador 1120-
FIC-100.
DESDE
1120LV028
M
1120FQIC100
FIT
028
VT VT VT
023X 023Y 023Z
M
M
VT VT VT
024X 024Y 024Z
VT VT VT TT
021X 021Y 021Z 021
1120PU002
T1 Control Modules
UN AF_EstacBbeoTit EM
1120PU001_005 Sub EM 1120PU002
Tag Service
BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR VIBRACION Y CAJA
1120-VT-021Y
RODAMIENTO
BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR VIBRACION Z CAJA
1120-VT-021Z
RODAMIENTO
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR
1120-VT-023X
VIBRACION X LADO NDE
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR
1120-VT-023Y
VIBRACION Y LADO NDE
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR
1120-VT-023Z
VIBRACION Z LADO NDE
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR
1120-VT-024X
VIBRACION X LADO DE
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR
1120-VT-024Y
VIBRACION Y LADO DE
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR
1120-VT-024Z
VIBRACION Z LADO DE
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
T2 Interlock
Tag Servicio MOTOR ELECTRICO BOMBA IMPULSION
1120-PU-002-MO1
AGUA FRE
UN AF_EstacBbeoTit EM 1120PU001_005 1120PU002
Tipico Motor M23 Tipo Interlock Intlck_1120BB_01
Description
1
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
Notas:
1. Corresponden a los estados de nivel bajo y bajo/bajo obtenidos a partir del Esquema
de Transmisores de Nivel 1120-LIT-001 y 1120-LIT-002 operando en condición
redundante (1oo2), considerando el modo de operación, Menor Nivel.
2. Corresponde a condición que permite arrancar la bomba 60 segundos después del
arranque de la bomba anterior.
TOF corresponden a la función Timer Off Delay, configurados cada uno con un
tiempo de 60 seg.
3. Operación de las bombas se detendrá al alcanzar el volumen máximo (1120-FQI-
108.HH) de extracción permitido para el río Titire para el mes en curso. Sin perjuicio
de lo anterior, el Sistema deberá alarmar al operador, cuando el volumen extraído,
alcance el 95% del volumen permitido para ese mes.
4. 1140-LIT-101, 1140-LIT-102 y 1140-LIT-104 corresponden a Instrumentos virtuales
obtenidos a partir del Esquema de Transmisores de Nivel 1140-LIT-101A y 1140-
LIT-101B de la Poza C1, 1140-LIT-102A y 1140-LIT-102B de la Poza C2 y 1140-
LIT-104A y 1140-LIT-104B de la Poza C4 respectivamente, operando en condición
redundante (1oo2), considerando el modo de operación, mayor Nivel.
Nota:
1. Las alarmas de bajo/bajo y bajo flujo, deberán estar inhibidas durante la partida de
la bomba.
1
7.3.4 Mensajes de Estados Binarios
No Aplica
7.3.5 Lazos de Control Regulatorio
No Aplica
7.3.6 Lazos de Control Avanzado
No Aplica.
1
7.4 Sub Módulo de Equipos 1120PU003
Este Sub Módulo de Equipos, está destinado a comandar la operación de la bomba 1120-PU-003.
Este Sub módulo de equipos no contiene ningún estado y es solo un Sub EM de agrupación.
DESDE
1120LV028
M
1120FQIC100
FIT
028
VT VT VT
033X 033Y 033Z
M
M
VT VT VT
034X 034Y 034Z
VT VT VT TT
031X 031Y 031Z 031
1120PU003
By Pass
Protect
Permit
Permit
QC
T2 Interlock
Tag Servicio MOTOR ELECTRICO BOMBA IMPULSION
1120-PU-003-MO1
AGUA FRE
UN AF_EstacBbeoTit EM 1120PU001_005 1120PU003
Tipico Motor M23 Tipo Interlock Intlck_1120BB_01
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
T2 Interlock
Tag Servicio MOTOR ELECTRICO BOMBA IMPULSION
1120-PU-003-MO1
AGUA FRE
UN AF_EstacBbeoTit EM 1120PU001_005 1120PU003
Tipico Motor M23 Tipo Interlock Intlck_1120BB_01
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
Notas: 1
1. Corresponden a los estados de nivel bajo y bajo/bajo obtenidos a partir del Esquema
de Transmisores de Nivel 1120-LIT-001 y 1120-LIT-002 operando en condición
redundante (1oo2), considerando el modo de operación, Menor Nivel.
2. Corresponde a condición que permite arrancar la bomba 60 segundos después del
arranque de la bomba anterior.
TOF corresponden a la función Timer Off Delay, configurados cada uno con un
tiempo de 60 seg.
3. Operación de las bombas se detendrá al alcanzar el volumen máximo (1120-FQI-
108.HH) de extracción permitido para el río Titire para el mes en curso. Sin perjuicio
de lo anterior, el Sistema deberá alarmar al operador, cuando el volumen extraído,
alcance el 95% del volumen permitido para ese mes.
4. 1140-LIT-101, 1140-LIT-102 y 1140-LIT-104 corresponden a Instrumentos virtuales
obtenidos a partir del Esquema de Transmisores de Nivel 1140-LIT-101A y 1140-
LIT-101B de la Poza C1, 1140-LIT-102A y 1140-LIT-102B de la Poza C2 y 1140-
LIT-104A y 1140-LIT-104B de la Poza C4 respectivamente, operando en condición
redundante (1oo2), considerando el modo de operación, mayor Nivel.
Nota:
1. Las alarmas de bajo/bajo y bajo flujo, deberán estar inhibidas durante la partida de
la bomba.
No Aplica
DESDE
1120LV048
M
1120FQIC100
FIT
048
VT VT VT
043X 043Y 043Z
M
M
VT VT VT
044X 044Y 044Z
VT VT VT TT
041X 041Y 041Z 041
1120PU004
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
T2 Interlock
Tag Servicio MOTOR ELECTRICO BOMBA IMPULSION
1120-PU-004-MO1
AGUA FRE
UN AF_EstacBbeoTit EM 1120PU001_005 1120PU004
Tipico Motor M23 Tipo Interlock Intlck_1120BB_01
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
Notas: 1
1. Corresponden a los estados de nivel bajo y bajo/bajo obtenidos a partir del Esquema
de Transmisores de Nivel 1120-LIT-001 y 1120-LIT-002 operando en condición
redundante (1oo2), considerando el modo de operación, Menor Nivel.
2. Corresponde a condición que permite arrancar la bomba 60 segundos después del
arranque de la bomba anterior.
TOF corresponden a la función Timer Off Delay, configurados cada uno con un
tiempo de 60 seg.
3. Operación de las bombas se detendrá al alcanzar el volumen máximo (1120-FQI-
108.HH) de extracción permitido para el río Titire para el mes en curso. Sin perjuicio
Nota:
1. Las alarmas de bajo/bajo y bajo flujo, deberán estar inhibidas durante la partida de
la bomba.
No Aplica
No Aplica
DESDE
1120LV058
M
1120FQIC100
FIT
058
VT VT VT
053X 053Y 053Z
M
M
VT VT VT
054X 054Y 054Z
VT VT VT TT
051X 051Y 051Z 051
1120PU005
T1 Control Modules
UN AF_EstacBbeoTit EM
1120PU001_005 Sub EM 1120PU005
Tag Service
MOTOR ELECTRICO BOMBA IMPULSION AGUA FRESCA RIO TITIRE - TRANSMISOR
1120-VT-054Z
VIBRACION Z LADO DE
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
T2 Interlock
Tag Servicio MOTOR ELECTRICO BOMBA IMPULSION
1120-PU-005-MO1
AGUA FRE
UN AF_EstacBbeoTit EM 1120PU001_005 1120PU005
Tipico Motor M23 Tipo Interlock Intlck_1120BB_01
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
Notas:
1. Corresponden a los estados de nivel bajo y bajo/bajo obtenidos a partir del Esquema
de Transmisores de Nivel 1120-LIT-001, 1120-LIT-002 operando en condición
redundante (1oo2), considerando el modo de operación, Menor Nivel.
Nota:
1. Las alarmas de bajo/bajo y bajo flujo, deberán estar inhibidas durante la partida de
la bomba.
(valor a ser confirmado durante la Puesta en Servicio). Una vez que la válvula de salida
alcance este valor, ésta considerará la salida de control entregada por el Controlador 1120-
FIC-100.
1
7.7 Módulos de Control de la Unidad AF_EstacBbeoTit
7.7.1 Módulos de Control
T1 Control Modules
UN AF_EstacBbeoTit EM Sub EM
Tag Service
1120-FIT-102 SUMIDERO DE AGUA FRESCA TITIRE - FLUJO DESCARGA ESTACION TITIRE
1120-FIT-107 SUMIDERO DE AGUA FRESCA TITIRE - FLUJO RETORNO SUMIDERO AGUA FRESCA
1120-FV-107 SUMIDERO DE AGUA FRESCA TITIRE - FLUJO RETORNO SUMIDERO AGUA FRESCA
SUMIDERO DE AGUA FRESCA TITIRE - TRANSMISOR DE NIVEL ULTRASONICO
1120-LIT-001
ESTACION TITIRE
1120-LIT-002 SUMIDERO DE AGUA FRESCA TITIRE - TRANSMISOR DE NIVEL RADAR ESTACION TITIRE
1120-PIT-101 PRESIÓN DESCARGA ESTACIÓN TITIRE
1120-XS-100 INT FALLA HEAT TRACE - CALEFACTOR DE LINEA
1140-PIT-008 CERRO PELLUTA - TRANSMISOR PRESION EN CERRO PELLUTA
Nota:
3. El flujo total entregado por la Estación de Bombeo Titire, tag 1120-FI-108 será
determinado ya sea a través de la lectura del transmisor de flujo localizado en la
descarga de la estación, tag 1120-FIT-102, o bien, a partir de la lectura indirecta
obtenida de la suma de todos los caudales medidos de los flujómetros de las bombas
de Impulsión activas, 1120-FI-100, menos el flujo de recirculación medido en la línea
de retorno, tag 1120-FIT-107, donde:
1120FI100 𝐹𝐼𝑇 ó
El flujo total entregado por la Estación de Bombeo Titire 1120-FI-108 utilizará una u
otra lectura (medida mediante el flujómetro 1120-FIT-102 o bien la calculada), en
función de cuál de ellas se encuentra operativa (sus instrumentos no están en falla).
En caso que ambas lecturas se encuentran operativas, el sistema utilizará la mayor de
éstas.
Notas:
2. La función del lazo de control del flujo de retorno de la Estación Titire, tag 1120-FIC-
107, corresponde a:
caudal generado, ya sea por la condición de flujo excesivo, o por la salida del
controlador 1140-PIC-010A.
El Set Point utilizado por este controlador de Nivel 1120-LIC-003B será de 25%
(Valor a definir durante la puesta en marcha), de forma que la salida de control de este
controlador hacia el Controlador de Impulsión 1120-FIC-100, sea la máxima (SP
Externo, en función de agua disponible).
En caso que el nivel disminuya del Set Point definido, la salida de control disminuirá
(MV Controlador 1120-LIC-003B, SP Ext controlador 1120-FQIC-100), hasta llegar
a su mínima salida configurada para este controlador (MVMIN), provocando la
disminución del flujo de descarga de las bombas en operación, y la activación de las
reglas del bloque Interventor 1120-FQIC-100_INT, disminuyendo la cantidad de
bombas de la Estación.
Por otra parte, en caso que el nivel aumente del Set Point definido, la salida de control
aumentará (MV Controlador 1120-LIC-003B, SP Ext controlador 1120-FQIC-100),
hasta llegar a su máxima salida configurada para este controlador (MVMAX),
provocando el aumento del flujo de descarga de las bombas en operación, y la
activación de las reglas del bloque Interventor 1120-FQIC-100_INT, aumentando la
cantidad de bombas requeridas.
Por otra parte, este controlador se desactivará (trackeará), si todas las bombas se 1
encuentran detenidas.
Por otra parte, el Set Point Máximo al cual puede operar este controlador, dependerá
del modo de operación considerado para la Estación Titire/Sistema Agua Fresca,
según la siguiente descripción:
En este modo de operación, el Límite Superior del Set Point del Sistema, será
determinado entre el menor valor entre el valor calculado para completar la cuota
de extracción del mes, y el Set Point manual de la línea de agua fresca ingresado
por el Operador mediante 1000-FIK-001.
⎡ ⎤
⎢ 𝑉 𝑉 ⎥
𝑆𝑃 ⎢ ⎥
⎢ 24 ℎ 𝑥 𝐷í𝑎𝑠 𝐷í𝑎 ⎥
⎣ 𝑑 ⎦
Donde:
VMax : Volumen Máximo permitido por mes.
VAcum : Volumen acumulado de agua desde inicio del mes al día actual
DíasMes : Días Totales que tiene el mes en curso (28, 29, 30 o 31
dependiendo el mes del año en curso).
DíaActual : Días Transcurridos en el mes (0 a 30)
La Tabla 41 enumera las condiciones mensuales, que son los factores limitantes
para el flujo y el volumen, que se pueden sacar del río Titire cada mes.
Volumen
Máximo Flujo
Mensual Total 1
Nro Promedio Nro días
Mes permitido
Mes (m3/h) Mes
(Millones M3)
(Nota 1)
(Nota 1 y 3)
1 Enero 2520 31 1.87
2 Febrero 2520 28 (Nota 2) 1.69
3 Marzo 2520 31 1.87
4 Abril 2520 30 1.81
5 Mayo 2520 31 1.87
6 Junio 2520 30 1.81
7 Julio 2142 31 1.59
8 Agosto 1750 31 1.30
9 Septiembre 1480 30 1.07
10 Octubre 1166 31 0.87
11 Noviembre 2520 30 1.81
12 Diciembre 2520 31 1.87
Tabla 41 - Condiciones Mensuales Extracción Agua Río Titire
Notas:
trabajo del Controlador, esté dado por el ingreso manual del flujo a utilizar/flujo
requerido del Sistema, ingresado mediante la entrada manual, tag 1000-FIK-001.
Este valor será ingresado por el Operador, en función del caudal
observado/disponible en el cauce del río Titire.
El Límite inferior del Set Point (SPLLIM) del Controlador 1120-FICQ-100 será de
1000 m3/hr, mientras que su valor máximo será 2772 m3/hr.
1120-FICQ-100_INTERV
Parámetros Parámetros del Valor
Bloque Controlador
PV1_HTH Variable Manipulada 90%
Controlador
PV1_LTH Variable Manipulada 40%
Controlador
PV2_HTH Error Controlador 300 m3/hr
1120-FICQ-100_INTERV
Parámetros Parámetros del Valor
Bloque Controlador
PV2_LTH Error Controlador -300 m3/hr2
PV3_HTH Presión Cerro Pelluta 200 kPa
PV3_LTH Presión Cerro Pellura 100 kPa
En base a este diseño, la acción de control generada por el Controlador de Nivel 1120-
LIC-003B, provocará que en caso que el nivel de la sentina sea menor su Set Point,
una disminución en su salida de control, generando una correspondiente disminución
en el Set Point ingresado al controlador 1120-FQIC-100. Esto último, producirá, la
disminución del porcentaje de apertura de las válvulas de descarga de las bombas de
la Estación, además de activar las reglas de disminución de cantidad de bombas,
generando la detención paulatina de éstas, en caso que no se recupere el nivel.
El Valor Máximo de Trabajo del Sistema de Impulsión será de 2772 m3/hr, mientras
que su valor mínimo será de 1000 m3/hr.
En caso que el Agua en Titire no alcance para cumplir este requerimiento, el Sistema
hará uso de las bombas disponibles en la Estación de Bombeo Vizcachas, según se
describe en la sección 7.10.5, “Lazos de Control Regulatorio”; del documento
Filosofía de Control – Controlador 1130-PC-101, N° MQ13-02-DC-1130-IN0001.
8 UNIDAD AF_ESTACCHOQUE
1
La estación de reducción de presión (Estación Choke), está localizada aproximadamente en el KM
79.7 de la tubería de agua fresca, y está considerada para ajustar los Set Point de presión de la tubería,
acorde a los cambios en los flujos de impulsión, tal de asegurar el gradiente hidráulico y evitar la
condición de Slack Flow.
LOOKUP TABLE
FLOW PIPELINE SET POINT
InletPre = f(PipelineFlow)
PIC
010A +
Note 2
SP: 200 kPa
PIT PIT
010A 010B
PIC
018
ESTACION BOMBAS PIC
PIT PIT
VIZCACHA 018 013
014
M M
1140PV014
ESTACION BOMBAS
TITIRE PIC
015
1140PV015
PIC
016
1140PV016
PIC
017
1140PV017
La Estación Choke está compuesta por una válvula de aislación, tag 1140-XV-011, y dos (2) etapas
de reducción. La primera etapa de reducción de presión, está compuesta por una válvula de Control
de Presión, 1140-PV-018, controlada por el controlador de presión 1140-PIC-018, la cual está
destinada a mantener la presión de la columna, medida a través del transmisor de presión 1140-PIT-
018. La segunda etapa de reducción, está compuesta por cuatro (4) ramas de reducción de presión,
donde sólo una funciona a la vez, cada una compuesta por una válvula reductora de presión y una
placa orificio.
Cada rama de flujo está diseñada y es capaz de controlar la presión solo en cierto rango de flujo. Por
lo tanto, solo una rama de flujo operará a la vez, dependiendo del caudal medido de la tubería.
La primera rama es una línea de 24 "con una placa orificio tag 1140-FO-004 y una válvula de control
de presión de 24" 1140-PV-014. Está diseñada para caudales entre 2160.36 m3/h a 2772 m3/h.
La segunda rama es una línea de 20"con una placa orificio tag 1140-FO-005 y una válvula de control
de presión de 18" 1140-PV-015. Está diseñada para caudales entre 1656 m3/h a 2160 m3/h.
La tercera rama es una línea de 18"con una placa orificio tag 1140-FO-006 y una válvula de control
de presión de 16" 1140-PV-016. Está diseñada para caudales entre 1224 m3/h a 1656 m3/h.
La cuarta rama es una línea de 16 "con una placa orificio tag 1140-FO-007 y una válvula de control
de presión de 14" 1140-PV-017. Está diseñada para caudales entre 1000.8 m3/h a 1224 m3/h.
En la entrada de la estación Choke, el lazo de control del controlador de presión 1140-PIC-018 regula
1
la presión en la línea basado en el punto de ajuste del flujo de la tubería para asegurar un flujo
completo. También sirve para proporcionar una presión constante aguas abajo de las válvulas. Los
controladores 1140-PIC-014, 1140-PIC-015, 1140-PIC-016 y 1140-PIC-017 por su parte (uno para
cada rama), son los encargados de controlar la presión de entrada a las Ramas de la Estación Choke,
ajustando la posición de la válvula reductora, en función de la lectura de la presión de entrada de la
Estación Chocke, tal que en conjunto con la placa orificio de la rama, logren la presión de salida
requerida.
Hay varios casos de flujo en los que se pueda operar la tubería, en función del agua fresca disponible
en los ríos Titire y Vizcachas. La Tabla 11 del Informe Hidráulico de Estado Estacionario enumera
casos de flujo de muestra en los que puede operar la tubería y el punto de ajuste en la presión de salida
correspondiente en la estación choke. La estación choke está diseñada para un caudal entre 1000 m3/h
(siendo el caudal durante operaciones de “pigging” de 8” y 24") y 2772 m3/h.
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
Notas: 1
1. La válvula de aislación de la Estación Reductora, deberá operar en base a la siguiente
descripción:
Válvula deberá abrir, si al menos una bomba en Titire o Vizcacha se encuentra
funcionando.
Válvula deberá cerrar, un (1) minuto después de que todas las bombas en Titire
y Vizcachas se encuentran detenidas.
8.1.3 Alarmas y Set Points de Procesos
T3 Alarmas y Set Point de Procesos
UN AF_EstacChoke EM Sub EM
Tag Service Rango Unidad SP HYS HH H L LL
1140-PIT-013 PRESION ENTRADA 0-10000 kPa 500 910 9000
RAMAS ESTACION CHOKE 0
1140-PIT-018 PRESION ENTRADA 0-18000 kPa 360 910 5900
ESTACION CHOKE 0
Notas:
La Tabla 49 muestra los valores considerados para el Set Point de este controlador.
Flujo Tubería de
Impulsión Presión Entrada [kPa] Válvula Chocke (1140-PIC-
1
018.SPExt)
[m3/hr]
0 8780
1000 8328
1224 8155
1656 7800
2160 7139
2520 6551
2772 6105
Tabla 49 - Tabla Flujo Impulsión/Presión Entrada Estación Chocke
La LookUp table, interpolará entre los puntos discretos definidos en esta tabla, tal de
proveer una variación continua de presión, a las variaciones solicitadas de caudal.
El flujo de entrada a esa LookUp Table, será obtenido de un bloque selector PV/SP,
tag 1120-FQIC-100.PVSP, similar al utilizado en los controladores de agua de
dilución de Molienda.
(valor a ser ajustado en terreno). Caso contrario, considerará el valor del SP del
Controlador 1120-FQIC-100 (si el error es menor a este valor).
Dependiendo el estado de operación del Sistema de Impulsión (en qué rama está), así
como el Set Point de Flujo requerido para éste por el operador, el Sistema deberá
modular el caudal impulsado, ya sea:
iii. Una vez que tanto la válvula 1140-PV-018 así como la válvula de la
rama en operación estén en al valor indicado en la en la Tabla 51, la
válvula de la nueva rama se abrirá en rampa hasta que ésta alcance
un 40%.
iii. Una vez que la Rama en operación llegue al valor de tracking, la rama
nueva deberá abrirse hasta llegar a su valor máximo de operación
mediante rampa incremental.
iv. Una vez que la rama nueva esté en su posición máxima de operación,
la rama antigua deberá cerrarse, mediante una rampa decreciente.
El cambio de rama requerido, dependerá del rango de caudal en que se requiere operar,
según la siguiente tabla:
Caudal Cierre Válvula Apertura Válvula
Requerido Rama Activa Válvula Rama Rampa Válvula Rama Rampa
[m3/hr] Inicial Tack a Decr Final Track a Incr
2160 a 2772 Línea 24", Placa N/A N/A N/A N/A
1140-FO-004 y válv
1140-PV-014
1656 a 2160 Línea 18", Placa 20% 0.25 %/s 50 % 1 %/s
1140-FO-006 y válv
1140-PV-016
6. Cuando una válvula de control u otro elemento de alguna de las ramas deba entrar en
mantenimiento o ser reemplazado, el operador deberá modificar el requerimiento de
flujo de agua fresca de forma que una rama diferente se seleccione, asegurando la
continuidad del proceso, así como no exceder el flujo permitido por la tubería.
Este controlador, trabajará con un Set Point inicial de 200 kPa (valor a ser ajustado
durante la puesta en servicio).
1
9 UNIDAD AF_POZASCARC
A continuación se describen los elementos considerados en la Unidad AF_PozasCarac.
FIC FY
<
014 014
FIT
014
1140FV014
800 m3/hr
M LIT LIT
102A 102B
FIC
141
1140LV102
FIT
141
1oo3
1140FV141
PIC 800 m3/hr
013A
C2
LIT LIT
SP: 130 kPa 101A 101B
M FIC
143
PIT
014 FIT
1140LV101 143
C1 800 m3/hr FUNCION
LIT LIT
M 104A 104B
FIC
268
FIT LIC
1140LV104 268 018
M
1140FV268
LIT
018
C4
Notes:
1. Pond Discharge can work in the following schema: C1 and C4, or C2 and C4. PLANTA DE
2. Controller 1140‐PIC‐010 will consider a ‐300 kPa and 300 kPa MV span for adjusting will PIC‐018 controller 3930TK002 PROCESOS
3. Controller 1140PIC013A will untruck when 1140FIC014 has taken control of override.
3930TK001
Considera a su vez, un segundo controlador de presión, tag 1140-PIC-013A, el cual actuará sobre
una de las válvulas de alimentación de las pozas (1oo3), dependiendo de la selección que haya
hecho el operador para tales efectos.
By Pass
Protect
Permit
Permit
QC
T2V Interlock
Tag Servicio VALVULA ALIMIMENTACION AGUA
1140-LV-102
FRESCA POZA C2
UN AF_PozasCarac EM Sub EM
Tipo
Tipico VLV E5, FL KEEP_LAST KL S/POS CL Intlck_1140_VLV_ENT_POZA
Interlock
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
T2V Interlock
Tag Servicio VALVULA ALIMIMENTACION AGUA
1140-LV-104
FRESCA POZA C4
UN AF_PozasCarac EM Sub EM
Tipo
Tipico VLV E5, FL KEEP_LAST KL S/POS CL Intlck_1140_VLV_ENT_POZA
Interlock
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
1
Nota:
Notas:
10 UNIDAD AF_DESCPOZAS
La unidad DescPozas considera la coordinación de las descargas/extracción de agua de las pozas, tal
que éstas puedan abastecer adecuadamente con agua a la Planta Papujune.
Notas
El Set Point del Controlador 3930-FIC-014, estará dado por la salida de control del
controlador de nivel 3930-LIC-018, mientras que los Set Point asociados a los
controladores 1140-FIC-143, 1140-FIC-141, 1140-FIC-268, estarán dados por la
siguiente expresión:
Se deberá considerar una botonera local que permita seleccionar, las opciones Poza
C1 Habilitada, Poza C2 Habilitada, Poza C4 Habilitada, y Ninguna Poza Habilitada.
Las opciones Poza C1 Habilitada, Poza C2 Habilitada serán excluyentes entre sí. La
Opción Ninguna Poza Habilitada, deshabilitará la selección de cualquiera de las pozas
que estén habilitada.
11 UNIDAD AF_QUETNKAREA
La Unidad AF_QueTnkArea tiene por función, albergar la lógica destinada a controlar el ingreso de
Agua Fresca al Estanque de Alimentación de la Mina, así como medir los consumos de Agua Fresca
que el área presente.
La Unidad AF_QueTnkArea, está compuesta un lazo de control de nivel, tag 2910-LIC-015, que actúa
en cascada sobre el lazo de flujo de alimentación al Estanque, tag 2910-FIC-009, de forma de mantener
un nivel adecuado en éste, así como limitar que le caudal ingresado, no supere los límites definidos
por el diseño hidráulico.
Considera además, una válvula de aislación de entrada, Tag 2910-XV-011, la cual se usará para
cerrar/inhabilitar el ingreso de Agua al Estanque, en caso que así sea requerido, así como mediciones
de los consumos de agua realizados tanto por la Planta de Osmosis Reversa, como de los consumos
generales del área al medir el caudal demandado por la matriz de agua de la mina.
Description
Interlock
By Pass
Protect
Permit
Permit
QC
Tag Servicio Notes
Notas:
1. En modo automático, la válvula 2910-XV-001 se abrirá 10 seg después de que la
válvula 1140-XV-011 se haya abierto, y se cerrará 5 min después que ésta se haya
cerrado.
Notas:
1. Los flujómetros 2910-FIT-009, 2910-FIT-012 y 2910-FIT-013 están considerados
para medir el flujo de entrada a Quellaveco, así como los consumos de la Planta de
RO, y la matriz de distribución del área respectivamente. Todas estas mediciones
deben ser monitoreadas y registradas por el Sistema.
Nota:
El nivel de alarma alto alto (2910-LAHH-015) se activa cuando el nivel del tanque
alcanza el nivel crítico, con el riesgo de desbordamiento. Esta condición anulará el
controlador de flujo 2910-FIC-009 y cerrará completamente la válvula de control de
flujo (2910-FV-009). Una vez que el nivel vuelva a estar por debajo del nivel crítico,
el controlador de flujo reanuda el control de la válvula de control.
Estación Reductora
En base a lo anterior, el diseño considera cuatro (4) sub modos operacionales de limpieza, los cuales
sólo podrán ser seleccionados si el Modo “Limpieza” ha sido seleccionado y activado previamente.
La descripción de los sub módulos operacionales corresponde a:
Al seleccionar este sub modo, el flujo máximo de la tubería quedará limitado a 1000
m3/hr.
En este sub modo, sólo se podrán utilizar bombas de la Estación de Bombeo Titire,
quedando limitada la cantidad máxima de bombas del Módulo de Equipos
1120PU001_005 (estructura START2CTRL/AGGRE08) a dos (2) bombas.
Corresponde al Sistema de Limpieza que permite atender la tubería de 28”, aguas abajo
del cerro Pelluta hasta la Estación Reductora de Diámetro.
Al seleccionar este sub modo, el flujo máximo de la tubería quedará limitado a 1360
m3/hr.
En este sub modo, tanto bombas de Titire o Vizcachas podrán ser utilizadas.
Dependiendo si el operador seleccionó ocupar bombas de Titire o Vizcachas, la cantidad
máxima de bombas del Módulo de Equipos 1120PU001_005 (estructura
START2CTRL/AGGRE08) en Titire serán (2) bombas, mientras que en Vizcacha la
cantidad máxima de bombas del Módulo de Equipos 1130PU001_008 (estructura
START2CTRL/AGGRE08) serán cuatro (4) bombas.
Al seleccionar este sub modo, el flujo máximo de la tubería quedará limitado a 1000
m3/hr.
En este sub modo, tanto bombas de Titire o Vizcachas podrán ser utilizadas.
Dependiendo si el operador seleccionó ocupar bombas de Titire o Vizcachas, la cantidad
máxima de bombas del Módulo de Equipos 1120PU001_005 (estructura
START2CTRL/AGGRE08) en Titire serán (2) bombas, mientras que en Vizcacha la
cantidad máxima de bombas del Módulo de Equipos 1130PU001_008 (estructura
START2CTRL/AGGRE08) serán tres (3) bombas.
Corresponde al Sistema de Limpieza que permite atender la tubería de 8”, aguas debajo
de la Estación Reductora hasta el Estanque Quellaveco.
Al seleccionar este sub modo, el flujo máximo de la tubería quedará limitado a 1000
m3/hr.
En este sub modo, tanto bombas de Titire o Vizcachas podrán ser utilizadas.
Dependiendo si el operador seleccionó ocupar bombas de Titire o Vizcachas, la cantidad
máxima de bombas del Módulo de Equipos 1120PU001_005 (estructura
START2CTRL/AGGRE08) en Titire serán (2) bombas, mientras que en Vizcacha la
cantidad máxima de bombas del Módulo de Equipos 1130PU001_008 (estructura
START2CTRL/AGGRE08) serán tres (3) bombas.
Los sub modos operacionales de limpieza, sólo podrán ser seleccionados, si el Modo “Limpieza”,
1000-HS-001_PIG ha sido activado. La activación de este modo deberá ser informada al operador
activando la indicación 1000-XL-001.
Para activar el Modo Limpieza, el modo “Tubería Desactivada” debe estar activo, y todas las bombas
de Titire y Vizcachas deberán están detenidas.
Este documento ha sido revisado como se indica abajo, y describe en el registro de revisiones
en la página siguiente. Por favor destruir todas las revisiones previas.
Filosofía de Control
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Proyecto Quellaveco Fecha 20-Dic-2017
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TABLA DE CONTENIDOS
1.0 GENERALIDADES................................................................................................................... 4
2.0 DESCRIPCIÓN DEL SISTEMA DE CAPTACIÓN TITIRE ....................................................... 8
3.0 OPERACIÓN DEL SISTEMA DE CAPTACIÓN TITIRE ........................................................ 10
4.0 DESCRIPCIÓN DEL SISTEMA DE ABASTECIMIENTO PRESA VIZCACHAS ................... 14
5.0 OPERACIÓN DEL SISTEMA DE ABASTECIMIENTO PRESA VIZCACHAS....................... 17
6.0 MEDICIÓN DE FILTRACIONES ............................................................................................ 26
7.0 ESTACIONES DE AFORO .................................................................................................... 27
LISTADO DE TABLAS
Tabla 1-1 Obras Hidráulicas de la Bocatoma Titire y Presa Vizcachas ........................................... 4
Tabla 2-1 Obras Hidráulicas del Sistema de Captación Titire ......................................................... 8
Tabla 4-1 Obras Hidráulicas de la Presa Vizcachas ...................................................................... 14
Tabla 5-1 Caudales de Diseño de las Líneas de Entrega .............................................................. 21
Tabla 7-1 Coordenadas de Estaciones de Aforo – Bocatoma Titire .............................................. 28
Tabla 7-2 Coordenadas de Estaciones de Aforo – Presa Vizcachas ............................................ 28
LISTADO DE FIGURAS
Figura 2-1 Arreglo General de la Captación Titire ............................................................................. 8
Figura 3-1 Diagrama de Control de las Compuertas Radiales ........................................................ 11
Figura 3-2 Diagrama de Control de Compuerta de Regulación ...................................................... 12
Figura 4-1 Arreglo General de la Presa Vizcachas ......................................................................... 14
Figura 5-1 Diagrama de Operación Temporal de la Compuerta de Cierre Definitivo ..................... 18
Figura 5-2 Diagrama de Control de la Compuerta de Cierre Definitivo ........................................... 19
Figura 5-3 Diagrama de Operación de la Compuerta de Desagüe ................................................. 20
Figura 5-4 Componentes de las dos Conducciones de Descarga .................................................. 21
Figura 5-5 Esquema de Control de Conducto de Entrega .............................................................. 23
Figura 5-6 Esquema de Control - Regulación de Caudales de Entrega ......................................... 24
Figura 5-7 Esquema de Control - Compuerta de Operación Obra de Desagüe ............................. 25
Figura 7-1 Ubicación de las Estaciones de Aforo de la Presa Vizcachas y Bocatoma Titire.......... 27
Figura 7-2 Diagrama Funcional - Estaciones de Aforo en el Río Vizcachas .................................. 29
Figura 7-3 Diagrama Funcional - Estaciones de Aforo en el Río Titire ........................................... 30
Filosofía de Control
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Quellaveco Project 14-May-2019
Contract Q1CO Page 1 of 55
Rev. 1
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Process
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Record of Revisions
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CONTENTS
Process
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Rev. 2
This Document has been reviewed as indicated below and described in the revision record on the following
page. Please destroy all previous revisions.
Pipeline
Anglo American Quellaveco S.A. MQ13-02-RE-1000-PL0002
Project Quellaveco Date 22-May-2019
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Rev. 2
Record of Revisions
Pipeline
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Rev. 2
Contents
1.0 Executive Summary .......................................................................................................................... 5
2.0 Steady State Hydraulics Analysis ..................................................................................................... 6
2.1 Introduction ................................................................................................................................... 6
2.2 Parameter and Data for Hydraulics Modeling .............................................................................. 6
2.2.1. Pipeline Elevation Profile ..................................................................................................... 6
2.2.2. Pipeline Sizes and Wall Thickness ....................................................................................... 8
2.2.3. Modeling of Pumps and Pump Curves.................................................................................. 8
2.2.4. Tank Level and Required Pipeline Delivery Pressure ........................................................ 10
2.2.5. Design Conditions and Margins .......................................................................................... 10
2.2.6. Other Parameters ................................................................................................................. 10
2.3 Case Matrix for Pipeline Hydraulics Design .............................................................................. 12
2.4 SPS Model development ............................................................................................................. 13
2.5 Steady State Hydraulics Results at Different Flow Rates ........................................................... 14
2.6 Hydraulics Results of the Branch Pipeline Delivering Water to Tank 2910-TK-001................. 25
2.7 Conclusion .................................................................................................................................. 27
3.0 Analysis of the Existing Pipeline from Tie-in to Pools................................................................... 35
3.1 Introduction ................................................................................................................................. 35
3.2 Parameters and Data for Modeling ............................................................................................. 35
3.2.1. Pipeline Elevation Profile ................................................................................................... 35
3.2.2. Design Conditions and Margins .......................................................................................... 41
3.3 Pressurized Flow Analysis .......................................................................................................... 41
3.4 Pressurized Flow Results ............................................................................................................ 42
3.5 Open Flow Analysis .................................................................................................................... 46
3.6 Open Channel Results ................................................................................................................. 49
3.7 Conclusion .................................................................................................................................. 51
4.0 Analysis on the Influence of Sedimentation and Suspension ......................................................... 52
4.1 Introduction ................................................................................................................................. 52
4.2 Particle Properties ....................................................................................................................... 52
4.2.1. Size Distribution ................................................................................................................. 52
4.2.2. Specific Gravity .................................................................................................................. 54
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4.3 Mass Flow Rate of Suspended Particles in the Pipeline ............................................................. 54
4.3.1. Concentration ...................................................................................................................... 54
4.3.2. Intake Structure Filtration ................................................................................................... 56
4.4 Erosion Rate Modeling ............................................................................................................... 58
4.5 Deposition Velocity Modeling .................................................................................................... 64
4.6 Conclusion .................................................................................................................................. 67
5.0 Bibliography ................................................................................................................................... 67
Appendix A Pipeline System Schematic ................................................................................................. 68
Appendix B : Model Schematics of the Pumped Section of the Pipeline ............................................... 69
Appendix C : Pump Curves at the Titire Pump Station ........................................................................... 70
Appendix D : Pump Curves at the Vizcachas Pump Station ................................................................... 71
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1.0 ExecutiveSummary
This steady state hydraulics report documents the analysis that was conducted to determine the required
line sizes, design pressures, and pump requirements at the Titire River and the Vizcachas Reservoir
pump stations, and control requirements at the choke station for the Quellaveco fresh water pipeline. A
number of cases were examined in order to arrive at a system that could meet the varied operational
scenarios expected of the pipeline system. The report also contains an analysis of the influence of
sedimentation and suspension on the system.
1) The pipeline starting from the Titire River and the Vizcachas Reservoir intake structures to the
highest elevation location at Pelluta Hill.
2) The pipeline section from Pelluta to the HDPE tie-in, including control valves.
3) The 8” branch (about 740 meters in length) that ties in at around 86 KM downstream of Pelluta Hill
(6 km downstream of the choke station) to deliver a portion of the water to tank 2910-TK-001.
4) The existing gravity driven section of HDPE piping to the Caracoles ponds
The line size for the pumped section from Titire and Vizcachas up to Pelluta Hill will be 24”.
Immediately downstream of Pelluta Hill, the pipeline will be 28” up to the next high point 26.5 km
downstream. A 28” pipeline is required for this gravity driven section of the pipeline to provide an
acceptable hydraulic grade line. The remainder of the pipeline is 24” up to the termination point at the
HDPE pipe at Caracoles Station (KP 86.8). The branch to deliver water to tank 2910-TK-001 is 8” as
shown on the P&ID (MQ11-02-DR-1140-PD1005). The HDPE section of the system begins at KP 86.8.
A 30-inch HDPE SDR 9 is used between KP 86.8 and KP 88.7. At this point the HDPE transitions to a 2
24-inch SDR 11 that runs to Pond 4 at KP 89.3. Due to the HDPE line being in operation, it is
recommended that a test is performed in order to get the wall thickness in each section. While not vital to
the results seen in the steady state report below, it gives a better idea of the operating conditions of the
pipeline. It will also be necessary to understand the maximum pressure that can be achieved in the line in
case of a pressure being introduced. As discussed with the client, a proposed solution of testing the line’s
wall thickness was proposed to be performed using ultrasonic testing. If this is done, then the report can
be updated to include the results from this analysis.
A total of 36 cases were simulated to cover the full flow rate range of the pipeline.
A detailed hydraulics analysis of the continuation of the pipeline after the 30”/24” HDPE pipeline tie-in
was added in this revision of the steady state report. There is an existing pipeline that begins as a 30” pipe
before reducing to a 24” pipe. Flow in this section of the pipeline is driven only by gravity. This report
contains an analysis ensuring that this pipeline will be able to continue operating at the new conditions.
Conservative parameters were used in order to account for unknown present conditions of the line. Initial
values of certain parameters were provided in the as-built’s from AAQSA, however due to the pipeline 2
currently being in operation, it is unknown what the exact conditions are. The estimated flow rate is the
maximum required flow rate of 2772 m3/h (770 lps). The conclusion is that the existing 30”/24” HDPE
pipeline will be able to continue to transfer water from the pipeline to the ponds.
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The estimate on the sedimentation and erosion of solid particles in the internally coated carbon steel
pipeline from the Titire River and Vizcachas Reservoir to the ponds was added in this revision of the
steady state hydraulics report. The analysis of the influence of sedimentation and suspension looks at
these same pipeline sections, with a focus on the effect of the particles present in the system. The
analysis shows the risk of erosion on the pipeline, and allows us to obtain the deposition velocity. The
analysis results indicate that no concerns from erosion or sedimentation are expected for the pipeline
under pipeline design flow rate range.
2.0 SteadyStateHydraulicsAnalysis
2.1 Introduction
The purpose of this section is to document the hydraulics and provide data for the detailed engineering
design of the internally coated carbon steel pipeline from the Titire River Pump Station and the
Vizcachas Reservoir Pump station to HDPE tie-in. The pipeline design basis, conditions, and parameters
are described in the following sections. SPS (Synergi Pipeline Simulator) version 10.4 by DNV-GL was
used to complete this analysis.
In addition, this revision of the hydraulics report considers the following aspects:
1) The considerations of pipeline hydraulics in the removal of the previously proposed tank and
pressure regulation valve at Pelluta Hill. The removal of the tank at Pelluta Hill makes the whole
pipeline a continuous pipeline system.
2) The updates on pipeline elevation profile based on the latest Lidar survey data
4) The consideration of removing proposed transfer tank 1140-TK-002. This tank would have added
the benefit of holding pressure, however this report helps understand if there is no transfer tank, if
the pipeline will still allow for continuous flow.
Pipeline
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HDPE Tie-In
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Table 1 shows the MAOP based on the pipe wall thickness used in the hydraulics model. The pipeline is
internally coated for corrosion protection. The pipeline sizes were the results of pipeline design
optimization approved by the client in the FEED verification (MQ13-02-RE-1140-GA-0001_R0). The
internal coating thickness is 0.508 mm for the hydraulics. The absolute roughness of the internal coating
is normally around 5 micron. Studies show that the coating surface roughness will normally reduce due
to the pipe flow erosion. The roughness slightly increases only in the case of 90o jet flow impacts
(Sunde, 2015). The roughness of the internal coating used in the hydraulics modeling is 10 micron
(0.0004 inch). A schematic of the Pipeline System can be referenced in Appendix A.
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Figure 3: Individual Pump Curve for the Titire Pump Station (Sulzer Multiple stage Vertical Pump)
Figure 4: Individual Pump Curve for the Vizcachas Pump Station (Ruhpumpen Horizontal Pump)
The pumps run at a constant speed. The flow rates of pumps are controlled by the control valves at pump
discharges (LV1120018, LV1120028, LV1120038, LV1120048 at Titire pump station, and LV1130018,
LV1130028, LV1130038, LV1130048, LV1130058, LV1130068, LV1130078 at Vizcachas pump
station).
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model from the ambient pressure and temperature conditions. The viscosity, P, of the fluid at pipeline
pressure and temperature condition is given by:
P = P0 exp (VPMI • 'P + VTMI • 'T)
Where P0 is the base viscosity at atmospheric pressure and 15.56 oC
The design life of the pipeline is 29 years. The pipeline material will be Carbon Steel pipe with internal
FBE coating. The effective roughness of 0.009906 mm (0.00039 in) commonly used for the pipe with
internal coating is adopted in the hydraulics evaluations.
The Titire River pump station is equipped with 5 pumps (4 in operation and 1 stand-by) per P&ID
MQ11-02-DR-1120-PD 1001. The Vizcachas Reservoir pump station is equipped with 8 pumps (7 in
operation and 1 stand-by) per P&IDs MQ11-02-DR-1130-PD 1001 and MQ11-02-DR-1130-PD 1002. A
high level station piping pressure loss was estimated in the model based on this information.
The hydraulics modeling and design are based on the following assumptions that need to be confirmed
as the project progresses.
1) The normal Titire pump suction head is calculated based on the submerge level in the sump. It is
assumed that the static pressure at normal sump level is 48 KPag based on the sump elevation levels
shown on page 24 of MQ12-02-CM-1100-PD0001 Rev R (Memoria De Calculo – Analisis Regimen
Permanente Del Sistema De Aduccion De Agua Fresca). It is assumed that the static pressure
corresponding to the minimum and low sump levels are 11.5 KPag and 20 KPag, respectively. The
available pump suction pressure is calculated in the hydraulics model also considering the velocity
head at different flow rates. The Vizcachas pump station suction pressure is assumed to a low value.
The available head need to be verified with the reservoir water intake design.
2) The hydraulics model is based on the elevation profile from the Rev C Alignment Sheets and the
latest Lidar survey data. The hydraulics needs to be updated or verified when there is major re-routes
of the pipeline or change of locations for the pipeline facilities and tie-ins.
3) The current report documents only the steady state hydraulics results. The transient hydraulics
simulations will be addressed in a separate report. The wall thickness selected considered steady state
flow conditions, shut-in static conditions at different segments of the pipeline, and the margin for
surge pressure during worst transient cases. As a lower cost and more reliable measure, surge
mitigation and control will be described and recommended based on the transient hydraulics report to
provide protection of the system in transient conditions with the design pressure limits that the
selected wall thickness would provide for accidental conditions.
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The flow rates for the laterals and the main line are based on the water balance provided by the client.
The followings are considered in the case matrix of the pipeline hydraulics:
1) The case matrix only considers steady state cases necessary for pipeline system sizing and hydraulics
design.
2) The design flow rate for the mainline is considered to be 2520 m³/h (700 l/s). The maximum flow
rate of the pipeline is 2772 m3/h (770 l/s). This will give the pipeline a minimum availability of 91%
for maintenance or shut-down at unexpected situations.
3) The minimum pipeline pigging flow rate is set to be 1000.8 m³/h (278 l/s). This is corresponding to
the flow rate at a pigging velocity of approximately 1 m/s for running the pig in a 24 inch pipeline.
4) The cases shown in the hydraulics simulations have flow rates ranging from 230.4 m3/h (64 l/s) to
2772 m3/h (770 l/s). The results for cases with flow rate below 1000.8 m3/h (278 l/s), cases 5.8 to
case 5.10, are only informative but not for design. The minimum flow rate for the pipeline design is
1000.8 m3/h ( 278 l/s).
5) The pipeline will be designed for full shut-down (0 flow rate case). The full shut-down case will be
covered in the transient hydraulics scope.
6) There are other flow rates (e.g. 600 l/s) presented in the hydraulics simulations to provide
intermediate data points for valve sizing conditions and pump performance verification.
7) The hydraulics report provides the combined and individual pump flow rate and pump head
following the pump curves. The numbers of pump need to be operated and the individual pump flow
rate were determined based on the pump curves provided by pump vendor described in section 2.2.3.
Based on the above considerations Tables Table 3 and Table 4 show the case matrix for the pipeline
hydraulics design of the pumped section and the gravity section respectively.
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Table 4: Case Matrix for Hydraulics Design of the 8” Line to Tank 2910-TK-001
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Figure 5 Pipeline Pressure Profile from Titire River to the Tie-in for Cases 1.1 to 1.6
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Figure 6 Pipeline Pressure Profile from Titire River to the End of the Pipeline for Cases 2.1 to 2.7
Figure 7 Pipeline Pressure Profile from Titire River to the End of the Pipeline for Cases 1.1, 2.1, 3.1, 3.2 and 4.1
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Figure 8 Pipeline Pressure Profile from Titire River to Tie-in for Cases 7.1 to 7.10 for Choke Station Sizing
Tables Table 5 to Table 8 summarize the hydraulics results for the individual pump TDH and power at
the Titire and Vizcachas pump stations with flow rates shown in Table 5 based on the vendor pump
curves. Tables Table 9 and Table 10 show the CV and pressure drop of pump discharge control valves
for the flow rates shown in Table 3.
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Table 5: The Pump Station Head and Flow Rates for Cases 1.1 to 1.6
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Table 6: The Pump Station Head and Flow Rates for Cases 2.1 to 2.7
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Table 7: The Pump Station Head and Flow Rates for Cases 3.1, 3.2 and 4.1
Table 8: The Pump Station Head and Flow Rates for Cases 5.1 to 5.10
PumpHydraulicsConditions Units Case5.1 Case5.2 Case5.3 Case5.4 Case5.5 Case5.6 Case5.7 Case5.8 Case5.9 Case5.10
TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver
Location Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation
3
PumpFlowRate m /h 694.8 630 561.6 720 550.8 612 432 403.2 518.4 230.4
NumberofPumpinOperation 4 4 4 3 3 2 2 2 1 1
PumpStationTotalFlow m3/h 2779.2 2520 2246.4 2160 1652.4 1224 864 806.4 518.4 230.4
TDH,MinimumSumpLevel m 723.2 741.4 757.2 714.1 759.1 746.0 782.0 787.2 765.6 821.5
TDH,LowSumpLevel m 722.4 740.5 756.3 713.3 758.2 745.1 781.2 786.3 764.7 820.6
TDH,NormalSumpLevl m 719.6 737.7 753.6 710.5 755.5 742.3 778.4 783.6 762.0 817.9
PumpSuctionPressure,MinimumSumpLevel kPag 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5
PumpSuctionPressure,LowSumpLevel kPag 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0
PumpSuctionPressure,NormalSumpLevl kPag 47.9 47.9 47.9 47.9 47.9 47.9 47.9 47.9 47.9 47.9
PumpDischargePressure kPag 7328.2 7511.4 7671.4 7235.8 7690.9 7558.0 7922.6 7975.1 7756.4 8322.1
RequiredSinglePumpHydraulicsPower(100%
efficiency),MinimumSumpLevel kW 1406 1310 1193 1442 1176 1281 948 891 1113 531
RequiredSinglePumpHydraulicsPower(100%
efficiency),LowSumpLevel kW 1404 1309 1191 1441 1175 1280 947 890 1112 531
RequiredSinglePumpHydraulicsPower(100%
efficiency),NormalSumpLevel kW 1399 1304 1187 1435 1171 1275 944 887 1108 529
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Table 9: The Flow Conditions and CV of LV1120018, LV1120028, LV1120038, and LV1120048
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Table 10: The Flow Conditions and CV of LV1130018, LV1130028, LV1130038, LV1130048, LV1130058, LV1130068,
and LV1130078
2.1 0.0 0
2.2 5956.4 5518.4 437.9 309.6 173
2.3 6051.7 5517.9 533.8 291.6 147
2.4 5852.7 5523.2 329.5 327.6 211
2.5 360.0 374
2.6 5654.8 5524.1 130.7 360.0 369
2.7 6126.9 5516.3 610.6 273.6 130
3.1 0.0 0
3.2 0.0 0
4.1 0.0 0
5.1 0.0 0
5.2 0.0 0
5.3 0.0 0
5.4 0.0 0
5.5 0.0 0
5.6 0.0 0
5.7 0.0 0
5.8 0.0 0
5.9 0.0 0
5.10 0.0 0
Pressure transmitters will be installed at the Pelluta Hill location between the 24” pipeline pig receiver
and the 28” pipeline pig launcher. The small tuning at the choke station will be done when the pressure
is in the normal range of 90 to 210 KPag. The low pressure alarm will be issued when the pressure is
lower than 13 KPag indicating the needs to further close the valve at the downstream choke station. A
high alarm will be issued when the pressure is higher than 210 KPag indicating the blockage of the
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downstream choke station requiring pump shut down. The high alarm signal can be used as reference for
operator intervention. A high high alarm will trigger the Titire and Vizcachas pump shut down when the
pressure is above 480 KPag. The choke station will regulate the required head to avoid slack flow
condition downstream of the Pelluta Hill. The inlet and outlet pressure conditions at different flow rates
for the choke station are listed at Table 11. Figure 9 and Figure 10 show the outlet and inlet pressures of
the choke station at different flow rates. It demonstrated that both the inlet and outlet pressures of the
choke station are correlated with the set points of the flow rate. There is a deterministic relationship
between the flow rate and the inlet/outlet pressure.
Table 11: Flow Control of the Choke Station
The cases shown in Table 11 have flow rates ranging from 230.4 m3/h (64 l/s) to 2772 m3/h (770 l/s).
The results for cases with flow rate below 1000.8 m3/h (278 l/s), cases 5.8 to case 5.10, are only
informative but not for design. The minimum flow rate for the pipeline design is 1000.8 m3/h (278 l/s).
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The shut-in cases produce the highest surge pressure that is critical for the definition of the pipeline
design pressure. The surge cases of the pipeline will be analyzed in details in the transient hydraulics
report. The final pressure profile at shut-in status was also simulated. Figure 11 shows the final settled
pressure in the system (Case 6.1) after the choke station is properly closed following the shutdown
sequence. The corresponding settled in pressure in the system need to be below the MOP (Maximum
Operation Pressure). The defined MOP based on the selected pipe wall thickness shown in Table 1 is
covering the pressure very well.
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(km)
Figure 11 The shut-in Pressure of the pipeline section from Titire River Pump Station to HDPE Tie-in (Case 6.1)
There must also be the addition of a control valve before the HDPE tie-in to ensure that the steel line
remains pressurized. This valve was sized based on the following flow rates and pressure drops.
This control valve is necessary due to the addition of open channel flow in the pipeline.
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2.6 Hydraulics Results of the Branch Pipeline Delivering Water to Tank 2910-TK-001
The size of this pipeline was shown as 8” on the P&ID (MQ11-02-DR-1140-PD1005). Figures Figure 12
and Figure 13 show the steady state hydraulics results for cases 7.1 to 7.9 of the 8” branch pipeline.
To limit the flow rate getting into the branch pipeline to tank 2910-TK-001, a flow control valve is
required at the inlet of tank 2910-TK-001. The flow condition for the design of the flow rate control at
the tank is shown in Table 12. The same outlet pressure seen in the cases is due to the tank pressure. The 2
valve can be set to operate at the necessary flows during operation.
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2.7 Conclusion
The results of the Steady State Hydraulics have resulted in the following findings and recommendation
(Table of results repeated for convenience of data retrieval):
1) The line sizes, wall thickness, MAOP, locations, and elevations are summarized in the following
table:
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PumpHydraulicsConditions Units Case5.1 Case5.2 Case5.3 Case5.4 Case5.5 Case5.6 Case5.7 Case5.8 Case5.9 Case5.10
TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver TitireRiver
Location Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation Pumpstation
3
PumpFlowRate m /h 694.8 630 561.6 720 550.8 612 432 403.2 518.4 230.4
NumberofPumpinOperation 4 4 4 3 3 2 2 2 1 1
PumpStationTotalFlow m3/h 2779.2 2520 2246.4 2160 1652.4 1224 864 806.4 518.4 230.4
TDH,MinimumSumpLevel m 723.2 741.4 757.2 714.1 759.1 746.0 782.0 787.2 765.6 821.5
TDH,LowSumpLevel m 722.4 740.5 756.3 713.3 758.2 745.1 781.2 786.3 764.7 820.6
TDH,NormalSumpLevl m 719.6 737.7 753.6 710.5 755.5 742.3 778.4 783.6 762.0 817.9
PumpSuctionPressure,MinimumSumpLevel kPag 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5
PumpSuctionPressure,LowSumpLevel kPag 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0
PumpSuctionPressure,NormalSumpLevl kPag 47.9 47.9 47.9 47.9 47.9 47.9 47.9 47.9 47.9 47.9
PumpDischargePressure kPag 7328.2 7511.4 7671.4 7235.8 7690.9 7558.0 7922.6 7975.1 7756.4 8322.1
RequiredSinglePumpHydraulicsPower(100%
efficiency),MinimumSumpLevel kW 1406 1310 1193 1442 1176 1281 948 891 1113 531
RequiredSinglePumpHydraulicsPower(100%
efficiency),LowSumpLevel kW 1404 1309 1191 1441 1175 1280 947 890 1112 531
RequiredSinglePumpHydraulicsPower(100%
efficiency),NormalSumpLevel kW 1399 1304 1187 1435 1171 1275 944 887 1108 529
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TitirePumpDischargeControlValve
Case InletPressure OutletPressure PressureCut FlowRate CV
kPag kPag kPag m3/h gpm/psi^0.5
1.1 7236.2 7001.7 234.5 694.80 530
1.2 7409.9 6389.0 1020.8 633.6 232
1.3 7275.2 6108.2 1166.9 680.4 233
1.4 8192.6 5792.7 2399.9 252.0 60
1.5 7732.2 5955.6 1776.6 486.0 135
1.6 7059.4 6592.2 467.2 741.6 401
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VizcachasPumpDischargeControlValve
Case InletPressure OutletPressure PressureCut FlowRate CV
kPag kPag kPag m3/h gpm/psi^0.5
1.1 0.0 0
1.2 6050.1 5625.0 425.1 291.6 165
1.3 5702.6 5629.0 73.7 352.8 481
1.4 5652.9 5631.8 21.1 360.0 918
1.5 5654.8 5630.2 24.6 360.0 851
1.6 6126.9 5622.3 504.6 273.6 143
2.1 0.0 0
2.2 5956.4 5518.4 437.9 309.6 173
2.3 6051.7 5517.9 533.8 291.6 147
2.4 5852.7 5523.2 329.5 327.6 211
2.5 360.0 374
2.6 5654.8 5524.1 130.7 360.0 369
2.7 6126.9 5516.3 610.6 273.6 130
3.1 0.0 0
3.2 0.0 0
4.1 0.0 0
5.1 0.0 0
5.2 0.0 0
5.3 0.0 0
5.4 0.0 0
5.5 0.0 0
5.6 0.0 0
5.7 0.0 0
5.8 0.0 0
5.9 0.0 0
5.10 0.0 0
Note: Cases 3.1-5.10 do not experience flow from Vizcachas, which is why these have a value of 0 for
2
those cases.
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3) The main pipeline needs to have a flow control at the choke station at around KP 79+660. The
flow conditions for the choke station are shown in the following table
Case SuctionPressure DischargePressure PressureCut FlowRate CV
kPag kPag kPag m3/h gpm/psi^0.5
1.1 5799.2 670.0 5129.2 2772.0 454
1.2 5799.2 670.0 5129.2 2772.0 454
1.3 5799.2 670.0 5129.2 2772.0 454
1.4 5799.2 670.0 5129.2 2772.0 454
1.5 5799.2 670.0 5129.2 2772.0 454
1.6 5799.2 670.0 5129.2 2772.0 454
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4) The Branch delivery water to tank 2910-TK-001 will be 8”. The 8” line needs to have a flow
control to prevent flow shortcut into the tank. The flow control requirements are shown in the
following table.
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3.0 AnalysisoftheExistingPipelinefromTieǦintoPools
3.1 Introduction
A steady state analysis is performed on where the pipeline will connect to the existing 30 inch transfer
line to the water collection pools. This pipeline is already responsible for this transfer of water from
6000-TK-001; however this ensures that the pipeline can continue to operate properly under the new
operating conditions. With the removal of tank 1140-TK-002, the pipeline will tie-in directly to the
existing line. Two possible flow scenarios were examined, pressurized and open channel flow. In the
end, per the client’s request, we are continuing forward with open channel flow. Below is our analysis of
both.
3.2 Parameters and Data for Modeling
3.2.1. Pipeline Elevation Profile
The pipeline elevation profile was made from the information provided for each branch. The outline of
the whole pipeline was created from where the pipeline goes from 6000-TK-001 to C2. This is outlined
in MQ09-16-DR-6020-CE6213. The new pipeline tie-in location was determined from the elevation of
the tank. This tie-in location was determined to be approximately 3.5 km down the pipe at 3926 m. The
30 inch pipeline then continues for approximately 2 more kilometers after the tie-in location, where it
tees off into two branches. One branch continues to pond C2, and the other branch continues for another
300 meters before coming to another tee. This tee then goes to ponds C1 and C4.The branches paths are
outlined in MQ09-24-DR-6020-CE1101, with the elevations for C1 outlined in MQ09-24-DR-6020-
CE6009 and C4 outlined in MQ09-24-DR-6020-PD7107. These provided us the elevation of the pipeline
at each distance, and the location of the air valves. The air valves are located primarily along the 30 inch
section of the line, with a few on the branches. However, these air valves are for when the line
experiences open channel flow, so should not open now that the line is pressurized. It also allows us to
see where the pipelines will connect, as well as branch apart to reach the three different pools. After tie-
in, the pipeline is approximately 2 km long until the branches separate, beginning at an elevation of 3926
m and ending at a lowest point of 3860.5 m, for a total change of 66 m. The diameter for each section
was taken from MQ11-02-DR-6020-PD1003.
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To Pond 4:
The first portion of this pipeline is shared by the pond 1 and pond 4 delivery. The second portion is
delivered to pond 4.
To Pond 2:
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To Pond 1:
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ElevationProfile
3930
Tee 1
30Inch
3920
3910
Pipeline 24Inch
Elevation(m)
3900
TieͲin
3890 Pond1
3880 Pond2
Pond4
3870
3860
Tee
3850 2
0 0.5 1 1.5 2 2.5 3
Distance(km)
As seen in the model above, there are pressure control valves at the end of all the pipeline branches.
These control the back pressure of the system to try and achieve a pressurized flow through the system,
keeping the pressure above 0 at all points. This also adds the benefit of limiting the flow of the system.
These valves were all sized and controlled in the model, the results of which are discussed below. These
valves will need to be fine-tuned for operation however.
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The pressure at the inlet, as seen above, is within our design margins. For the maximum flow rate, the
pressure at the inlet is 21.3 psig (146.9 kPag). At the minimum flow rate, the pressure at the inlet is 3.95
psig (27.2 kPag).
As seen in the above tables, the head curve is consistently above the elevation. This indicates that fluid is
filling the pipe down the line. Through operation of the pipeline however, especially at lower flow rates, it
is possible that the pressure will decrease at the inlet. This will cause the transfer line to not be completely
filled with water, causing the system to be in open channel flow. The system will be able to operate in
open channel flow for periods of time when the flow drops below 864 m3/h.
The results above are for a roughness of 0.0004 in. If a roughness of 0.0018 in is used conservatively, the
inlet pressure is increased for all flow rates. 864 m3/h corresponds to approximately 4.5 psig (31.0 kPag),
and 2772 m3/h corresponds to approximately 23.4 psig (161.3 kPag). The low flow is above 0 psig which
avoids open channel flow, and the high flow is below the maximum pressure of the system.
It is also noteworthy that the system will not be continuously run at the maximum flow rate. The average
flow expected is 2520 m3/h. This will correspond to an inlet pressure of 18.5 psig (127.6 kPag), which is
within our range.
These results were obtained through the addition of control valves at the output of all the branches. These
control valves were sized and controlled through our model. There was a sensor at the inlet of the valves,
allowing for pressure readings to be sent to the controller. We then set pressures for the valves that would
control the flow so that the pressure at the inlet was set between the ranges. The control valves summary
can be seen below. The set points for the flow are: Valve 1- 80 psig (551.581 kPag), Valve 2- 101 psig
(696.37 kPag), and Valve 4- 94 psig (648.107 kPag).
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The above table shows how the flow and pressure of the system is affected for the three set points that we
set for the control valves. These set points were chosen through an iterative procedure in which flow was
being directed based on the size of the three ponds. The pond C4 is the largest at 1,148,454 m3, with the
other two ponds approximately 150,000 m3. The basis of the control is for flow to primarily go to pond 4,
due to its much larger size, and then as the flow rate increases, to transfer to the other lines. The primary
purpose of the control valves is to pressurize the line, in order to avoid open channel flow. These control
valves hold the pressure through the line, all the way up to the tie-in, in which there was a design
condition due to the choke station.
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It is also important to note that at the end of the steel line, there must be a control valve. This control
valve will serve the purpose of continuing to hold the back pressure in the steel line, ensuring flow. The
pressure that this valve must hold is 25 psig (172.37 kPag). The valve is sized to open linearly under the
following conditions. A surge relief valve must also be added, which will be discussed in the transient
report.
6
7
8
9
10
11
12
13
14
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The table above shows the slope percentages used in the SWMM model, on the left, and the slopes
obtained from the elevation profiles on the right. One limitation of the elevation plot in SWMM is that
the uphill section cannot be modeled in the software as this is not desirable in an open channel flow
scenario. This is why one area is highlighted red, as the software was unable to model the downhill
slope. Therefore, the total elevation change across this segment was used in order to get the slope used in
the model.
3
4
7
8
As mentioned before, these two sections elevation profiles only use the average slopes in each of the
pipeline links. This is due to these two lines primarily being closed and filled with water.
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Velocities (m/s):
Velocities (m/s):
An Excel spreadsheet was also created in order to test the accuracy of the values above. The Manning
roughness of 0.009 was tested using this spreadsheet.
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The Froude number is a way of figuring out what type of flow regime will be present in the system. It is
௩
calculated through the equation ݎܨൌ . When this number is above 1, the flow is supercritical.
௦௧ሺሻ
This is what we find above for all pipe segments, most of which have a fairly high Froude number.
Supercritical flow means that the liquid will be have a fast flow through the system, normalizing the flow
scenarios for the different diameters. The higher the Froude number, the faster the flow.
One thing to note about the spreadsheet solution is that the velocities are lower than the ones found
through SWMM. Both are found using slightly different methods, but the final result is similar in the high
velocities.
Pond 2:
Velocities (m/s):
Pond 1:
Velocities (m/s):
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As seen above, link 4 is completely filled towards pond 1, and link 8 towards pond 2. This means that
these sections are pressurized when flowing at this flow rate. However, since the valves at the end of
branches 1 and 2 will be closed during normal usage, the lines will be filled with water and pressurized
regardless. Due to the elevation changes, pond 2 will have a static pressure of 51 psig (351 kPag) and
pond 1 will have a static pressure of 34 psig (234 kPag). If flow is diverted to pond 2, then the entire
branch of ponds 1 and 4 will fill with water. This provides a static pressure of approximately 53 psig (365 2
kPag). However, if diverted to pond 1, it will only experience approximately 28 psig (193 kPag).
The high velocities in certain sections are a function of the steep slopes present in certain areas of the
system. The open channel flow will work in the pipeline, these areas however must be examined with a
greater frequency, as they are more likely to fail. Due to the high velocities, these sections are at a much
greater risk for erosion on the line, causing the potential for leakages. It is also our recommendation to
examine these sections before they are put in operation. If something was to happen in these areas, it is
our recommendation that the line is installed in such a way to remove these steep slopes. It is also against
our recommendation to have an uphill segment, as is present going to pond 4. While the system still
works, it is not common for an open channel system to have this steep uphill section and we advise that it
is removed if work has to be done to the pipeline.
Finally, an important consideration with open channel flow is that there must be a control valve before
where the steel pipeline ties-in to the HDPE line. This is to ensure that the steel line is still receiving the
pressure necessary for a fully pressurized flow in order to not cause damage to the system. This pipeline
will ensure that the back pressure is held in the steel line. This will be done by having the pressure at the
inlet of the valve held at 25 psig (172.369 kPag). Another benefit of this is to ensure that the two lines
2
stay separated from each other, in case of a surge in either.
3.7 Conclusion
After discussions with client on both proposed methods, open channel flow was decided to be the desired
method of operation of the HDPE pipeline, as long as certain cautions were taken. Fluor recommends
that a pressurized flow is used in the system in order to control the velocity in the system, however due
to other potential concerns with a pressurized line; the HDPE line will be operated in open channel flow.
It is Fluor’s recommendation that if something is to happen to the pipeline that there are modifications to
the slope of the pipeline. There also must be tests done in order to analyze the current condition of the
HDPE pipe as the line has been in use.
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4.0 AnalysisontheInfluenceofSedimentationandSuspension
4.1 Introduction
The purpose of this section is to discuss the effects of sediments and particle erosion of the new
internally coated carbon steel pipeline from the Titire Pump Station to the HDPE tie-in, and then the
HDPE line itself. The Vizcachas reservoir has a much lower amount of sedimentation that accesses the
pipeline, so for the sake of this analysis can be conservatively considered the same.
120
100
%masssmaller
80
60
40
20
0
0 0.5 1 1.5 2
ParticleSize(mm)
IntakeParticleSizeData D88.3=0.2mm
D85=0.145mm D50=0.053mm
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120
100
%masssmaller
80
60
40
20
0
0 0.05 0.1 0.15 0.2 0.25
ParticleSize(mm)
PipelineParticleData D50=0.043mm
D85=0.079mm D95=0.129mm
D99=0.180
120
100
%masssmaller
80
60
40
20
0
0 0.5 1 1.5 2
ParticleSize(mm)
IntakeParticleSizeData 0.2mm=D85.89
D85=0.159mm D50=0.055mm
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120
100
%masssmaller
80
60
40
20
0
0 0.05 0.1 0.15 0.2 0.25
ParticleSize(mm)
PipelineParticleData D50=0.043mm
D85=0.080mm D95=0.127mm
D99=0.173mm
For the case of our erosion estimates, the density of quartz sand is used. This is a density of 2650 kg/m3.
The quartz sand also has a hardness of 7 Moh, which is used in the erosion rate model.
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The HDPE pipeline will have different erosion rates due to the higher velocity that will be experienced in
the line, along with the different material used. DNV O501 guidelines were once again used in order to
get the erosion values per year, and an analysis of the pipeline life total erosion. It is important to note as
well that this is only an analysis from the available information; the actual erosion results may be either
higher or lower than assumed.
The first scenario analyzed for the HDPE line is the straight pipe erosion. Due to the multiple possible
scenarios that could be experienced, multiple erosion rates are found. This also highlights the sensitivity
of the erosion rate.
First are the scenarios for a Manning Roughness of 0.009. The maximum velocity experienced in the
branch going to pond 4 is 13.98 m/s. First, a study was conducted for this velocity, assuming that the
whole pipe is being affected by the erosion. In reality, since the flow is in open channel, only a portion of
the area will be exposed to erosion. As seen below, the smaller the area, the higher the erosion rate. For
this purpose, it was assumed that 50% of the pipe was filled, when from our analysis earlier, it is likely
that a smaller portion is exposed to erosion, increasing the rate more.
Table 24 HDPE Straight Pipe Erosion, High Flow, 100% Pipe Filled, Roughness 0.009
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Table 25 HDPE Straight Pipe Erosion, High Flow, 50% Pipe Filled, Roughness 0.009
An analysis was also performed on a lower flow rate scenario to analyze how the erosion will be outside
of this high velocity section. Again, it is assumed that 100% of the line is filled. For 50% of the line filled,
the erosion rate should be doubled.
Table 26 HDPE Straight Pipe Erosion, Average Flow, 100% Pipe Filled, Roughness 0.009
The cases for a roughness of 0.011 were also tested, and will be shown later in the summary table.
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90 Degree Bend:
Bends in the pipeline were also measured for their erosion rate. This is due to the higher likelihood of
erosion occurring at these points of the pipeline. Due to the nature of the HDPE, a bend of 60*D was
utilized, estimated from Google Earth. This gives a radius of curvature of about 30 m, which means that
the erosion experienced should not be extremely higher than that of a straight pipe flow. The results are
analyzed below, with the same portions being analyzed. It is important to note that the section
experiencing the maximum flow condition will have a bend in it, however we do not know its radius of
curvature. We do not expect the HDPE to have as small a radius of curvature as steel.
Table 27 HDPE Bend Erosion, Average Flow, 100% Pipe Filled, Roughness 0.009
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Table 28 HDPE Bend Erosion, Maximum Flow, 100% Pipe Filled, Roughness 0.009
Table 29 HDPE Bend Erosion, Maximum Flow, 50% Pipe Filled, Roughness 0.009
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Since there are two different roughness being analyzed, the results of all the erosion calculations are
summarized below.
As noted earlier, these erosion rates are based on equations that use variables that can be different
throughout the lifecycle of the pipeline. Such variables that may change throughout the life cycle is the
flow rate, the amount of suspended solids in the system, and the wall thickness of the pipeline. Therefore,
the above models give a conservative estimate on what the erosion in the HDPE line may look like. In
order to accurately gauge the erosion seen in the pipeline, the wall thickness must be monitored every few
years. This will give a true erosion rate for the line. It is suggested that areas that will be experiencing
high velocities and turbulent flows are the areas focused on. It is important to note that pigging is not
possible in this HDPE line, and therefore another method of measuring the wall thickness must be used.
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Once the critical velocities have been found, the minimum critical velocity for design can be found in
order to ensure that no deposits are formed. From here, the corresponding minimum flow rate can be
found to ensure that this condition is met. Below are the results for both the 24 inch and 28 inch pipeline,
operating at 770 l/s.
Table 31 Results of Deposition Velocity Model for 24" and 28" Pipe at 770 l/s
For the HDPE line, the minimum flow rate will be determined by the 24 inch lines deposition rate.
Therefore this is what we will analyze below.
Judging from the table above, the minimum flow rate to avoid deposition is below the minimum flow rate
of the line, therefore deposition in the HDPE line will not pose a problem for solid deposits.
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4.6 Conclusion
It is found in the model analysis using available water testing report data that the pipe has a low risk of
erosion. It is also found the flow rate corresponding to the minimum critical velocity that should be met
in the main pipeline. The minimum flow rate from the Titire River to the Vizcachas Tie-in is 64 L/s. This
flow rate is lower than the deposition flow rate of 105.6 L/s. There will be some solid settlement at this
flow rate. However, the influence of the solid is low due to the low concentration of solid and very low
total water flow rate of 64 L/s. The settlement can be cleaned through pigging or line washing at higher
flow rate above 200 l/s. In the HDPE line however, there should not be any deposition seen due to the
high velocities experienced.
5.0 Bibliography
Sunde, A. (2015). Properties of Thermal Sprayed Coatings for Internal Use of Pipes and Bends.
Norwegian University of Science and Technology.
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AppendixA PipelineSystemSchematic
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AppendixB :ModelSchematicsofthePumpedSectionofthePipeline
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AppendixC :PumpCurvesattheTitirePumpStation
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AppendixD :PumpCurvesattheVizcachasPumpStation
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The Quellaveco project is a greenfield development 127.5 ktpd of ore through primary crushing,
grinding, and collective copper–molybdenum flotation, and a selective molybdenum flotation
process.
The facility that the Fluor Pipeline Group is designing is the Fresh Water Pipeline Facility. This
water supply infrastructure is in a remote location called High Mountain (WBS Area 1000) and
includes two independent feed sources (Units 1120 and 1130) and a 90 km pipeline system (Unit
1140), which has an overall design capacity of 770 L/s, and transport water to three water storage
ponds at the Caracoles area next to the process plant (which are required for construction and
have a total capacity of 1.8 Mm3). This capacity will provide more than 30 days of make-up fresh
water.
The fresh water is supplied from two feed sources, the Titire and Vizcachas Rivers. The fresh
water is expected to be of poor quality: Titire river water has high chlorides (as high as 3328
ppm) especially during the dry season while Vizcachas river water has less chlorides (66 ppm)
The pH range is from 5.6 to 7.8. Both river water sources have significant biological activity
related to microbial induced corrosion. Build-up of biological growth will be more evident in
Vizcachas pump station as it has more stagnant sections of pipe and is to be run less frequently.
These sections will need periodic draining or cycling of pumps to prevent build-up of the
biological growth.
Independent pumps stations will extract water from both of these sources. The fresh water system
will be permanently fed by the Titire River (Unit 1120) while flow is available. The secondary
source of water supply comes from a dam on the Vizcachas River (Unit 1130), with a storage
capacity of 60 Mm3. The use of water from the Vizcachas River Reservoir will be reserved for
periods when the Titire source is not sufficient during the dry seasons. In addition to the water in
the Vizcachas River Reservior, water may be used from the Caracoles water storage ponds during
the dry season.
The pipeline operates as a fully pressurized pipeline with independent feed pipes from the two
pumping stations joining at a common header at the Vizcachas pump station and flows past the
highest point of the route that is the Pelluta Hill, which is 21 km downstream of the Titire intake,
and at an approximate elevation of 4,820 m.a.s.l. From the Pelluta Hill, the flow is fed by gravity
to the pipeline and a portion of the flow enters through a 8”-branch feeding the Quellaveco Mine
Tank while the majority of the flow enters through a 24”-pipeline connecting to an existing
HDPE pipeline that ends at the Caracoles ponds at the mine site. A pressure control valve is
installed at the end of the steel line prior to connection with HDPE line. This control valve will
serve the purpose of continuing to hold back the pressure in the steel line, ensuring flow.A choke
station is required to be installed in the section between the Pelluta Hill and the end of the
pipeline to maintain the hydraulic grade line and to prevent slack flow
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The total distance of the flow through this pipeline is approximately 86.54 km.
A description of each unit and its control philosophy is provided in the ensuing sections:
2.1 UNIT 1120 – Titire River Intake and Pump Station 1120-PC-101
2.1.1 River Intake DESACTUALIZADO
Reference P&ID: MQ11-58-DR-1120-PD1001
The Titire intake (designed by third party) will be located at approximately 4332 m.a.s.l. It is a
reinforced concrete hydraulic structure whose function is to capture water from the Titire River
and deliver to the pumping station.
The river intake consists of Fixed Barrage, Mobile Barrage, Intake, Desander and Purging
sections.
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When in Local Mode, Operator may operate through switches provided on the hydraulic unit.
Remote control is inhibited. The gates cannot be operated when Out of Service Mode is selected.
When in Remote mode, the 1120-GA-011 and 1120-GA-012 shall automatically open when
1120-FT-508 exceeds 362.2 m3/s.
The remote operation of the gates 1120-GA-011 and 1120-GA-12 will be carried out from the
Main Control Room. This is made possible through Profinet link between the hydraulic control
units 1120-GA-011-HY1, 1130-GA-012-HY1’s PLCs and PCS 1120-PC-101 located at Titire
E/R.
The following are lists of interface signals (through Profinet) between the PCS and the hydraulic
control units:
PENDIENTE DATA TRANSFER
1120-GA-011-HY1
Controls 1120-GA-011
Tag No. Service
1120-HSO-500 Gate 1120-GA-011 Open Command
1120-HSC-500 Gate 1120-GA-011 Close Command
1120-ZLO-500A Gate 1120-GA-011 Open Indication (Cylinder 1)
1120-ZLC-500A Gate 1120-GA-011 Close Indication (Cylinder 1)
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The following signals are associated with these motor actuated gates.
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Purging Operation
Purge gates 1120-GA-016 and 1120-GA-017 have a motorized On/Off actuator and are
independently operated to divert the sediments accumulated in the desander. Purging can be done
one section at a time to minimize the reduction of water flow into the sump during purging
operation. When the gates are opened, the sediments are transferred to the sediment pool and is
driven to the tankers through a portable submersible pumps 1120-PU-006.
The following signals are associated with these motor actuated gates:
Tag No. Service
1120-HSO-506 1120-GA-016 Open Command
1120-HSC-506 1120-GA-016 Close Command
1120-ZLO-506 1120-GA-016 Open Indication
1120-ZLC-506 1120-GA-016 Close Indication
1120-HSO-507 1120-GA-017 Open Command
1120-HSC-507 1120-GA-017 Close Command
1120-ZLO-507 1120-GA-017 Open Indication
1120-ZLC-507 1120-GA-017 Close Indication
These gates can be operated locally or remotely. However, remote-manual operations shall be
restricted to close the gate during emergency case only. The normal operations shall be carried
out locally through the local push button integrated to the motor actuator, or through the manual
hand wheel.
When purging during wet season, the Operator shall closely monitor the sump level as substantial
amount of water may be displaced to the sediment well, causing rapid decrease in sump level that
may result in nuisance pump trip due to low low sump level. In this case, the Operator shall turn
off one or more pumps as necessary.
The Operator may also temporarily turn off one or two pumps at the beginning of purging
operations. One or wo pumps may be brought online again when the percentage opening of the
gate valve, tagged as 1140-ZI-013 indicated in the HMI is relatively low which indicates that
more river water may be available compared to that which is displaced during purging.
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When purging is performed during dry season, since the pump discharge flow is maintained to
keep sump level to the normal level, any decrease in flow into the sump will result in auto
adjustment of the pump discharge flow rates and / or shutting off of one or more pumps.
Except for gates 1120-GA-01 and 1120-GA-012 which are controlled by the hydraulic control
unit with integrated PLC, all field instruments and motor actuated valves’ signals are connected
and wired to the field Remote IO cabinet 1120-IO-002, that connects to the PCS in Titre E/R
though fiber optic link.
For more information on the Titre River Intake control philosophy, refer to MWH’s (Stantec)
Filosofia de Control – Presa Vizcachas Y Bocatoma Titire, Do No. MQ11-58-RE-1100-IN0020.
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The feed system will consist of a pump station (Titire River Fresh Water Pumps 1120-PU-
001~005) and Titire River Sump (1120-SU-001).
FIC-505
The Titire river water entering the Titire Pumping Station flows by gravity into the concrete Titire
Fresh Water Sump (1120-SU-001). The sump is designed to provide adequate hold up time to
allow for the operation of the pumps and designed and tested per HI 9.8 (2012). The sump liquid
level is maintained by motor actuated sluice gate valve 1120-GA-013 in the intake structure. The
sluice gate valve is set to maintain sufficient level in the Titire Fresh Water Sump. The
accumulated water in the sump is then transferred by five multi-stage vertical pumps (1120-PU-
001/002/003/004/005) into the pipeline.
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The Titire pumping station will be operated in two modes, Wet Mode and Dry Mode. A soft
selector switch 1120-HS-001 is provided on the OW (Operator Workstation) for Operator to
select between the two modes.
Wet Operation Mode (1120-HS-001_WET) is selected during the wet season, and a Flow
Management strategy should be considered. For this case, there is abundantly available water and
there is no need to have a flow control condition. The Flow Management operation would be to
decide on a monthly average and then select how many pumps are needed to achieve that
average. The pumps will be running at their rated capacity. The monthly average is a strategic
value that considers history, water in ponds, future operations, and status of the average versus a
30 year permit. Pump-out shall be maximized but in order to not exceed the monthly target, some
pumps maybe shut off few days before the end of the month, while the other pumps are running
at full capacity.
In Wet Operation Mode, the sump level will be maintained by level controller 1120-LC-001 by
throttling the intake gate 1120-GA-013.
Table 1 lists the monthly conditions, which are the limiting factors for the flow and volume,
which can be removed from the Titire River each month.
Total
Max Ave
Monthly
Flow
Allowed
Month Rate No. of Days
Volume
(L/s)
(Million M3)
(Note 1)
(Note 1)
January 700 31 1.87
February 700 28 (Note 2) 1.69
March 700 31 1.87
April 700 30 1.81
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Notes:
1) Based on Table 2 in Schlumberger Water Services Report dated Nov 14th, 2013
referencing document RDNo.0126-2010-ANA-DARH.
2) 29 days on leap year. Rate’s and averages are still the same.
The second operating mode, Dry Operating Mode (1120-HS-001_DRY) is selected to maximize
the recovery of available water (“chase the river”) during the dry season when there is less water
in the river than the monthly target. During this period, the only source of information for the
operator to know what flow is available in the river is the intake flow meter 1120-FIT-505.
In Dry Operation Mode, the sump level controller 1120-LC-001 will force the intake gate 1120-
GA-013 to fully open, allowing maximum flow into the pumping station.
The PCS will initially decide the number of pumps to run based on the intake flow rate. The
Total flow will be divided in 4 ranges (because of the 4 pumps running), so that the number of
pumps to start/stop will be according to the selected range:
Flow range =192.6-385 L/s (25-50%): Start only 2 pumps. The pumps will automatically adjust
to maintain the required minimum flow conditions of the individual pumps.
Flow range =385.1-577.5 L/s (50-75%): Start only 3 pumps. The pumps will automatically adjust
to maintain the required minimum flow conditions of the individual pumps.
Flow range =577.6 L/s and above (<75%): Start 4 pumps. The pumps will automatically adjust to
maintain the required minimum flow conditions of the individual pumps.
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The PCS will prompt the operator to confirm the number of pumps that should run, based on the
above range. After the operator confirms, he will then press the group start soft switch 1120-HS-
101, and the PCS will command the necessary number of pumps to start sequentially, with a
preset time delay.
After the last pump has started, the Level Controller 1120-LC-002 will be activated, and the
pump discharge valves 1120-LV-018/028/038/048/058 will be throttled to ensure that the sump is
not drained and sufficient level is maintained.
The PCS shall be configured to allow for automatic service rotation of the operating pumps. A
run time counter will be provided in the PCS system to keep track of the current running hours of
each pump. When the pump is in automatic mode, the PCS will notify the operator in the event
that the run time on the standby pump is 15% less of the run time of the longest running pump. If
confirmed by the operator to make the change, the system will automatically start to bring the
standby pump online. Alternatively, the operator has the ability to enter in a predetermined value
for the number of minutes between changing of pumps. A notification will be provided to the
operator that the timer has been reached and if he wishes to proceed. The system will look at both
of these limitations and select the first option to be fulfilled and both are then reset, when the
pumps are rotated.
Any station start-up will start the pump with the least run time first.
The pipeline flow point will be set according to the Pipeline or pumping station Operating Mode.
When Titire is in Wet Mode, the Operator shall decide the number of pumps to run and the
Pipeline flow set point will be adjusted accordingly. Four pumps running means that the flow is
set at 2772 m3/h, three pumps at 2079 m3/h, and so on.
In Dry Mode or Pigging Mode, Operator shall manually key in values between 278 L/s
(corresponding flow rate during Pigging Operations of 24” or 8” line) and 770L/s.
On the Operator’s Workstation, a Pipeline Flow Set Point (tagged as 1000-FC-001_SP) and
Number of Running Pumps (tagged as 1120-HS-002) Input Windows shall be configured so that
the Operator can choose different values.
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In the event that the flow entered for the pipeline doesn’t match the flow entered for the Titire
Pump Station, the Vizcachas Pump Station flow setpoint shall be the difference.
The pipeline operator enters in daily a pipeline flow value. The daily value does not have to equal
the total required mine site operational daily value as the operator can decide to utilize water in
the Caracoles Ponds to supplement the pipeline flow. The value is the L/s of water that is required
to be supplied to the plant for the day. In the event that the Pipeline Flow Control Setpoint is less
than the Titire Pump Station total flow output, insufficient flow is determined.
Insufficient flow means the total discharge flow is below the operator entered pipeline flow
setpoint. Insufficient flow can occur due to various reasons but the most common would be the
Titire Pump Station Flow output being lower than the pipeline setpoint. If this is the case the
Vizcachas pumps will be started to supply the deficit.
However, the Vizcachas pumps can only operate with a flow setpoint equal to or 10% higher than
its pump minimum flow. So in the event that the Titire deficit is below the Vizcachas pump
minimum flow (41 L/s / 148 m3/h) plus 10% (163m3/h), the PCS shall notify the operator prior
to making an automatic adjustment to be equal to its minimum flow for the Vizcachas pumps.
The only flow control in Titire is the common spill back flow controller 1120-FC-107 with
magnetic flow transmitter 1120-FIT-107 and control valve 1120-FV-107. This controller prevents
the Titire discharge flow to exceed the Titire pump station design flow which is 770L/s.
The spillback line can also be used for locally draining the pump discharge header into the sump,
during periodic maintenance, through manual operation of the spillback valve. When draining,
the Operator shall set the Pipeline to Off Mode (1000-HS-001_OFF). Controller 1120-FC-107
shall be set to Manual Mode, and the Operator can input 100% opening of the control valves
1120-FV-107 to allow for maximum flow during draining.
In case the pump discharge flow falls below normal, low flow alarm (1120-FAL-
018/028/038/048/058) will be generated and when flow reaches the pump minimum flow
requirement, low low flow (1120-FALL-018/028/038/048/058) will be activated to trip the
respective Titire pumps. Feed source will switch to Vizcachas River and Vizcachas pumps will
supply the required difference in flow.
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For each pump the minimum flow set point shall be higher than the minimum pump flow
requirement. The minimum flow set point shall be 25% of the rated flow, which will be verified
at a later date by the pump supplier.
a. Totalizes the flow rate from the operating pumps, based on the following algorithm:
The total flow delivered by Titire (1120-FQI-108) to the pipeline is the total available flow
from the pumps 1120-FIQ-100 minus the flow rate at the spill back line 1120-FIT-107.
b. Limits the totalized Titire flow rate 1120-FQI-108 to 770 L/s, in excess of which will be
returned to sump via spillback controller 1120-FC-107. The set point for the returned flow
rate is determined by 1120-FC-100 using the following algorithm:
When the result returns a negative (-) value, the controller 1120-FC-107 shall force the spill
back control valve 1120-FV-107 to close position.
A flow totalizer shall be configured in PCS and shall notify the operator when total annual limit
of 19 Mm3 from Titire River is about to be reached. The Operator can decide to reduce the flow
set point if necessary.
Pressure surges in pipeline can be caused by blocked discharge or shut in conditions. The
discharge pressure of each pump is monitored by a local pressure indicator. For pumps 1120-PU-
001/002/003/004/005, the respective pressure indicators are 1120-PI-015/025/035/045/055.
These pressure indicators are used by operations on a routine basis to check pump performance.
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The discharge header pressure is monitored by PCS via pressure transmitter 1120-PIT-101.
As pressure surges, this pressure transmitter will generate a high pressure alarm (1120-PAH-101)
and when the discharge header pressure reaches high high pressure setpoint (1120-PAHH-101) a
controlled shutdown is triggered of the Titire pumps. When the high high pressure trip fails and
pressure continues to surge, a surge relief valve installed in the discharge header (1120-SRV-001)
will open and blow-off relief water into the Titire Sump.
At high pressure alarm, the spill back flow controller 1120-FC-107 will be overridden. The spill
back control valve 1120-FV-107 will be fully opened to allow maximum spill back flow and
reduce the pump discharge flow to the pipeline thus relieving the pipeline from over pressure.
Once header pressure is back to normal, that is 10% less than the PAH set point, flow controller
1120-FC-107 will resume control of the spill back line.
A high high pressure trip shall also override the spill back flow controller 1120-FC-107. The
spill back control valve 1120-FV-107 will be fully opened. When the header pressure is 10% less
than the PAH value, or reaches the SRV closing set point (6412 kPag), whichever comes first, the
valve will be fully closed.
The opening pressure for the Titire SRV shall be set such that it will always open ahead of
Vizcachas SRV, to prevent sending the Titire water to the Vizcachas Dam, potentially
contaminating the dam water.
The pumps will be allowed to start when the level in the Titire Sump (1120-SU-001) is sufficient
(above low) and they will automatically trip once the sump level reaches low low liquid level
(LLLL) to prevent the pumps from running dry.
During wet season, Wet Operation Mode is activated. Sump level is maintained at normal level
through the level controller 1120-LIC-001which consists of level transmitters (1120-LIT-001 and
1120-LIT-002) and a motor actuated type gate valve 1120-GA-013 (MWH supply and install), at
the Titire inlet piping to the sump.
The gate valve will actuate based on a level setpoint (1120-LC-001_SP) in the sump, which will
be entered by the operator. As the level rises in the sump, the gate valve will start to close and as
the level decreases in the sump, the gate valve will fully open. If the sump hits the high level
setpoint the gate valve will fully close thus preventing any flow from entering the sump.
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During dry season, Dry Operation mode is activated, the sump level controller 1120-LC-001 will
force the intake valve 1120-GA-013 to fully open. The Level control shall be taken over by the
level controller 1120-LC-002, where the sump level is maintained by controlling the pump
discharge flow rate through the pump discharge control valves 1120-LV-018/028/038/048/058.
The sump level is monitored by PCS via ultrasonic level transmitter 1120-LIT-001 and radar
level transmitter 1120-LIT-002. PCS receives individual signals from these transmitters and
calculates the average, and is displayed on the Operator Workstation (OW) tagged as 1120-LI-
001. In the event that the average is more than 5% different than one individual level indicator,
an alarm will be generated to notify the operator of the deviation.
Low Level Alarm 1120-LAL-001 is generated at OW when sump level falls below the setpoint.
Low low level trip and alarm 1120-LALL-001 (1oo2 voting) is generated by PCS when water
reaches critically low level, and the pump motors 1120-PU-001/002/003/004/005-MO1 shall be
tripped.
Upon high high liquid level (1140-LAHH-101/102/104) at the Caracoles ponds, the Titire River
Pumps shall be shutdown.
The Titire River Pumps are provided with pump bearing temperature and vibration transmitters,
connected to PCS. The PCS shall generate a high pump bearing temperature alarm 1120-TAH-
011/021/031/041/051, high vibration alarm 1120-VAH-011/021/031/041/051 (x, y, and z axis)
and pump motor bearings high vibration alarms 1120VAH-013/023/033/043/053 and 1120-VAH-
014/024/034/044/054 (x, y, and z axis) when temperature and vibration exceeds normal
operating conditions. This is to limit the possibility of damage to or mechanical issues with
bearings, seals or misalignment during pump operation.
PCS shall generate high high temperature trip and alarm 1120-TAHH-011/021/031/041/051 and
high high vibration trip and alarms 1120-VAHH-011/021/031/041/051 (x, y, and z axis), 1120-
VAHH-013/023/033/043/053 (x, y, and z axis) and 1120-VAHH-014/024/034/044/054 (x, y, and
z axis) when temperature and vibration reaches critical level, and trip the respective pump motors.
Pump motors are also provided with bearing RTD, winding RTD sensors. These are directly
connected to the IED. Upon detecting trip set point, the IED shall trip the motor, thereby shutting
off the pump.
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A field installed Emergency shutdown pushbutton switch is provided for each pump to allow
pump shutdown in case of an emergency event.
Normally, there are 3 pump modes available, OPERATION / MAINTENANCE / OFF. The
pumps shall be set to OPERATION-AUTO MODE to allow auto start/stop based on PCS logic.
Only four pumps are allowed to be in Duty modes, and one pump in Standby Mode. Pumps in
MAINTENANCE or OFF mode shall not be selected as in Duty or in Standby Mode.
Duty and standby pumps shall be rotated / cycled based on the number of hours/days run. This is
to avoid pumps from running for a very long time thereby minimizing maintenance issues on the
pumps. PCS logic shall be configured and will use an hour meter function block for each pump
to facilitate auto-cycling of pumps.
During pump cycling, the Stop sequence philosophy shall be based on First Start, First Stop
scheme, and vice versa.
A lockable Local/Remote switch is also provided for each motor to prevent remote pump control
from PCS during maintenance.
Pump Start-up
Pump motors are allowed to run only when their respective start permissive is activated
on the following criteria:
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Start-up Overrides:
During pump start-up the following alarms and trips will be overridden until a preset time
delay. Pump failure to start after the time delay will halt the pump start sequence:
PCS in Titire (1120-PC-101) and PCS in Vizcachas (1130-PC-101) exchange data thru the PCS
control network to facilitate integrated control of Titire and Vizcachas Pumping stations.
However, direct control of pumps shall be performed by their respective PCS. For example, PCS
in Titire shall only control pumps in Titire and will not have direct control of Vizcahas Pumps
and vice-versa.
Titire totalized flow rate will be added to Vizcachas totalized flow (1130-FQI-108), which is
equivalent, to the total pipeline flow rate and will be tagged as 1130-FIQ-101. When the total
flow 1130-FIQ-101 falls below the pipeline operator setpoint continuously for 5 minutes, the
Vizcachas pumps will be started automatically. The number of pumps to be operated depends on
the flow deficit in the Titire. Refer to section 2.2 for details.
Data sent from Vizcachas PCS to Titire PCS for Titire pump control
Total Vizcachas flow rate 1130-FQI-108.
Vizcachas totalized flow rate will be added to Titire totalized flow, which is equivalent to the
total pipeline flow rate and will be tagged as 1120-FIQ-101. This will also be displayed in the
OW, and sent to controller 1120-FICQ-100. Basically, total pipeline flow indication in Titire and
Vizcachas, tagged as 1120-FIQ-101 and 1130-FIQ-101, respectively are identical.
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Diversion Channel
The Diversion channel is a reinforced concrete structure that diverts the river during the
construction stage of the dam.
Vizcachas Dam
The Vizcachas Dam is a structure of rolled concrete with a maximum height of 41m. In the
central part of the dam there are two galleries that are part of the drainage system.
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Spillway
The spillway consists of a free discharge landfill constructed of concrete armed resting on the
central part of the Vizcachas Dam, with a capacity of 75.43 m3/s.
Drainage System
The drainage system consists of a reinforced concrete tower of 37m height supported on the face
upstream of the Vizcachas dam and a square section duct of reinforced concrete of 13.80 m of
horizontal length that crosses the body of the dam, and finally an inclined section that connects to
the conduit in the body of the dam and then to the well dissipater of the bypass system. The tower
houses a flat gate 1130-GA-021 for the operation control of 1.20 m x 1.80 m dimension of the
span that is operated from the crest of the dam through a hydraulic control unit 1130-GA-021-
HY1. Hydraulically, it has been designed for a drainage capacity lower than the design flow of
the spillway (251.58 m3 / s) and for emptying the reservoir in less than 15 days.
The collection and delivery system is made up of a concrete collection tower 35.00 m high, a 54
"diameter stainless steel pipe and a system of six pipes for the delivery of the regulated flows.
The tower houses a flat gate for the opening and closing of the system of 1.20 m x 1.80 m
hydraulic winch controlled gate 1130-GA-022 that is operated from the crest of the dam though a
hydraulic power unit 1130-GA-023-HY1. Hydraulically the entire system is designed for a total
discharge of 6,208 m3 / corresponding to the sum of the delivery flows and the flow of supply to
the pumping station (1,808 m3 / s total) and to the minimum flow of the drainage work (4.40 m3 /
s of reserve water from the Special Project Pasto Grande (PERPG).
The Vizcachas Dam construction is divided into two phases: Operation during filling phase and
Normal operation. It is expected that the Vizcachas PCS in Pumping Station E/R and Main
Control Room where the dam is remotely operated will be ready only during the Normal
operation. Gates are locally operated though their Hydraulic Control Units installed in Hydraulic
Booth.
During the Filling phase, the dam is filled until elevation 4352.20 msnm, then the final closure
gate 1130-GA-024, temporarily operated by the hydraulic control unit 1130-GA-021-HY1, is
placed and covered with a concrete plug. Below diagram presents control diagram of the final
closing gate.
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After the concrete plug is placed, the operation gate 1130-GA-021 is operated until the dam level
reaches elevation 4357.00 msmn., through the hydraulic control unit 1130-GA-021-HY1.
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During the Normal Operation phase, the operation and control of gates 1130-GA-021, 1130-GA-
023, 1130-GA-022, and 1130-FL-003/004 will be carried out from the Main Control Room. This
is made possible through Profinet link between the hydraulic control units 1130-GA-021-HY1,
1130-GA-023-HY1’s PLCs and PCS 1130-PC-101 located at Vizcachas E/R.
The following are lists of interface signals (through Profinet) between the PCS and the hydraulic
control units:
1130-GA-021-HY1
Controls 1130-GA-021
Tag No. Service
1130-HSO-505 Drain Operation Gate 1130-GA-021 Open Command
1130-HSC-505 Drain Operation Gate 1130-GA-021 Close Command
1130-ZLO-505 Drain Operation Gate 1130-GA-021 Open Indication
1130-ZLC-505 Drain Operation 1130-GA-021 Gate Close Indication
1130-PAH-505 Hydraulic Unit 1130-GA-021-HY1 Pressure High
1130-LAL-505 Hydraulic Unit 1130-GA-021-HY1 Oil Level Low
1130-YL-505AA Drain Operation Gate 1130-GA-021 Local Operation Mode Indication
1130-YL-505AB Drain Operation Gate 1130-GA-021 Remote Operation Mode Indication
1130-YL-505AC Drain Operation Gate 1130-GA-021 Out of Service Indication
1130-YL-505B Drain Operation Gate 1130-GA-021 Emergency Close Indication
1130-GA-023-HY1
Controls 1130-GA-022, 1130-GA-023, 1130-FL-003 through hydraulic winches 1130-HT-002, 1130-
HT-001 and 1130-HT-003, respectively
Tag No. Service
1130-HSO-506 Drain Emergency Gate 1130-GA-023 Open Command
1130-HSC-506 Drain Emergency Gate 1130-GA-023 Close Command
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When set in Auto-Remote Mode, the Operation Gate 1130-GA-021 starts to open when the flow
rate measured by 1130-FT-503 at the Pasto Grande exceeds 4.40 m3/s, discharging the excess
flow to the Vizcachas River through drainage channel. This gate can also be used to temporarily
regulate the flow of the Delivery systems, in case or emergency or maintenance of equipment
installed in the delivery lines
Water enters the delivery system through the gate 1130-FL-003 which has a safety lock to allow
maintenance of gate 1130-GA-022, then to a distribution header. From the header there are six
delivery branches.
One branch goes to the Vizcachas Pumping station and is designed for a 770 L/s maximum flow
that corresponds to flow requirement of Quellaveco Mining project. This branch consists of a
motor actuated gate valve 1130-HV-563.
The other five branches caters for the following flow requirements and each consists of a motor
actuated gate valve (HV), automatic flow controller (FC) with magnetic flow meter (FIT) and
flow control valve (FV):
Titire Compensation Flow: 0.77 m3/s max, 1130-HV-553, 1130-FC-558, 1130-FIT-
558, 1130-FV-558
Vizcachas Compensation Flow: 0.037 m3/s max, 1130-HV-543, 1130-FC-548, 1130-
FIT-548, 1130-FV-548
Caudal Moquegua Chincune: 0.651 m3/s, 1130-HV-533, 1130-FC-538, 1130-FIT-
538, 1130-FV-538
Caudal Ecologico: 0.15 m3/s, 1130-HV-523, 1130-FC-528, 1130-FIT-528, 1130-FV-
528
Agua de Reserva PEPG: 4.40 m3/s, 1130-HV-513, 1130-FC-518, 1130-FIT-518,
1130-FV-518
The motor actuated gate valves (HV) on these 6 branches are remote-manually operated from the
Main Control Room.
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Filtration Measurement
Thin wall triangular weirs will be placed to measure the filtration flows. The landfills will be
located at the exit of the 4 galleries, 2 at the upper and 2 at the lower galleries. Each landfill has
an ultrasonic type level sensor and is listed below.
During dam construction, when PCS is not yet ready to receive the above signals, a temporary
method of measuring the filtration leak will be implemented by Stantec.
Dam Level is monitored via the level transmitter 1130-LIT-504. A Low low dam level 1130-
LALL-504 shall initiate trip on Vizcachas Pumping stations.
Flow at Aforo V1 Descarga Rio Vizcachas, Aforo V2 Embalse Vizcachas and Aforo 3 Pasto
Grande are being monitored by flowmeters 1130-FIT-501, 1130-FIT-502 and 1130-FIT0503,
respectively.
Except for gates which are controlled by the hydraulic control unit with integrated PLC, all field
instruments and motor actuated on-off and control valves’ signals are connected and wired to the
field Remote IO cabinet 1130-IO-002, that connects to the PCS in Vizcachas E/R though fiber
optic link.
For more information on the Vizcachas Dam control philosophy, refer to MWH’s (Stantec)
Filosofia de Control – Presa Vizcachas Y Bocatoma Titire, Do No. MQ11-58-RE-1100-IN0020.
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station in the event that the Titire Pumping Station is shut down or insufficient flow is available
in the Titire River.
The Vizcachas pumping station consists of eight multi-stage horizontal pumps at an elevation of
approximately 4335 meters above sea level and approximately 88 kilometers from the Quellaveco
mine site. From the pump station, this feed pipe will then join the Titire feed pipe forming a
common header going to the pipeline.
The Vizcachas River Pumps are automatically started based on a selection of flow deficit range
from Titire pumping station. Once a flow range is selected, the number of pumps will be
automatically determined and will begin to operate. The pumps are stopped sequentially when the
demand decreases due to Titire discharge flow returning to its design flow. They are also stopped
automatically based on a high pressure in the discharge header or a high high level at Caracoles
Ponds in the Quellaveco mine site. These eight pumps have the ability to operate independently
from each other or in parallel with each other. The system is designed to allow a maximum of 7
pumps to run at any one time and to have one pump as a common spare (7 operating, 1 spare).
The eight pumps are divided into two sets of four. Each set is supplied by a common suction line
and the discharge header of each set combines to form one common header. The discharge
headers are provided with spillback control. The spillback header is used to return the excess flow
from the total discharge flow of the operating pumps (however few or many), relative to the
maximum discharge limit of 700 L/s.
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When Titire Wet Mode is activated, the Vizcachas pumping station will be set to Idle Mode since
Titire is expected to meet the Pipeline flow set point. To ensure that no pump will be running in
Vizcachas, the PCS shall prohibit any pumps from running automatically. Therefore any
deviation between Pipeline and Titire flow set points shall not cause the Vizcachas pumps to start.
During pump cycling, the Operator will be prompted, once a week, to switch to Vizcachas Pump
Cycling Mode to allow pump cycling.
When the Titire operates in Dry Mode, Vizcachas shall be automatically switched to ‘Online
Mode’ which means that Vizcachas pumps can be started based upon the flow deficit in Titire,
provided all permissives are fulfilled and no interlock is active.
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Flow Control
The individual pumps are flow controlled to allow for adjustment of the pump flowrates of each
pump.
In Dry season (Titire Dry Mode and ‘Vizcachas Online Mode’ are activated), when Titire total
discharge flow is inadequate, that is, less than the pipeline setpoint for 5 minutes, the flow
controller 1130-FICQ-101 will start the Vizcachas pump(s) to supply the deficit. When the Titire
discharge flow starts to increase, the Vizcachas demand will start to decrease. When the demand
continues to decrease in 5 minutes (TBC), flow controller 1130-FICQ-101 will then stop the
Vizcachas pumps sequentially until the Titire pumps are able to supply the entire flow.
Excess flow means the pumps are discharging beyond the required flow. Excess flow needs to be
returned via spillback control. The combined discharge header is provided with spillback which
has a motorized control valve controlled by flow controller 1130-FC-107 to open and return the
excess flow to the dam as read by magnetic flowmeter with flow indicator 1130-FIT-102.
Vizcachas pumps 1130-PU-001~008 are designed for a rated flow of 360 m3/h (100 L/s) and are
expected to run based on demand scheme to make up for the deficit flow delivered by the Titire
pumping station.
The flow at the discharge of each pump is controlled by the individual flow controllers 1130-FC-
018/028/038/048/058/068/078/088 that controls the respective pump discharge control valves
1130-FV-018/028/038/048/058/068/078/088.
The total flow delivered to the Pipeline by Vizcachas (1130-FQI-108) is the total available flow
from the pumps 1120-FIQ-100 minus the flow rate at the spill back line 1130-FIT-107.
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When the total flow in Titire falls below the pipeline setpoint for 5 minutes, controller 1130-
FICQ-101 will start one Vizcachas pump initially, then progressively start other pumps until the
total pipeline flow rate (Titire + Vizcachas) reaches the pipeline setpoint for at least 5 minutes.
The total flow will be divided in 7 ranges (because of the 7 pumps running), so that the number of
pumps to start/stop will be according to the selected range, which is the flow deficit in Titire
defined by 1000-HS-001_SP – 1120-FIQ-100.
Flow range =95.27-175 L/s (343-630 m3/h): Start 2 pumps. The pumps will automatically adjust
to maintain the required minimum flow conditions of the individual pumps.
Flow range =175.28 - 275 L/s (631-990 m3/h): Start 3 pumps. The pumps will automatically
adjust to maintain the required minimum flow conditions of the individual pumps.
Flow range =–275.28 - 375 L/s (991-1350 m3/h): Start 4 pumps. The pumps will automatically
adjust to maintain the required minimum flow conditions of the individual pumps.
Flow range =–375.28 - 475 L/s (1351-1710 m3/h): Start 5 pumps. The pumps will automatically
adjust to maintain the required minimum flow conditions of the individual pumps.
Flow range =–475.28 - 575 L/s (1711-2070 m3/h): Start 6 pumps. The pumps will automatically
adjust to maintain the required minimum flow conditions of the individual pumps.
Flow range =575.28 L/s (2071 m3/h) and above: Start 7 pumps. The pumps will automatically
adjust to maintain the required minimum flow conditions of the individual pumps.
If two or more pumps are needed to run, there shall be a time delay of 60 seconds before the next
pump starts. This is to avoid pumps from being started at the same time causing a large starting
electric current that could have adverse effect on the electrical systems.
1130-FCQ-101 calculates the set point for the spillback flow rate 1130-FCQ-107 based on the
following algorithm:
When the result returns a negative (-) value, controllers 1130-FCQ-107 shall force the control
valve 1130-FCV-107 to fully close.
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When the actual flow rate in Titire is less than the desired set point, the deficit flow shall be taken
from the Vizcachas pumping station. Low flow deficit means demand from Vizcachas will also
be limited to whatever the deficit is, and only one pump is expected to run. There is a chance that
the flow deficit is less than the Vizcachas pump minimum flow requirement. When this is the
case, the Vizcachas Pumps will be tripped due to a Low Low Flow Trip. This FALL trip will
repeatedly occur to all pumps in Vizcachas, which tries to supply the deficit.
To prevent this from happening, the flow set point on each flow controller (1130-FC-018~088) at
the Vizcachas pump discharge shall be set to minimum of 110% of pump minimum flow. Based
on Ruhrpumpen pump curve, the pump minimum flow is 148 m3/h. Hence Vizcachas pump shall
only start to run when the deficit is 163 m3/h or more, for 5 minutes. Any excess flow will be
returned to the Vizcachas dam through spill back line.
Similarly, when the demand in Vizcachas decrease due to increased available flow in Titire,
running pumps on Vizcachas shall be turned off based on the new demand subject to 5 minutes
time delay, and in the following manner:
Flow range of equal or less than 174 m3/h for 2 minutes, with 1 pump running: Stop the pump
Flow range of equal or less than 342 m3/h for 5 minutes, with 2 pumps running: Stop 1 pump
Flow range of equal or less than 630 m3/h for 5 minutes, with 3 pumps running: Stop 1 pump
Flow range of equal or less than 990 m3/h for 5 minutes, with 4 pumps running: Stop 1 pump
Flow range of equal or less than 1350 m3/h for 5 minutes, with 5 pumps running: Stop 1 pump
Flow range of equal or less than 1710 m3/h for 5 minutes, with 6 pumps running: Stop 1 pump
Flow range of equal or less than 2070 m3/h for 5 minutes, with 7 pumps running: Stop 1 pump
In a transient event where Vizcachas pumps are offline and only Titire pumps are operating, and
an operator inadvertently opens the Vizcachas spillback valve, Titire water could backflow to the
Vizcachas header and Titire water could go to the Dam potentially contaminating the Dam water.
To prevent this, a check valve is installed immediately downstream of the spillback take-off.
PCS shall be configured to allow for automatic service rotation of the operating pumps.
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When Titire station is in Dry Mode, a run time counter will be provided in the PCS system to
keep track of the current running hours of each pump. The PCS will notify the operator in the
event that the run time on the standby pump is 15% less than the run time of the longest running
pump. If confirmed by the operator to make the change, the system will automatically start to
bring the standby pump online. Alternatively, the operator has the ability to enter in a
predetermined value for the number of minutes between changing of pumps. A notification will
be provided to the operator that the timer has been reached and if he wishes to proceed. The
system will look at both of these limitations and select the first option to be fulfilled and both are
then reset, when the pumps are rotated.
When Titire station is in Wet Mode, pumps will be cycled every once a week. PCS shall notify
the Operator to perform pump cycle. The operator shall switch Vizcachas station to Pump Cycle
Mode. A Vizcachas Pump Cycle group start soft button switch shall be provided on the OW.
Once activated, pump cycle sequence shall start.
Each pump will be started one at a time for a period of TBC minutes. Pump discharge flow
controller set point will be equal to the pump minimum flow plus 10%. Spill back Flow
controller 1130-FC-107 will fully open the motorized valve 1130-FV-107, so that flow from
pump discharge will be circulated back to Vizcachas Dam.
The discharge pressure of each pump is monitored by a local pressure indicator. The respective
pressure indicators are 1130-PI-012/22/032/042 and 1130-PI-052/062/072/082.
Low pressure alarm (1130-PAL-101) is generated at PCS in case of low pressure detection.
In case of pressure surges, the pressure transmitter will generate a high pressure alarm (1130-
PAH-101) and when the discharge header pressure reaches the 1130-PAHH-101 will trigger a
shutdown of the Vizcachas pumps. When the high high pressure trip fails and pressure continues
to surge reaching the set point for the surge relief valve installed in the discharge header, 1130-
SRV-001 will open and blow-off relief water into the Vizcachas Dam.
Each pump is provided with a suction strainer. The strainers are manual-type wherein manual
cleaning needs to be performed when the differential pressure is high due to clogging.
Differential pressure across the pump suction strainers is monitored using differential pressure
transmitters 1130-PDIT-010/020/030/040/050/060/070/080. An alarm is generated at PCS (1130-
PDAH-010/020/030/040/050/060/070/080) in case of high differential pressure across the suction
strainers, which is an indication that the filters need to be cleaned. The respective pump shall be
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tripped when the filter differential pressure reaches a high-high level (1130-PDAHH-
010/020/030/040/050/060/070/080).
Level Control
There is no level control in Vizcachas Pumping station. However, pumps are provided with
high-high level trips based on water level in Caracoles Ponds.
Pumps are provided with pump bearing (drive end and non-drive end) vibration transmitters
connected to the PCS.
The PCS shall generate a high-high vibration trip and alarm 1120-VAHH-
011021/031/041/051/061/071/081 & 1120-VAHH-012/022/032/042/052/062/072/082 when
vibration reaches critical levels, and trip the respective pump motors.
Pump motors are also provided with bearing RTD, winding RTD and bearing vibration sensors.
These are directly connected to the IED. Upon detecting trip set point, the IED shall trip the
motor, thereby shutting off the pump.
A field installed Emergency shutdown pushbutton switch is provided for each pump to allow
pump shutdown in case of an emergency event.
There are 3 pump modes available, OPERATION / MAINTENANCE / OFF. The pumps shall be
set to OPERATION-AUTO MODE to allow auto start/stop based on PCS logic.
Only 7 pumps are allowed to be in Duty modes, and one pump in Standby Mode. Pumps in
MAINTENANCE or OFF mode shall not be selected as in Duty or in Standby Mode.
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Duty and standby pumps shall be rotated / cycled based on the number of hours/days run. This is
to avoid pumps from running for a very long time thereby minimizing maintenance issues on the
pumps. A PCS logic shall be configured and will use hour meter function block for each pump to
facilitate auto-cycle of pumps.
During pump cycling, the Stop sequence philosophy shall be based on First Start, First Stop
scheme, and vice versa.
A lockable Local/Remote switch is also provided for each motor to prevent remote pump control
from PCS during maintenance.
Pump motors are allowed to run only when their respective start permissives are activated on the
following criteria:
During pump start-up the following alarms and trips will be overridden until a preset time delay.
Pump failure to start after the time delay will halt the pump start sequence:
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The 87 kilometers of fresh water pipeline will start from the Titire Pumping Station and end at
the Caracoles storage ponds, with tie-in pipelines from the Vizcachas Dam and to the Quellaveco
mine. The system also includes pigging stations with launchers and receivers at key locations.
The pipeline also requires a choke station which is designed to prevent slack flow in the pipeline.
The receiving tank of the conveyed water for Quellaveco mine site is the Quellaveco Mine
Water Tank fed by an 8”-branch. Another 24” water line ties in directly to an existing HDPE line
which continues into the Caracoles Ponds. The Quellaveco Mine Water Tank flow is based on a
level control while the rest of the flow goes by gravity to the Caracoles ponds.
Water is transported via the Titire pipeline and will then merge with the Vizcachas pipeline at
KM 14.7 to form the main pipeline (NPS 24). This pipeline will transport the flow of water to a
launcher / receiver station located at Pelluta hill, 21 kilometers downstream of the Titire pump
station. From this location, the pipeline increases in diameter (NPS 24 to NPS 28) due to
hydraulic gradient required for the elevation profile in this section and continues flowing
towards another launcher / receiver station at the next high point at KM 48.5. Once this point is
reached, the pipeline diameter will constrict from NPS 28 to NPS 24. Water will continue
flowing towards the choke station located at approximately KM 79.7. From the Choke Station,
pipeline will tie-in to the existing 30” HDPE pipeline which will then distribute the water to the
three Caracoles Ponds through individual branch line. At the end of each HDPE branch line is a
manual valve with positioner indicator to know the opening status of each valve. At the end of
steel line prior to connection to HDPE line is a pressure control valve which holds back the
pressure in steel line to ensure flow. A portion of the water flow will be diverted into a smaller
diameter pipeline (NPS 8), branching from KM 85.7, moving towards the Quellaveco transfer
tank (2910-TK-001) approximately 0.8 kilometer from the main transport pipeline (NPS 24).
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The Pelluta Hill is the highest or peak point of the system with elevation of 4820 m.a.s.l.
Pressure at Pelluta Hill is monitored by the PCS. There are two pressure transmitters 1140-PIT-
011 and 1140-PIT-008, connected to Vizcachas PCS 1130-PC-101 and Titire PCS 1120-PC-101,
respectively via FO links between CFUs in Pelluta hill and Vizcachas and Titire PCS. This makes
it possible to still monitor the pressure if and when the Vizcachas PCS is down, by having a
redundant pressure monitoring from Titire station. The pressure transmitters are installed at the
highest elevation of the hill, between the 24” pipeline pig receiver and the 28” pipeline pig
launcher, so as to monitor the pressure for either slack flow indication or downstream blockage
indication.
The choke station will perform small fine tuning when the pressure at Pelluta Hill is in the normal
range of 90 to 210 kPag.
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Low pressure alarm (1140-PAL-011 / 008) will be generated when the pressure is lower than 13
kPag, indicating slack flow condition and requiring the choke station valve to further close.
High pressure alarm 1140-PAH-011 / 008) will also be generated when the pressure is higher
than 210 kPag, indicating blockage of the downstream choke station, potentially leading to
pressure surge. This scenario is addressed in Section 2.3.3., Case 2.
A high high alarm (1140-PAHH-011/008) will trigger the Titire and Vizcachas pump shut down
when the pressure is above 480 kPag. The choke station will regulate the required head to avoid
slack flow condition downstream of Pelluta Hill.
Loss of FO Link between Pelluta Hill and Choke Station, between Vizcachas and Pelluta Hill and
between Choke Station and Primary Crusher
Any loss of communication between the Titire, Vizcachas and Primary Crusher PCSs due to FO
link failure shall cause a Pipeline shutdown. Pipeline Shutdown sequence shall be initiated
according to section 2.4.3. Pumps shall be prohibited to start.
Risk assessment shall be performed by Operations team and shall be properly documented in the
Operating Manual if they decide to operate the Pipeline manually, without the FO link.
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The Choke Station is located along the pipeline route at approximately KM 79.7 and is provided
to adjust the pipeline pressure set points corresponding to the flowrate changes to ensure the
hydraulic grade line is maintained and slack flow is avoided.
The pipeline flow set point will be used as the governing parameter for PCS to set the back
pressure controller set point 1140-PC-018_SP and outlet pressure controller set point 1140-PC-
013_SP. The initial values will be based on Table 11 of the Steady State Hydraulic Study MQ13-
02-1000-PL0002.
During commissioning, a temporary ultrasonic flowmeter will be strapped onto the inlet pipe of
the choke station, and pressure set points will be adjusted based on the actual flow readings.
During actual operations, the Pipeline flow set point 1000-FC-001-SP will be used as the basis of
pressure set points for Choke back pressure and choke outlet.
At the inlet of choke station, a back pressure controller 1140-PIC-018 that consists of pressure
transmitter 1140-PIT-018 and control valve 1140-PV-018 is installed. This controller serves the
purpose of maintaining a specific pressure in the pipeline based on the pipeline flow set point to
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ensure full flow in the pipeline. It also serves the purpose of providing a constant pressure to the
valves and orifices downstream of the valve.
The Choke Station is comprised of various pressure reducing devices, a combination of restriction
orifices and control valves which aim to reduce the pressure, in multiple stages until the desired
choke outlet pressure set point is reached.
There will be several flow cases wherein the pipeline can be operated, based on the available
fresh water on the Titire and Vizcachas rivers. Table 11 of the Steady State Hydraulic Report lists
sample flow cases on which the pipeline maybe operated, and the corresponding outlet pressure
set point at the choke station. The choke station is designed for a pipeline flowrate between 278
L/s (being the flowrate during 8” and 24” pigging operations) and 770 L/s.
Accordingly to preliminary sizing done by Fluor, a single choke stream is not sufficient to cover
the entire flow range and the corresponding pressure cut. It was determined that multiple choke
streams are required, each stream to cater for specific smaller flow range between 278 L/s to 770
L/s. Preliminary sizing resulted in 4 choke streams each consisting of a control valve and orifice
connected in series and are sized to share the required pressure cut corresponding to the flow
range. Each flow stream is designed and capable of pressure control at the certain flow range
only. Thus, only one flow stream shall operate at a time, depending on the measured pipeline
flowrate.
The first branch is a 24” line with a flow orifice 1140-FO-004, and a 24” pressure control valve
1140-PV-014. It is designed for flow rates between 600.1 L/s to 770 L/s.
The second branch is a 20” line with a flow orifice 1140-FO-005, and a 18” pressure control
valve 1140-PV-015. It is designed for flow rates between 460.1 L/s to 600 L/s.
The third branch is an 18” line with a flow orifice 1140-FO-006, and a 16” pressure control valve
1140-PV-016. It is designed for flow rates between 340.1 L/s to 460 L/s.
The fourth branch is a 16” line with a flow orifice 1140-FO-007, and a 14” pressure control valve
1140-PV-017. It is designed for flow rates between 278 L/s (240 L/s min) to 340 L/s.
The control valves at each branch shall provide the final pressure tuning to the downstream
system.
The PCS shall be configured to fully close the pressure control valves on the non-operating flow
branches.
The control valve and orifice sizing calculation determines the maximum D/P across the control
valve and orifice, so that there will be no choke flow on all flow cases. All pressure cut values are
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preliminary and will be finalized in collaboration with the selected vendor. Cavitation and high
noise may be possible, but should be mitigated by using a Noise and Cavitation abatement trim,
and other possible design, and shall be proposed by the vendor as applicable.
A pressure transmitter at the choke station outlet 1140-PIT-013 provides fine-tuned pressure
control. The measured pressure is sent to the pressure controllers 1140-PC-014/015/016/017,
which shall give the control output to the respective PVs.
An on-off valve 1140-XV-011 is installed at the choke inlet and closes when there is high high
(1140-PAHH-014) pressure at the choke station outlet measured by 1140-PIT-014, which may be
caused by failure of any pressure controllers in the choke station. A pressure high high will also
shutdown the Titire and Vizcachas pumps, and closes the inlet valves of Quellaveco Fresh Water
Tank (2910-XV-011), roughly 5 minutes after the choke inlet valve has closed.
There is a self-regulating pressure relief valve 1140-SRV-101 installed at a branch line of the
choke inlet and discharges to the outlet piping. This valve opens when the choke station inlet
pressure exceeds the designed hydrostatic pressure, and closes when pressure is normalized.
When a control valve in any of the flow branches needs servicing or replacement, the respective
pressure controller shall be set to manual mode by the Operator, forcing the valve to fully close.
A manual valve is installed at the inlet and outlet of the control valves to allow isolation and
removal of the valve during servicing.
The operator shall first check the flow range limits of the control valve needing servicing and
verify if the Pipeline flow set point is lower than the low range flow value of that valve. This will
cause the pressure controller 1140-PC-013 to select from the next smaller branch, to ensure
continuous flow and at the same time not exceeding the allowable pipeline flow rate.
If allowable, Operator may set the flow set point above the high range flow value of the branch
being serviced, so that the pressure controller 1140-PC-013 may select flow branch that has
higher flow range.
Monitoring and control signals at the choke station will be connected to the Titire PCS 1120-PC-
101 through a remote IO cabinet and linked to PCS via fiber optic link.
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the Maximum Allowable Surge Pressure (MASP) of the pipeline when the surge mitigation
measures are implemented.
The surge analysis considers the following transient hydraulic cases and simulation results and
mitigation requirements are also discussed:
Case 1: Pump trips at the Titire Pump Station or Vizcachas Pump Station due to blackout
The simulation shows that the maximum surge pressure generated did not exceed the system
MASP. No surge mitigation is required.
When the choke station is blocked, a water hammer will be initiated at the inlet of the closed
valve. The superposition of the water hammer surge and the continuous line packing pressure
caused by the pumping makes the pressure in several sections much higher than the static
gravity pressure. The simulation shows that the maximum surge pressure generated has
exceeded the system MASP. The following surge relief mitigation methods are
recommended:
2.1) Add a choke station bypass line with a surge relief valve (valve with spring loaded
actuator)
a) The inlet pressure set point for the bypass valve to open is 9170 kPag
b) The inlet pressure set point for the bypass valve to close is 9150 kPag
In the simulation, the valve at the choke station closes 100% in 60 seconds. The
bypass valve takes as long as 1 minute to be fully opened from a fully closed
position.
2.2) Shutdown the Titire pumps when the pump discharge pressure reaches 7200 kPag or
the Vizcachas pumps (when running) at 6639 kPag
2.3) In case the Titire pumps fail to shutdown, a surge relief valve at Titire pump station
is recommended with valve opening pressure set at 7377 kPag and valve closing pressure
set at 6688 kPag. Similarly, when the Vizcachas pumps fail to shutdown, a surge relief
valve at Vizcachas pump station is recommended with opening and closing pressure set
at 7377 kPag and 6688 kPag, respectively.
With this mitigation in place, the maximum surge pressure no longer exceeds the system
MASP.
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Case 3: Pipeline blockage due to Closure of Control Valve at the HDPE Tie-In Area
The flow to Caracoles ponds is stopped due to accidental closing of control valve at the
HDPE tie-in area. The surge relief valve 1140-SRV-102 included at the end of steel line
was sized to open when there is a substantial pressure build-up in the system caused from
the control valve being accidentally closed. It will open in time to ensure that the rest of
the steel line does not experience too high pressure. Opening pressure is set at 689.5 kpag
and closes at 620.5 kpag.
Case 4: Accidental blockage of Pelluta Hill flow path during pigging operation
The flow at Pelluta Hill location is blocked in 30 seconds due to unforeseen situation
when an operator attempts to launch a pig. The pump at Titire will continue to run
without shutting down. Surge mitigation is required at the Titire pump station or at
Vizcachas pump station, whichever is supplying the flow. The Titire or Vizcachas surge
relief opening pressure shall be set at 7377 kPag and the valve closing pressure at 6688
kPag. With this mitigation, the maximum surge pressure does not exceed the system
MASP.
The flow to all ponds in Caracoles is blocked due to accidental closing of all individual
manual valves to ponds. One surge relief valve 1140SRV-114 is placed where the valve
for pond 4 is located will be able to relieve the surge for the whole HDPE line without
causing problems to the rest of the pipeline. The relief valve should have a set point of
723.95 kpag in order to open up when all of the valves are blocked. This valve is able to
handle the maximum flow input to the system, ensuring that the pressure stays down in
the entire line, protecting it. However, a surge relief valve will still be required at this
point in order to relieve pressure and ensure flow. Without it, if all three valves are
blocked, the pressure increase could transfer back through the line, increasing the
pressure in other sections above the maximum allowable pressure. Having the surge relief
also allows for continuous flow in the system without requiring shutting down the line
immediately.
Transient hydraulics simulations show that the proposed surge mitigation devices, interlock, and
set points are sufficient in mitigating the instantaneous surge pressures initiated. The maximum
surge pressure is controlled below the MASP with the surge mitigation method.
For complete details about the surge analysis, refer to the Transient Analysis Report (MQ13-02-
RE-1000-PL0003).
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Pigging stations with launchers and receivers are provided in the following locations along the
pipeline for cleaning and inspecting the pipeline without stopping the flow.
Titire Pump Station
Pelluta Hill
Pipeline Size Reduction
Choke Station
Quellaveco Tank Feed Pipe
Design of the pigging station is by Fluor while the pig launcher/receiver is by Vendor.
Intelligent pigging technology shall be used for in-line inspection and cleaning. Pigging is done
manually and should be guided by a Standard Operating Procedure for safe and efficient
operations. Launchers and Receivers are provided with local pressure gauge and pig signalers /
detectors for local monitoring during pigging operations.
An “Upstream of Pelluta Hill Pigging Mode” soft switch 1140-HS-001 shall be configured in the
OW. Activation of this switch is done at the Control Room via OW. ‘Upstream of Pelluta Hill
Pigging Mode’ indication 1140-XL-001 shall be displayed on the OW Graphics. The flow rate
will be automatically changed to 278L/s, and only Titire pumping station will be operated. Pump
run cycling logic is overridden and Operator shall manually choose 2 pumps to be in Duty Mode
and 3 pumps in Off Mode. The second pump shall start only after the first pump has run for at
least 60 sec.
A “Downstream of Pelluta Hill Pigging Mode” soft switch 1140-HS-002 shall be configured in
the OW. Activation of this switch is done at the Control Room via OW. ‘Downstream of Pelluta
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Hill Pigging Mode’ indication 1140-XL-002 shall be displayed on the OW Graphics. The flow
rate will be automatically changed to 378 L/s, and either or both the Titire and Vizcachas
pumping stations will be operated. Pump run cycling logic is overridden and Operator shall
manually choose either 2 Duty pumps and 3 Off pumps from Titire or 4 Duty pumps and 4 Off
pumps from Vizcachas.
A “Choke Station to Caracoles Tie-in Station Pigging Mode” soft switch 1140-HS-003 shall be
configured in the OW. Activation of this switch is done at the Control Room via OW. ‘Choke
Station to Caracoles Tie-in Station Pigging Mode’ indication 1140-XL-003 shall be displayed on
the OW Graphics. The flow rate will be automatically changed to 278L/s, and either or both the
Titire and Vizcachas pumping stations will be operated. Pump run cycling logic is overridden and
Operator shall manually choose either 2 Duty pumps and 3 Off pumps from Titire or 3 Duty
pumps and 5 Off pumps from Vizcachas.
A “Choke Station to Quellaveco Tank Pigging Mode” soft switch 1140-HS-004 shall be
configured in the OW. Activation of this switch is done at the Control Room via OW. “Choke
Station to Quellaveco Tank Pigging Mode” indication 1140-XL-004 shall be displayed on the
OW Graphics. Pigging of this 8” section will be done while the 24” pipeline section is running.
The flow rate will be changed to 278L/s, and either or both the Titire and Vizcachas pumping
stations will be operated. Pump run cycling logic is overridden and Operator shall manually
choose either 2 Duty pumps and 3 Off pumps from Titire or 3 Duty pumps and 5 Off pumps from
Vizcachas.
Pigging Mode is permitted to be activated only after the Pipeline Off Mode is activated, that is ,
all pumps in Titire and Vizcachas shall be in ‘Off’ position.
In order not to exceed the required pipeline flow rate during pigging operations, the flow set point
of the spill back line flow controller in Titire, 1120-FIC-107 will be adjusted according to the
pigging flow rate, that is, 1120-FQI-100 minus 278L/s or 378L/s.
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2.3.5 Caracoles Tie-in Station and Ponds Pressure and Level Monitoring and Control
From the Choke Station, a portion of water will be sent to the 8” pipeline feeding the Quellaveco
Mine Water Tank (2910-TK-001).
Majority of the water is sent to the 24” pipeline which is tied back to an existing HDPE pipeline
at the Caracoles Tie-in station where back pressure controller consisting of a pressure transmitter
1140-PIT-105 and a control valve 1140-PV-105, is installed to ensure that the pipeline is
pressurized, and that the outlet pressure from the HDPE pipe is atmospheric. The water is
ultimately drained by gravity into the Caracoles Ponds, three large basins with a total capacity of
1.8 Mm3 which consequently feeds the Transfer Tank (3930-TK-001) at Papujune Processing
Plant.
The existing Caracoles Ponds (C-1, C-2, C-4) are provided with hydrostatic type level
transmitters (1140-LIT-101A/B, 1140-LIT-102A/B, 1140-LIT-104A/B) interlocked with the
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Titire/Vizcachas Pumps to allow for pump shutdown at high high liquid level (1140-LAHH-101,
1140-LAHH-102, 1140-LAHH-104). The ponds’ existing inlet and outlet manual valves will be
fitted with limit switches (1140-ZLO/ZLC-134A, 1140-ZLO/ZLC-132A, 1140-ZLO/ZLC-142A
and 1140-ZLO/ZLC-134B/C, 1140-ZLO/ZLC-132B/C, 1140-ZLO/ZLC-142B/C, respectively)
for remote valve status indication in the OW.
Monitoring and control signals at Caracoles will be connected to the Titire PCS 1120-
PC-101 through a remote IO cabinet and linked to PCS via fiber optic link.
The control philosophy for this section of the pipeline will be integrated to the Papujune Process
Plant Control Philosophy document.
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2.3.6 Quellaveco Mine Transfer Tank Pressure, Flow and Level Monitoring and Control
Reference P&IDs: MQ11-02-DR-2910-PD1001
Level in the Quellaveco Transfer Tank (2910-TK-001) is monitored by PCS via a level
transmitter 2910-LIT-015.
Low Level Alarm 2910-LAL-015 is generated at OW when tank level falls below the normal
operating condition.
High Level Alarm 2910-LAH-015 is generated at OW when tank level rises above the normal
operating condition.
High high level trip and alarm (2910-LAHH-015) is generated when the tank level reaches
critical level, risking overflow. This event will override the flow controller 2910-FIC-009 and
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will fully close the flow control valve (2910-FV-009). Once the level goes back below the critical
level, the flow controller resumes control of flow control valve.
The Inlet valve (2910-XV-011) shall close whenever the choke inlet valve 1140-XV-011 closes
due to for example, PAHH at choke station inlet 1140-PAHH-014. An interlock shall be
configured such that 2910-XV-011 shall close when 1140-XV-011 is fully closed (1140-ZLC-011
is activated) after five minutes.
To limit the flow rate getting into the branch pipeline to tank 2910-TK-001, a flow controller
2910-FIC-009 consisting of a flow transmitter 2910-FIT-009 and a control valve 2910-FV-009, is
required at the inlet of tank 2910-TK-001. The flow condition for the design of the flow rate
control at the tank is shown in Table 13 of the Steady State Hydraulics For Detailed Engineering,
MQ13-02-RE-1000-PL0002.
Magnetic flowmeters 2910-FIT-012, 2910-FIT-013 are installed at the tank outlet to RO Plant
and Distribution Matrix, respectively. Flow rates and total flow on this piping are monitored in
the OW.
Monitoring and control signals at Quellaveco Tank will be connected to the Titire PCS 1120-PC-
101 through a remote IO cabinet and linked to PCS via fiber optic link.
When in Auto Operation Mode, the pumps are started and stopped automatically based on control
logics as defined in this Control Philosophy, the Functional Control Specification and Logic
Diagrams.
Changing to Manual or Pigging Mode shall be possible only after Off Mode is activated.
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When in Manual Operation Mode, the pumps are manually started and stopped based on Operator
selection and the pump auto cycling logic is bypassed. The maximum allowed number of pumps
that can be started shall be based on the Total Pipeline and Titire flow set points entered by the
Operator.
All shutdown interlocks and start permissive shall still be active. Controllers shall still be in Auto
mode.
Changing to Auto or Pigging Mode shall be possible only after Off Mode is activated.
When in Pigging Mode, the Pigging Mode Selection window shall pop-up for the Operator to
select. Refer to section 2.3., in Pigging Stations section.
Changing to Auto or Manual Mode shall be possible only after Off Mode is activated.
Stop all running pumps in Titire and Vizcachas, the following signals are activated:
1120-HSC-010/020/030/040/050 and 1130-HSC-010/020/030/040/050/060/070/080 to
stop pumps 1120-PU-010/020/030/040/050 and 1130-PU-010/020/030/040/050/060
/070/080, respectively.
Then close Titire Intake gate valve 1120-GA-013
Simultaneously, fully close all pump discharge control valves 1120-LV-
018/028/038/048/058 on Titire and 1130-FV-018/028/038/048/058/068/078/088 on
Vizcachas
Then, fully close spill back flow control valve 1120-FV-107 and 1130-FV-107 on Titire
and Vizcachas, respectively
One minute after all pumps are stopped, fully close inlet valve 1140-XV-011 on Choke
Station
Five minutes after the choke inlet valve closed, fully Quellaveco Tank inlet valve 2910-
XV-011
Controllers may be set to Manual Mode in order to manually throttle the control valves.
For instance, when draining the water through the Titire or Vizcachas spill back line.
Reset is not required for Pipeline to resume operation, either in Auto, Manual and Pigging Modes.
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Stop all running pumps in Titire and Vizcachas; the following signals are activated:
1120-HS-010/020/030/040/050-SP to stop pumps 1120-PU-010/020/030/040/050, and
1130-HS-010010/020/030/040/050/060/070/080-SP to stop pumps 1130-PU-
010/020/030/040/050/060/070/080.
Then close Titire Intake gate valve 1120-GA-013
Simultaneously, fully close all pump discharge control valves 1120-LV-
018/028/038/048/058 on Titire and 1130-FV-018/028/038/048/058/068/078/088 on
Vizcachas
Then, fully close spill back flow control valve 1120-FV-107 and 1130-FV-107 on Titire
and Vizcachas, respectively
One minute after all pumps are stopped, fully close inlet valve 1140-XV-011 on Choke
Station
Five minutes after the choke inlet valve closed, fully close Transfer tank inlet valve 1140-
XV-021 and Quellaveco Fresh Water Tank inlet valve 2910-XV-011
Pipeline shutdown shall also be initiated when there is a total power blackout at either Titire or
Vizcachas Pumping station, or loss of power at Pelluta, Choke Station, Quellaveco Tank Area
and Caracoles Tie-in and Pond Area.
All alarms and shutdown initiators shall be manually reset, before Pipeline can be operated. A
shutdown reset soft switch shall be configured at the OW.
A dedicated set of vibration and temperature sensors will be installed on the pump and will be
connected to the Machine Condition Monitoring System (MCMS) field IO cabinets, linked to the
Main panel at Main Control Room via fiber optic link.
The MCMS provides continuous analysis of the Titire and Vizcachas pumps, detecting bearing
damage, unbalance, misalignment and rotor defect detection, using proprietary software. The
MCMS is a dedicated system and is used only for monitoring and does not have any control
function.
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Electric heat tracing (ET) provides protection on piping from damage caused by freezing,
particularly on non-flowing pipe branches (dead leg) such as maintenance bypass lines and
drains.
An ET Panel provides power to the heat trace cables. An ET Panel Common alarm signal is
connected to PCS, to notify operator in the Control Room.
Upon confirmed Fire detection, FAP shall send a hardwired signal to the PCS which shall initiate
shutdown of the respective facility.
When PCS commands an on-off valve to open or close but did not receive an open or close
position limit switch detection, after a preset time delay
When PCS received an open or close position limit switch detection, but did not commanded
the on-off valve to open or to close
When PCS commands a pump motor to start or stop but did not receive run or stopped status
from the IED. In this case, the automatic start sequence shall be aborted
When the level transmitter readings on sump are at least 5% different. The Alarm will be
masked when one transmitter is under maintenance.
When the level transmitter readings at the respective ponds are at least 5% different. The
Alarm will be masked when one transmitter is under maintenance.
When the pressure transmitters readings on Pelluta Hill are at least 1% different. The Alarm
will be masked when one transmitter is under maintenance.
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1.0 GENERALIDADES
1.1 Objetivo
El presente documento de Filosofía de Control tiene por objeto describir resumidamente los
criterios y los modos de operación del proyecto “Sistema de Suministro de Agua Bocatoma
Titire y Presa Vizcachas - Alta Montaña”.
Se incluye también, dentro del presente documento, los criterios de la operación en la fase
de llenado de la presa Vizcachas y que tiene como obra provisional una compuerta de
regulación que permitirá, durante la época de avenidas, almacenar el agua en la presa y
garantizar el abastecimiento de agua requerido durante la fase previa a la operación normal
o regular asociado a las obras hidráulicas presentadas en la Tabla 1-1.
1.2 Introducción
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El diseño de la presa permite almacenar hasta 60 MMC; sin embargo, en un primer periodo
se llenará solo hasta 28 MMC.
Caudal ecológico
Completar el caudal de agua fresca para el Proyecto Quellaveco que sumado al caudal
que aporta la bocatoma Titire se debe alcanzar un caudal de 0,77 m3/s, que se requerirá
en períodos deficitarios de la Bocatoma Titire.
Para el control del sistema de abastecimiento de agua del rio Titire se implementarán dos (02)
estaciones de aforo: Una (01) aguas arriba y una (01) ubicada aguas abajo de la Bocatoma
Titire.
Para el control del sistema de abastecimiento de agua fresca del rio Vizcachas se ha
considerado tres estaciones de aforo, ubicadas de la siguiente manera: Una (01) a la salida
del embalse Pasto Grande, una (01) aguas arriba del embalse Vizcachas y la tercera aguas
abajo de la presa Vizcachas.
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1.4 Definiciones
Valor medido: Es el valor que envía un sensor-transmisor y que se compara con el valor
deseado y permite enviar la señal de control.
Controlador: Dispositivo programable (PLC o PC) que procesa las señales del sensor-
transmisor (entradas) y ejecuta las ordenes de control hacia el actuador (señales eléctricas)
a partir de un algoritmo (software).
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Lazo de Control: Es el proceso de control automático. Está compuesto del actuador, el sensor-
transmisor y el controlador.
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2.1 Generalidades
La Bocatoma Titire es una estructura hidráulica de concreto armado cuya función es captar
agua del río Titire para derivarla hacia la Estación de Bombeo y de allí al Proyecto Quellaveco.
Consta de las siguientes obras:
Barraje Fijo
El barraje fijo está compuesto por un vertedero de descarga libre de concreto armado de 34
m de longitud diseñado para soportar una descarga de 362,20 m3/s, que corresponde a una
avenida de un periodo de retorno de 100 años.
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Barraje Móvil
El barraje móvil de descarga controlada está conformado por una estructura de concreto
armado que aloja a dos compuertas radiales, de 3,00 m de ancho, por 4,00 m de altura y un
radio de 4,00 m, que tienen la función de activar el proceso de limpieza que arrastra los
materiales gruesos acumulados en la toma, mantener un tirante de agua para el ingreso del
agua a la toma y abrirse ante una avenida importante para ayudar en el proceso de descarga.
Toma
La obra de toma está conformada por un canal de ingreso de sección variable que cuenta
con una reja metálica de protección de 2,20 m de ancho por 0,90 m de altura, el cual da una
capacidad de captación de 0,77 m3/s. La toma cuenta con una compuerta de regulación plana
de 1,50 m de ancho por 0,77 m de altura antes del ingreso al canal de conducción.
Ducto de Conexión
El ducto de conexión está conformado por un canal curvo en concreto armado, de sección
cerrada para minimizar las pérdidas por infiltración y evitar la incorporación de aguas de
lluvias con sólidos externos.
Desarenador
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La operación del sistema de captación del rio Titire consiste en un sistema de regulación que
se ha diseñado para operar normalmente en forma Remota-Automática. La regulación se
controla desde la sala eléctrica 1120-ER-001, localizada aproximadamente a 50,00 m de las
obras de captación, mediante un Interface Hombre Maquina (HMI) y un software de
operación, especialmente desarrollado para cumplir con el abastecimiento de agua y con los
requerimientos del sistema de bombeo.
También se podrá operar de forma local en caso de pruebas, mantenimiento o por una
emergencia, la cual se realizará mediante botoneras al pie de las instalaciones.
Las señales de control, tanto en la operación local como remota, se centralizan en el tablero
RIO (Remote Input Output) localizado en la caseta hidráulica 1120-CH-001 y desde allí se
transmiten por medio de una red profibus DP, en cable de cobre, a la sala eléctrica de la
estación de bombeo.
Para la operación de las compuertas radiales se cuenta con dos cilindros hidráulicos
accionados por una unidad hidráulica, controlada por un PLC (Control Lógico Programable),
ubicado en el tablero de la unidad hidráulica.
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El desarenador Titire cuenta con dos naves de sedimentación que pueden operar en forma
independiente, es decir, mientras una nave está operando normalmente la otra puede estar
en proceso de purga.
Para controlar el ingreso de agua a las naves del desarenador se cuenta con las compuertas
planas deslizantes: 1120-GA-014 y 1120-GA-015. Ambas compuertas cuentan con actuador
eléctrico tipo ON/OFF, que pueden ser controladas en forma “Remota-Manual” desde la sala
eléctrica o en modo “Local-Manual”. No tiene un control automático pero si se monitorea el
estado por medio de los fines de carrera. El modo “Remoto-Manual” será de uso restringido
solo para cerrar la compuerta en caso de emergencia, no deberá ser utilizada para abrir la
compuerta de ingreso estando abierta la respectiva compuerta de purga. El modo “Local-
Manual” es el que corresponde a la operación normal, tiene dos opciones: mando eléctrico a
través de la botonera incorporada al cuerpo del equipo o mediante la volante manual
articulada al sistema de transmisión del mismo. La decisión de abrir o cerrar dependerá de la
programación según la experiencia en la acumulación de sedimentos.
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4.1 Generalidades
La Presa Vizcachas es una presa de CCR (Concreto Compactado con Rodillo) cuya función
es embalsar las aguas del río Vizcachas.
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Sistema de Desvío
El sistema de desvío está conformado por un canal inicialmente denominado de desvío por
tener la función de desviar el río durante la etapa de construcción de la presa. Es una
estructura de concreto armado que tiene un tramo inicial de sección cerrada con una ataguía
conformado por un terraplén de tierra y un tramo final de sección abierta con una poza
disipadora. Hidráulicamente se ha diseñado para la etapa de construcción con una capacidad
de 186,00 m3/s, que corresponde a una avenida de un periodo de retorno de 20 años.
Asimismo, se ha previsto un encauzamiento temporal con muros de gaviones. Esta obra está
diseñada para una capacidad de 4,80 m3/s que corresponde a una avenida de un periodo de
retorno de 2 años en época de estiaje y comprende dos líneas de gaviones tanto aguas arriba
como aguas abajo de este sistema. La sección de los gaviones será de tipo escalonada, con
un ancho y altura variable, recubierto también de geotextil y geomembrana en toda su
extensión.
Presa Vizcachas
La presa Vizcachas es una estructura de CCR (Concreto Compactado con Rodillo), tiene una
altura máxima de 41,00 m, una cara vertical aguas arriba y una cara inclinada aguas bajo de
0,8H:1,0 V. En la parte central de la presa se cuenta con dos galerías que forman parte del
sistema de drenaje de la fundación y de la cortina de inyecciones. En el cuerpo de la presa
Vizcachas se apoyan estructuras hidráulicas y atraviesan conductos que son parte de la
operación hidráulica del sistema.
Aliviadero
El aliviadero está conformado por un vertedero de descarga libre construido de concreto
armado apoyado en la parte central de la presa Vizcachas. El aliviadero tiene una capacidad
de 251,58 m3/s que corresponden a una avenida de un periodo de retorno de 10.000 años y
tormenta de 48 horas que incluye el efecto de laminación del embalse. El aliviadero descarga
durante la operación en una poza disipadora, antes de devolver las aguas hacia el río
Vizcachas.
Sistema de Desagüe
El sistema de desagüe está conformado por una torre de concreto armado de 37,00 m de
altura apoyado en la cara aguas arriba de la presa Vizcachas y un ducto de sección cuadrada
de concreto armado de 13,80 m de longitud horizontal que cruza el cuerpo de la presa, y
finalmente un tramo inclinado que empalma al conducto en cuerpo de presa y luego a la poza
disipadora del sistema de desvío.
La torre alberga a una compuerta plana para el control de operación de 1,20 m x 1,80 m de
dimensión del vano que se opera desde la cresta de la presa. Hidráulicamente se ha diseñado
para una capacidad de desagüe inferior al caudal de diseño del aliviadero (251,58 m3/s) y
para un vaciado del embalse en un tiempo inferior a 15 días.
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La torre aloja a una compuerta plana para la apertura y cierre del sistema de 1,20 m x 1,80 m
que se opera desde la cresta de la presa. Hidráulicamente todo el sistema está diseñado para
una descarga total de 6,208 m3/ correspondiente a la suma de los caudales de entrega y del
caudal de alimentación a la estación de bombeo (1,808 m3/s totales) y al caudal mínimo de la
obra de desagüe (4,40 m3/s de agua de reserva del Proyecto Especial Pasto Grande o
PERPG).
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Operación normal.
Obras Civiles:
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Control
En la compuerta de cierre definitivo se operará desde el inicio del llenado hasta la cota
4352,20 m.s.n.m. correspondiente con el nivel de solera del conducto de desagüe y conducto
de entrega. Cuando se llega a este nivel se cierra la compuerta de cierre definitivo y se coloca
el “tapón de concreto” tal como se muestra en el siguiente gráfico.
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5.3.1 Generalidades
Para la operación normal se requiere que se complete las obras indicadas en el ítem 5.2 al
100%, así como el sistema de control remoto centralizado en la caseta de bombeo.
A partir del nivel NAMI (elevación 4.357,00 m.s.n.m.) se inicia la descarga regulada de agua
a la planta de bombeo y a los usuarios al mismo tiempo, a través del sistema de tuberías y
válvulas de entrega que permite la conducción a la planta de bombeo de agua para las
instalaciones de producción del Proyecto Quellaveco y garantizar la entrega de caudales para
atender los compromisos sociales y ambientales del mismo.
En la fase de “operación normal”, se realizará de la misma forma cualquiera sea el nivel de
regulación de la presa, esto es, cuando el volumen neto de regulación de agua en la presa
sea de 28,5 MMC o 60 MMC, dado que, en ambos casos, los equipos de regulación de caudal
de entrega a los usuarios ya estarán operativos.
La “operación normal” o “regular” de las instalaciones de la presa de Vizcachas se realizan
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en forma regulada a través del conducto de entrega o a través del conducto de desagüe en
casos de mantenimiento del sistema de entrega.
Cuando el embalse Pasto Grande descargue caudales mayores a 4,40 m3/s, el caudal que
exceda a este valor será descargado al río Vizcachas a través del conducto de desagüe.
CAUDAL
MEDICIÓN DESCRIPCIÓN CARÁCTER
(m3/s)
1 Alimentación estación bombeo 0,770 Variable
2 Tambo Bajo 2 (Compensación Titire) 0,770 Meses Set a Dic Variable.
Tambo Bajo 1 (Compensación
3 0,307 Meses Set a Dic Variable.
Vizcachas)
- Último cuatrimestre del año
4 Moquegua (Compensación Chincune) 0,651(i) Promedio anual. Variable.
- 0,217(ii): Promedio anual.
5 Caudal Ecológico 0,150 Permanente
6 Agua de Reserva PEPG 4,400 Eventual. Variable.
i. Este caudal corresponde al flujo máximo entregado en el último cuatrimestre del año.
ii. El valor indicado corresponde al caudal medio anual entregado según cédula agraria de cultivo.
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Los caudales indicados en la Tabla 5-1 deberán ser tomados en cuenta bajo las siguientes
consideraciones:
Caudal de compensación (medición 1): 0,77 m3/s máximo. Es una entrega orientada a
complementar el caudal captado por la bocatoma Titire, en el caso eventual que este
último sea deficitario. La medición y control de este caudal se realiza en las instalaciones
de la estación de bombeo Tubería: 1130-9106-AG1-30-FW-N.
Caudal “Tambo Bajo 2” (medición 2): 0,77 m3/s máximo. Corresponde a la devolución al
río Vizcachas del caudal captado por la bocatoma Titire. Tal devolución sólo se realiza
en los meses secos de septiembre a diciembre. Tubería: 1130-9105-AG1-18-FW-N.
Considerando los dos puntos anteriores se tiene que, en el caso más desfavorable, los
caudales “Alimentación Estación de Bombeo” y “Tambo Bajo 2” (mediciones 1 y 2) suman
0,77 m3/s. Esto significa que la apertura de la válvula FV 1130558 depende del caudal
medido en la entrada del desarenador de Titire (sensor FIT 1120505) para completar los
0,77 m3/s. Esta regulación se realiza en forma automática, a partir del cálculo realizado
con el software de la sala eléctrica de la estación bombeo
Caudal “Tambo Bajo 1” (medición 3): 0,307 m3/s. Corresponde a la devolución al río por
compensación del caudal captado en la presa Vizcachas. Tal devolución sólo se realiza
en los meses secos de septiembre a diciembre. La apertura de la válvula 1130-FV-548
es automática. Tubería: 1130-9104-AG1-14-FW-N.
Caudal “Moquegua” (medición 4): 0,651 m3/s. Corresponde a la entrega máxima al río
por este concepto en el último cuatrimestre de cada año. El caudal 0,217 m3/s
corresponde a un valor promedio anual según cédula agraria de cultivo. La apertura de
la válvula 1130-FV-538 es automática. Tubería: 1130-9103-AG1-18-FW-N.
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Los valores de caudal requerido en cada línea, según los puntos de medición del 2 al 6 de la
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Tabla 5-1, son consignas que se digitan en el sistema de control de la estación de bombeo
para controlar las válvulas tipo anular que regulan el caudal.
La válvula FV tipo anular regula el caudal deseado, es decir los valores indicados según los
puntos de medición (puntos de medición del 2 al 6). El medidor magnético FE monitorea el
caudal y este valor es leído por el sistema de control “FIC” el cual envía órdenes de abrir o
cerrar la válvula FV para obtener el valor de caudal deseado. Este es un lazo control cuyo
algoritmo de automatización está en el sistema de control de la estación de bombeo
expresado en el diagrama como “I”.
Todas las señales son enviadas al tablero RIO, ubicado en la sala eléctrica de la presa y
desde allí se transmite la información al sistema de control, ubicado en la sala eléctrica de la
estación de bombeo, donde se procesa la información y se opera el sistema de entrega para
el control de caudales en cada línea.
Para el caso de la regulación del caudal para alimentar la estación de bombeo (punto de
medición 1), éste se realiza en la tubería de conducción dentro de la estación de bombeo.
Cuando el embalse Pasto Grande descargue caudales mayores a 4,40 m3/s, el caudal que
exceda a este valor será descargado al río Vizcachas a través del conducto de desagüe, con
un caudal regulado a través de la compuerta 1130-GA-021, que cuenta con un sistema de
control automático.
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Esta compuerta será utilizada también para regular el caudal de entrega a los usuarios, en
forma temporal, en caso de emergencia o mantenimiento de los equipos instalados en las
líneas de entrega. En tal caso, se cerrará el ingreso de agua al conducto de entrega utilizando
la compuerta de emergencia 1130-GA-022 y se efectuará la descarga regulada a través del
conducto de desagüe controlando la apertura de la compuerta 1130-GA-021.
Esta compuerta de operación de la obra de desagüe cuenta con un cilindro hidráulico y una
unidad hidráulica controlada por PLC, como se muestra en el esquema simplificado
presentado a continuación. El PLC está comunicado por la red Profibus DP con el sistema de
control de la sala eléctrica en la estación de bombeo desde donde se podrá tener un control
remoto – manual de acuerdo a las indicaciones del jefe de la estación de bombeo.
1130-HT-001
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Se colocarán vertederos triangulares de pared delgada con sus respectivos sensores para
medir los caudales de filtración. Los vertederos se ubicarán en la salida de las 04 galerías,
02 superiores y 02 inferiores. Serán de acero inoxidable, de 5 mm de espesor, instalados en
un muro de concreto perpendicular al flujo. El ángulo de la forma triangular será de 45 grados
con un corte de biselado de inclinación de 45 grados, y el ancho del borde en el contacto con
el agua será 2 mm.
Cada vertedero cuenta con un sensor de nivel tipo ultrasonido soportado en la pared de la
galería y se encontrará a una distancia aproximada de 1.50 m del vertedero. Los sensores
envían sus señales a un datalogger, ubicado en la sala eléctrica 1130-ER-002, donde se
calcula el caudal en tiempo real y el acumulado evacuado de las 04 galerías de drenaje. La
señal de los sensores que llega al datalogger será de 4 - 20 mA, El datalogger será
programado para realizar el cálculo de la medición del caudal de filtraciones en forma mensual
durante la construcción de la presa y tres veces al día durante el proceso de llenado del
embalse. Excepcional medición se realizará luego de un sismo, para el cual se deberá hacer
mediciones cada hora durante las 3 horas posteriores al sismo. Así también el datalogger
estará conectado al sistema DCS mediante la señal digital Profibus para ser monitoreado en
forma remota desde la sala eléctrica del sistema de bombeo.
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7.1 Generalidades
En el rio Titire se tiene dos estaciones ubicadas: una aguas arriba de la Bocatoma Titire (T2)
y una aguas abajo (T1), en el siguiente cuadro se muestra las coordenadas en el sistema de
referencia del proyecto. Las dos estaciones T1 y T2 de aforo de la Bocatoma Titire se han
diseñado hidráulicamente para medir flujos 0,60 a 26,00 m3/s.
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Todas las estaciones de aforo consideran un único instrumento de medición de caudal basado
en tecnología de ondas de radar. Este instrumento entrega señales eléctricas que varían entre
de 4 a 20 mA, proporcionalmente a la medición. El sensor mide velocidad y nivel y calcula el
caudal del rio con los parámetros hidráulicos respectivos.
7.2.1 Rio Vizcachas
En el rio Vizcachas se tiene tres (03) estaciones de aforo, los cuales están implementadas
con un sistema de transmisión-recepción inalámbrico para transmitir las señales a la estación
de bombeo. El medidor de caudal, el datalogger y el módulo de comunicación inalámbrica
serán alimentados desde baterías recargadas por paneles solares. El datalogger será capaz
de registrar las señales y calcular valores acumulados (por ejemplo realizar cálculos cada
minuto y acumular cada hora o semanas) entre otros procesos programables que permita no
perder la información en caso que se produzca interrupción en tiempo real. En el siguiente
esquema funcional simplificado de las estaciones de aforo del rio Vizcachas se grafica los
componentes y su conexionado.
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PLC 23 A PLC
ITEM TAG TIPO DIRECCION COMENTARIO estado 1 estado 0 MIN MAX UNID
1 1130506_BIT BOOL DB200.DBX0.0 BIT DE RASTREO DE COMUNICACION 2HZ ‐‐‐ ‐‐‐ ‐‐‐
2 1130506_ALM BOOL DB200.DBX0.1 ALARMA/FALLA EN UNIDAD HIDRAULICA NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
3 1130506_PE BOOL DB200.DBX0.2 ALARMA PARADA DE EMERGENCIA GENERAL NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
4 1130506_TAB BOOL DB200.DBX0.3 ALARMA DE INTERRUPTOR GENERAL ABIERTO (400 VAC) NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
5 1130506_PSHH BOOL DB200.DBX0.4 ALARMA PRESION MUY ALTA EN SISTEMA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
6 1130506_SAT BOOL DB200.DBX0.5 ALARMA SATURACION DE FILTRO ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
7 1130506_LSL BOOL DB200.DBX0.6 ALARMA NIVEL BAJO DE ACEITE NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
8 1130506_TSL BOOL DB200.DBX0.7 ALARMA TEMPERATURA BAJA DE ACEITE ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
9 1130506A_FB BOOL DB200.DBX1.0 CONFIRMACION DE ARRANQUE MOTOR 1 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
10 1130506A_OL BOOL DB200.DBX1.1 FALLA SOBRECARGA DE MOTOR 1 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
11 1130506A_TERM BOOL DB200.DBX1.2 FALLA TERMICO DE MOTOR 1 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
12 1130506B_FB BOOL DB200.DBX1.3 CONFIRMACION DE ARRANQUE MOTOR 2 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
13 1130506B_OL BOOL DB200.DBX1.4 FALLA SOBRECARGA DE MOTOR 2 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
14 1130506B_TERM BOOL DB200.DBX1.5 FALLA TERMICO DE MOTOR 2 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
15 1130506_ZSO BOOL DB200.DBX1.6 COMPUERTA DE EMERGENCIA DESAGUE ABIERTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
16 1130506_ZSC BOOL DB200.DBX1.7 COMPUERTA DE EMERGENCIA DESAGUE CERRADO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
17 1130506_PSHO BOOL DB200.DBX2.0 ALARMA PRESION ALTA AL ABRIR COMPUERTA DE EMERGENCIA DESAGUE ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
18 1130506_PSHC BOOL DB200.DBX2.1 ALARMA PRESION ALTA AL CERRAR COMPUERTA DE EMERGENCIA DESAGUE ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
19 1130506_PEL BOOL DB200.DBX2.2 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA DE EMERGENCIA DESAGUE NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
20 1130506_LOC BOOL DB200.DBX2.3 COMPUERTA DE EMERGENCIA DESAGUE EN MODO LOCAL ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
21 1130506_REM BOOL DB200.DBX2.4 COMPUERTA DE EMERGENCIA DESAGUE EN MODO REMOTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
22 1130507_ZSO BOOL DB200.DBX2.5 COMPUERTA DE TUBERIA DE ENTREGA ABIERTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
23 1130507_ZSC BOOL DB200.DBX2.6 COMPUERTA DE TUBERIA DE ENTREGA CERRADO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
24 1130507_PSHO BOOL DB200.DBX2.7 ALARMA PRESION ALTA AL ABRIR COMPUERTA DE TUBERIA DE ENTREGA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
25 1130507_PSHC BOOL DB200.DBX3.0 ALARMA PRESION ALTA AL CERRAR COMPUERTA DE TUBERIA DE ENTREGA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
26 1130507_PEL BOOL DB200.DBX3.1 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA DE TUBERIA DE ENTREGA NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
27 1130507_LOC BOOL DB200.DBX3.2 COMPUERTA DE TUBERIA DE ENTREGA EN MODO LOCAL ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
28 1130507_REM BOOL DB200.DBX3.3 COMPUERTA DE TUBERIA DE ENTREGA EN MODO REMOTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
29 1130508_ZSO BOOL DB200.DBX3.4 COMPUERTA DE REJA ABIERTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
30 1130508_ZSC BOOL DB200.DBX3.5 COMPUERTA DE REJA CERRADO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
31 1130508_PSHO BOOL DB200.DBX3.6 ALARMA PRESION ALTA AL ABRIR COMPUERTA DE REJA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
32 1130508_PSHC BOOL DB200.DBX3.7 ALARMA PRESION ALTA AL CERRAR COMPUERTA DE REJA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
33 1130508_PEL BOOL DB200.DBX4.0 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA DE REJA NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
34 1130508_LOC BOOL DB200.DBX4.1 COMPUERTA DE REJA EN MODO LOCAL ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
35 1130508_REM BOOL DB200.DBX4.2 COMPUERTA DE REJA EN MODO REMOTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
36 BOOL_35 BOOL DB200.DBX4.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
37 BOOL_36 BOOL DB200.DBX4.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
38 BOOL_37 BOOL DB200.DBX4.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
39 BOOL_38 BOOL DB200.DBX4.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
40 BOOL_39 BOOL DB200.DBX4.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
41 BOOL_40 BOOL DB200.DBX5.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
42 BOOL_41 BOOL DB200.DBX5.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
43 BOOL_42 BOOL DB200.DBX5.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
44 BOOL_43 BOOL DB200.DBX5.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
45 BOOL_44 BOOL DB200.DBX5.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
46 BOOL_45 BOOL DB200.DBX5.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
47 BOOL_46 BOOL DB200.DBX5.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
48 BOOL_47 BOOL DB200.DBX5.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
49 INT_0 INT DB200.DBW6 PARA VARIABLES DE VALOR ENTERO A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
Página 1 de 12
PLC 23 A PLC
Página 2 de 12
DESDE PLC A PLC‐023
Página 3 de 12
PLC021 A PLC
ITEM TAG TIPO DIRECCION COMENTARIO estado 1 estado 0 MIN MAX UNID
1 1130505_BIT BOOL DB200.DBX0.0 BIT DE RASTREO DE COMUNICACION 2HZ ‐‐‐ ‐‐‐ ‐‐‐
2 1130505_ALM BOOL DB200.DBX0.1 ALARMA/FALLA EN UNIDAD HIDRAULICA NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
3 1130505_PE BOOL DB200.DBX0.2 ALARMA PARADA DE EMERGENCIA GENERAL NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
4 1130505_TAB BOOL DB200.DBX0.3 ALARMA DE INTERRUPTOR GENERAL ABIERTO (400 VAC) NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
5 1130505_PSHH BOOL DB200.DBX0.4 ALARMA PRESION MUY ALTA EN SISTEMA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
6 1130505_SAT BOOL DB200.DBX0.5 ALARMA SATURACION DE FILTRO ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
7 1130505_LSL BOOL DB200.DBX0.6 ALARMA NIVEL BAJO DE ACEITE NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
8 1130505_TSL BOOL DB200.DBX0.7 ALARMA TEMPERATURA BAJA DE ACEITE ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
9 1130505A_FB BOOL DB200.DBX1.0 CONFIRMACION DE ARRANQUE MOTOR 1 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
10 1130505A_OL BOOL DB200.DBX1.1 FALLA SOBRECARGA DE MOTOR 1 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
11 1130505A_TERM BOOL DB200.DBX1.2 FALLA TERMICO DE MOTOR 1 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
12 1130505B_FB BOOL DB200.DBX1.3 CONFIRMACION DE ARRANQUE MOTOR 2 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
13 1130505B_OL BOOL DB200.DBX1.4 FALLA SOBRECARGA DE MOTOR 2 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
14 1130505B_TERM BOOL DB200.DBX1.5 FALLA TERMICO DE MOTOR 2 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
15 1130505_ZSO BOOL DB200.DBX1.6 COMPUERTA DE OPERACIONES ABIERTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
16 1130505_ZSC BOOL DB200.DBX1.7 COMPUERTA DE OPERACIONES CERRADO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
17 1130505_PSHO BOOL DB200.DBX2.0 ALARMA PRESION ALTA AL ABRIR COMPUERTA DE OPERACIONES ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
18 1130505_PSHC BOOL DB200.DBX2.1 ALARMA PRESION ALTA AL CERRAR COMPUERTA DE OPERACIONES ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
19 1130505_PEL BOOL DB200.DBX2.2 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA DE OPERACIONES NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
20 1130505_LOC BOOL DB200.DBX2.3 COMPUERTA DE OPERACIONES EN MODO LOCAL ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
21 1130505_REM BOOL DB200.DBX2.4 COMPUERTA DE OPERACIONES EN MODO REMOTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
22 BOOL_21 BOOL DB200.DBX2.5 COMPUERTA DE TUBERIA DE ENTREGA ABIERTO ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
23 BOOL_22 BOOL DB200.DBX2.6 COMPUERTA DE TUBERIA DE ENTREGA CERRADO ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
24 BOOL_23 BOOL DB200.DBX2.7 ALARMA PRESION ALTA AL ABRIR COMPUERTA DE TUBERIA DE ENTREGA ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
25 BOOL_24 BOOL DB200.DBX3.0 ALARMA PRESION ALTA AL CERRAR COMPUERTA DE TUBERIA DE ENTREGA ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
26 BOOL_25 BOOL DB200.DBX3.1 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA DE TUBERIA DE ENTREGA ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
27 BOOL_26 BOOL DB200.DBX3.2 COMPUERTA DE TUBERIA DE ENTREGA EN MODO LOCAL ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
28 BOOL_27 BOOL DB200.DBX3.3 COMPUERTA DE TUBERIA DE ENTREGA EN MODO REMOTO ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
29 BOOL_28 BOOL DB200.DBX3.4 COMPUERTA DE REJA ABIERTO ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
30 BOOL_29 BOOL DB200.DBX3.5 COMPUERTA DE REJA CERRADO ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
31 BOOL_30 BOOL DB200.DBX3.6 ALARMA PRESION ALTA AL ABRIR COMPUERTA DE REJA ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
32 BOOL_31 BOOL DB200.DBX3.7 ALARMA PRESION ALTA AL CERRAR COMPUERTA DE REJA ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
33 BOOL_32 BOOL DB200.DBX4.0 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA DE REJA ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
34 BOOL_33 BOOL DB200.DBX4.1 COMPUERTA DE REJA EN MODO LOCAL ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
35 BOOL_34 BOOL DB200.DBX4.2 COMPUERTA DE REJA EN MODO REMOTO ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
36 BOOL_35 BOOL DB200.DBX4.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
37 BOOL_36 BOOL DB200.DBX4.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
38 BOOL_37 BOOL DB200.DBX4.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
39 BOOL_38 BOOL DB200.DBX4.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
40 BOOL_39 BOOL DB200.DBX4.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
41 BOOL_40 BOOL DB200.DBX5.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
42 BOOL_41 BOOL DB200.DBX5.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
43 BOOL_42 BOOL DB200.DBX5.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
44 BOOL_43 BOOL DB200.DBX5.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
45 BOOL_44 BOOL DB200.DBX5.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
46 BOOL_45 BOOL DB200.DBX5.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
47 BOOL_46 BOOL DB200.DBX5.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
48 BOOL_47 BOOL DB200.DBX5.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
Página 4 de 12
PLC021 A PLC
Página 5 de 12
DESDE PLC A PLC021
Página 6 de 12
DESDE PLC A PLC021
ITEM TAG TIPO DIRECCION COMENTARIO estado 1 estado 0 MIN MAX UNID
1 1120500_BIT BOOL DB200.DBX0.0 BIT DE RASTREO DE COMUNICACION 2HZ ‐‐‐ ‐‐‐ ‐‐‐
2 1120500_ALM BOOL DB200.DBX0.1 ALARMA/FALLA EN UNIDAD HIDRAULICA NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
3 1120500_PE BOOL DB200.DBX0.2 ALARMA PARADA DE EMERGENCIA GENERAL NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
4 1120500_TAB BOOL DB200.DBX0.3 ALARMA DE INTERRUPTOR GENERAL ABIERTO (400 VAC) NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
5 1120500_PSHH BOOL DB200.DBX0.4 ALARMA PRESION MUY ALTA EN SISTEMA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
6 1120500_SAT BOOL DB200.DBX0.5 ALARMA SATURACION DE FILTRO ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
7 1120500_LSL BOOL DB200.DBX0.6 ALARMA NIVEL BAJO DE ACEITE NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
8 1120500_TSL BOOL DB200.DBX0.7 ALARMA TEMPERATURA BAJA DE ACEITE ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
9 1120500A_FB BOOL DB200.DBX1.0 CONFIRMACION DE ARRANQUE MOTOR 1 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
10 1120500A_OL BOOL DB200.DBX1.1 FALLA SOBRECARGA DE MOTOR 1 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
11 1120500A_TERM BOOL DB200.DBX1.2 FALLA TERMICO DE MOTOR 1 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
12 1120500B_FB BOOL DB200.DBX1.3 CONFIRMACION DE ARRANQUE MOTOR 2 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
13 1120500B_OL BOOL DB200.DBX1.4 FALLA SOBRECARGA DE MOTOR 2 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
14 1120500B_TERM BOOL DB200.DBX1.5 FALLA TERMICO DE MOTOR 2 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
15 1120500_ZSO BOOL DB200.DBX1.6 COMPUERTA RADIAL 1 ABIERTA ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
16 1120500_ZSC BOOL DB200.DBX1.7 COMPUERTA RADIAL 1 CERRADA ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
17 1120500_PSHO BOOL DB200.DBX2.0 ALARMA PRESION ALTA AL ABRIR COMPUERTA RADIAL 1 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
18 1120500_PSHC BOOL DB200.DBX2.1 ALARMA PRESION ALTA AL CERRAR COMPUERTA RADIAL 1 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
19 1120500_PEL BOOL DB200.DBX2.2 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA RADIAL 1 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
20 1120500_LOC BOOL DB200.DBX2.3 COMPUERTA RADIAL 1 EN MODO LOCAL ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
21 1120500_REM BOOL DB200.DBX2.4 COMPUERTA RADIAL 1 EN MODO REMOTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
22 BOOL_21 BOOL DB200.DBX2.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
23 BOOL_22 BOOL DB200.DBX2.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
24 BOOL_23 BOOL DB200.DBX2.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
25 BOOL_24 BOOL DB200.DBX3.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
26 BOOL_25 BOOL DB200.DBX3.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
27 BOOL_26 BOOL DB200.DBX3.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
28 BOOL_27 BOOL DB200.DBX3.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
29 BOOL_28 BOOL DB200.DBX3.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
30 BOOL_29 BOOL DB200.DBX3.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
31 BOOL_30 BOOL DB200.DBX3.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
32 BOOL_31 BOOL DB200.DBX3.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
33 BOOL_32 BOOL DB200.DBX4.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
34 BOOL_33 BOOL DB200.DBX4.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
35 BOOL_34 BOOL DB200.DBX4.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
36 BOOL_35 BOOL DB200.DBX4.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
37 BOOL_36 BOOL DB200.DBX4.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
38 BOOL_37 BOOL DB200.DBX4.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
39 BOOL_38 BOOL DB200.DBX4.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
40 BOOL_39 BOOL DB200.DBX4.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
41 BOOL_40 BOOL DB200.DBX5.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
42 BOOL_41 BOOL DB200.DBX5.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
43 BOOL_42 BOOL DB200.DBX5.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
44 BOOL_43 BOOL DB200.DBX5.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
45 BOOL_44 BOOL DB200.DBX5.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
46 BOOL_45 BOOL DB200.DBX5.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
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DESDE PLC A PLC021
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DESDE PLC A PLC021
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DESDE PLC A PLC021
ITEM TAG TIPO DIRECCION COMENTARIO estado 1 estado 0 MIN MAX UNID
1 1120501_BIT BOOL DB200.DBX0.0 BIT DE RASTREO DE COMUNICACION 2HZ ‐‐‐ ‐‐‐ ‐‐‐
2 1120501_ALM BOOL DB200.DBX0.1 ALARMA/FALLA EN UNIDAD HIDRAULICA NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
3 1120501_PE BOOL DB200.DBX0.2 ALARMA PARADA DE EMERGENCIA GENERAL NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
4 1120501_TAB BOOL DB200.DBX0.3 ALARMA DE INTERRUPTOR GENERAL ABIERTO (400 VAC) NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
5 1120501_PSHH BOOL DB200.DBX0.4 ALARMA PRESION MUY ALTA EN SISTEMA ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
6 1120501_SAT BOOL DB200.DBX0.5 ALARMA SATURACION DE FILTRO ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
7 1120501_LSL BOOL DB200.DBX0.6 ALARMA NIVEL BAJO DE ACEITE NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
8 1120501_TSL BOOL DB200.DBX0.7 ALARMA TEMPERATURA BAJA DE ACEITE ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
9 1120501A_FB BOOL DB200.DBX1.0 CONFIRMACION DE ARRANQUE MOTOR 1 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
10 1120501A_OL BOOL DB200.DBX1.1 FALLA SOBRECARGA DE MOTOR 1 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
11 1120501A_TERM BOOL DB200.DBX1.2 FALLA TERMICO DE MOTOR 1 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
12 1120501B_FB BOOL DB200.DBX1.3 CONFIRMACION DE ARRANQUE MOTOR 2 ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
13 1120501B_OL BOOL DB200.DBX1.4 FALLA SOBRECARGA DE MOTOR 2 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
14 1120501B_TERM BOOL DB200.DBX1.5 FALLA TERMICO DE MOTOR 2 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
15 1120501_ZSO BOOL DB200.DBX1.6 COMPUERTA RADIAL 2 ABIERTA ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
16 1120501_ZSC BOOL DB200.DBX1.7 COMPUERTA RADIAL 2 CERRADA ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
17 1120501_PSHO BOOL DB200.DBX2.0 ALARMA PRESION ALTA AL ABRIR COMPUERTA RADIAL 2 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
18 1120501_PSHC BOOL DB200.DBX2.1 ALARMA PRESION ALTA AL CERRAR COMPUERTA RADIAL 2 ALARMA NORMAL ‐‐‐ ‐‐‐ ‐‐‐
19 1120501_PEL BOOL DB200.DBX2.2 ALARMA PARADA DE EMERGENCIA LOCAL COMPUERTA RADIAL 2 NORMAL ALARMA ‐‐‐ ‐‐‐ ‐‐‐
20 1120501_LOC BOOL DB200.DBX2.3 COMPUERTA RADIAL 2 EN MODO LOCAL ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
21 1120501_REM BOOL DB200.DBX2.4 COMPUERTA RADIAL 2 EN MODO REMOTO ACTIVADO DESACTIVADO ‐‐‐ ‐‐‐ ‐‐‐
22 BOOL_21 BOOL DB200.DBX2.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
23 BOOL_22 BOOL DB200.DBX2.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
24 BOOL_23 BOOL DB200.DBX2.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
25 BOOL_24 BOOL DB200.DBX3.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
26 BOOL_25 BOOL DB200.DBX3.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
27 BOOL_26 BOOL DB200.DBX3.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
28 BOOL_27 BOOL DB200.DBX3.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
29 BOOL_28 BOOL DB200.DBX3.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
30 BOOL_29 BOOL DB200.DBX3.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
31 BOOL_30 BOOL DB200.DBX3.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
32 BOOL_31 BOOL DB200.DBX3.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
33 BOOL_32 BOOL DB200.DBX4.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
34 BOOL_33 BOOL DB200.DBX4.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
35 BOOL_34 BOOL DB200.DBX4.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
36 BOOL_35 BOOL DB200.DBX4.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
37 BOOL_36 BOOL DB200.DBX4.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
38 BOOL_37 BOOL DB200.DBX4.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
39 BOOL_38 BOOL DB200.DBX4.6 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
40 BOOL_39 BOOL DB200.DBX4.7 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
41 BOOL_40 BOOL DB200.DBX5.0 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
42 BOOL_41 BOOL DB200.DBX5.1 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
43 BOOL_42 BOOL DB200.DBX5.2 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
44 BOOL_43 BOOL DB200.DBX5.3 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
45 BOOL_44 BOOL DB200.DBX5.4 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
46 BOOL_45 BOOL DB200.DBX5.5 PARA SEÑALES DIGITALES A SER TRANSFERIDAS ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐
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DESDE PLC A PLC021
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DESDE PLC A PLC021
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