weir netherlands b.v

Weir Netherlands b.v.

P.O. Box 249, 5900 AE Venlo, the Netherlands Egtenrayseweg 9, NL-5928 PH Venlo

4495 Registration No.: 12032525

Tel: +31(0)77 3895200 Fax: +31(0)77 3824844 Email: [email protected] www.weir.nl

ExcellentEngineeringSolutions

To : CBA. Alumínio, São Paulo Brazil Attention : Mr. Renato Moura Carlos Parisi Luiz Pozzi Cláudio Pavanelo Date : 3 may 2007 Project : Red Mud high concentration disposal system Proposal No. : 07EK0214-QR3 Record No. : i/s/br/CBA/07EK0214-QR3 Scope Description : System components and GEHO triplex single acting crankshaft drive piston

diaphragm pumps, model TZPM 2000

To: CBA Proposal No. 07EK0214-QR3

Revision 3 dated 3, May 2007

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Contents

1 Introduction 3

2 Engineering conditions 5

3 Scope of Work 6 3.1 Included in scope of work 6 3.2 Work to be performed by Engineering and Construction Partners 9 3.3 Not included in Geho System Scope of work 9 3.4 Battery limits 9 3.5 Spare parts Consumption 10 3.6 Labour Requirements 10 3.7 Specific advantages of the proposed system 11

4 Pricing schedule 12 4.1 Additional options Erro! Indicador não definido.

5 Commercial Notes 14

6 Technical Description GEHO piston diaphragm pump TZPM 2000 16 6.1 Work not included in pumps supply 20

Attachment 1: Scope split between WMN and local engineering company / local contractor 21

Attachment 2: Basic system set up 24

Attachment 3: Technical Description of ABB Drive Components 25



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1 Introduction

Dear Mr. Moura, Parisi, Pozzi, Pavanelo, As per our discussion we have the pleasure to quote to you attached for the supply of know how, engineering services and equipment to allow your contractor to complete the installation of a High Concentration Slurry Disposal system for red mud. The proposal is based on the concept to allow the contractor to install the system at the lowest possible costs. This is achieved through the supply by GEHO Pumps of the main components and of engineering and services of only the essential work, which requires GEHO’s specific support and technology. A local contractor will cover all other aspects with respect to completeness of the scope. Most alumina plants operate a HCSD system for red mud with a stand by capability installed for selected components including the main line GEHO pump. This quotation includes two (2) triplex single acting crankshaft drive piston diaphragm pumps, model TZPM 2000, of which one (1) will be in operation and one (1) will act as stand-by. In chapter 6, the scope of supply regarding these TZPM 2000 pumps is clearly defined. For your reference and consideration, chapter 4.1. shows the items that are quoted optionally. The system proposed provides for the red mud filter cake dumped in the Agitated Retention Tank to be conditioned to the correct rheological properties. This ensures the mud has the proper flowing behavior to spread out on the disposal site at an angle of repose, virtually without release of water. The correct behavior is primarily achieved through shear thinning and addition of water. A control loop continuously monitors the differential pressure and density of the slurry. If required the rheology of the slurry is altered automatically through the addition of water. We propose the ART be placed next to the strainers. Two centrifugal booster pumps (one (1) operating and one (1) stand by) feed the mud through the installed suction strainer. The strainer ensures that oversized material does not enter the mainline pump. The slurry is transferred to the mainline GEHO piston diaphragm pumps via atmospheric air vessels. The GEHO piston diaphragm pump model TZPM 2000 will develop the pressure required to transfer the mud to the end of either the 21.4 km pipeline or the 4 km pipeline. After award GEHO Pumps will perform site rheological verification tests. We will be responsible for the (basic) design of the system and the control and operating philosophy through the supply of drawings and data sheets as per our quotation. Detailed engineering as well as actual construction work and supply of suction as well as discharge piping (16” pipeline, acc. GEHO basic engineering) is left to the local contractor. GEHO Pumps will actively support and advice your contractor during the project execution from the Netherlands: drawings will be reviewed and commented and the completed installation will be reviewed. GEHO pumps will assist in commissioning and start up of the components and system. The system will be designed for a life to exceed 30 years of operation. Spare parts costs will be low due to the use of the piston diaphragm pump, which makes use of a rubber diaphragm to protect the vital parts from the abrasive slurry. As a result only the mainline pump valves are subject to abrasion apart from the booster pump internals. The consistency of the mud contains no excess water (water and energy is saved) and is disposed with release of hardly any water. This normally eliminates the need for a recirculation system, further reducing operating costs. Rain water will run off the sloped deposit at a low velocity to limit any erosion and often may be released to the environment. The system in our estimation and depending on your schedule should be made operative after approximately 16 months from award and receipt of payment security.



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Yours faithfully, Weir Minerals Netherlands b.v. GEHO PUMPS Erik van der Kuy Erik Vlot Theo Tosserams Area Sales Manager. Product Manager Systems Applications Engineer GEHO Pumps



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2 Engineering conditions

Description of plant: � Type : Alumina plant � Capacity : 1.5 Million Ton / Year based on 8000 operating hours � capacity : 187.5 t/h Description of waste products:

Slurry quantity m3/h

Waste product min. Max.

Particle size distribution available yes/no Please attached

Sample available yes/no

Chemical composition available yes/no please attached

Red Mud 29 290 no yes no

Required technical conditions: Pastinho Dam Palmital Dam � Length to furthest end on disposal area (m) : 21.4 km 4 km � Total static head (m) : -102 m + 88 m � Drawing of disposal site available : yes � Solids concentration : To be advised.

Depending on the chosen dam

Climatic conditions: � Installation : outdoor sheltered � Temperature ambient : min. 5°C, max. 45°C Water requirements Water requirements for slurry preparation � Consumption : 140 m3/h � Pressure : 500-700 kPa � Quality : Process water - pH neutral Water requirements for pipe flushing � Consumption : 290 m3/h � Pressure : 200-300 kPa � Quality : Process water - pH neutral Water requirements for pump operation � Cooling of gearbox : to be defined after detailed engineering Flushing of pump � Consumption : approx. 40 m3/h � Pressure : 200-300 kPa � Quality : Process water - pH neutral



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3 Scope of Work

3.1 Included in scope of work The slurry preparation, transportation and disposal system incl. agitator, charge pumps and GEHO piston diaphragm pumps, according GEHO proprietary design criteria and specifications

Item Qty. Description

1 2 Agitator for Agitated Retention Tank (ART) for optimisation of the slurry consistency and homogenisation, comprising of:

� High-torque agitator, make Hoesch, complete with gearbox and motor drive, specifically designed for this severe duty.

� Basic design of the Tank (overall dimensions) by GEHO PUMPS

The tank itself (detailed Tank design - fabricated steel, diameter approx. 5.6 m, height approx. 7.8 m - and the steel structure) is not included in our offer. For this we advise to contact a local supplier.

2 2 Slurry Control Unit (SCU) for the on-line monitoring of the slurry quality, comprising of: � Peristaltic pump complete with drive (GEHO supply). � Differential pressure measurement (GEHO supply). � Density measurement (GEHO supply). � Basic design for control loop (GEHO supply). � Control loop PLC (GEHO supply)

- Not required in case option for system control cabinet will be included. � Control loop shut off and flush valves (GEHO supply) � Pipe loop piping and air over slurry pulsation damper by third party. � Slurry control unit to be mounted at the ART tank wall by third party. � All wiring to be third party.

3 2 Water dosing system: (GEHO supply) � Motor operated water valve, flow meter, pressure transmitter, pressure switch. � Water flow required is 175 m3/h, water pressure required between 5 – 7 bar, water supply

by third party. � Installation and wiring by third party.

4 4 Booster pump, centrifugal type: � With suction directly from the ART. � Pump in high-chrome, wear resistant execution for pump casing and impeller. � Specifically engineered for high viscous red mud slurry application. � Base frame. � E-motor. � Counter flanges. � Gland water harness including flow switch. � Civil work, piping and wiring by third party.

5 1 Lobster pot: Basic design by GEHO Pumps.



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The lobster pot itself is not included in our offer. For this we advise to contact a local supplier. Please refer to chapter 4.1 for second lobster pot option.

6 2 In-line suction strainer

Please refer to chapter 4.1 for dual strainer set-up.

7 2 Suction air vessel: � In main pump suction line � To provide a virtually momentum-free absorption of pressure pulsations � To protect booster pump from pressure surges � Including suction pressure transmitter � Including pressure gauge � Compressed air connection

8 2 � Main line pump: GEHO triplex single-acting crankshaft driven piston diaphragm pump

type TZPM 2000. For scope of supply, please refer to chapter 6 of this quotation.

9 1 Process control system � Both mainline pump and slurry control unit have dedicated plc with graphic user interface. � Integration of (automated) process control to be executed by third party. � Signals can be made available in hardwire execution. Communication via ethernet is

optional. Please refer to chapter 4.1 for main control system option.

10 1 Discharge pipeline (NOT Included in our scope – to be supllied by others) � Nominal 16 inch, 160 bar design, length either ca. 21.4 km or 4 km

11 Lot Low pressure slurry valves (GEHO supply): � Manually operated � Isolation, booster pump suction � Flush water, booster pump suction � Drain, booster pump discharge � Isolation, booster pump discharge � Flush, lobster pot � Drain lobster pot � Flush, suction strainer � Drain suction strainer � Isolation, GEHO pump suction � Flush water, GEHO pump suction � ART drain valve

12 Lot High pressure valves (GEHO supply): � Manually operated � Drain, GEHO discharge � Isolation, GEHO discharge

13 1 Lot of commissioning spare parts (GEHO supply)



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14 Lot General components and instrumentation (GEHO supply): � Level sensor for agitated retention tank � Slurry dilution valve in booster pump suction � Pressure transmitters discharge pipeline

15 1 System and GEHO pump supervision and commissioning by GEHO service engineer, three trips for a total duration of 9 weeks

16 1 System commissioning by one GEHO system engineer one trip for a total estimated duration of 1 week

17 1 Basic system engineering package The price allows for the basic system design of the preparation and transportation system. This basic design package will serve as input for the required detail design to be performed by a third party. The basic system design includes: � Design basis � Basic P&I drawing � Basic pump station layout. � Basic design lobster pot � Discharge pipeline diameter and wall thickness calculations. � Equipment list � Valve list � Drive list � Operation and control philosophy � Operating manual for slurry control unit � Laboratory testing of samples. A representative sample of 10 litres to be provided within 2

weeks after signing of contract. � Three design meetings in Brazil

18 1 Free annual installation performance review by GEHO Customer Care Department



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3.2 Work to be performed by Engineering and Construction Partners

� Engineering and detailed design � Mechanical � Electrical � Civil � Structural � Piping � Programming

� All hardware as partially indicated above. � Agitator retention tank (ART), including all connections, totally enclosed. � Mounting and assembling of all Slurry Control Unit components onto the ART. � Lobster pot. � Discharge pipeline, including all accessories, routing, structural calculations, stress analysis. � All other components as per the requirements of the system.

� Pump station detail design. � All interconnecting piping and wiring.

3.3 Not included in Geho System Scope of work The Purchaser / Contractor will have to provide the following utilities, equipment and services: � Civil engineering and construction. � Installation labour. � Electrical hook-up of drives and control systems. � Initial filling of lubricants, gas, propelling liquid and so on. � Finish painting. � All interconnecting piping and wiring to and from units. � Feed line(s) from drum filters the agitated retention tank. � Approximately 140 m³/h ‘make up’ water supply to the proposed water dosing system. � Approximately 290 m³/h flush water supply. � Air-conditioned control room for VFD and or System PLC control. � conditioned air at 500-700 kPa for operation of propellant inlet/outlet valves fitted to the diaphragm stroke

control system � external piping to the unit � anchor bolts supply � platforms, stairways and safety railing as may be required � Board and lodging of GEHO staff during all visits on site It is expected that the local contract partner will fill in all gaps between what is in the scope of supply of Geho Pumps and the requirements from the plant owner.

3.4 Battery limits � Top of ART tank filter cake feed opening. � Mainline pump discharge flange. � Make up water dosing valve entrance. � Electrical power supply connections. � Electrical control connections outside control cabinet and pump.



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3.5 Spare parts Consumption A GEHO representative will assist the staff, which manages the pumps, to evaluate the usage and make arrangements to assure the availability of the spare parts. The manufacture of these parts concurrent with the pump will result in cost savings and a discounted price. Complete parts lists for all equipment and accessories supplied will be submitted within 3 months from the date of contract award.

3.6 Labour Requirements Operating � Once the installation is properly installed and commissioned, it will run fully automatically and can be

controlled from the Central Control Room (CCR) or if so, to local control room. The proposed equipment therefor does NOT require any ADDITIONAL operating personnel.

Maintenance � The design of the installation is based on rigid and wear resisting components In combination with a very

easy and quick access of these wear components, the replacement of wear parts will require only a short interval, typically approximately 2 hours for 1 pump. Total maintenance required will not exceed approx. 250 hours annually, which results in an unequalled high pump availability of more than 98%!



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3.7 Specific advantages of the proposed system Since early eighties, it is possible to transport high-density slurries (practically without free water) through a long distance pipeline. It is subsequently possible to dispose (waste) slurry in an environmentally safe and sound way. These possibilities became economically viable through the development of high-pressure piston diaphragm pumps. Compared with the conventional ways of transportation by means of conveyor belts, trucks or low density slurry pumping, the proposed high-density ash transportation and disposal technology offers you following: Environmental advantages: � Minimal or no ground water pollution because of the solidification of the slurry on the disposal site. � Minimal or no dusting because of the solidification of the slurry. � Easy drainage of rainwater. � Hills can be easily constructed in order to recreate the original landscape. � Possibility of re-cultivation / re-vegetation. � The pipeline can be buried underground and remains invisible. � No topographic limitations to the pipeline systems. � No pollution during transportation because of fully enclosed pipeline system. � Disposing high-density tailings requires less volumetric space than low-density tailings.

Operational advantages: � The slurry preparation, transportation and disposal is completely automated. The entire system can be

operated and controlled at one location. This location can be the power plant's Central Control Room. Thus no additional manpower is required.

� The slurry preparation, transportation and disposal is continuous and trouble free. � The system is not influenced by weather conditions etc. � No additional manpower or machinery is required to spread the waste over the whole area of the

disposal site. � Therefore no accommodations for personnel or equipment on the disposal site are required. � Flexibility: a later change of the pipeline routing is possible at low costs. � The pipeline system provides adequate standby facility and allows for more freedom of layout (routing). � The installation offers high availability and reliability in summer as well as in winter seasons. � The installation is maintenance friendly. � Easy cleaning possibilities of installation and pipeline. � Self-cleaning of pipeline because of positive displacement pump characteristics. Financial advantages: � The pump system is designed to operate 25 to 30 years, thus reducing the depreciation per year. � The energy consumption of a pump system is low due to low flow rate and high pump efficiency

(90…95%). � High operating costs (high spare parts consumption and labour) of trucks and belts are eliminated. � No energy consumers (infra structure!) on the disposal site. � Less volumetric space required for disposal lead to lower costs for disposal site preparation. � Low capital costs for lagoon & dam construction. � No costs for removal of scaling in pipeline. The above issues have been purposefully kept brief, but show that the proposed system is proven technology, ecological preferable and certainly reducing the total operating and investment costs.



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4 Pricing schedule

Slurry preparation, transportation and disposal system designed to be operated remotely from a control room, comprising of an agitated retention tank, charge pump and GEHO piston diaphragm pump.

Item Qty. Description Price in EURO

1 2 Agitator for Agitated Retention Tank (ART) Included

2 2 Slurry Control Unit (SCU) Included

3 2 Water dosing system Included

4 4 Booster pump, centrifugal type Included

5 2 Lobster pot, basic design only, with a lot of valves Included

6 4 In-line suction strainer, including valves Included

7 2 Suction air vessel Included

8 2 Main GEHO TZPM triplex single acting crankshaft driven piston diaphragm pump type 2000

For scope of supply, please refer to chapter 6!

Included

9 1 Process control system Included

10 1 Discharge pipeline Contractor

11 Lot Low pressure slurry valves Included

12 Lot High pressure slurry valves Included

13 1 Lot of commissioning spares Included

14 1 Main system control cabinet incl. engineering, programming and testing. A SCADA communication card will be incorporated

Included

15 4 VFD for booster pump Included

16 1 MCC’s for WMN supplied motor drives Included

17 1 Additional commissioning by GEHO system engineer, one trip for a total estimated time period of 3 weeks on site

Included

18 1 On site commissioning of main system control cabinet incl. SCADA communication, two trips for a total estimated time period of 8 weeks on site

Included

19 Lot General components and instrumentation Included

20 1 Supervision during installation and commissioning by GEHO service engineer

Included

21 1 Commissioning by GEHO system engineer Included

22 1 Basic system engineering package Included

23 1 Free annual installation performance review Included

Total lump sum price EURO 6,772,000.00



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In attachment 1 a detailed split between WMN scope and a local contractor scope, which served as a basis for this quotation, can be found. In attachment 2 the basic set up of the proposed system is shown.



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5 Commercial Notes

This proposal is without prejudice and has been prepared and submitted only for the purpose of providing you with a general outline of a dense slurry disposal system and the tentative capital expenditure. It may serve as a basis for further discussion and the development of the Design Basis. General conditions All tenders and contracts for the performance of deliveries by Weir Netherlands b.v. are governed by the ORGALIME General Conditions for the supply of mechanical, electrical and associated electronic products (S2000) of August 2000. A print of these General Conditions will be made available upon request. The following terms are in addition to and continue from the General Conditions to this Quotation. Payment Terms The proposal prices are based on the following payment schedule: 20% Down payment by bank remittance against our order acknowledgement. 30% after completion of basic design as per document list, by payment against an Irrevocable confirmed

Letter of Credit in conformity with ICC Uniform Customs and Practice for Documentary Credits (UCP 500), 1995 Revision, Publication No. 500.

50% By payment at sight against shipping documents against an Irrevocable confirmed Letter of Credit in conformity with ICC Uniform Customs and Practice for Documentary Credits (UCP 500), 1995 Revision, Publication No. 500.

The LC shall be opened within 60 days after the date of the Purchase Order or the Letter of Intent with an instruction to proceed, by a First-Class Bank for the benefit of the seller and confirmed by ABN/AMRO Bank upon the authorization or request of the issuing bank. The LC shall not expire earlier than 2 months from the contractual time for delivery and shall allow a period of 21 days after the date of shipment for the presentation of those documents, which will be mutually agreed to. The LC shall allow partial shipment. All charges within the country of the Buyer are for the Buyers' account, whereas all charges outside the country of the Buyer are to be borne by Seller. Pricing The proposal prices would remain fixed and firm throughout the validity period and the execution of the contract provided dispatch from our works is accepted in accordance with the offered lead time. Validity This proposal will remain valid and open for acceptance for a period of 120 days from the date of our offer. Trade (Shipping) terms Our point of delivery is FOB North Sea Port and will be governed by the provisions of INCOTERMS 2000. Time for delivery Due to the high plant load, the current lead time for the equipment (Ex-Works Venlo, the Netherlands) is depending on time of award and can be advised upon your request and an indication of time of award. At present time for ex works delivery is 20 months. Time for delivery will not be subject to a liquidated damages clause. Inspection is a respected right of our customers. Inspection must not interfere with work in progress and must be mutually acceptable and arranged with prior notice.



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Guarantee Seller agrees to repair or replace any product Seller manufactured which is found by Seller to be defective in materials or workmanship, providing that notice of claim of defect is received by Seller within one (1) year from initial equipment start-up or eighteen (18) months after shipment by Seller, whichever occurs first. Sellers' guarantee is contingent upon the use of spares supplied by Seller. Seller shall not be liable under any circumstances to indemnify or compensate the Purchaser for any special, incidental or consequential damages. This guarantee shall not be construed to cover corrosion, erosion, abrasion or wear resulting from normal use of the pumping unit in the specified service. Confidentiality All information, documents, etc. contained in or related to this Proposal and all attachments hereto are proprietary and shall be treated as confidential by the recipient. Such information and documents shall not be divulged by recipient or its personnel to any third party, unless recipient has first received written permission. The information contained herein is not to be released or disclosed for any other use or purpose other than evaluation of this Proposal and any subsequent Purchase Order resulting from this Proposal.



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6 Technical Description GEHO piston diaphragm pump TZPM 2000

Item No. Qty Unit Description 1 2 Ea. Pump(s) : GEHO model TZPM and size 2000, three-cylinder, single-acting,

crankshaft driven piston diaphragm pump(s), featuring: Power-end: � cast power-end frame with shaft seals and inspection covers to seal

against exterior contamination � piston rod stuffing box to prevent lube oil contamination and leakage � direct-driven crankshaft i.e. without drive shaft and gearing � forged alloy steel crankshaft supported on self-aligning roller bearings � heavy duty anti-friction bearings used throughout � crossheads with replaceable guides � crosshead extension/piston rods constructed in sections to enable

simple replacement of pistons � integral pressurised lube oil system with one 100% capacity pump

powered by a 0,75 kW motor and a single cartridge type filter and supplemented by an independent splash lubrication system

� a turning gear device for manually rotating the pump in an unloaded condition

� lock-out of the motor driver when the turning gear is engaged Water-end: � water-end segmented to permit removal and replacement of individual parts required for maintenance � self-actuated, spring-loaded cone type pump poppet (check) valves with elastomer valve ring and valve

seats of sufficient size and material to minimize wear and abrasion encountered in abrasive slurry service. The valve seating surfaces are conically shaped and soft-seated with both a metal to metal contact surface, and also a metal to elastic contact surface. The metal to metal contact absorbs the high pressure differential across the valve. The sealing ring projects past the cone and is subject to abrasive wear and fatique caused by slurry particles pushed or forced into the elastomer contact surface. Generally the ring, worn on one side, can be reversed and re-used

� the common size pump check valves are mounted individually and are readily accessible for maintenance

� the valve seats are full taper to enable oil-hydraulic release for ease of replacement � oil-hydraulic tensioning in one pass of the valve housing cover studs for ease and speed of valve

maintenance � pre-moulded, contoured and guided diaphragms to protect the pump moving parts against abrasive wear � diaphragm housings shaped to minimise stresses in the clamping rim area, which is cold rolled to prevent

stress risers � oil-hydraulic diaphragm housing cover studs tensioning in one pass to eliminate inaccuracies and

additional stress from conventional torque methods � coating of all critical, larger diameter studs to prevent fatique cracking due to corrosion in the presence of

moisture; in particular the diaphragm housing cover and the valve housing cover studs � clamped liner for easy replacement � the piston slides in a precision-machined cylinder liner which is coated with 0.2 mm hard chrome plating

to provide a longer wear life and less frequent replacement � the cup seal is a proprietary design which is suitable for high operating pressures and provides a long

wear life � the Teflon-impregnated guide ring prevents the piston body from rubbing the cylinder � suction stroke sealing is accomplished by utilizing a standard lip seal



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� the piston design reduces friction between the piston and cylinder wall which allows for more efficient operation

� cylinder flushing to minimise wear and to provide coolant � ample size pump suction manifold terminating in a single ANSI B16.5 flange connection � ample size pump discharge manifold with ANSI B16.5 flange � one (1) suction airvessel to provide a virtually momentum-free absorption of pressure pulsations due to

flow fluctuation through the compression of air � two (2) GEHO nitrogen precharged discharge pulsation dampener(s) free draining and with renewable

bladder to reduce the pressure variation at the manifold outlet for both flow and acceleration induced pressure disturbances through the compression of nitrogen gas. Actual dampening depends on factors like precharge pressure and line discharge pressure

� nitrogen charging valve(s) � the pulsation dampener(s) will be designed and manufactured in accordance with the requirement of

ASME Section VIII Div. I 2004. The completed unit(s) will be registered with and stamped in accordance with the requirements of Lloyd’s Inspection Service or the equivalent

� An internal pressure relief system with one spring-loaded, self-seating relief valve (common to all diaphragm chambers) installed on the propellant liquid side of each diaphragm, which is fitted with proprietary non-return valves to protect each diaphragm chamber individually from over-pressurisation

Instruments and controls: � diaphragm stroke control with automatic adjustment of fill/drain valve actuation and opening time as

applicable � modular propelling fluid supply system minimizing the components mounted to the pump frame and for

accessibility and ease of maintenance � propelling fluid supply system with integral sump, one intermittently operating pump powered by a 0.75

kW motor and auxiliaries � proprietary design initiators � GEHO design, electrically actuated and pneumatically operated propelling fluid fill and drain valves to

provide a compact assembly and a quick response time � instrument wiring to a single terminal box � Siemens S7 PLC with program scan time less than 20 milliseconds � the GEHO piston diaphragm pump is equipped with a control panel IP55 enclosure which monitors and

controls proper operation of the pump functions (mounting adjacent to the pump for operator convenience)

� the control system will conduct and monitor the pump starting, operating and shutdown sequences including all pump auxiliaries

� Ethernet and hardwired communication to customer SCADA system *) � potential free contacts to motor control centres in the field and information of pump status to DCS system � flow switch to ensure proper operation of the lubrication system � automatic shutdown or alarm (at customer’s option) upon diaphragm rupture � automatic alarm upon overpressure in the discharge dampener gas side � automatic shutdown upon overpressure � the alarm, trip and relief valve set pressures standard are 5, 10 and 15% over the rated pump discharge

pressure *) For communication with the SDCD Honeywell through SCADA/Ethernet we will prepare a communication

protocol (software block) with available signals from the slurry system and its components. We can not take any responsibility of integration of these signals in the customer’s SDCD Honeywell as we are not familiar with this specific system and the total plant philosophy.



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Interactive, GEHOgraphics touch panel with high intensity monochrome display, providing: � Touch-sensitive screen for easy operator commands � visualisation of pump functions � read-out of variables � manual override of on-board control elements � alarm and event record display Shipping preparation: � shop coating all exterior ferrous metal surfaces to prevent oxidation � assembly to the extent possible as allowed by shipping limitations or for protection of components � protection against the entrance of moisture and dust � coating all non-painted surfaces with a rust inhibitor compound � a three-layer 140-220 micron Sigma coatings’ paint system with Polyamide cured epoxy primer and

acrylic-Polyurethane finish paint in Blue color, RAL 5005 Materials of construction: Power end: � frame: nodular cast iron � crankshaft: forged steel � crosshead extension/piston rod: AISI 4140 plasma nitrated Liquid end: � cylinder liner: hard chrome plated steel � diaphragm housing: forged steel � valve housing: forged steel � dampener: forged steel Item No. Qty Unit Description 2 2 Ea. Pump gear drive system , comprising:

� one (1) Flender or equal, double engagement, crowned gear coupling, oil filled and mounted between

gearbox and pump � one (1) Flender or equal helical gear reducer � one (1) Flender or equal flexible coupling with accessible flexible elements and mounted between motor

and gearbox � coupling guards � structural steel base plate with horizontal positioning screws and jack bolts � pre-assembly � gear reducer lube oil cooler � one ABB variable speed AC, medium voltage, motor driver � one ABB variable frequency converter � one ABB reduced voltage transformer

Please refer to attachment 3 for detailed technical description of the quoted drive components!

� painting of all drive components in accordance with manufactures standard procedure and standard color � Motor starters (MCC) for auxiliary motors (main motor will be started through VFD) � testing in accordance with manufacturers standard tests



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Item No. Qty Unit Description 3 1 Set Special tools required for the normal maintenance of the pump(s), comprising:

� cylinder liner removal kit � valve seat mounting tool � valve seat removal tool � (cone) valve nut wrench � (cone) valve spring collet � diaphragm housing cover swivel bracket � air-driven hydraulic pump � nitrogen charge device � hydraulic diaphragm housing stud tensioner

Item No.

Qty Unit Description

4 1 Lot Submittal of drawings and data in English language and according to the time periods shown in the following table:

Within 8 weeks after receipt of purchase award the following drawings will be furnished for review: � drawing index � document submittal schedule � production schedule � inspection and test plan � pump torque-speed curve � dimensional outline drawing � foundation drawing � flushing requirements � piping and instrument diagram � instrument list � logic diagram � electrical schematics � wiring and connection diagrams � pump control panel lay-out � performance test procedure A progress report will be submitted bi-monthly Within 4 weeks after shipment the following will be furnished � manufacturing databook � installation, operations, and maintenance manuals (including those from sub-suppliers) on CD-rom Electronic data and drawings will be submitted in the following formats: � drawings: dxf-files � text: PDF-Format � spreadsheets: PDF-Format



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Item No. Qty Unit Description 5 1 Lot Quality assurance and quality control , comprising:

� implementation of a Quality Management System, which meets the requirements of ISO 9001 and has

been surveyed and approved by Lloyd’s Register Quality Assurance � certification, inspection and testing in accordance with an Inspection and Test Plan (ITP), which has been

proven adequate by successful manufacture and operation of similar pumps � submittal of a Manufacturing Data Book Item No. Qty Unit Description 6 2 Ea. Factory acceptance test , comprising:

� complete check out and adjustment of instrumentation and the control system � pressureless run-in � functional test of the PLC software � observation of mechanical performance and demonstration of alarm and trip signals � verification of hydraulic performance and rating values on water in accordance with the Hydraulic

Institute/ANSI Standard: ANSI/HI6.6-1994 with type II test acceptance values � post-test inspection to confirm the good operation of pump components � a report of the data obtained and calculations made as result of the test

6.1 Work not included in pumps supply The Purchaser will provide the following utilities, equipment and services: � supply of nitrogen to pre-charge pulsation dampener/accumulator bladders. The nitrogen filled cylinder

shall be complete with pressure regulating valve and flexible charging hose � conditioned air at 500-700 kPa for operation of propellant inlet/outlet valves fitted to the diaphragm stroke

control system � water supply at 300-400 kPa for cleaning or flushing of the pump. The water (intermittent) capacity shall

equal or exceed 10% of the pump rated capacity � first charge and change of lubricants and propelling liquid � flushing water piping terminating immediately downstream the suction isolation valve and upstream the

discharge isolation valve � external piping to the unit � anchor bolts supply � electrical cabling and installations off-machine � platforms, stairways and safety railing as may be required



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Attachment 1: Scope split between WMN and local engineering company / local contractor

No. Description Qty. Weir Minerals Netherlands b.v

Local engineer / contractor

1.

Basic engineering for system: • Design basis • Basic P&I drawing • Operating and control philosophy • Basic pump station lay out • Basic piping design • Equipment list • Valve list • Driver list • Three design meetings in Brazil

1 lot x

2. Basic design of Agitated Retention Tank (ART) 1 lot x

3. Design and supply of agitator including gear box, motor drive and MCC 2 x

4. Detailed design of ART including strength calculations 1 lot x

5. Supply of pre fabricated ART in carbon steel, approximately Ø 5600 mm x 8000 mm high 2 x

6. Design and supply of level sensor for ART 2 x

7. Installation and wiring of level sensor 2 x

8. Basic design of control loop 1 lot x

9.

Design and supply of main control loop components: peristaltic pump, pressure transmitters, density meter, diaphragm type pulsation damper, control loop valves

2 x

10. Detailed design of control loop 1 lot x

11. Supply of interconnecting piping, air over slurry pulsation damper, interconnecting wiring, installation and wiring of control loop components

2 x

12. Design and supply of water dosing unit 2 x

13. Supply of interconnecting piping + wiring, installation and wiring of water dosing unit 2 x

14. Design and supply of booster pumps including motor drive, VFD and gland water harness 4 x



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15. Supply of interconnection piping, interconnecting wiring, installation and wiring of booster pump, inclusive of gland water

4 x

16. Basic design of lobster pot 1 lot x

17. Detailed design of lobster pot including strength calculations 1 lot x

18. Supply and installation of lobster pot 2 x

19. Design and supply of suction strainers 4 x

20. Installation of suction strainers and interconnection piping 4 x

21. Design and supply of GEHO pump including suction air vessel, diaphragm type pulsation damper, gear box, motor drive, VFD and PLC

2 x

22. Installation of GEHO pump including all required wiring and piping (air, cooling water, suction and discharge piping)

2 x

23. Design and supply of low and high pressure slurry valves (manual operated) 1 lot x

24. Installation of slurry valves 1 lot x

25. Main system process control PLC 1 x

26. Installation and wiring of control PLC 1 x

27. Cabling from main system PLC SCADA to customer DCS 1 lot x

28.

Functional review of third party documents with respect to slurry system. Documents with respect to civil, structural, electrical and auxiliary piping will not be reviewed.

1 lot x

29. MCC’s as required for WMN supplies 1 lot x

30. Installation and wiring of MCC’s 1 lot x

31. Suitable control room (air conditioned if required) for installation of main system PLC’s, VFD’s and MCC’s as required.

1 lot x

32. Commissioning and start up of GEHO pump and system as included in WMN offer 1 lot x

33. Commissioning and start up support by local contractor (not included in WMN offer) 1 lot x



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34. Civil design and supplies as required for completion of the project 1 lot x

35. Structural steel design and supplies as required for completion of the project 1 lot x

36. Electrical design and supplies as required for completion of the project 1 lot x

37. Mechanical design and supply as required for completion of the project 1 lot x

38. Auxiliary piping design and supply as required for the completion of the project 1 lot x

39. Instrument air, make up water, cooling water, seal water and power supply as required for the project 1 lot x

40. Detailed design of high pressure discharge piping, including supports and stress analysis calculations 1 lot x

41. Supply of all required low and high pressure slurry piping, including supports 1 lot x

42. Design and supply of red mud cake feed system to ART 1 lot x

43. Installation of complete system with respect to civil, electrical, structural, mechanical and piping including all interconnecting wiring

1 lot x

44. All other design and supplies as are required for the completion of the project 1 lot x

45. Project + site management 1 lot x

46. Quality management and checking on site 1 lot x

47. Performance test support 1 lot x

48. FOB delivery North Sea port of WMN supplies 1 lot x

49. Custom duties, taxes, transportation to site and dry storage of imported supplies 1 lot x



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Attachment 2: Basic system set up



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Attachment 3: Technical Description of ABB Drive Components

Please see the separate document!