02.34 25635-220-3PS-MHCB-00001 Technical PDF

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000
TABLE OF CONTENTS
SECTION 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
DESCRIPTION
PAGES
GENERAL ...................................................................................................................... 3 CODES AND STANDARDS ........................................................................................... 3 OPERATING CONDITIONS........................................................................................... 4 DESIGN AND CONSTRUCTION REQUIREMENTS ...................................................... 4 WELDING .....................................................................................................................28 PAINTING .....................................................................................................................29 QUALITY ASSURANCE, ASSEMBLY, INSPECTION AND TESTING...........................29 ASSEMBLY AND SHIPMENT .......................................................................................31
Electronic documents, once printed, are uncontrolled and may become outdated. Refer to the electronic documents in Project InfoWorks stobambas for current revision. BECHTEL Confidential BECHTEL 2010. All rights reserved
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1.0
GENERAL This specification and all attachments hereto cover the furnishing of all labor, materials, equipment and services in connection with the design, fabrication, testing and preparation for shipment of the In Plant Belt Conveyor and ancillary equipment, for installation by others at Las Bambas Project for Xstrata Tintaya S.A.
2.0
CODES AND STANDARDS The design, material, fabrication and testing of the In Plant Belt Conveyor and ancillary equipment shall comply with the latest issues, addenda and supplements of the applicable codes and standards issued by the organizations listed below, as well as any applicable laws and regulations of local authorities. AISC AGMA ANSI ASTM AWS CEMA DIN IBC ISO MSHA NEMA OSHA American Institute of Steel Construction American Gear Manufacturers Association American National Standards Institute American Society for Testing and Materials American Welding Society Conveyor Equipment Manufacturers Association Deutsches Institut fr Normung International Building Code International Organization for Standardization Mine Safety and Health Administration (US Department of Labor) National Electrical Manufacturers Association Occupational Safety and Health Administration (US Department of Labor)
In the event of conflict requirements between Codes, standards, and this specification, the most stringent requirements shall apply.
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3.0 3.1 3.1.1
OPERATING CONDITIONS Site Conditions Site conditions are indicated in the Technical Specification for General Site Condition 25635-220-3PS-G000-00001. Operating Conditions The In Plant Conveyor design capacity and operating conditions shall be in accordance with data sheets listed in the Section 2 of the Material Requisition. The In Plant Conveyor shall be located outdoor, at the coarse ore reclaim, pebble crushing, concentrator and filter plant areas. Equipment will operate 24 hours per day, 365 days per year, under the conditions specified in data sheets listed in the Section 2 of the Material Requisition. Mechanical Availability for the equipment shall be at least 92%.
3.2 3.2.1
3.2.2
3.2.3
3.2.4
4.0 4.1 4.1.1
DESIGN AND CONSTRUCTION REQUIREMENTS General In Plant Conveyor shall be the manufacturers standard heavy-duty design and shall be complete with all pertinent accessories, according to section 1 of the Material Requisition, and ready to operate for the service specified herein, and in accordance with drawings and documents listed in Section 2 of the Material Requisition. Standard replacement parts shall be readily available and all equipment and materials shall be new. The equipment shall be in accordance with General Specification for Mechanical Equipment, N 25635-220-3PS-M000-00001. SELLER shall identify and submit in writing to BUYER the proposed forging and casting shops. BUYER will have the option to reject a particular source. Safety requirements for all equipment, safety devices or safeguards shall be at least equivalent to those complying with the standards approved by OSHA, MSHA and all applicable local regulations. SELLER shall supply a list of recommended Spare Parts for commissioning, start up, one year operation and maintenance, in accordance with Section 1 Scope of Work and Pricing, in the Material Requisition.
4.1.2
4.1.3
4.1.4
4.1.5
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4.1.6
Equipment arrangement shall provide ample operating and maintenance access to all components, including clean up of spillage. Necessary and sufficient, vertical and horizontal clearances shall be provided for servicing and removal of all components. SELLER shall complete the data sheets for the propose of furnishing engineering information and guarantee the equipment efficiency when operating at the design conditions as given on the data sheets. Local fabricated steel components shall be ASTM A-36 or local equivalent. SELLER shall supply all bolts, nuts, washers and fasteners required to fully assemble equipment. These parts shall be tagged and boxed with an allowance for an additional 10% per size shall be identified on the Bill of Materials.
4.1.7
4.1.8 4.1.9
4.1.10 The equipment and ancillaries shall be designed for a minimum 25-year life expectancy. 4.1.11 All calculations and dimensions on drawings shall be in the metric SI system of units. Additional English units within brackets are acceptable. 4.1.12 Supplier documentation requirements shall be according to Section 3 Drawing and Data Requirements, of the Material Requisition. 4.1.13 One complete set of any special tools required for assembly and maintenance shall be included with each equipment, in accordance with Section 1 Scope of Work and Pricing, of the Material Requisition. 4.2 4.2.1 Lifting Lugs All heavy accessory equipment shall be furnished with lifting lugs for crane handling. Lifting lugs shall be positioned to give maximum balance with an even weight distribution and minimize handling hazards. Each lug shall be designed to carry a minimum of twice the lifting load. The gross weight of the lift shall be stenciled or painted in a conspicuous location and identified as the gross lifting weight. Wherever practicable, location of center of gravity of the gross lifting weight shall also be identified. It is recognized that separate type and location will be required for lifting lugs depending on purpose of handling i.e. those required for handling during transportation from the shop to the jobsite and those required for handling during installation and maintenance. Discrete lifting lugs will then be provided with each piece. Lubricants SELLER shall recommend lubricant type, quantity and lubrication interval schedule for the equipment, in accordance with the lubrication data sheet requirements.
4.2.2
4.3 4.3.1
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4.3.2
SELLER recommendations will be used by the BUYER to supply all equipment lubricants and what required for preoperational testing and commissioning of the equipment. Recommended lubrication intervals for the equipment shall be clearly shown on a chart or drawing for maintenance purposes. Text on chart or drawing shall be in Spanish. All lubricants shall be compounded so that they will perform the intended function under the specified environmental conditions. This applies to both shop and field lubricated items. General Mechanical Requirement Conveyors shall be designed on the basis of CEMA Standards Six Edition (or DIN 22101) for heavy duty, high reliability service unless specified otherwise herein. Conveyors and components shall be manufacturer's heavy duty design, for the service specified. The maximum angle of inclination for all conveyors except for the High Angle ones, shall be 15. Maximum loading angle shall be 8 for all conveyors. Maximum angle of inclination shall be restricted to belt velocity and transported material, according to CEMA VI. Belt sag between the carrying idlers shall be limited to 1% for coarse ore and 2% for others. Return belt sag shall be limited to 3% of the return idler spacing. All drives and conveyor components shall be sized to start the conveyor under maximum design load. Conveyors with vertical concave curves shall be designed to prevent belt lift off under empty, loaded, or partially loaded conditions. Empty belt weight shall be used in calculations with belt loaded to the tangent point of the curve. Convex curves shall be calculated to impose lower load than the idler load rating. Reduced idler spacing shall be computed for the selected curve radius. All mechanical components shall be sized for maximum belt tension loads which can be developed by the motor nameplate horsepower, at full load speed. Head and tail pulleys shall be raised above the contact line between the conveyor belt and the center idler roll. To facilitate cleanup of conveyors, a minimum clearance of 0.75 m shall be provided between the return belt line and grade or floor level. This area shall be designed to be clear of members, such as cross bracing, conduit, and piping, which would hinder cleanup. All conveyors shall allow a minimum of 0.60 m clearance under the tail pulley.
4.3.3
4.3.4
4.4 4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
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4.5 4.5.1
Idlers General All idlers shall be of the wide base frame type. Idler rolls shall have rigid steel dead shafts, anti-friction deep groove ball bearings and multi-labyrinth seals. Idler rolls shall be fitted with end shields to protect the bearings and seals. Idler seals shall be multi-labyrinth type for minimum rolling resistance, suitable for taconite type service. The idler seals shall be "sealed for life" and factory greased. All idlers shall be identified by manufacturer's brand name and model number. Roller ends shall be free of sharp edges and burrs. Minimum L-10 Life rating of idler bearings shall be 60 000 hours at conveyor design capacity and speed. All idlers shall be designed to readily shed spilled material. Mounting holes for all idlers shall be slotted. At loading and impact areas, idlers shall be spaced to satisfy impact load requirements. Return idler frames shall have a minimum belt edge clearance of 150 mm on either side between belt and steel idler frame brackets. All impact and carry idlers mounted under skirtboards shall be designed in such a manner that they can be removed or replaced without interference or dismantling of skirts, chutes or frames. All idler rolls shall have a minimum shell thickness 4 mm for CEMA C and 6 mm for CEMA D and CEMA E.
4.5.2
Carrying Idlers Carrying idlers shall be of 35 troughing angle, three equal roll with end rolls interchangeable with center rolls. The spacing between idlers shall be 1 500 mm maximum except under skirtboards where the spacing shall be 600 mm maximum.
4.5.3
Training Idlers All training idlers shall be of the positive action type, with ball bearing actuating rollers mounted on both sides of the idler bracket which shall be free to swivel about a vertical pivot on the base, or actuating shoe type, which can be used where belt lift might occur as on conveyors with concave curves. Training idlers shall be placed within 15 m of both the head and tail pulley and at no more than 30 m centers with a minimum of two per conveyor. For proper belt training at the loading area, an inverted V return idler shall be installed ahead of the tail pulley.
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4.5.4
Transition Idlers All transition idlers shall be of the adjustable troughing angle type adjustable in approximately 2.5 angle increments and shall be provided in all locations where the conveyor belt changes from flat to trough and vice versa and where the distance from last 35 troughing idler to pulley exceed normal troughing idler spacing.
4.5.5
Impact Idlers The impact idlers shall be the rubber disc cushion type and shall be provided at all loading sections. All impact idlers and carrying idlers mounted under skirtboards shall have removable end brackets to facilitate maintenance access under the skirtboards (spacing shall be 350 mm maximum).
4.5.6
Return Idlers Return idlers shall be rubber (Shore A hardness of 60 to 70) disc flat type for fabric belting. Idlers shall be furnished with wide clearance deep drop brackets. An inverted V idler shall be provided adjacent to the tail pulley for training the return side of the belt. Return idlers shall be spaced at 3000 mm intervals maximum in fabric belts. All idlers within 30 meters of a conveyor head (discharge) pulley shall be of the self cleaning type.
4.5.7
Belt Scale Idlers The carrying idlers frame shall be adjusted to the type of belt scale used in Seller facilities.
4.6 4.6.1
Pulleys General The Seller shall design each conveyor with the minimum number of pulleys based on the Sellers analysis and recommended practice. Pulley loads shall be determined from the larger of either the tension developed using connected motor horsepower or 75% of the tension developed during acceleration. All drive pulleys shall have a minimum angle of wrap of 180. Snub pulleys shall not be used at head and tail terminals, and may be used only when approved by the Buyer. Standard pulleys shall be constructed to meet the tolerances (when not called for herein) and load rating specified in ANSI B105.1 "Standards for Welded Steel Conveyor Pulleys".
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4.6.2
Pulley Assemblies and Shipping Pulley assemblies, including pulley, shaft, bearings, pillow blocks and coupling halves, shall be completely shop assembled. All critical dimensions shall be verified and all motions shall be checked and tested in the shop prior to shipment. Pulley assemblies shall be shipped as complete units. Shafts and pulleys shall be designed independently. Calculations shall not credit either shaft or pulley as lending strength to the other. Spacer tubes, when used, shall in no case enter into the calculations as lending strength to the pulley rim or to the shaft. All components of a given "Pulley Assembly" shall be interchangeable with all other pulleys of that design. Each conveyor width shall be limited to two pulley sizes.
4.6.3
Standard Pulleys The face width of pulleys shall be minimum 150 mm wider than the belt width, and shall be 200 mm wider than the belt width above 1 500 mm wide belt. Standard pulleys shall be crown faced. Crown faced pulleys shall have a taper of 5 mm per meter of pulley width. Crowning of pulleys by varying the thickness of lagging is not acceptable. All drive pulleys shall have 25 mm thick rubber lagging with 15 mm diamond pattern grooves on 65 mm centers, 55-65 durometer hardness (Shore A). All other pulleys shall have 15 mm thick plain rubber lagging, 45-55 durometer hardness. All lagging will be vulcanized to the pulley. Pulleys with shaft diameters less than 150 mm (6 inch) shall be provided with compression or expansion type hubs with one square key in each hub. Pulleys with 150 mm (6 inch) diameter or larger shaft shall be provided with Ringfeder type locking devices. Concentricity about shaft centerline shall be such that total indicated runout shall not exceed the value indicated in the data sheets.
4.6.4
Engineered Pulleys Engineered pulleys shall be used for all high tension steel cable belts and where belt tension exceeds 123 kN/m (700 piw). Engineered pulleys shall be flat face, 300 mm (12 inch) wider than the belt width, with machine turned rims. Concentricity before machining shall be such that the finished thickness is not less than the calculated required thickness nor more than 25% greater. Concentricity about shaft centerline, after machining, shall be in accordance with the requirements stated on the attached conveyor data sheets.
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Lagging thickness on pulleys shall be as indicated in the data sheets. Lagging shall be vulcanized to the pulley and shall be of uniform thickness. Rubber hardness of drive pulley lagging shall be in accordance with the requirements stated on the attached conveyor data sheets. Pulleys shall be designed with rigid end discs that are no less than 20 mm thick. Pulleys shall be welded connection with cast or forged steel, T-shaped end discs. The welded connection between the shell and end disc shall be a full penetration weld, in an area of reduced stress peaks where first class welding and testing of the seams shall be possible. The allowable stress in the pulley end disc and rim shall not exceed 40 MPa (6000 psi) (alternating range). Welding shall be ground smooth with the base metal. Pulleys shall be statically balanced in accordance with ISO Standard 1940/1-1986 Grade G40. All Welding according to Section 5.0. 4.6.5 Pulley Standardization It is intended to have a minimum number of pulley assembly sizes for each conveyor. Pulley assemblies shall be standardized for interchangeability in diameter, face widths, shaft sizes and pillow blocks. Pulleys shall be interchangeable for each conveyor within the following services: 4.7 4.7.1 High tension service, including head, high tension bend, and drive pulleys Low tension service, including take-up, low tension bend and tail pulleys.
Shafting Pulleys All drive shafts shall be designed to transmit the connected motor power including service factor, as well as locked rotor torque. Shafting shall be designed using the ASME code for the design of transmission shafting. Shafts shall be sized and selected for maximum interchangeability. Full radius fillets shall be provided when shaft ends are reduced in diameter for bearings or couplings. All keyways shall be in-line and square. Keys shall be supplied with shafts. Keys shall be shop fitted to shafts and taped in place for shipping. The allowable design stresses for pulley shafting shall be in accordance with the stress levels as stated on the attached conveyor data sheets. A combined shock and fatigue service factor of Kb = 1.75 shall be applied to the computed bending moment, and a service factor of Kt = 1.25 shall be applied to the
4.7.2
4.7.3
4.7.4
4.7.5
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computed torsional moment of shafts used with standard pulleys. For shafts with engineered pulleys Kb = 2.5 and Kt = 1.75 shall be applied. 4.7.6 Slope, in radians, of the shaft deflection curve at pulley hubs under pulley design load conditions shall not exceed 0.001 for engineered pulleys with fabric belting and 0.0015 for standard pulleys. All commercial sized shafting shall be cold rolled steel (CRS). Shafts larger than 150 mm in diameter shall be forged and shall be ultrasonically tested before machining. Shaft ends shall be chamfered. Turned down shaft ends shall have a finish of 0.8 m or better. Turndown radius shall have a finish of 1.6 m or better and shall be at least 25% of the minor shaft diameter. End turn-down on shafts under 150 mm in diameter shall not be allowed. Undercut at radius shall not be permitted. Shafts larger than 150 mm in diameter shall be non-destructively tested for flaws before and after machining, by ultrasonic method (before) and by magnetic particle or die penetrant methods (after).
4.7.7
4.7.8
4.7.9
4.7.10 Ultrasonic examination shall be performed in accordance with ASTM A388 utilizing the back reflection technique. All shafts shall be examined in the radial and axial directions (through diameter and end to end). Ultrasonic acceptance criteria shall be: No indications greater than 75% of the reference back reflection. No areas showing a 90% or greater loss of back reflection.
4.7.11 Magnetic particle examination shall be performed in accordance with ASTM E709. Acceptance criteria will be: No cracks No linear indications greater than 1.6 mm that are circumferentially oriented. No linear indications greater than 2.5 mm that are axially oriented.
4.7.12 Liquid (dye) penetrant examination shall be performed in accordance with ASTM E165. Acceptance criteria shall be: No cracks No linear indications greater than 1.6 mm that are circumferentially oriented. No linear indications greater than 2.5 mm that are axially oriented.
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4.8 4.8.1
Bearings and housings Pillow blocks, flanged units and take-up units shall have double-roller, fully selfaligning, bearings with adapter sleeve mounting. Misalignment shall not be limited by the seal. Each pulley shaft shall have one fixed and one expansion type bearing, the fixed bearing being on the drive end of any driven shaft. All bearings shall have provisions for grease lubrication and be fitted with taconite seals. Grease fittings shall be standard button head type for grease-gun lubrication. Where access is limited, grease lines shall be extended to a location where they will be grouped for ease of re-greasing. Taconite seals shall be provided with their own grease fittings. Where shafts terminate at bearings, the housings shall be equipped with dust-tight end discs. Pillow blocks shall have cast steel or ductile iron split housings. Pillow blocks larger than 62 mm shall be furnished with four-bolt bases. Bolts shall have self-locking nuts or shall be provided with two nuts per bolt. Bearings shall be specified in 13 mm increments. Pillow blocks shall be mounted on the top surface of supporting steel. Suitable adjusting, (jacking) screws and lugs shall be welded to supporting steel to facilitate alignment of components. Pillow blocks furnished for pulleys shall be furnished with shim sets, consisting of three 3.2 mm thick and two 1.6 mm thick shims. All bearings shall be rated to provide a minimum L-10 life of 80.000 hours. The bearings for the drive, bend (high tension) and head pulleys for the conveyors shall be equipped with a temperature monitoring system. Each pillow block shall be equipped with a RTD type sensor PT100 type, 3 wires, which will be connected to the Buyers central control room. Conveyors Drives Conveyor drives shall be located as indicated on general arrangement drawings attached. Soft starting shall be provided on conveyors in accordance with the requirements stated on the attached conveyor data sheets. Decelerating or coasting time shall be verified for each conveyor. Where required, the drive unit shall include a brake or flywheel system to control the belt coasting time during emergency stops. Accelerating time of conveyors with soft starting device will normally be set so that the peak accelerating torque does not exceed 150% of the running torque requirement.
4.8.2
4.8.3
4.8.4
4.8.5
4.8.6 4.8.7
4.9 4.9.1
4.9.2
4.9.3
4.9.4
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4.9.5
Tensions developed during conveyor acceleration shall not exceed 150% of rated belt tension under any loading conditions. Each conveyor shall be driven through a gear reducer. Other than shaft mounted reducers (up to 45 kw or 150 mm dia. shaft), coupling and motor shall be assembled on a common base (to floor) for ease of removal and service. All conveyor drive units shall be of sufficient capacity to start and stop the belt conveyors under maximum loading conditions. All drive systems and conveyor components (motor, reducer, coupling, holdbacks and v-belt) shall be selected considering plugged chute condition in loading area, most adverse condition. The Drive System shall comply will the following requirement: TMs > TCs TMs = Starting motor torque (limited by hydraulic coupling) TCs = Conveyor starting torque TCs = (ETs + Fr) x Rdp ETs = Starting effective tension (Note 1) Rdp = Drive Pulley radius Fr =Tq + Ts (Plugged chute condition, see CEMA Chapter twelve, sixth edition) Tq = The resistance for shearing the material Ts = The resistance for material against skirtboard wall The calculation must be done considering a wet capacity, volumetric density, load percentage and belt speed as mentioned in data sheets and also has to avoid belt lift and any slip between pulley and belt.
4.9.6
4.9.7
4.9.8
Speed reducers shall be direct coupled right angle, parallel shafts, or shaft mounted helical gear type. The right angle type shall be considered first. Shaft mounted reducers shall be limited to drives not exceeding the 45 kW. A common structural baseplate shall be furnished for all reducers and motor mountings except for shaft mounted reducers. All base-plate mounted drive components shall be supplied with suitable adjusting screws and lugs welded to base-plate to facilitate aligning of components.
4.9.9
4.9.10 The mechanical horsepower rating of all gear reducers shall be based on a service factor of 1.5 times the connected motor nameplate power rating. The mechanical rating shall permit overloads of 275% of the connected motor torque rating, during momentary peak loads not exceeding six (6) peaks per hour.
Must be calculated according to the installed motor

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4.9.11 The thermal rating of all reducers shall be in accordance with General Specification 25635-220-3PS-M000-00001, for Mechanical Equipment but not less than 1.0. Reducer bearings shall be anti-friction type with a minimum L-10 life rating as stated on the attached conveyor data sheets. 4.9.12 Each gear set shall have an AGMA durability rating of not less than 1.5 and an AGMA strength rating of at least 2.0 times the durability rating. 4.9.13 The housing shall be of sufficient strength to prevent twisting or angular misalignment of the internal parts by uneven tightening of mounting bolts. Reducer housings shall be provided with oil filler plug, oil drain plug, oil level indicator, and breather with provision for exclusion of dust. Flushable external combination grease and contact or taconite type labyrinth seal with separate grease fittings shall be furnished wherever shafts project through housing. Each taconite seal shall be provided with a grease fitting. 4.9.14 All reducers shall be splash lubricated with natural mineral or fossil oil, and dust-tight housings. When immersion heaters are used, the reducer manufacturer shall provide high and low temperature switches. When cooling of the reducer is required, this shall be accomplished by reducer driven fans only. Maximum operating oil temperature of the reducers shall not exceed 70C. 4.9.15 Conveyor drives, of 55 KW or greater, shall utilize parallel shaft or right angle bevel helical speed reducers and comprise the following: Electric motor, flexible high speed coupling, gear reducer. High speed flywheel, if required by system analysis. High speed brake disc and brake, as applicable. Holdback integral with gearbox, as applicable. Low speed coupling rigid coupling shrunk onto the gear reducer output shaft and the pulley shaft. Coupling halves connected via bolts through clearance holes having friction between the coupling halves transmit the torque and coupling halves are spigot aligned. Safety guards. Drive frame for complete assembly of the above items. The drive frame assembly shall have provision to align all components of the drive to the gear reducer while installed to the pulley shaft, and shall consider access for gear reducer drainage and filling, access to bearing seals for re-lubrication, access to vibration sensor points, access to oil level gauges and provide for motor and other cable connections from below the frame.
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4.9.16 Holdbacks shall be used on all conveyors to prevent reversal of conveyors when stopped under full design load. For shaft mounted drives hold backs shall be integrally mounted with the reducer high-speed shaft. For other drives hold backs shall be mounted on a pulley shaft extension opposite the drive and shall be the full phased roller type as made by Marland or equal. Holdbacks shall be sized per manufacturer's recommendations for the specified service and shall be based on the motors nameplate kW (or hp) rating with a minimum SF of 1.5. 4.9.17 For all inclined conveyors under 55 Kw of power shall be acceptable to include internal backstop in the reducer. 4.9.18 All steelflex couplings shall have a service factor of 2.0. 4.10 Conveyor Belting
4.10.1 General Belting must conform to the manufacturer's recommendations for minimum number of plies required for load support, impact and troughing with the indicated idlers for the application. Belting for replacement and splicing shall be readily available. Belting shall provide adequate load support while allowing sufficient transverse flexibility to contact the center roll at all times, in either the loaded or empty condition. The top and bottom cover for all conveyors shall be RMA Grade II. Conveyor belt selection shall be based upon starting any conveyor in the fully loaded condition. Only one type of belt shall be furnished for each belt width. Seller shall indicate the maximum operating tensions on the attached data sheets, based on belt tensions calculated from installed motor nameplate horsepower. Extreme climatic conditions and the material being handled shall be given careful consideration in regard to the cover compounding and structural design of the belt. Belting manufacturer shall verify all pulley diameters, minimum radius requirements for all vertical curves, take-up travel and transition distance. 4.10.2 Fabric Belting Fabric belting shall have at least an ultimate strength of 10 times the maximum operating belt tension. Fabric shall be free from longitudinal and transverse wrinkles, and yarns shall lie straight to ensure proper tension distribution. Repaired carcass faults are not acceptable. Small cover or edge patches applied at factory may be allowed subject to approval of Buyer or his representative, where no carcass or breaker strip material has been exposed.
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Belt width tolerances shall not exceed plus or minus 1% of belt width. Variance in specified cover thickness shall not exceed the following: Up to and including 4 mm Over 4 mm (0.16") (0.16") 0.2 mm (0.008") 5% No Limit No Limit
Minus tolerance Plus tolerance
Cut edge belting is acceptable for polyester or nylon carcasses only. Fabric carcass containing rayon or cotton or combination of both shall have molded edges only. 4.10.3 Belt Splices All conveyor belt splices shall be vulcanized type. The effective strength of each splice shall be at least 100 percent of the belt rating including the service factor under static conditions. The cement and tiegum shall be packed in dated containers. The belting supplier shall provide the services of a belting manufacturers engineer to supervise the initial belt splices. Seller shall provide instructions on proper storage and storage life of belt splicing material and spare belting.
The splicing joints of steelcord belts shall be inspected by X-ray and identified by location. The X-ray photographs shall become the property of the Buyer. Belting supplier shall provide Buyer with general layout drawings of splices, showing method and total belt overlap. Seller shall provide field splicing procedure. Belting supplier shall specify sufficient extra lengths for making vulcanized splices. Exact lengths of belting for each conveyor, including take up and splice allowance, shall be verified by belting supplier including take-up and splice allowances prior to cutting of belts. Belting supplier shall specify minimum take-up length required for each conveyor. Conveyors shall be furnished with belt splice stations as required. 4.10.4 Shipping Preparation Belts shall be manufactured in lengths requiring the minimum number of field splices. Belt length shall be stenciled on each shipping enclosure. 4.10.5 Belt Branding Each roll of belting shall be branded on the top cover with the following: Manufacturers name Brand name of belting Order and serial number Belt rating
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Belt weight per unit length
Example: Goodyear Plylon 440 Mfg. Order No. 1234 Serial ABCD P.O. No. 1A1B dtd 5 May 91 15 Kg per Meter 4.10.6 Testing The manufacturer shall perform tests in accordance with ASTM D 378 and ASTM D 2240, in order to demonstrate the following properties: a. b. c. d. 4.11 Belt: Fabric Belts: Carcass: Cover: Ultimate strength Elongation Adhesion, ply to ply Tensile strength Adhesion, Cover Durometer
Access to Drives and Removability Service platforms shall have a 1m minimum clearance around all equipment. Special attention shall be given to the requirement that all mechanical equipment be readily removable without dismantling any structural steel framing.
4.12
Wind Hoods (When specified) Belt hoods shall be provided by the Seller on all outdoor conveyors. Hinged type hoods shall be designed to enable complete and easy access for inspection and maintenance for conveyors less than 1,800 mm wide. Three-quarter hood covers shall be furnished on conveyors 1,800 mm and wider. Hoods shall be reinforced galvanized steel sheet metal construction. The hoods shall be fastened on the top of conveyor frame.
4.13
Guards
4.13.1 All guards including those for V-belt drives, couplings and exposed rotating shafts shall be supplied in compliance with the OSHA and MSHA regulations. Nonlubricated drives shall have guards of flattened, expanded metal for visual inspection. All guards shall be fabricated and mounted with provision for rapid and easy access to grease fittings. Grease fittings shall be located at points of easy and safe access by the operator. Grease fittings shall be positioned such that they are accessible without the need to open inspection doors or disconnect or dismantle safety screens or guards. Plastic, PVC, or other buyer approved tubing material shall be provided to connect all grease fittings to their respective bearings. Seller shall provide guards at all nip-points on the conveyor. 4.13.2 Guards shall have sheet metal top and expanded metal (weighing not less than 2 kg/m2 and openings shall not exceed 10 mm (3/8)) sides. All guards shall be
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designed to allow lubrication of the equipment without the removal or opening of the guards. 4.14 Take- ups
4.14.1 Take-ups shall be designed with sufficient adjustment length to allow for a minimum of two future splices. 4.14.2 Screw take-ups, where used, shall be protected screw type designed to operate in tension, and shall be complete assemblies consisting of frame, screw adjustment mechanism pillow blocks with roller bearings conforming to all requirements of Section 4.8. The screw take-up travel shall be a minimum of 0.6 m and only for conveyor belt length up to 33 m. 4.14.3 Gravity take-ups shall include a counterweight box to be filled with steel balls or steel plate. Seller shall indicate required weight on counterweight box and design for 25% more volume for additional weight and 25% additional travel distance. 4.14.4 Overhead counterweights shall be avoided by the use of suspension cables. Safety guards or fences shall be furnished by Seller to close off areas immediately under the counterweight. 4.14.5 Counterweight safety cages shall be located at floor or grade level and shall be made up of expanded metal weighing not less than 2 kg/m2 mounted on a structural frame. Expanded metal panels shall be 2.2 m high and shall be set 450 mm above concrete foundation or floor elevation. 4.14.6 Vertical gravity take-ups shall employ a dribble deflector canopy attached to pulley frame to prevent debris from falling onto the take-up pulley. 4.14.7 Horizontal gravity take-ups carriages shall have V-grooved wheels and rails, and be self-cleaning (inverted angle). Hold downs shall be provided to prevent the wheels from lifting off the rails. Counterweights shall be attached to the carriage frames by wire rope and sheaves. 4.14.8 Wire rope shall be flexible steel core hoisting rope with a minimum breaking strength of six (6) times the maximum calculated working load. Rope ends shall be fastened with clips sufficient to develop the full breaking strength of the rope. Sheaves shall be steel or cast steel with "lubrite" bushing or equal mounted on dead shafts. Sheave diameters shall be a minimum of 20 times the wire cable diameter. 4.15 Cleaners and Belt Washers
4.15.1 Except as noted below all belt conveyors shall be furnished with a dual belt scraper system to clean the carrying side of the belt at the head pulley. The scraper shall be a track mounted system as designed by Martin Engineering (or equal approved by buyer). The width of the scraper shall be no less than the belt width plus 100 mm.
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4.15.2 Spring-loaded, "V"-type plows over the full belt width +100 mm minimum shall be furnished just clear of the return strand of belting and immediately ahead of all takeup and tail pulleys, where material can be caught between belt and pulley. The V plow shall be mounted so that the steel framing cannot contact the belt after the wiper rubber has completely worn down. All plows shall be provided with a vertical adjustment and safety chain to prevent the plow from traveling with the belt in case of failure of the mounting. Scraper rubber hardness shall be a durometer (Shore A) of 60-80. Minimum thickness of rubber blade shall be 13 mm. 4.16 Chutes and Skirtboards
4.16.1 Seller shall supply all chutes, skirtboards and skirtboard supports from conveyor to conveyor or from conveyor to the mating flange of Buyer's equipment unless otherwise stated or as indicated on reference drawings. Buyer's equipment mating flange details will be given to the Seller at a later date. 4.16.2 General Construction Skirtboards for the conveyors shall be fabricated from 10 mm (3/8 inch) minimum thick ASTM A 36 steel. Chute corners shall be made dust-tight by seal welds. Chutes shall be of welded construction with bolted flanges and shall be bolted to their respective supporting frames. All chutes shall be provided with a minimum of two inspection doors, located on opposite sides of the chute. Where required for maintenance, additional doors and maintenance access shall be provided. All conveyor chutes and other components shall be designed for easy maintenance. All transfer chute designs shall be modeled precisely using Discrete Element Modeling (DEM) Software to validate the design. The model output shall be submitted for approval. All field and shop bolted connections shall be provided with gaskets, bolts, and lock washers. Rock boxes (except for copper concentrate) shall be provided for all chutes to break the horizontal and vertical velocity of flow and direct the material towards the center of the belt between the skirtboards. V-throat bootjack design shall be used for all transfer and loading points. Minimum chute wall and valley angles shall be determined for the type of material being conveyed with the selected chute lining material. Where material could build up in valleys, the chute or the chute liners shall provide a radiused or chamfered valley surface to reduce this. Chutes at all discharges shall be designed to collect belt scrapings, and direct them onto the next belt in the system. Inside chute width at discharge pulleys shall be designed to be wide enough to contain the material stream plus an adequate distance on each side that insures minimal wear. The minimum width shall be the belt width plus 300 mm. Discharge chute entrance shall be provided with a dust curtain.
Page 19 of 32
Chutes shall be designed to allow the installation and operation of ancillary equipment or systems (Tramp magnets, dust colector systems, etc). 4.16.3 Chute Valley Angles Minimum chute wall and valley angles shall be determined for the type of material being conveyed with the selected chute lining material. Where material could build up in valleys, the chute or the chute liners shall provide a radiused or chamfered valley surface to reduce this. All chute valley angles shall be a minimum of 65 from the horizontal. All chutes shall be provided with cleanout and inspection doors with gasket, latched and hinged (opening to the side). 4.16.4 Abrasion Resistant Lining Abrasion resistant liners shall be provided for the conveyors and used on surfaces where material contacts the walls of chutes and skirtboards. Individual liners shall be limited to 30 kg maximum and shall be a minimum of 25 mm thick. The chute liner patterns shall be standardized to minimize number of different sized pieces. Abrasion resistant liners shall be : Ultra High Molecular Weight Polyethylene (for copper concentrate) Steel 450-600 BHN (for copper ore)
In both cases shall be bolted with a minimum of three countersunk cap screws, with hex head nuts and lock washers. 4.16.5 Conveyor Skirtboards and Skirts Skirtboards shall be designed to allow a smooth flow of material and shall be of ample depth. Skirtboard length shall be 2.5 m (minimum) for every 100 m/min. of belt speed or as otherwise indicated on drawings. Skirtboards shall be designed for easy maintenance. Commercially available, over center, clamp type fasteners shall be used to clamp skirting rubber to the skirtboards. Skirtboards shall be provided with 13 mm thick 40 durometer rubber sealing strips manufactured by Corrosion Engineering (or equal approved by buyer). Skirtboard covers shall be 4.8 mm (minimum) mild steel with suitable stiffeners. Skirtboards for all conveyors shall also be provided with a cleanup hopper or hinged end cover on the tail end of the skirtboard to allow spilled material to be returned to the conveyor.
Page 20 of 32
Skirtboard exits shall be provided with rubber dust curtains to contain the dust for all conveyors. Seller shall include seals between chute and skirtboard. 4.17 Deck-Plates and Spill Barrier All conveyors shall have decking between carrying and return belt as follows: at loading areas, from fixed tail pulley to 3 idler spaces past end of skirtboard at gravity take-up, 3 idler spaces on either side of gravity take-up
Deck shall be a minimum of 4.0 mm thick steel with a crown. Spill barriers shall be installed under the return belt at sections of conveyor over roadways and pedestrian crossing. Barriers shall be a minimum of 4.0 mm thick steel with a trough. 4.18 Safety and Emergency Warning Devices All conveyor safety devices and equipment instrumentation shall be standardized consistent with Buyer's overall plant instrumentation devices. All control and alarm circuit contacts shall comply with Technical Specification for Instrument and Control supplied with Packaged Systems, document N 25635-2203PS-JQ07-00001. 4.18.1 Plugged Chute Detectors The Seller shall furnish a microwave level switch type, having DPDT dry contacts relay output. When discharge chute be supplied, the microwave barrier will be located under head pulley (at five). 4.18.2 Belt Side Travel Switches The Seller shall furnish belt side travel switches on each side of the conveyor belt. The switches shall be installed on all conveyors at head and tail pulleys. Each switch shall have DPDT contacts with independently adjustable alarm and shutdown positions. Each conveyor shall be furnished with a minimum of 4 travel switches, two at head end and two at tail end. The maximum spacing between two switches shall not exceed 60 m. For variable speed conveyor, analog transmitter 4-20 mA output will be required. 4.18.3 Zero Speed Switch The Seller shall furnish a proximity type zero speed switches on a non-drive pulley of each conveyor that has a minimum wrap angle of 180 . Conveyor speed trip point
Page 21 of 32
of the switch shall be adjustable. A suitable adjustable time delay device shall be provided as part of each zero speed switches to provide lock out of the "zero speed signal" during conveyor startup and acceleration. The switch contacts shall be DPDT. For variable speed conveyor, analog transmitter 4-20 mA output will be required. 4.18.4 Emergency Pullcord Switches All conveyors shall be equipped with manually reset type emergency stopping devices. Protection shall extend for the full accessible length of the conveyor, up to the guards on terminal pulleys. Pullcords shall be 4.8 mm galvanized steel cable coated to 6.5 mm in diameter with safety yellow polyethylene cover and shall be supported on 3 m maximum spacing. The pullcords shall be located at least 300 mm above the belt and also high enough such that material falling from the belt does not cause a nuisance trip. The pullcords shall be designed to be accessible to a person standing on the walkway beside the conveyor. The allowable spacing between switches shall be 30 m maximum. Any section of conveyor which is accessible from both sides shall be protected separately on both sides without interconnection. The switch contacts shall be DPDT. Pullcord supports shall be the pigtail type. The pull cord switch will have two contacts, one wired by direct current control to the MCC and the other as digital input to the Control System. 4.18.5 Warning Horns/Lights The Seller shall furnish horns and lights to warn that a stationary belt is about to be set in motion. For belts longer than 100 m, additionals horns/light will be required in order to all people along the belt be cautioned. Lights beacon shall be stroboscopic type. 4.18.6 Belt Rip The Seller shall furnish a belt rip switch. The belt rip switch shall have SPDT dry contacts. One pair shall be supplied after each load material chute. 4.18.7 Mechanical Limit Switch The Seller shall furnish a mechanical limit switch, for take up limit position. The limit switch shall have SPDT dry contacts. 4.18.8 Pulley Temperature Detection The Seller shall furnish a RTD temperature sensor (PT100, 3 wires) for bearing drive pulley temperature monitoring.
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4.19
Belt Scales Belt scales, when required, shall be designed in accordance with the attached data sheet. Belt Scales shall be furnished with calibration weights.
4.20
Tramp Magnets Where required, tramp magnets shall be supplied and installed according to manufacturers specification. Magnets shall be mounted by adjustable hangings from monorail trolleys that allow the magnets to be moved away from conveyors for maintenance or cleaning without disconnecting the power supply or removing transfer chute components, unless provision is made in the transfer chute to facilitate this. Magnet installations shall take into account requirements for using non magnetic steels and other materials for pulleys, chutes and local structures to avoid the magnetizing effects of magnetic fields.
4.21
Metal Detector Metal Detector, when required, shall be designed in accordance with the attached data sheet. Metal detectors shall be installed on conveyors as required, after any tramp magnet and before any transfer onto a long conveyor, at a sufficient distance so metals can not reach the transfer area. Detectors shall be selected and located to function with the type of belt installed and be adjustable sensitivity. Also is required an accessible area for metals extraction, before transfer points. Once activated the metal detector, the system shall activate a sprinkler that will paint the charge of ore running through the belt.
4.22
Dust Enclousures
4.22.1 Dust enclosures shall be provided for housing dust suppression spray nozzles on the crushed pebble conveyors. 4.22.2 The dust enclosure may consist of additional platework that will rest on the skirtboard. The receiving belt dust enclosure shall: Extend back toward the upstream side at least one belt width. Extend forward toward the downstream side at least three belt widths. Have a height above the lowest part of the belt of at least one belt width both upstream and downstream Have continuous tight skirt boards on both sides for the entire length of the cover.
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4.23
Conveyor Steelwork and Structures
4.23.1 General Conveyor steelframe, walkways, platforms, stairways, trusses and bents shall be furnished. 4.23.2 Design Requirements Conveyor structural design shall be in accordance with Technical Specification for Structural Requirements for Mechanical Equipment, document N 25635-220-3PSS000-00001. Foundation reactions and supporting calculations, including overall framing system shall be provided for review and foundation design. This review does not relieve the Seller of full responsibility for the performance and integrity of the structures. Design calculations shall be submitted for Buyer's record. 4.23.3 Loading Requirements Conveyor Dead Loads (DL) shall include the calculated weights of all fixed elements including electrical raceways and lighting. Live Loads (LL), Wind Loads (WL) and Seismic Loads as per Technical Specification for Structural Requirements for Mechanical Equipment, document N 25635-2203PS-S000-00001. Thermal Loads shall be based on atmospheric temperature range as indicated on the Data Sheets. Provisions shall be made for stresses and movements resulting from variations in temperature. Maximum Running Belt Tension Loads is that tension which can be developed by the motor nameplate horsepower, at full load speed, including motor service factor (but excluding any torque limiting device). Impact Loads shall be calculated in accordance with the requirements of the AISC Manual of Steel Construction and the Technical Specification for Structural Requirements for Mechanical Equipment, document N 25635-220-3PS-S00000001. Loading combinations shall be as follows: a) b) DL + LL + 1.5 x Maximum Running Belt Tension + Temp DL + LL + 1.5 x Maximum Running Belt Tension + Temp + WL or Seismic, with allowable stresses increased 33% DL + LL + Factor* x Maximum Running Belt Tension + Temp, with allowable stresses increased 33%
c)
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d)
DL + LL + Factor* x Maximum Running Belt Tension + Temp + WL or Seismic, with allowable stresses increased 50% *Factor to be used in formula c) or d): 2.15 for DC motor 2.25 for wound rotor motor 1.8 for squirrel cage motor Material Loads, which shall be included as live load, shall be as shown on the Data Sheets. At transfer points, loads from plugged chutes filled to capacity shall be included.
e) f)
DL + WL or Seismic (to check safety factor against overturning and uplift) Others combinations as per Technical Specification for Structural Requirements for Mechanical Equipment, document N 25635-220-3PS-S00000001. Of the above outlined loading combinations, the one that results in the highest stress for the structure or any element of the structure shall be used for the design.
g)
Impact loads shall be as follows: Along the length of the conveyor, vertical impact force equivalent to 25% of material, belt and moving parts of idlers. At transfer points, vertical impact force due to falling material.
4.23.4 Construction Fabrication shall be in accordance with the AISC "Specification for the Design, Fabrication and Erection of Structural Steel for Buildings." All welding on the conveying system structure and equipment shall be in accordance with the latest edition of the Structural Welding Code of the American Welding Society, AWS D1.1, or approved equal standard of quality. Construction shall be shop welded and field bolted. Unless otherwise shown, field connections shall be high strength bolts ASTM 325 in accordance with the AISC "Specification for Structural Joints Using ASTM A325 or A490 Bolts. Slip critical bolts shall be used. All shop welding shall be performed by welders who are qualified in accordance with AWS D1.1, latest revision. Performance qualification records of individual welders will be reviewed at Seller's shop by the Buyers representative prior to fabrication. Performance qualification of each welder must be current.
Page 25 of 32
Conveyor frames shall be of steel toe-in stringer construction with suitable diagonal and cross bracing. Supports shall be of moment connected design to permit easy cleaning. Diagonal bracing in the vicinity of floors, walkways or maintenance access shall not be used. Minimum vertical cleanup clearance at conveyor support bents and structures to be 1 m on short bents and 1.5 m where possible. 4.24 Miscellaneous Requirements Spillage Prevention and Cleanup Seller shall incorporate in his design methods to minimize spillage and to direct such spillage that may occur back onto the system or clear of operating machinery and belt and into areas accessible for cleanup. 4.25 Calculations Design calculations including structural connection calculations shall be submitted on all engineered equipment and structures. If a computer program or software is used by the Seller, all input and output data shall be submitted as well as the basis of the computations. All calculations shall be submitted for Buyer's review. The following is a list of the minimum type and number of calculations to be submitted. a. Full tension analysis for the following conditions: 1. 2. 3. 4. Normal running Maximum loading/tension/torque Acceleration/deceleration Standstill tension
b. Power calculations for the following conditions: 1. 2. 3. Normal running Fully loaded Maximum power condition
c. Pulley and shaft sizing and bearing selection d. Concave and convex curve calculations including belting selection 1. Curve analyses shall be performed for both carrying side and return side of vertical curves and for all belt tension/power conditions listed above. Concave vertical curve radii shall be sized to prevent lifting of the belt off the idlers under any condition. The highest possible tension at the curve
2.
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shall be computed (empty or full, winter or summer, reduced or full friction) and the empty belt weight shall be used to compute the required radius. The lowest possible tension at the curve shall be computed to maintain the minimum edge tension for fabric belts shall be 30 PIW: e. Take-up system calculations (travel, box size), elastic and permanent stretch. f. Reducer, high and low speed coupling selection calculations.
g. All structural calculations on pulley frames, stringers, stringer hangers, posts, columns, bents and associated structures. h. Torque vs. speed curves shall be prepared for each conveyor describing the load parameters at the input shaft of the drive assembly for the conditions defined in item b above. i. j. 4.26 Idler selection and spacing Seismic loading calculations
Electrical Requirements
4.26.1 All electrical components shall be in accordance with the Technical Specification for Electrical Equipment in Mechanical Packages N 25635-220-3PS-EKP0-00001, Technical specification for NEMA Low Voltage AC Induction Motors N 25635-2203PS-MUMI-00001 and NEMA Medium Voltage AC Induction Motors N 25635-2203PS-MUMI-00002. 4.26.2 Mechanical equipment SELLER shall be responsible to: select and supply the electric motor required for each application. Forward to BUYER the enclosed motor Data Sheets, drawings, and documentation associated with the motor for BUYER's review. Instruct the motor Vendor to ship motor to SELLER's shop for assembly and/or testing. Receive motor and verify technical and physical correctness, and assemble with mechanical equipment. 4.26.3 SELLER shall provide full details of electric power requirements for the equipment specified. Additionally, he shall identify the maximum and average power requirements, and estimated power demand per ton of product. 4.26.4 The enclosures for all electrical devices and terminal boxes shall be NEMA 4. 4.26.5 All equipment shall be furnished with grounding connection. 4.27 Instrumentation and Control Requirements
4.27.1 All instrumentation and controls shall be furnished in accordance with Technical Specification for Instruments and Control Supplied with Packaged System N 25635220-3PS-JQ07-00001.
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4.27.2 SELLER shall furnish control descriptions, wiring diagrams, control schematics of external circuits, device settings and ranges, for BUYER's use in detail design. 4.27.3 SELLER shall furnish or deliver all technical information for security devices, hook UPS, and calibration. 4.28 Structural Requirements
4.28.1 For seismic calculations, the International Building Code (IBC) shall apply. 4.28.2 The equipment and components shall be designed to withstand the seismic, wind and snow loading without damage in normal operation as specified in Technical Specification for Structural Requirements for Mechanical Equipment N 25635-2203PS-S000-00001, considering the seismic, wind and snow conditions per General Site Conditions N 25635-220-3PS-G000-00001. 4.28.3 SELLER shall furnish foundation loads in accordance with the same Technical Specification for Structural Requirements for Mechanical Equipment, document No. 25635-220-3PS-S000-00001. 4.28.4 Walkways and platform shall be equipped with IBC 2006 handrails and toe plates conforming to appropriate OSHA or MSHA requirements, and according to the Technical Specification for Structural Requirements for Mechanical Equipment No. 25635-220-3PS-S000-00001. 4.28.5 SELLER is to provide design and anchor arrangement for the equipment, including bolt quantity, location, type and diameter. 4.28.6 Vertical ladders are not acceptable as a primary means of access. Service platforms shall have a minimum width of 1 m, unless otherwise noted. 4.28.7 Handrails shall be 1.2 m high with two intermediate rails. 4.29 Environmental Requirements
4.29.1 Personnel noise exposure level shall conform to the requirements of OSHA 1910.95 and the local regulations. In the event of conflict between the codes and the local regulations, the most stringent requirements shall apply. 4.29.2 The noise level from each item of equipment is preferred to not exceed maximum allowable sound pressure level (SPL) of 85 dB(A) at a distance of one meter. 5.0 5.1 WELDING All steelwork shall be fabricated in accordance with the latest issue of the Structural Welding Code of the American Welding Society, AWS D1.1 and in accordance with the AISC Specification for Structural Steel Buildings (AISC 360-05) and Code of Standard Practice for Steel Building and Bridges (AISC 303-05).
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5.2
Structural drawings shall show welds requiring non-destructive tests, the extent of each type of test for each weld, the method of testing and the standards of acceptance. All welding shall be performed at the SELLER's shop, except as indicated in Section 8.5. All welding shall be as specified by AWS D1.1 Sections 2, 3, 4, and 5. Nondestructive examination shall be in accordance with the latest edition of AWS D1.1 with acceptance levels as indicated for Dynamically Loaded Structures Section 6.0. All pulley welds shall be visually examined and shall be tested in their entirety, by ultrasonic or radiography, and by the magnetic particle method. All welding procedures shall be in accordance with AWS D1.1, Sections 5.1 and 5.2. Welding and nondestructive examination procedures shall be submitted to and reviewed by the Buyer prior to production. Welder qualification records shall be reviewed by the Buyer's field inspection personnel. Pulleys shall be stress relieved after completion of all welding and before machining. PAINTING Unless otherwise specified in the equipment specifications or data sheets, all exposed metal surfaces except for machined surfaces shall be prepared, primed and finish painted according to the Technical Specification for Shop Priming and Painting No. 25635-220-3PS-NX00-00001, Class A-3 or according to Manufacturers standard procedures suitable for the intended service conditions, previously approved by BUYER. Mechanical, electrical and instrumentation components shall be shop prime and finish painted in accordance with the manufacturer's standard procedures. Handrails, walkways, ladders, and equipment safety guards shall be painted high visibility yellow. QUALITY ASSURANCE, ASSEMBLY, INSPECTION AND TESTING General
5.3
5.4
5.5
5.6 6.0 6.1
6.2
6.3
7.0
7.1
SELLER shall advise BUYER as to the quality control procedures and/or testing program followed to guarantee soundness and integrity of castings, forgings, and other materials used in this equipment. All equipment and assembly, including Control Panels shall be completely shop assembled, skid mounted and operationally shop tested. Acceptance criteria by SELLER. A record of tests performed, including tests required for compliance with specifications and correct fit-up.
7.2
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Functional and Operational Test 7.3 Non destructive tests scope and technique applied will be as per SELLERs standard. All magnetic particle examinations shall be performed in accordance with the true continuous magnetizing technique in accordance with ASTM E-709. Acceptance criteria will be as per SELLER. A record of tests performed, including tests required for compliance with regulatory or industry codes, shall be submitted to BUYER. SELLER shall retain originals of all test reports throughout the equipment warranty period. Witness and Hold points shall be according to Section 5 - Supplier Quality Surveillance Plan, in the Material Requisition. The supply shall include an integration test for the Overland Conveyor control system, which will be performed in the Electrical Equipments supplier installations with the control system interconnected with the remote I/O panels, operator workstation and electrical equipments. The test shall include: 1. Communications Test, to show that all components communicate correctly to each other. 2. Functionality Test, to show that the control functionality has been correctly programmed, configured and implemented by the Vendor as described in the Material Requisition and pertinent Technical Specifications. 7.8 For test purposes, the field signals will be simulated. The Vendor shall issue for approval an integration test protocol, including proposed test setup and test descriptions, eight weeks in advance of the scheduled FAT date, and immediately upon finishing the Test shall deliver a integration test Report. Assembly 7.9 Upon completion of shop test the SELLER shall be dismantled the equipment only to the extent necessary for packing and shipping. All components shall be matchmarked to facilitate field assembly. The match marks shall be stamped not painted, in conspicuous locations where they will not be obliterated prior to assembly. Fabricated steel components shall be shop-assembled and checked for fit and dimensional accuracy, and shall be match-marked prior to disassembly for shipment. Conveyor stringers and idlers shall be shipped assembled to the maximum practical extent, with lifting points clearly marked. Drive systems consisting completely of motor, gear reducer, complete pulley assemblies shall be assembled in shop on their own base and operated with no load, and shipped as large an assembly as practicable, after confirmation with assembly
7.4
7.5
7.6
7.7
7.10
7.11
7.12
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assembly drawings. Non drive pulley systems shall be fully assembled and confirmed per assembly drawings and shipped as large as assembly as practicable. Quality Assurance 7.13 SELLER shall furnish details of the quality assurance program to be applied during the preparation of fabrication of equipment. Program shall describe the measures to be used to control activities affecting the quality of equipment to be supplied in compliance with this Specification. SELLER quality assurance program shall be based on ISO 9001:2008 requirements or BUYER approved equivalent. Written certification shall be furnished by the SELLER that the equipment has been manufactured in compliance with the quality assurance program and requirement of the procurement documents. This certification will be the basis of Purchasers final payment of Purchase Order. The equipment components shall be completely shop assembled, inspected and tested in accordance with ISO 9001:2008 requirements or BUYER approved equivalent, prior to shipment to check for correct fit up and for compliance with Specification requirements. BUYER reserves the option to inspect the equipment in SELLERs shop and to witness tests. All critical dimensions shall be verified an all motions shall be tested, without load, using crushers own controls and wiring, prior to shipment. All locking and safety devices shall be tested for their intended functions. All motors and controls shall be operated at the specified voltage. ASSEMBLY AND SHIPMENT All critical dimensions shall be verified and all moving parts tested prior to shipment. All equipment shall be shipped in accordance to Section 7 of the Material Requisition, Shipping Terms, is exceeded, each equipment and ancillary must be divided in the largest sections possible, in order to comply with shipping limitations and facilitate assembly at field. Upon satisfactory performance, the equipment shall be dismantled only to the extent necessary for packing and shipping. All components shall be match-marked to facilitate field assembly. The match marks shall be stamped not painted, in conspicuous locations where they will not be obliterated prior to assembly. Machined surfaces shall be suitably protected for shipment. Steel tags shall be attached firmly by stainless steel wire or screws to each main part item / component or instrument shipped loose from main equipment. Large components that have to be shipped in smaller size pieces, due to shipping dimensional limits, may be welded at site. Equipment shall be modularized or assembled to a maximum extent to minimize field labor and these pieces shall consider bolted connections to locate the pieces at the correct position for welding. In this case, approval by BUYER will be required.
7.14
7.15
8.0 8.1 8.2
8.3
8.4
8.5
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8.6
The SELLER also shall confirm correct fit for all components and the entire satisfaction of the BUYER prior to shipment. All exposed machined surfaces shall be coated with an approved corrosion inhibitor compound and protected against damage. All equipment shall be shop assembled to the maximum extent practicable to verify proper fit. Where complete shop assembly is not possible, templates or any other means acceptable to both the BUYER and SELLER shall be used to verify proper fit of mating components. Such shipping assemblies shall have clearly marked lifting points, weights and indication of center gravity for safe handling during shipment and installation.
8.7
8.8
8.9
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02.34 25635-220-3PS-MHCB-00001 Technical PDF

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02.34 25635-220-3PS-MHCB-00001 Technical PDF

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Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

SECTION 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

3.0 3.1 3.1.1

4.0 4.1 4.1.1

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Must be calculated according to the installed motor

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Minus tolerance Plus tolerance

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Belt weight per unit length

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Conveyor Steelwork and Structures

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

5.6 6.0 6.1

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

8.0 8.1 8.2

Technical Specification for In Plant Belt Conveyor 25635-220-3PS-MHCB-00001-000

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