MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT

SHOUGANG PER S.A.A

N SHOUGANG

TITLE

This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

PAGE

992663-5921-D-E-ET-0002
N SANDVIK

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REVISIONS
IT: ISSUE
TYPE
Rev.

IT

A Preliminary
B - For Approval

C - For Information
D - For Quotation
Description

E - For Construction
F - As Purchased

G - As Built
H - Cancelled

By

Ver.

Apr.

Aut.

Date

FOR QUOTATION

MNS

MNS

MNS

MNS 02.06.2014

FOR QUOTATION

MNS

MNS

MNS

MNS 11.07.2014

SHOUGANG PER S.A.A

N SHOUGANG

TITLE

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT
992663-5921-D-E-ET-0002
N SANDVIK

C1847-TS-30-520-0-0

PAGE

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Content
1

OBJECTIVE OF SPECIFICATION ............................................................................................. 3

TERMS AND DEFINITION ......................................................................................................... 3

REFERENCE TO CONTRACTUAL DOCUMENTS .................................................................... 3

SITE DATA ................................................................................................................................ 4

SCOPE OF WORK ..................................................................................................................... 5

OPERATORS CABIN ................................................................................................................. 5

CODES & STANDARDS ............................................................................................................ 7

DESIGN & CONSTRUCTION ..................................................................................................... 9

PROTECTION TREATMENT ................................................................................................... 10

10

TESTING & INSPECTION ........................................................................................................ 10

11

PACKAGING, TRANSPORTATION & STORAGE ................................................................... 10

12

CLIENT SPECIFICATION SUMMARY ..................................................................................... 11

13

DOCUMENTATION .................................................................................................................. 13

MINE OPERATION EXPANSION

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SHOUGANG PER S.A.A

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This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0002
N SANDVIK

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PAGE

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REV.

1. OBJECTIVE OF SPECIFICATION
This specification establishes the minimum requirements for design, manufacture, testing at
manufacturers work, transportation & delivery of Operators Cabin.

2. TERMS AND DEFINITION

PS
PR
ITP

Stacker
Reclaimer
Inspection & Test Plan = Quality Control Plan (QCP)

3. REFERENCE TO CONTRACTUAL DOCUMENTS

The following documents are important for the requirements of this specification and part of
the attached specification package:

Title
Specification Drawings
Client Electric Design Criteria
Client Electric Specification
Steelstructure ITP

Paint ITP

Document Code / File Name

C1847-PS1-30-520-1-0.dwg
C1847-PR1-30-520-1-0.dwg
997601-5000-G-E-CD-001
992881-5700-G-E-CD-0001 Rev. C
997601-5000-G-E-ET-001
1847-QA-01_0 - ITP Steel structure
and / or
997601-5000-G-ST-ET-001 Rev.1
1847-QA-04_0 - ITP Paint
and / or
997601-5000-G-ST-ET-002 Rev.1

MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT

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N SHOUGANG

TITLE

992663-5921-D-E-ET-0002

This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

N SANDVIK

PAGE

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4. SITE DATA
4.1

LOCATION
The equipment described in this specification shall be installed in a iron ore mine located in
Distrito San Juan de Marcona / Peru in South America
The following site conditions are to be considered for selecting the equipment offered.

4.2

SITE CONDITIONS EXCERPT

Criteria

Value

Altitude

850m above sea level

Max. Air Temperature (for design)

35C

Min. Air Temperature (for design)

5C

Relative Humidity min. / max

50% / 90%

Wind Speed (operational)

90km/h

Atmosphere

Sea Breeze, highly corrosive and high

contamination level of an industrial type

Rated Seismic:

Zone 3
(According to the Peruvian Technical
Standard Structure 030)

Design should be considering tropical climate weather conditions with rapid condensations,
heavy rain, windblown to near horizontal. The air is dust laden.
The equipment will be in open area, exposed to the all-adverse weather condition.
Refer to Specification 992881-5000-G-E-CD-0001

4.3

4.4

ELECTRICAL DATA
Medium Voltage Supply:

4,16kV (+/- 10%)

Motor Supply Voltage:

480VAC, 3 phase, 60 Hz

Small Consumers:

480/230 VAC, 3/1 phase / 60Hz

MCC Control Voltage:

230VAC

Control Signal Voltage:

24VDC for PLC input/output signals

Protection Class:

IPW55 for motors (weather proofed)

IP65 for junction boxes, control boxes, control panels,
and field devices

APLICATION
The mine operation Expansion Project and Benefit plant shall be equipped with a new bulk
handling system (BHS) for iron ore.
The stockyard of the BHS shall be mainly composed of the following:

MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT

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992663-5921-D-E-ET-0002

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Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
4.5

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EQUIPMENT
-

1 Stacker

1 Reclaimer

5. SCOPE OF WORK
5.1

GENERAL
The scope of work includes design, manufacture, inspection at manufacturers works,
transportation, delivery of complete operator cabins and accessories required for specified
duty requirements of the above mentioned machines. Transportation requirements will be
covered in separate document.

5.2

SCOPE
Equipment

Qty

1.1

Stacker 01

C1847-PS1-30-520-1-0.dwg

Operator Cabin

1.2

Reclaimer 01

C1847-PR1-30-520-1-0.dwg

Operator Cabin

Sum

According Drawing

Equipment Type

6. OPERATORS CABIN
6.1

PURPOSE:
Used for operation of the stockyard stackers and reclaimers

6.1.1

Operators Cabin Requirements for Stacker and Bucket Wheel Reclaimer

the cabin must be designed as a complete closed cabin with proper isolation and
suitable view for the operating people, the total weight of the Cabine should be lower
than 1.800kg.
rigid strong self-carrying base frame with outside dimensions and connection points as
per attached drawing
bottom frame (with holes) able to carry platforms for cabins
support on the roof support points located as per drawing (proposal)
provisions for glass sections located on the floor should be divided into 3 pieces in a
portion of approx. A of total cabin width for left and right window and approx. 2/4 of
total cabin width for the window in the middle and have to be protected by steel bars.
glasses in operators windows should have window heating facility and anti-mirroredglass type
door and windows located as per sketch

SHOUGANG PER S.A.A

N SHOUGANG

TITLE

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

MINE OPERATION EXPANSION

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PAGE

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REV.

door as sealed industrial type with steel frame,

equipped with bronze hardware and master keyed lock,
panic bar operated emergency exit device, self-closing with arrestor at fully opened
double floor (twin deck construction) min. 400mm with support for operators chair
(supplied by SANDVIK) and opening outlet for cables
net height according attached drawings
walls steel plate construction with minimum plate thickness 2,5mm has to be thermal and
sound insulated with non-inflammable material
inner walls and ceiling or roof shall be heat isolated so as to prevent dew condensation
roof inclined and equipped with strong eye bolts for transportation and installation
cabins shall be heat, dust, rain, wind and noise isolated (noise level max 50dBA)
windows swivel type, capable to clean from in- and outside safety tubes around the
windows are required
3 wiper washer (1 on front window, 1 on each side window) heavy duty type with
minimum 5 litre water reservoir have to be installed, condensing water line from AC
should be connected to this reservoir.
split type air condition (cooling and heating), suitable for the specified ambient conditions
(heavy duty marine type HVAC) with R134A cooling fluid according client specification
cooling power: appr. 1x5,5kW detailed calculation required from the Cabin Supplier.
sealed doors and windows (UV and Ozone consistent)
door industrial steel type with its upper half glazed with tinted safety glass (coated glass)
eave and gutter shall be provided for the doors and windows
sun shades or sun visors shall be installed on the windows
space for dry chemical type fire extinguisher on wall has to be provided
lighting (anti vibrating type) with 500lx at floor level with dimmable on/off switch
according drawings and emergency light function (min. 0,5 hours)
illuminated, battery maintained emergency EXIT signs above doors have to be installed
removable cable ways in walls and roof for lighting and plugs as per SANDVIK
requirements
power sockets: 15A / 230V / 2 pin switched interlock socket outlets have to be used
one fold down chair has to be installed
clock installed on wall
storage locker for operation staff
provision of space for microwave oven (900W) and refrigerator (volume approx. 80l for
cooling, 10l for freezing) installed inside cabin (Equipments are not included in delivery)
provision of space for car radio with CD player and USB interface for MP3 and min. two
3-way loud speakers in front of the cabin has to be provided (Equipments are not
included in delivery).
serrated rubber carpet on floor

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This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0002
N SANDVIK

C1847-TS-30-520-0-0

PAGE

7/14
REV.

external air supply / pressurizing unit (overpressure to prevent entrance of dust and gas)
via 2 filter stages, low noise level not to disturb communication via radio has to be
provided
drainage of condensing water to outside of the container until ground level
mounting rail for electrical cabinet
installation and wiring of operators chair, HMI and electrical cabinet (supplied by
SANDVIK)
fire detection and hand fire extinguishers.
provision for radio/intercom system (specified or supplied by SANDVIK)
potential equalization: every delivered non electrical equipment has to be connected
continuously electro conductive for the purpose of potential equalization and has to be
connected to the interior grounding system (collector line or connection points), if
necessary with cable connection (NYY-J 16mm) or tin-coated copper cord.

7. CODES & STANDARDS

The manufacturer shall be qualified for producing operators cabins, supplied for power
stations, coal mines and terminals, in similar applications in term of capacity, length, width,
diameter etc. Supplier shall provide the relevant reference list for each proposed item.
All equipment covered under this specification shall comply with all currently applicable
statutes, regulations & safety codes of European Standard as nominated within this
documents or any relevant national or government standard of any member of the
European Communities or any relevant International Standard recognised by such a
member state, can be used for compliance provided that the standard offers guarantees of
safety, suitability and fitness for purpose.
Especially, the whole supply and any of its parts shall be designed, manufactured and
erected in accordance with Peruvian laws and the local directives in force and with any
prescription from public authorities.

7.1

7.2

GENERAL
ANSI

American National Standards Institute

DIN

Deutsches Institut fr Normung

ISO

International Organization for Standardization

MECHANICAL STANDARDS
ISO 2262:

Steel Shackles

ISO 2372:

Analysis of Vibration

ISO 5049/1:

Mobile Continuous Bulk Handling Equipment

BS 302:

Stranded Steel Wire Ropes

BS 3643:

ISO Metric Screw Threads

BS 4235:

Metric Keys and Keyways

MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT

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This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

7.3

992663-5921-D-E-ET-0002
N SANDVIK

BS 4500:

ISO Limits and Fits

BS 5304:

Safety of Machinery (Guarding)

BS 970:

Shafting

C1847-TS-30-520-0-0

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STRUCTURAL STANDARDS
DIN 267:

Metric Threads - Laminated Metric Thread Screws

DIN 1026:

Metric channels

BS-EN 287 Part 1:

Approval testing of welders/fusion welding

BS-EN 288 Part 3:

Specification and approval of welding procedures for metallic

materials

BS 5135:

Metal arc welding of carbon and carbon manganese steels

BS 4360:

Weldable structural steel

BS 2573 Part 1:

Classification, stress calculations and design of structures

BS 3923:

Methods for ultrasonic examination of welds

BS 2600:

Radiographic examination of fusion welded butt joints in steel

BS 4 Part 1:

I and H sections

BS 4848 Part 2:

Hot finished hollow sections

BS 6363:

Cold formed sections

BS 29:

Forgings

BS 3100:

Steel castings

BS 1452:

Cast iron

ISO - R657/EN10056:

Angles

SABS 094:

The use of high strength friction grip bolts and nuts

SABS 135:

ISO metric bolts, screws and nuts (hexagon and square) (coarse
thread free fit series)

SABS 1431:

Weldable structural steel

SABS 136:

Isometric precision hexagon-head bolts and screws, and hexagon

nuts (coarse thread medium fit series)

MINE OPERATION EXPANSION

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SHOUGANG PER S.A.A

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TITLE

This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0002
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C1847-TS-30-520-0-0

PAGE

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8. DESIGN & CONSTRUCTION

The equipment to be supplied shall be designed based on the information given in this
specification and additional requirements as per referenced documents. The bidder shall
carefully examine the data furnished and shall satisfy himself regarding the sound
performance of the equipment under specified operating condition.

8.1

GENERAL INFORMATION
The operator cabins shall be designed taking into account the following main requirements:
The operator cabins shall be supplied in accordance with the official instruction by codes
and standards, herein mentioned, to come into force at the date of order. In particular the
European Community standard 89/392/CEE, Machinery Directive shall be followed and
every ISPESL and CE certificates shall be provided. Its also clarified that all the codes and
standards expressly mentioned in this TS shall be applied within the limitation or reference
values specified. Use of FEM standards, Section II is allowed only if not in conflict with the
regulation, codes and standards expressly indicated in the Procurement Technical
Specification (PTS).
The operator cabins shall be designed for service defined as heavy duty and continuous
operation and shall be installed outside.
The operator cabins shall be suitable for the specified operating conditions and it shall be
designed and manufactured for a minimum service life of (30) thirty years.
All the auxiliary components and related accessories shall be designed in order to have a
mean time between maintenance (MTBM) not less than the scheduled maintenance step
activities for the main equipment.
All the main equipment, auxiliary components and related accessories shall be prefabricated as much as possible.
The operator cabins shall be designed considering all space requirements and all access
for field erection, pre-commissioning, commissioning and start-up, operation and
maintenance activities. If during any inspection activities, this requirement is not met, its
suppliers responsibility to perform all the necessary modification at its own care and cost.
Site welding activities shall be avoided or minimized.
Site painting activities shall be avoided or minimized.
Final equipment colours and shades will be communicated and are specified in the paint
ITP. All welds shall be continuous, seal type, in order to prevent the corrosion on all
structural parts where a visual checking and maintenance activities cannot be performed.
Tack welds are not permitted.

MINE OPERATION EXPANSION

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This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0002
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C1847-TS-30-520-0-0

PAGE

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REV.

9. PROTECTION TREATMENT

The design of protection against corrosion shall be done according to the

environment (severe marine and industrial atmosphere) and the functional
requirements (presence of coal dust). The result shall be proved by means of the
evidence on practical applications for a significant period and/or by laboratory tests.

All surfaces which are directly exposed to the external atmosphere shall be
galvanized and painted in accordance to paint specification.

The treatments against corrosion for all the other secondary structures shall be
designed and chosen by the designer(s) according to the above-mentioned
environmental conditions.

Until not revised by additional specification (paint ITP) 70m galvanized plus top
coat paint should be considered.

10.

TESTING & INSPECTION

10.1

GENERAL
Tests shall be done both at manufactures shop. If applicable prior to manufacturing the
manufacturer shall provide a Quality Control Plan (QCP) or an Inspection & Test Plan (ITP)
for approval by SANDVIK and if required by the client.
The ITP shall include hold and witness points for all parties involved.
Shop testing and inspection report shall be provided.

10.2

TEST SCOPE
All Operator Cabins shall be inspected and tested in accordance with the applicable
standards and/or codes with the following clarifications:

11.

The Operators Cabin will be pre-tested (functional and Cabin communication

network) at supplier site.

Dimensional check before shipment

Visual control

PACKAGING, TRANSPORTATION & STORAGE

Operators cabins shall be securely stored and transported with protective seaworthy
packing.

SHOUGANG PER S.A.A

N SHOUGANG

TITLE

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT

12.

CLIENT SPECIFICATION SUMMARY

12.1

OPERATORS CABIN

992663-5921-D-E-ET-0002
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The automatic levelling type operators cabin is positioned at the end of the boom in such
a position that the operator has full visibility of all operations when seated at the controls.
Provision shall be made for a glass section in the floor with bars covering it. The size of the
cab shall be adequate for the operator, assistant operator and the equipment therein and
shall allow ample space to permit convenient maintenance. The floor shall be of removable
checkered plates. The cabin must be dust tight.
A heavy duty, wall type, marine air-conditioning unit complying with the Air-Conditioning
Specification has to be provided with due consideration to the high ambient temperature
and humidity levels.

A pressurizing unit with replaceable dry filter shall also be provided

The condenser of the air-conditioner must be easily accessible for cleaning

The unit must have an integral heating facility

The unit must be easily accessible for maintenance.

A fully adjustable upholstered seat with armrests shall be provided for the operator and a
tip-up seat for an assistant.
The control consoles shall be mounted on and form an integral part of the operators swivel
chair.
All levers, handles, etc. for controlling the movements of the machine shall be arranged in a
convenient position on the consoles so as to enable the operator to manipulate and control
all operations with the minimum effort or strain. The arrangement of the various controls
shall be clearly shown on the drawings submitted with the tender.
A shelf for mounting of a radio and telephone for communication shall be provided in a
convenient place.
The major items of equipment are to be so arranged that they can be removed from the
cabin for repair without disturbing the walls, floor and structural frame work.
The cabin shall be completely manufactured from seawater resistant material and outer
cladding shall be welded onto the frames. The cabin shall be completely dust proof (IP65).
The roof and walls shall be suitably insulated. Insulpan or similar products are
permissible. Vendors must submit details of the type of insulation they propose to provide.
A durable PVC type inner cladding covering the insulation shall be provided.
A seawater resistant, hermetically sealed door, opening outwards with window and having
handles of robust construction shall be provided, arranged for exterior locking, connecting
to an exterior access platform. Exiting from inside must be possible without unlocking the
door.
The cabin shall be glazed as necessary on all sides and bottom, giving the operator full
visibility and a clear view at all times from the seated position. Structural members shall be
arranged to cause the minimum obstruction in the operators field of vision.
All the glazing of the operators cabin is to be of solar heat-reducing hardened safety glass,
of 6mm minimum thickness.
Self-aligning windscreen wipers shall be fitted to the main side and front windows.

SHOUGANG PER S.A.A

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TITLE

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

MINE OPERATION EXPANSION

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The automatic levelling shall be by means of hydraulic or electrical screw drive.

Operating noise levels inside the operators cabin shall not exceed 50dBA.
A walkway shall be provided around the cabin to allow for cleaning of the windows.
Electrically operated self-parking windscreen wipers shall be provided for the front windows.
A suitable storage locker for operating manuals is to be provided in the cabin.
A suitable shelf for mounting the computer equipment shall be provided in a position that
would allow the operator easy access to it.
A notice, stating the starting up and shutting down procedure of the machine mounted in a
glass frame, shall be provided in a prominent position in the operators cab. Language is
English and Spanish.
Two electrical plugs shall be mounted inside the cabin.

MINE OPERATION EXPANSION

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This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

13.

992663-5921-D-E-ET-0002
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DOCUMENTATION
Details of the requirements for documentation are defined in a separate specification and
shall comprise:

13.1

BIDDER DOCUMENTATION
The bidder shall present documents showing the equipment offered and prepare drawings
showing the positioning and functionality of the equipment in its working position.

13.2

1.

General arrangement and dimensional drawing including weight, fixing details, etc.

2.

Equipment list complete with designation, rating, type and make of components

3.

Wiring diagram with termination details

4.

Equipment layout

5.

Catalogues of components used

6.

Painting and constructional details

VENDOR MANUALS
It shall consist of
Detailed description of the equipment supplied; technical data sheet etc.
Spare list
Assembly-, Commissioning-, Operation-, Maintenance and Repair instructions;
Transport and storage instructions
The supplier shall submit a typical vendor manual from similar project to SANDVIK for
review and approval by SANDVIK.

13.3

QUALITY
The manufacturers Data report (MDR) shall consist of:

Quality inspection and test reports, certificate as per ITP-requirements

CE-Declaration according to the EC Machine Directive
CE-Declaration in accordance with the ATEX Directives if any
Supplier shall provide a Certificate of the companys integrated Quality System

The supplier shall submit a typical MDR from similar projects to SANDVIK for review and
approval by SANDVIK.

13.4

REQUIRED DOCUMENTS
GA Drawing:

21 days after signing the contract.

Final design drawing (CAD), documentation, bore holes position scheme and design
calculation with all relevant data shall be submitted no later than 21 days after signing the
contract.
Inspection and Testing Plan (refer to QA)
Spare Parts Catalogue

SHOUGANG PER S.A.A

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TITLE

Technical Specification Operator Cabin

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.

MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT
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Project specific operating, maintenance, lubrication manuals (no generic documentation)

including transportation, storage and assembly instructions shall be supplied electronically
(only native files) and in paper
Languages
German:

English:

1 electronically / 2 printed

Spanish:

1 electronically / 2 printed

If any doubt or in case any inconsistencies within this specification including its attachments
arise, please contact SANDVIK Mining and Construction Materials Handling GmbH & Co KG