EXX-EME-STD-0008 - Wear Liners For Plate Work and Chutes

••
exxaro
POWERING POSSIBILITY
MECHANICAL ENGINEERING STANDARD
EXX-EME-STD-0008
FOR
WEAR LINERS FOR PLATE WORK AND CHUTES
EXXARO
EXX-EME-STD-0008
COMPILED BY:
TITLE SIGNATURE DATE
MARIUS SMIT 18/11/2015
ACCEPTED AND APPROVED BY:
TITLE DATE
MANAGER MECHANICAL ENGINEERING
GROUP MANAGER ENGINEERING
Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 1 of22

••
exxaro
POWERING POSSIBILITY
EXX-EME-STD-0008 ~~II II
E p T D
DOCUMENT APPROVALS
ROLE NAME SIGNA#~ DATE
#
PRINCIPAL MECHANICAL
ENGINEER
HENNIE FOURIE
4/t;J/6
I~
DOCUMENT CONTROL
DOCUMENT INFORMATION
INFORMATION
Document Owner MARIUS SMIT
Publish Date 2015/11/18
DOCUMENT HISTORY
VERSION DATE CHANGES
Transfer from GMEP template to Exxaro template, modify table 1

1 2015/11/18
(previously table 8.2.1) and add paragraph 8.5 Lip liners.
Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 2 of22

EXX-EME-STD-0008 EPM/ENGINEERING-ENG-STD
VERSION DATE CHANGES
ABBREVIATIONS AND ACRONYMS
The following acronyms are applicable to this document: For more details, please consult the
Glossary.
ACRONYM DESCRIPTION
CSK Countersunk – In industry, countersunk nib bolts are sometimes

referred to as CSK nib bolts.
DEFINITIONS
The definitions listed below apply to this document. For more details, please consult the
Glossary.
TERM DEFINITION
Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 3 of 22

REFERENCES
The following documents are either Applicable Documents - applicable to the extent
specified herein and thus forming part of this document. The applicability will generally relate
to the Project in terms of policy, procedures, standards, qualification, etc.; or Reference
Documents - where the information concerned has been fully extracted from the reference
document and added to this document, or where the reference document contains
information relevant to this document, or for information only.
DOCUMENT NAME RELEVANCE
ISO 8501-1: Preparation of steel substrates before application of paints and related Applicable
products - Visual assessment of surface cleanliness
SANS1143: Countersunk and Mushroom Head Bolts Applicable
ESP-XX-0016: Engineering specification for corrosion control Applicable
Mine Health and Safety Act no. 29 of 1996 Applicable
Occupational Health and Safety Act no. 83 of 1993 Applicable
DOCUMENT DISTRIBUTION
This document is available for internal and external use at Exxaro Resources Technology
and related projects.

TABLE OF CONTENTS
1. PURPOSE ......................................................................................................................................7
2. SCOPE DEFINITION .....................................................................................................................7
3. BATTERY LIMITS..........................................................................................................................7
4. EXCLUSIONS ................................................................................................................................7
5. DEFINITIONS AND ABREVIATIONS ...........................................................................................7
6. RESPONSIBILITIES ......................................................................................................................7
7. REQUIREMENTS FOR WEAR LINING ........................................................................................8
7.1 GENERAL ............................................................................................................................8
7.2 WEAR LINING REQUIREMENTS FOR SPECIFIC APPLICATIONS .................................9
7.3 CERAMIC WEAR LINERS .................................................................................................10
7.3.1 General .................................................................................................................10
7.3.2 Standard ceramic tiles...........................................................................................11
7.3.3 Engineered tiles ....................................................................................................11
7.3.4 Liner thickness ......................................................................................................12
7.3.5 Surface preparation for ceramic tiling ...................................................................12
7.3.6 Ceramic tile layout .................................................................................................12
7.3.6.1 General .................................................................................................12
7.3.6.2 Protection of epoxy adhesives .............................................................12
7.3.7 Permanent marking of ceramic lined plate work ...................................................14
7.4 REQUIREMENTS FOR STEEL LINERS ...........................................................................15
7.4.1 General .................................................................................................................15
7.4.2 Steel lining layout ..................................................................................................16
7.4.3 Steel lining fixing requirements .............................................................................18
7.4.4 Surface preparation for steel liners .......................................................................20
7.4.5 Steel liners in dead box areas ...............................................................................20
7.5 Lip liners .............................................................................................................................20
8. MANUFACTURING REQUIREMENTS .......................................................................................20
9. PACKING, DELIVERY, OFF LOADING AND STORAGE ON SITE ..........................................20
10. ASSEMBLY, INSTALLATION, ERECTION AND CONSTRUCTION REQUIREMENTS ...........21
10.1 CERAMIC TILES................................................................................................................21
10.1.1 Attachment of tiles.................................................................................................21
10.1.2 Erection and installation of ceramic lined components .........................................21
10.2 INSTALLATION OF STEEL LINERS .................................................................................21
11. COMMISSIONING REQUIREMENTS .........................................................................................21
12. PROJECT DOCUMENTATION ...................................................................................................22
12.1 DRAWINGS .......................................................................................................................22

12.2 DATA SCHEDULES ..........................................................................................................22
FIGURES
Figure 1: Chamfering of tiles for welding. ................................................................................................ 9

Figure 2: Tile staggering ........................................................................................................................ 13
Figure 3: Corner tiles ............................................................................................................................. 13
Figure 4: Bending stresses .................................................................................................................... 14
Figure 5: Chute stiffeners ...................................................................................................................... 14
Figure 6. Staggered Liner Arrangement ............................................................................................... 16
Figure 7. Correct and Incorrect Placement of Liners in Corners .......................................................... 17
Figure 8. Steel Liner Countersunk Hole Detail ..................................................................................... 19
TABLES
Table 1: Mass of Ceramic tiles ................................................................................................................ 8

Table 2. Lining requirement for plate work components in different applications ................................ 10

1. PURPOSE
This Exxaro Wear Protection for Plate Work and Chutes (number EXX-EME-STD-
0008) states the standard requirements for metallic and ceramic wear lining for
plate work and chutes in abrasive environments. The life cycle phases covered
are from design up to commissioning.
2. SCOPE DEFINITION
This specification details the requirements for metallic and ceramic wear lining for
plate work and chutes in abrasive environments. The specification covers chutes,
bins and underpans as well as plate work surfaces of vibrating feeders and screen
underpans requiring wear lining. It includes the specification, design and
installation of wear lining. It also informs designers of plate work and chutes of the
lining requirements to be provided for in the design phase.
3. BATTERY LIMITS
This specification is applicable to all wear areas that will be lined with steel or
ceramic liners, excluding pipe work.
4. EXCLUSIONS
The specification is limited to wear lining and excludes the specification, structural
and functional design requirements of the components to be lined.
5. DEFINITIONS AND ABREVIATIONS

Ceramic tiles refer to high alumina ceramic tiles containing not less than 92%
Al2O3 with a minimum density of 3.52g/cm3 (3520 kg/m3).
6. RESPONSIBILITIES
The Exxaro Principal Mechanical Engineer is responsible for this standard.

7. REQUIREMENTS FOR WEAR LINING
7.1 GENERAL
The type of lining specified dictates the design of the equipment being lined. The
designer must make provision for the thickness of the lining when specifying inside
dimensions of components to be lined.
The mass of the lining material and the stiffness requirement for lining shall be
taken into account by the designer when designing components requiring lining.
The designer shall ensure that the lined components are of suitable section sizes
to be installed and handled safely during construction and maintenance.
Liners shall be designed taking into consideration instrumentation positions and

requirements.
Lined items shall be designed to ensure safe maintenance access for replacement
of liners or panels.
The typical mass of ceramic tiles is shown inTable 1.
Table 1: Mass of Ceramic tiles

Length Width Thickness Mass/area
covered
[mm] [mm] [mm]
[kg/m2]
150 100 6 24
150 100 12 48
150 100 20 75
150 100 25 96
150 100 50 192
The thickness, type of lining material and area to be lined shall be indicated on
detail drawings.
Welding shall be done on the outside of the component and not on the side that
must be lined. Where internal welding is required, it shall be grinded flush to
prevent interference with the installation of tiles.

Where internal welds cannot be removed to ensure the structural integrity of the
component, liners shall be chamfered to accommodate the weld. This is
applicable for all corners, angles and joint sections as shown in Figure 1.
Figure 1: Chamfering of tiles for welding.
All work executed shall satisfy the requirements contained in the approved Quality
Control Plan, by the engineer.
Liners must be guaranteed for at least 12 months against latent defects.
Alternative lining materials than that specified may be offered for consideration by
Exxaro. Such requests shall be accompanied by full technical details of the
material and evidence that the proposed alternative shall be more cost effective
than the material specified by Exxaro. Alternative proposals shall only be
implemented after obtaining approval from the Exxaro engineer.
7.2 WEAR LINING REQUIREMENTS FOR SPECIFIC APPLICATIONS
Table 2 indicates the lining requirement for plate work components in different coal
applications. Wear liners shall be designed considering high and low wear areas.
The designer shall specify liners considering cost and wear patterns.
It is the designer’s responsibility to review the general availability of the liner

thickness specified prior to detailing wear liners, as availability may vary from time
to time.

Table 2. Lining requirement for plate work components in different applications

Max UHMW-PE Steel Ceramic protection
particle (Ultra High liner thickness
size Molecular thickness
Description Impact Non-
[mm] Weight Poly- [mm]
area impact
Ethylene)
[mm] area
[mm]
[mm]
ROM 1200 25
ROM 50 25 25
Product & Waste 50 25 12
Product 1 6
Dribblings 1 6 20
Screen underpans 10 25
Screen underpans 1.6 6
Mixing box 25
Degrit/classifying cyclone boxes 1.6 12
Cones:
50 12
Vertical section
25
Conical section
Cones:
6
Vertical sections 4
12
Conical sections
7.3 CERAMIC WEAR LINERS
7.3.1 GENERAL
Standard tiles rather than engineered tiles shall be used wherever possible.
Cutting of tiles shall be by means of diamond saw cutting or green cutting.

Chipping of tiles shall not be allowed under any circumstance.
The epoxy adhesive shall have minimum 38MPa tensile strength and 80MPa
compressive strength. The supplier shall specify the adhesive best suited for
application on passivated 3CR12 plate work.

The ceramic tile supplier will be required to provide product and workmanship
guarantees for each application.
A minimum steel plate thickness of 6 mm is required for plate work to be tiled.
Stiffeners must be typically placed at 500 x 500 mm increments. Appropriate

stiffeners shall be installed if the existing stiffeners are deemed to be inadequate.
Additional bracing must be provided if the lining is at risk during lifting or handling
of the lined component.
Backing plates and stiffeners shall be the same material as the plate work.
Ceramic lining shall be done in the workshop or on site and shall be carried out in
a controlled environment under cover. Very large components can be lined in situ
with the approval of Exxaro. Lined items shall be devided into sections to ensure
transport of lined panels from fabricators to site as far as practically possible.
Tile layout drawings with unique numbers per item shall be provided for all tiled
surfaces on the Exxaro drawing template.
The layout of the tiles shall be detailed and submitted to Exxaro for approval. Liner
designs shall be done to minimize the use of special tiles as far as practically
possible to the discretion of the engineer.
The weight of the complete assembly, including backingplate and liner materials
shall be clearly shown on the drawing.
7.3.2 STANDARD CERAMIC TILES
Standard ceramic tiles 6, 12, 20, 25 or 50 mm thick shall be used. Standard tiles
shall be rectangular, starting from 100 x 25 mm to 150 x 100 mm in the thickness
specified. The maximum tile size shall be 100 x 150 mm. The maximum tile size
shall be used wherever possible on large flat surfaces.
7.3.3 ENGINEERED TILES
Engineered tiles shall be used for specific applications like square to round
sections where the use of standard tiles is not feasible.

7.3.4 LINER THICKNESS
A distinction shall be made in the tile thickness between the impact areas and the
non-impact zones of plate work as indicated in Table 2.
7.3.5 SURFACE PREPARATION FOR CERAMIC TILING
All surfaces shall be properly prepared before tiling in accordance with ESP-XX-
0016-01. Steel surfaces to be lined shall be ground flush. No weld beads shall
protrude on the inside of the steelwork.
Bins and chutes fabricated from 3CR12 will require sandblasting to Standard Sa
2½ as per ISO 8501-1 before application of tiles. Tiling shall cease when
discolouration of the steel is noticed. When discolouration is noticed, the remaining
area to be tiled will be sandblasted again before tilling continues.
7.3.6 CERAMIC TILE LAYOUT
7.3.6.1 General
Each tile shall be in intimate contact with the adjacent tile. In exceptional cases a
maximum joint width of 3 mm shall be allowed, provided that such tiles are in direct
contact for at least 90% of the length of the contact area.
The maximum allowable height variation (step) between adjacent tiles shall be 2
mm.
The bottom edge of a chute shall have a steel lip protruding to provide additional
tile support and prevent chipping of tiles.
Supporting bars shall be fitted inside large plate lining areas where support is
required.
Tiling on inspection and maintenance doors shall be flush with the lining of the
main platework.
7.3.6.2 Protection of epoxy adhesives

Epoxy shall be protected against abrasion material and tiles against damage in the
following ways:

a. Tiles shall be staggered to ensure that the epoxy route ends at a T-piece. The
shortest side of the tile shall always be in the direction of the flow as indicated
in Figure 2.
Material
flow
direction
Figure 2: Tile staggering

b. Corner tiles shall be used to line corners. Where the use of corner tiles is not
possible the following shall apply for bottom corners(Figure 3):
Preferred Acceptable Unacceptable
Figure 3: Corner tiles
c. The dimensions of engineered corners tiles shall be such that it can be

replaced with standard tiles, i.e. the layout shall allow for engineered and
standard tiles to be interchangeable as shown above.
d. Material flow shall be distributed over the largest area to minimise localised
wear when viewing a section of a chute.
Correct Unacceptable Unacceptable

e. Prevent bending stresses on ceramic lining at all flanged connections (Figure

4).
Unacceptable
Acceptable
Figure 4: Bending stresses
f. If a chute is flexible, stiffeners shall be used shown in Figure 5.
Stiffeners
Figure 5: Chute stiffeners
7.3.7 PERMANENT MARKING OF CERAMIC LINED PLATE WORK
All components lined with ceramic tiles shall have a permanent and clearly visible
warning stating

Ceramic lined: No cutting,

welding or hammering.
and stenciled onto the exterior of the component, on all sides visible from
walkways.
7.4 REQUIREMENTS FOR STEEL LINERS
7.4.1 GENERAL
Where the use of steel liners is indicated, VRN 500 or approved alternative of the
specified thickness shall be used.
Liner plates shall preferably be square, rectangular or triangular. Preference shall

be given to square plates to allow turning through 90 or 180 degrees where the
total plate is not immersed in the flow stream.
Liners shall be a maximum size of 300 mm x 300 mm. The maximum diagonal
dimension of any liner plate shall be less than the minimum chute outlet dimension
to ensure that dislodged liners can be discharged through the chute. The
maximum weight of a liner shall be limited to 25kg for liners with limited
maintenance access for rigging equipment.
Liner shall be arrange (pattern) to allow for standardization of plates as far as

possible to the discretion of the Exxaro engineer. Similar chutes will have identical
liner layouts. The starting point of the liner pattern for set out shall be similar for all
chutes.
A detailed drawing of the chute face shall be made, indicating the following:
 arrangement of the liner plates on the face, corners and angles

 mark number of each plate
 the dimensions of each plate
 thickness of each plate
 back marking of each plate
 gaps and overlapping distances between plates
 stiffeners in relation to the holes

The liner layout must be submitted to Exxaro for approval.
7.4.2 STEEL LINING LAYOUT
Liner plates shall be arranged on any chute face in staggered rows across the flow
of material. No long joints will be permitted in the direction of the flow of material.
This must be achieved through a combination of square and rectangular (triangular
where applicable) plates fitted in a staggered pattern from row to row. Figure 6
shows a typical staggered arrangement.
Figure 6. Staggered Liner Arrangement
Steel liners shall be mounted in intimate contact with the chute, bin or hopper
steelwork.
Individual liner plates must be removable without restriction from surrounding

plates. Liner plates with a thickness of 20mm and below shall have a gap of 5mm
between them. Liner plates with a thickness of more than 20mm shall have a gap
of 10mm between them.
Liners shall overlap each other in corners. Liners shall be chamfered to clear welds
in internal corners. The correct and incorrect placement of liners in corners is
indicated in Figure 7 below.

Figure 7. Correct and Incorrect Placement of Liners in Corners

7.4.3 STEEL LINING FIXING REQUIREMENTS
The liner plates will be attached to the chute or bin plate work by means of
countersunk-head nib bolts as specified in SANS1143: “Countersunk and
Mushroom Head Bolts”, Table 2.
All nuts shall be easily accessible for liner replacement. Outside stiffener positions
must be taken into account for liner spacing and layout. Cutting away or removal of
stiffeners to accommodate fixing holes and/or nuts shall not be allowed.
Each steel liner shall be fitted with a minimum of 4 bolts
Bolt holes shall be such that no two holes on the same or adjacent plates are
closer than 80 mm.
Countersunk bolt holes for the fixing of liner plates of various thicknesses shall be
as indicated in Figure 8.

Figure 8. Steel Liner Countersunk Hole Detail

7.4.4 SURFACE PREPARATION FOR STEEL LINERS
Painting, for insulation purposes, of internal surfaces of hoppers, bins or chutes,

fabricated from 3CR12 where steel liners of different material to the bin will be
fitted, the surfaces to be lined, shall be painted as per specification.
7.4.5 STEEL LINERS IN DEAD BOX AREAS
There shall be no distinction between liners in dead box areas and normal flow
areas.
7.5 LIP LINERS
Lip liners shall generally be of the same material as the adjacent liners, i.e.
ceramic lip liners shall be used where the adjacent plate work is lined with ceramic
tiles and steel liners used where the adjacent plate work is lined with steel liners.
The chute designer shall confirm the suitability of the material for the specific
application, dependent of material abrasiveness, size and impact energy.
Lip liners mass must not exceed 25kg per individual section to ensure ease of
replacement. In large chutes this will require that a lip liner consist of multiple
sections.
Lip liners must be easily adjustable to allow adjustment during commissioning.
8. MANUFACTURING REQUIREMENTS
Specific manufacturing requirements will be determined during detail design, if
required.
9. PACKING, DELIVERY, OFF LOADING AND STORAGE ON

SITE
Size and stiffness of platework sections shall be considered in the design to ensure
shipping of components without damage to liners.
Further details shall be furnished in the tender document.

10. ASSEMBLY, INSTALLATION, ERECTION AND

CONSTRUCTION REQUIREMENTS
10.1 CERAMIC TILES
10.1.1 ATTACHMENT OF TILES
Tiles shall be fitted according to the approved detail drawings.
Tiles shall be attached by means of epoxy adhesive. This may be a one-part or

two-part resin/hardener compound, but shall not contain any filler material which
may adversely affect the strength of the epoxy bond. Epoxies shall be specified by
the Contractor to suit the application. Data sheets of proposed epoxy shall be
provided for review.
The ceramic tiles shall provide a complete lining system, thus preventing any
ingress of moisture through gaps between tiles. The epoxy adhesive shall be used
solely for adhesion of tile to substrate and tile to tile, and not for filling gaps
between tiles. A proper wear resistant epoxy shall be used to fill all gaps between
liners.
10.1.2 ERECTION AND INSTALLATION OF CERAMIC LINED COMPONENTS
Due care shall be taken to prevent damage to ceramic lining during installation of
lined components. Additional stiffeners shall be used to prevent flexing of the
components if necessary.
10.2 INSTALLATION OF STEEL LINERS
Installation of steel liners shall be done in accordance with the approved Quality
Control Plan and detail drawings, after approval by the Exxaro Engineer.
11. COMMISSIONING REQUIREMENTS

High impact areas and wear patterns must be verified after commissioning and
compared to the liner design. Where differences exist that compromises the wear
life of components, it shall be rectified.

12. PROJECT DOCUMENTATION
12.1 DRAWINGS
All drawings shall be according to Exxaro drawing numbering and standards.
12.2 DATA SCHEDULES
Material data sheets and batch test certificates shall be submitted for all liners on
delivery, including backing material and epoxy and adhesive information.

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••

MECHANICAL ENGINEERING STANDARD

WEAR LINERS FOR PLATE WORK AND CHUTES

TITLE SIGNATURE DATE

MARIUS SMIT 18/11/2015

ACCEPTED AND APPROVED BY:

MANAGER MECHANICAL ENGINEERING

GROUP MANAGER ENGINEERING

Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 1 of22

ROLE NAME SIGNA#~ DATE

Document Owner MARIUS SMIT

Publish Date 2015/11/18

VERSION DATE CHANGES

Transfer from GMEP template to Exxaro template, modify table 1

Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 2 of22

VERSION DATE CHANGES

ABBREVIATIONS AND ACRONYMS

CSK Countersunk – In industry, countersunk nib bolts are sometimes

Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 3 of 22

DOCUMENT NAME RELEVANCE

SANS1143: Countersunk and Mushroom Head Bolts Applicable

ESP-XX-0016: Engineering specification for corrosion control Applicable

Mine Health and Safety Act no. 29 of 1996 Applicable

Occupational Health and Safety Act no. 83 of 1993 Applicable

Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 4 of 22

Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 5 of 22

12.2 DATA SCHEDULES ..........................................................................................................22

Figure 1: Chamfering of tiles for welding. ................................................................................................ 9

Table 1: Mass of Ceramic tiles ................................................................................................................ 8

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5. DEFINITIONS AND ABREVIATIONS

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7. REQUIREMENTS FOR WEAR LINING

Liners shall be designed taking into consideration instrumentation positions and

The typical mass of ceramic tiles is shown inTable 1.

Table 1: Mass of Ceramic tiles

150 100 50 192

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Figure 1: Chamfering of tiles for welding.

Liners must be guaranteed for at least 12 months against latent defects.

7.2 WEAR LINING REQUIREMENTS FOR SPECIFIC APPLICATIONS

It is the designer’s responsibility to review the general availability of the liner

Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 9 of 22

Table 2. Lining requirement for plate work components in different applications

Product & Waste 50 25 12

Screen underpans 1.6 6

Degrit/classifying cyclone boxes 1.6 12

7.3 CERAMIC WEAR LINERS

Cutting of tiles shall be by means of diamond saw cutting or green cutting.

Doc ID: EWPM-8453-222 Version: 1.1 Date: 2015-11-18 Page: 10 of 22

A minimum steel plate thickness of 6 mm is required for plate work to be tiled.

Stiffeners must be typically placed at 500 x 500 mm increments. Appropriate

7.3.2 STANDARD CERAMIC TILES

7.3.3 ENGINEERED TILES

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7.3.4 LINER THICKNESS

7.3.5 SURFACE PREPARATION FOR CERAMIC TILING

7.3.6 CERAMIC TILE LAYOUT

7.3.6.2 Protection of epoxy adhesives

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Figure 2: Tile staggering

Preferred Acceptable Unacceptable

Figure 3: Corner tiles

c. The dimensions of engineered corners tiles shall be such that it can be

Correct Unacceptable Unacceptable

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