AA SPEC 673018

AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

CONTENTS

PAGE

1

SCOPE

2

2

TECHNICAL REQUIREMENTS TO BE SPECIFIED SPECIFI ED BY THE ENGINEER

2

3

DEFINITIONS

2

4

REQUIREMENTS

3

4.1 4.2 4.3 4.4 4.5

STANDARD DEVICES PLC SOFTWARE AND CONTROLS ENCLOSURES LABELING WEIGHTOMETERS

3 10 10 10 10

5

QUALITY ASSURANCE PROVISIONS PROVISI ONS

10

6

TEST AND INSPECTION INSPECTIO N METHODS

11

6.1

TEST AND CALIBRATION CERTIFICATES

11

7

PACKING AND MARKING

11

7.1 7.2

PACKING MARKING

11 11

APPENDIX A: RELATED DOCUMENTS

12

APPENDIX B: RECORD OF AMENDMENTS

12

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AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

1

SCOPE This specification details the requirements for the design, selection, supply, delivery and commissioning of conveyor belt protection instruments and systems. This specification addresses issues related to the design and selection of equipment for the designer as well as the specification of such equipment to the supplier.

2

TECHNICAL REQUIREMENTS TO BE SPECIFIED SPECIFI ED BY THE ENGINEER The Engineer shall specify project information, including:

3

•

Title of the project

•

Reference number for tender

•

Issue, date and revision of this specification to be used

DEFINITIONS For the purpose of this specification the f ollowing definitions shall apply: apply: BS

:

British Standards

FAILSAFE SYSTEM

:

A system which defaults to a safe state under failure conditions

HAZOP

:

Hazard and Operability Study

IEC

:

International Electrotechnical Commission

IP

:

Ingress Protection

MCC

:

Motor Control Centre

PFD

:

Process Flow Diagram – Schematic Illustration of the System

PID

:

Project Initiation Document – Key Information Required to Start Project

PLC

:

Programmable Logic Controller

SANS

:

South African National Standards

SCADA

:

System Control and Data Acquisition

UPS

:

Uninterruptible Power Supply

VSD

:

Variable Speed Drive

The following terms are defined in the General Conditions of Contract: •

Anglo American, Approved, Company, Contractor, Engineer.

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AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

Should any contradictions exist, the Contractor shall bring it to the Engineer’s attention for clarification.

4

REQUIREMENTS

4.1

STANDARD DEVICES

4.1.1

General All equipment shall be compliant to AA STD 673007, General Requirements for Instrumentation, AA SPEC 673001, Programmable Logic Controllers and AA SPEC 673002, Supervisory Control and Data Acquisition Systems. All devices listed below shall be treated as safety critical interlocks which may not be bypassed for normal conveyor operation. operation. Each interlock trip shall result in a conveyor conveyor trip i.e. resulting in a fail safe state for the entire conveyor system. Provision for bypass for abnormal conditions may only be made through PLC Software and logged accordingly.

4.1.2

Minimum Specification This is a minimum specification for instrumentation to be installed on conveyors, transfer points and Silos / Bins. For each mine, an evaluation and confirmation of the layout, control & process requirements, maintenance requirements, spares holding, etc shall be carried out to reach a final decision on the required instrumentation to be utilized. The mechanical contractor shall give guidelines regarding design parameters for all transfer points as well as all chutes regarding regarding access to these areas. This information will determine the most suitable suitable instrumentation to be used. used. Special cognisance cognisance shall be taken regarding the type and composition of material being conveyed i.e. size, coarse, fine and moisture content. All this information shall be clearly indicated on PFD’s, PID’s and General Arrangements. Consideration shall be given regarding hazardous area zoning classifications as this will have implications on the types of instrumentation to be used. A HAZOP study shall be carried out and completed to ensure adherence to safe operational and maintenance practices and statutory legal requirements. Safety requirements shall not be compromised under any circumstances.

4.1.2.1 Conveyors up to 200 metres metres and transfer point point Conventional / Non-Intelligent Conveyor Management System •

Pull keys every 50 meters apart (both sides of the conveyor - depending on access)

•

All pull keys shall be clearly numbered

•

Minimum of 3 pull keys on very short conveyors (head / centre / tail)

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AA SPECIFICATION

673018 ISSUE 1

CONVEYOR BELT PROTECTION SYSTEMS

COPYRIGHT •

Pigtails fitted every 2,6 meters

•

2 x Belt Alignments (Head and Tail)

•

1 x Belt Tear (Tail only)

•

1 x Belt Rip / Deadpan Switch (1 after each feed point)

•

1 x Speed Switch (Head only)

•

2 x Start-up Sirens and Light (Head and Tail) [minimum 105dB]

•

•

•

•

Blocked Chute Detectors (Tilt Switch - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Microwave - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Radar - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Nuclear - Quantity to be determined by size and nature of transfer point)

•

Licenses for the nuclear devices shall be obtained from the relevant authorities

•

4 x Take-up Tower Traveling Limit Switches

•

Maintenance Stop / Start Stations for all multiple motor drives (Electrical)

•

Maintenance Stop / Start Stations for belt splicing stations Note: Every pull key requires 2 contacts. This is applicable to both sides of the conveyor, to indicate which side of the conveyor the pull key is tripped.

•

1 x PLC Indication

•

1 x MCC Hardware Trip (safety circuit)

4.1.2.2 Conveyors 200 metres up to 1000 metres and transfer point Semi-Intelligent Conveyor Management System •

Pull keys every every 100 meters apart (both sides of the conveyor - depending on access)

•

All pull keys shall be clearly numbered

•

Pull keys shall a have siren (minimum 105dB) and light every pull key

•

Pigtails fitted every 2,6 meters

•

2 x Belt Alignments (Head and Tail)

•

2 x Belt Tears (Head and Tail)

•

1 x Belt Rip / Deadpan Switch (1 after each feed point)

•

2 x Speed Switches (Head and Tail)

•

2 x Start-up Sirens and Light (Head and Tail) [minimum 105dB]

•

Blocked Chute Detectors (Tilt Switch - Quantity to be determined by size and nature of transfer point) and / or

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Anglo Technical accepts no liability for any damage whatsoever that may result from the use of this material or the information contained therein, irrespective of the cause and quantum thereof.

AA SPECIFICATION

673018 ISSUE 1

CONVEYOR BELT PROTECTION SYSTEMS

COPYRIGHT •

•

•

Blocked Chute Detectors (Microwave - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Radar - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Nuclear - Quantity to be determined by size and nature of transfer point)

•

Licenses for the nuclear devices must be obtained from the relevant authorities

•

4 x Take-up Tower Traveling Limit Switches

•

4 x Take-up Trolley Traveling Limit Switches (if applicable)

•

1 x Take-up Trolley Traveling Alignment Switch (if applicable)

•

Maintenance Stop / Start Stations for all multiple motor drives (Electrical)

•

Maintenance Stop / Start Stations for belt splicing stations Note: Every pull key requires 2 contacts. This is applicable to both sides of the conveyor, to indicate which side of the conveyor the pull key is tripped.

•

1 x PLC Indication

•

1 x MCC Hardware Trip (safety circuit)

Additionally the numerical number of the pull key which has caused the trip shall be indicated. 4.1.2.3 Conveyors 1000 metres metres and longer and and transfer point Fully-Intelligent Conveyor Management System •

Pull keys every every 100 meters apart (both sides of the conveyor - depending on access)

•

All pull keys shall be clearly numbered

•

Pull keys shall have a siren (minimum 105dB) and light every pull key

•

Pigtails fitted every 2,6 meters

•

2 x Belt Alignments (Head and Tail)

•

Additional Belt Alignment at bends (Before and after Bend) – where applicable

•

2 x Belt Tears (Head and Tail)

•

1 x Belt Rip / Deadpan Switch (1 after each feed point)

•

•

•

•

2 x Belt Rip Devices– Becker (Head and Tail) [Conveyor belt supplier dependentloops installed] 2 x Speed Transmitters - Doppler (Head and Tail) [Contact less – need speed indication] 2 x Start-up Sirens and Light (Head and Tail) [minimum 105dB] Blocked Chute Detectors (Tilt Switch - Quantity to be determined by size and nature of transfer point) and / or

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Anglo Technical accepts no liability for any damage whatsoever that may result from the use of this material or the information contained therein, irrespective of the cause and quantum thereof.

AA SPECIFICATION

673018 ISSUE 1

CONVEYOR BELT PROTECTION SYSTEMS

COPYRIGHT •

•

•

Blocked Chute Detectors (Microwave - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Radar - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Nuclear - Quantity to be determined by size and nature of transfer point)

•

Licenses for the nuclear devices shall be obtained from the relevant authorities

•

4 x Take-up Tower Traveling Limit Switches

•

4 x Take-up Trolley Traveling Limit Switches (if applicable)

•

1 x Take-up Trolley Traveling Alignment Switch (if applicable)

•

Maintenance Stop / Start Stations for all multiple motor drives (Electrical)

•

Maintenance Stop / Start Stations for belt splicing stations Note: Every pull key requires 2 contacts. This is applicable to both sides of the conveyor, to indicate which side of the conveyor the pull key is tripped.

•

1 x PLC Indication

•

1 x MCC Hardware Trip (safety circuit)

Additionally the numerical number of the pull key which has caused the trip shall be indicated. 4.1.2.4 Silos and Bins (Application Dependent) •

•

•

•

•

•

Blocked Chute Detectors (Tilt Switch - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Microwave - Quantity to be determined by size and nature of transfer point) and / or Blocked Chute Detectors (Nuclear - Quantity to be determined by size and nature of transfer point) Licenses for the nuclear devices shall be obtained from the relevant authorities 2 x Silo Level Transmitters (Radar {recommended} - Quantity to be determined by size and nature of silo/bin) and / or 2 x Silo Level Transmitters (Ultrasonic - Quantity to be determined by size and nature of silo/bin) Note: Start-up Siren and Lights / Blocked Chute Detection at all other transfer points

All other instrumentation shall be supplied as per specific requirements e.g. Belt Weighers, Metal Detectors, Samplers, Hydraulics, Dust Suppression, etc All this information must be shown on the PFD’s and PID’s

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AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

4.1.3

Pull wire switches Pull keys or a pull key tensioning device shall be installed around the tail end of the conveyor and installation installation shall be around the tail-end guard. guard. The guard shall not be able to be removed without the tensioning device being unsecured. Once the tensioning device is unsecured, the conveyor belt shall trip. Emergency push stop stations shall be positioned at any inspection hatches for emergency incidents. The push button stations may either be connected into the pull key wiring, or directly into the MCC hard wired safety circuit.

4.1.4

Belt slip protection Belt speed devices shall be fitted to all conveyors. Standard centrifugal or the proximity type may be used for interlocking purposes in a chain of conveyors. For longer belts, the Doppler type of unit shall be fitted, allowing the comparisons between the speeds of the conveyor at the head and tail ends. Any major differences in these speeds shall cause the conveyor to trip.

4.1.4.1 Fixed Speed Belt For fixed speed conveyors, the trip setting shall be 80% of full speed. Allowance shall be made in the software for starting the conveyor. 4.1.4.2 Variable Speed Belt For variable speed belts, a start-up and operational philosophy shall be determined in a design criteria document which defines the type and location of instrumentation as prescribed by the Engineer. 4.1.5

Take-up over travel Take-up over travel protection shall be located at the extreme positions of travel of a counterweight and / or moving take-up device. There shall be two levels of protection at each point of position detection, namely limit detection and ultimate limit detection. •

•

Ultimate limit detection shall be hard wired to the MCC drive(s) to trip the device under extreme travel conditions. Limit detection shall form part of the control system design criteria and is not necessarily hardwired hardwired to the MCC as it is a warning / control device.

The following detection devices are required: •

•

Limit switches and ultimate limit switches at the top and bottom of gravity take-up towers. Limit switches and ultimate limit switches at the extreme positions of travel of the horizontal take-up.

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AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

4.1.6

Blocked chute detection Blocked chute detection devices shall be installed at the discharge of the conveyor belt to prevent contact of discharged material with the belt. The devices shall be selected according to the individual applications and consideration should be given to the material composition, preferably dry and free flowing. f lowing.

4.1.6.1 Tilt switches Tilt switches are suitable for standard chutes where coal is reasonably free flowing and blockage detection can be be relatively early. early. These devices are are normally located into the top of the chute and are dependent upon the trajectory of t he coal flow. 4.1.6.2 Rotating vane Rotating vane or “paddle wheel” devices can normally be installed where it is impractical to install the Tilt switch. switch. These devices can be fitted to the side of the chute for easy access and removal. 4.1.6.3 Microwave units Microwave units can be installed in areas of poor access although the need for regular cleaning of the lenses is essential. 4.1.6.4 Nuclear level devices These devices are more suitable for taller chutes where access to other devices is restricted. These devices will cater for coarse, fine and moist materials. 4.1.7

Fire detection systems

4.1.7.1 Fire detection systems Fire detection devices shall be installed on conveyor belts where specified by the Engineer in writing. Fire detection systems may be stand-alone devices and/or incorporated into the pull wire switch system. The devices, when activated, shall disconnect the electrical supply to the conveyor belt drive and consequently trip the conveyor belt. 4.1.7.2 Fire deluge systems Fire deluge systems shall be fitted to elevated gantries above the height of 10 meters. Deluge on, and subsequent tripping of the conveyors shall be carried out by means of the Ember Detectors and the Line Linear Detectors respectively. Monitoring of the deluge status in the respective zones shall be carried out by the SCADA system.

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AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

4.1.8

Magnetic removal of tramp iron Belt magnets shall be provided where necessary to protect the conveyor belt by removing magnetic objects. A magnetic detector shall be fitted after the belt magnet to trip the conveyor belt in the event of failure of the removal action Personnel and Equipment protection requirements.

4.1.9

Pre start warning systems Pre start warning devices shall be installed along the entire length of the conveyor belt system to warn personnel that the conveyor belt is about to start moving. The following important points should be noted: •

•

•

4.1.10

The pre start warning devices shall be audibly and visually detectable alongside the entire length of the conveyor belt installation. The pre start warning warning signal shall be activated and in operation for at least 20 seconds (configurable) before the conveyor belt drive is started. The pre start warning warning signal shall remain in operation until such time as the conveyor belt is moving along its entire length.

Conveyor Conveyor belt speed monitoring and control Start up speed monitoring, and running speed control philosophy shall be determined in a design criteria document which defines the parameters for belt speed monitoring and control and associated instrumentation for approval by the t he Engineer.

4.1.11

Lightning protection The conveyor belt protection system shall be electrically isolated from the control system and control networks in accordance with the requirements of SANS 10313 or BS 6651.

4.1.12

Electromagnetic radiation Assessment of the effects of strong electromagnetic radiation shall be in accordance with the requirements of BS 6656.

4.1.13

Earthing systems Any equipment or devices that are required to be directly connected to the control system shall be earthed as per AA STD 673013, Instrument Installation.

4.1.14

General requirements All protection devices on the conveyor belt system shall be individually identifiable on the control system Human Machine Interface to allow accurate and fast diagnostics. The need for a UPS shall be evaluated and installed as necessary to ensure safe operation/protection at all times. The control electronics of intelligent drive devices shall be connected in such a way that power to the electronics is maintained even when the motor power supply is disconnected.

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AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

4.2

PLC SOFTWARE AND CONTROLS Configurable in the PLC software:•

Number of consecutive belt starts after consecutive false starts shall not exceed 2 times before a physical inspection has taken place to ascertain the fault and an approval to restart for the 3rd time has been obtained.

•

Pre Start Warning period

•

Safety and Process Interlocks

•

Sequence starting

•

Ramp-Up and Ramp-Down 





•

Long conveyors with VSD’s VSD’s shall shall be able to Ramp-Up to full or pre-set pre-set speed speed Process or Safety interlocks shall cause the conveyor to “Coast “Coast to Stop” i.e. simulation of loss of power The only time a Ramp-Down stoppage shall be allowed is in the event event of of a controlled shut down from the control room

In the event of a new conveyor structure being designed and built, the structural designers shall be aware that under normal operation the conveyor belt will “coast to stop”. Any excessive stresses on the conveyor structure caused by “coasting to stop” shall be taken into account as an integral part of the initial conveyor design. All safety devices and process interlocks form part of the overall safety system of the conveyor. At no time, unless a formalized approval is obtained obtained by the Engineer, Engineer, shall any of these devices be bridged (either in software of physically) or removed from position. Under no circumstances, unless a formalized approval is obtained by the Engineer, shall any conveyor be started without any of the abovementioned safety equipment being installed, functional, operable and part of the safety control circuit.

4.3

ENCLOSURES Enclosures shall comply with AA SPEC 673004, Control Cubicles, with a minimum IP 65 rating, unless otherwise specified by the t he Engineer in writing.

4.4

LABELING Labeling shall comply with AA STD 673013.

4.5

WEIGHTOMETERS AA SPEC 673024, Weigh Equipment, refers.

5

QUALITY ASSURANCE PROVISIONS PROVISI ONS The requirements of AA STD 100 shall apply.

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AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

ATD C&I D 10 Software Project Management, Software Factory Acceptance Testing, Commissioning and Handover shall be applied (C1 – C5 Commissioning procedures)

6

TEST AND INSPECTION INSPECTIO N METHODS Devices shall be inspected and tested in accordance with the requirements of the Contractor's approved procedures.

6.1

TEST AND CALIBRATION CERTIFICATES The contractor shall provide test certificates for the installation as per AA STD 673013.

7

PACKING AND MARKING

7.1

PACKING The Contractor shall provide for the protection of the equipment against damage. All connections and entries shall be sealed before packing to prevent the ingress of dirt or moisture. All equipment shall be wrapped wrapped and packed and crated where where necessary. The packing shall be designed to give protection against delivery by truck over long distances on gravel roads. Where airfreight is to be used, the equipment shall be protected against low pressure and low temperature conditions. The packing shall be suitable to protect the equipment during storage on site in the prevailing weather conditions.

7.2

MARKING Each separately packed and transported piece of equipment shall be clearly and indelibly marked with the following information that shall also be written on an itemized packing list: •

Receiver’s name

•

Receiver’s address

•

Detailed list of contents per container

•

Project details

•

Contract number

•

Container number of total consignment

•

Contractor’s details

•

The Manufacturers name and/or logo shall be on all documentation.

•

The serial number shall be engraved on all devices.

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Anglo Technical accepts no liability for any damage whatsoever that may result from the use of this material or the information contained therein, irrespective of the cause and quantum thereof.

AA SPECIFICATION CONVEYOR BELT PROTECTION SYSTEMS

673018 ISSUE 1 COPYRIGHT

APPENDIX A: RELATED DOCUMENTS AA SPEC 673018 Conveyor Belt Protection Systems

The latest issue of the t he following documents shall be deemed to form part of this t his specification: AA STD 100

:

AA SPEC 673024

Quality Requirements for Suppliers of Critical Equipment Weigh Equipment

AA STD 673007

:

General Requirements for Instrumentation

AA STD 673013

:

Instrument Installation

AA SPEC 673001

:

Programmable Logic Controllers

AA SPEC 673002

:

Supervisory Control and Data Acquisition Systems

AA SPEC 673004

:

Control Cubicles

ATD C&I D 10

:

Software Project Management

BS 6651

:

Code of Practice for the Protection of Structures against Lightning

BS 6656

:

Assessment of Inadvertent Ignition of Flammable Atmospheres by Radio Frequency Radiation - Guide

SANS 10313

:

The Protection of Structures against Lightning

APPENDIX B: RECORD OF AMENDMENTS Issue 0

:

New document based on AAC Specification 673018 Rev 0 with general updates and amendments to Clause 4; Appendix C: Item 4 Motor Control Centre added; Appendix D added. (TR Foulger) September 2009

Issue 1

:

Clause 4.1.2 added; Clauses 4.1.4.1 & 2 added; Clauses 4.1.6.1, 2, 3 & 4 added; Appendix C deleted (B Barton, M Andrews) November 2009

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