AA_SPEC_254001 Stacker Reclaimer Spec
Short Description
Descripción: Stacking and Reclaiming Equipment – Mechanical and Structural...
Description
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
This document supersedes AAC_SPEC_254001
CONTENTS
PAGE
1
SCOPE
2
2
TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER
2
3
DEFINITIONS
2
4
REQUIREMENTS
3
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11
GENERAL M ATERIA L TO B E HANDL ED ENVIRONMENT DESIGN M ATERIA LS MECHANICAL STRUCTURAL C ASTINGS FORGINGS CORROSION PROTECTION S AFETY
3 3 3 4 4 5 16 18 19 20 20
5
QUALITY QUAL ITY ASSURANCE ASSURA NCE PROVISIONS
21
6
TEST AND INSPECTION METHODS
21
6.1 6.2 6.3 6.4
GENERAL TESTS L OAD A ND OPERATING TESTS TRUCTURAL TESTS STRUCTURAL GEAR REDUCERS
21 21 22 23
7
PACKING AND MARKING
23
7.1 7.2
P ACK ING M ARK ING
23 24
APPENDIX A : REL ATED DOCUMENTS
25
APPENDIX B : RECORD OF AMENDMENTS
28
AA_SPEC_25400100.DOC
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1
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
SCOPE This specification details the structural and mechanical requirements for stacking and reclaiming equipment.
2
TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER The following shall be specified on every invitation to tender. •
•
3
Title, number, issue and date of this specification The equipment requirements. requirements. For other requirements requirements refer to the enquiry or contract document.
DEFINITIONS For the purpose of this specification the following definitions shall apply: AGMA
:
American Gear Gear Manufacturers Association Association
APPROVED
:
Approved by the the Engineer in writing writing
ASTM
:
American Society Society for Testing and Materials. Materials.
BSI
:
British Standards Institute
CONTRACTOR
:
The company, partnership or person contractually obliged to supply products or services to the purchaser.
CRITICAL
:
A component or permanent assembly the failure of which, by analysis, judgement and experience, is likely to result in hazardous or unsafe conditions for individuals using, maintaining or depending upon the equipment equipment or structure of which it is a part: OR A component or permanent assembly which the failure of which is likely to very significantly affect the performance of important equipment and structures of which it is a part: OR A component or permanent assembly which requires 24 hours or more to replace.
DEFECTIVE
AA_SPEC_25400100.DOC
:
A part or parts of the equipment that fails in one or more respects to comply with the requirements of the specification
APPROVED
12 February 2008
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
ENGINEER
:
Consulting Engineer, Consulting Mechanical and Engineer of AA or their appointed representatives
ISO
:
International Standards Organisation
MAJOR
:
A component or permanent assembly, other than Critical, the failure of which is likely to materially reduce the ability to use the equipment or structure of which it is a part.
MINOR
:
A component or permanent assembly the failure of which is not likely to materially reduce the ability to use the equipment of which it is a part
PURCHASER
:
The company designated as the recipient of finished products or services
PURCHASERS REPRESENTATIVE
:
A company, company, partnership partnership or person person authorised authorised by the Engineer to act on the purchaser's behalf
QUALITY SURVEILLANCE AUTHORITY
:
An approved inspection agency appointed by the the contractor contractor
SANS
:
South Africa National Standard
SAE
:
Society of Automotive Engineers (American)
SAIW
:
South African Institute of Welding
4
REQUIREMENTS
4.1
GENERAL
Electrical
This specification deals with specific requirements for stacking and reclaiming handling equipment.
4.2
M ATERIA L TO B E HANDL ED The equipment shall be designed to handle the material and at the rate specified in the contract.
4.3
ENVIRONMENT The equipment shall be capable of the duty specified in the contract when exposed to the operating environment. The Contractors shall ascertain any further details not covered in the enquiry from the Engineer.
AA_SPEC_25400100.DOC
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
4.3.1 4.3.1
Noise levels: noise level of the equipment when operating at full rated capacity shall not exceed 80dBA measured at a point one metre above ground and one metre from any bogie. The noise level inside the cab(s) cab(s) with doors and windows closed closed shall not exceed 70dBA. 70dBA .
4.3.2 4.3.2
Wind speed: the maximum regional basic wind speed in the area of deployment for a 50-year mean return period shall be obtained from SANS 10160, unless otherwise stated in the contract. In countries other than South Africa the applicable local data shall apply. apply.
4.4
DESIGN
4.4.1 4.4.1
General General desig n: equipment shall be designed in accordance with current technology and engineering engineering practice. The design shall comply comply with requirements requirements of this specification and and relevant company, national and international standards (see Appendix A). The requirements of the South African Minerals Act and the Inspector of Machinery shall be complied with where applicable.
4.4.2 4.4.2
Desig Desig n audit : the mechanical and structural integrity of the major items of plant shall be subject to an independent independent review/audit review/audit by an auditor approved approved by the purchaser. purchaser. The Contractor shall make available to the auditor all necessary design information as required in the contract document.
4.5
M ATERIA LS
4.5.1
Plate: all steel plate materials shall be to SANS 1431 Gr. 350WC, or as agreed by the Engineer in countries other than South Africa.
4.5.2
Forgings: forging shall be within the limiting ruling section for the material and conditions specified with a minimum 3:1 forging ratio.
4.5.3
Castings: shall comply with EN 10293 unless the design design requires better. Castings shall only be repaired in accordance with repair procedures submitted for approval by the Engineer at the time of tender.
4.5.4 4.5.4
Slew rol ler and rin gs: the material shall shall have a maximum maximum grain size of of 5 or finer. It shall be vacuum degassed to a maximum of 2.5 parts per million hydrogen. The following properties shall be stated at time of tender by the contractor for the bearings: •
Case depth
•
Case hardness
•
Core minimum yield strength
•
Case/core transition thickness.
Steel cleanliness shall be to ASTM E45 plate II to be obtained by electroslag re-melting, consumable electrode vacuum arc re-melting or equivalent.
AA_SPEC_25400100.DOC
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Average of the 10 worst field ratings in in any specimen shall shall not be in excess excess of: A - 0 maximum B - 0 maximum C - 0 maximum D - 1.5 maximum for both the fine and thick series.
4.6
MECHANICAL
4.6.1
General: mechanical components of the stacker/reclaimer shall be designed generally in accordance with the procedures of FEM 2.131/2.132.
4.6.2 4.6.2
Desig Desig n loads : shall comply with the requirements of FEM 2.131/2.132 with the following amendments. Mechanism loads shall include all of the structural load cases specified by ISO 5049-1. Case I and II loads in ISO 5049-1 shall be modified to be consistent with corresponding amendments to structural loadings as detailed in Clause 4.7.1 of this specification. Loads considered in fatigue life calculations shall include bucket wheel stalls which shall be assumed to occur at a frequency of 2 per hour over the operating life of the machine. Stall torque during these stall events shall be assumed to reach 1.1 times the torque setting of the torque limiting clutch/coupling. clutch/coupling. Case II loads for the bucket wheel shall include the rapid rotational deceleration of the wheel, decelerating uniformly to rest from full rotational speed over a distance of 300 mm at the bucket lip.
4.6.3 4.6.3
Desig Desig n lif e: mechanism components shall be designed to achieve a life equivalent to 100,000 hours of continuous operation of the stacker/reclaimer stacker/reclaimer system. The corresponding design lives (continuous operation) for the major drives shall be assumed as follows: •
Bucket Wheel Drive
100,000 hours
•
Conveyors (Boom, transfer, movable)
70,000 hours
•
Luff Mechanisms
30,000 hours
•
Slew Mechanisms
70,000 hours
•
Travel drives
30,000 hours
•
Other drives
20,000 hours
AA_SPEC_25400100.DOC
APPROVED
12 February 2008
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
4.6.4 4.6.4
Buc ket wheel and dri ve: the bucket wheel shall be of the cell-less type. The bucket wheel drive shall if necessary be provided with suitable mechanical and/or electrical devices to limit the torque in the gearbox and drive shafts so that no damage is caused when the wheel stalls from full speed.
4.6.5 4.6.5
Ball and rol ler bearings : rolling element bearings shall have a minimum modified L10 life commensurate with a total operating life for the stacker/reclaimer of 100,000 hours, operating continuously at the worst combination of load and speed. The modified L 10 life shall be calculated using the rating method of ISO 281.
4.6.6 4.6.6
Slew bearings : The slew bearing shall be designed to have the factors of safety for the failure modes listed below under the calculated load conditions. Classical Fatigue Spalling. The modified modified L 10 life shall not be less than 15 years under load case I load combinations. The modified L 10 life shall be calculated using the rating method of ISO 281. The experience and recommendation of the bearing manufacturer shall also be sought. Static Capacity or Brinelling. Brinelling. The maximum allowable allowable static load that a raceway can can carry shall be 1.5 times the static capacity (C o). The maximum maximum allowable allowable static static load shall be greater than 2 times the maximum calculated static load under load case III load combinations. The experience and recommendation of the bearing manufacturer shall also be sought. Core Crushing. Crushing. The static shear yield at certified certified strength shall be greater greater than 2 times the calculated sub-surface yield stress under load case II I load combinations. Certification of hardness profile and core tensile and yield strengths shall be submitted to the engineer within within 10 days of heat treating the raceways. raceways. Data for the certificate shall shall be obtained by processing a test bar of the same cross section from the same heat of steel along with the raceways and using the bar to determine hardening patterns and core properties.
4.6. 4.6.7 7
Plummer block s: shall have self aligning aligning bearings. bearings. Housings shall be cast steel or malleable iron. iron. Four holding down down bolts shall be be employed unless unless otherwise approved. approved. Pulley shaft bearings shall have one fixed and one floating bearing.
4.6.8 4.6.8
Plain bearings : shall be bushed with an approved SAE or British Standard leaded bronze in accordance with the requirements of BS 4480.
4.6. 4.6.9 9
Lubric ation system: Grease passage shall be available to all the lubricating areas.
4.6.10 4.6.10
Sealin Sealin g devic es: shall be designed for outdoor service in the presence of fine abrasive dust. Particular attention shall be given to bearing seals to prevent prevent ingress of moisture moisture and foreign material. Rolling element bearings and plain journal bearings shall have primary labyrinth and Neoprene Neoprene line contact seals. Plummer blocks shall be supplied supplied with multiple labyrinth labyrinth seals designed to receive adequate adequate lubrication lubrication grease. grease. Lubricated bearings shall have pressure relief holes to avoid seal damage and over lubrication. Felt or fibre packing shall not be used for dynamic seals.
AA_SPEC_25400100.DOC
APPROVED
12 February 2008
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Propriety equipment shall have sealing devices as recommended by the manufacturer for the duty and specified environment. 4.6.11
Shafts: less than 100mm diameter for non critical duty shall be ductile shafting to SANS 1431 Grade 300WA or 350WA. Shafts over 100mm diameter and shafts in critical areas shall be to BS 970 Part 2 Grade 826M40 with mechanical properties to BS 2772 Part 2 Grade 826M31 and comply with the following requirements: requirements: The shaft shall be designed to minimise the possibility of failure through corrosion fatigue, the maximum stress in the shaft during operation shall be below the fatigue regime for t he material. Shaft flanges shall be forged integral with the shaft, unless otherwise approved in writing by the engineer. Section changes shall have large fillets, with a radius of at least 10% of the shaft diameter. Fillets shall be polished. Shafts shall have a surface texture of Ra 0,8mm on bearing surfaces and shall be measured in accordance with the requirements of BS 1134.
4.6.12
Couplings: shall be rated for more than the peak motor torque or motor fault torque, which ever ever is the greater. Couplings shall provide provide for parallel, parallel, angular angular and axial misalignment misalignment of the shaft. Fluid couplings shall be used for drives over 7.5 kW and be fitted with a thermal, fusible plug.
4.6.13 4.6.13
Power trans mis sio n: sprocket drives are not permitted except with the approval of the Engineer. Pulleys (and sprockets if permitted) shall be attached to shafts using 'Ringfeder', 'Taperlock' or other approved locking devices selected with due regard to starting, stalling and pulsating torques. Pulleys (and sprockets if permitted) shall run true and be statically balanced, but not by the addition of masses by welding or the removal of parent material by drilling.
4.6.14 4.6.14
Gearbo Gearbo xes and gears: all gearing shall be rated for capacity in accordance with the appropriate standards of the American Gear Manufacturers Association (AGMA) using conservative interpretations interpretations of the Standards. For design checking purposes it shall be assumed that full load rated output power of the drive motor is applied to each gear gear wheel for the whole of the operational operational life. In the case of multiple or variable speed drives, the most unfavourable combination combination of load and speed shall be assumed to apply for the whole of the operating life. Spur and helical involute gearing shall be rated in accordance with AGMA.908-B89 and 2001-D04. In determining gear capacity using this standard, the following procedures procedures shall be adopted.
AA_SPEC_25400100.DOC
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
The effects of torsional torsional vibration shall shall be considered considered in rating the gearing. gearing. In no case however shall the level of torsional oscillation (p-p) exceed 40% of the average torque. In the case of epicyclic (or planetary) gearing stages where the load sharing principle is limited to a simple floating sun pinion, then an appropriate allowance shall be made for mal-distribution mal-distribution of torque between the planet pinions. pinions. This mal-distribution mal-distribution factor shall be appropriate to the geometry adopted but not less than a multiplier of 1.15 applied to the forces and torques calculated from a perfect load distribution within the planet system. Gearboxes shall be designed for outdoor mounting and resistant to the environmental conditions, i.e. rainwater, abrasive dusts, and shall operate without the addition of external cooling systems up to a bulk oil temperature temperature of 70°C. A metal plate shall be fixed fixed to the casing and indicate rating and lubricant required. The gear casing shall allow access for inspection and maintenance particularly sludge removal and shall be approved by the Engineer. Gear casings shall be tolerant of operating overload and erection forces without distortion. Casings shall be be steel or malleable malleable cast iron. Gear boxes shall be be free of weld splatter, metal debris and coated inside with an approved heat and oil resistant paint. Where natural convection is insufficient to remove heat from the gearbox, fans shall be provided. Fans shall be mounted on the reduction box arranged to be cleanable and not collect dust or rainwater. Fans shall operate efficiently efficiently for both directions directions of rotation of the gearbox. Means shall shall be provided provided to maintain the oil temperature temperature at the optimum especially at partial load. Oil seals shall be suitable for the lubricant, operating temperature, dust conditions, ambient conditions conditions and environment specified. Labyrinth seals seals shall be re-greasable. re-greasable. Oil seals shall withstand all pressure fluctuations within the gearbox due to blocked vents or temperature fluctuations. Vents shall have replaceable replaceable filters, unless unless otherwise approved. approved. Dessicant pots shall shall be used to prevent condensation in the gearbox where operating temperature is low or oil has a moisture affinity. Gearboxes shall have fill plugs, in line filters with pressure bypass (where applicable), drain plugs and a graduated graduated oil level indicator, all accessible accessible after installation. installation. No sight glassware allowed. Where applicable, magnetic plugs shall be included in the filter system or the drain plugs. The drain plugs shall be at the lowest possible position of the gearbox. Only input and and output shafts shall pass through through the casing. casing. External shafts shall be protected against corrosion corrosion and spillage. spillage. Gears shall be totally enclosed enclosed and splash or pressure lubricated. Load tests shall be conducted during commissioning commissioning (see Clause 6.0) at which time noise levels shall be measured and results approved by the Engineer. 4.6.15 4.6.15
Gear Gear accur acy/qualit y: the manufacture of the gears and gearboxes shall conform to the accuracy requirements requirements of the relevant AGMA standards.
AA_SPEC_25400100.DOC
APPROVED
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
The assumption used in the rating procedures for such matters as alignment, lead variations, profile profile error, shall be attained attained or surpassed in practice. practice. The Engineer shall shall approve the method of verification of gear rating, quality and accuracy within the approved drawing tolerances. 4.6.16 4.6.16
Gearbo Gearbo x bearing: where a gearbox is split across a bearing, the bearing shall be housed in a separate ring or cartridge. cartridge. Gearbox bearings bearings shall be of the ball or roller roller type and shall have a modified L 10 life commensurate with a life of 100,000 operating hours for the stacker/reclaimer equipment. The modified L 10 life shall be calculated using the rating method of ISO 281. For this life rating it shall be assumed that input to the gearbox is the most arduous combination of torque and speed when the drive motor is operating at full output.
4.6.17 4.6.17
Gearbo Gearbo x lub ric ation : gearbox oil circulation pumps shall be a type and configuration suitable for handling viscous fluids and provided with adequate net positive suction head to avoid cavitations and related related noise. The design viscosity for this purpose purpose shall be the viscosity of the bulk oil at start-up of the machine under the coolest operating conditions. The pump suction shall be designed for a low oil velocity, and be free of elbows and other restrictions to smooth flow. For the bucket wheel drive and other gearboxes mounted on luffing booms, the above requirement shall apply over the whole of the luffing range to the maximum and minimum angle limits.
4.6.18 4.6.18
Shaft mou nted gearboxes: shaft mounted gearbox/motor units of more than 250 kW rated power shall be flange and spigot mounted.
4.6.19 4.6.19
Drive base plates: motors gearboxes and couplings shall be mounted on a common fabricated or cast baseplate rigid in all directions to withstand the static and dynamic loading of motor/gearbox and transport/erection forces without excessive deflection about the mountings or connected shafting. shafting . Drive base plates shall be machined, unless otherwise agreed at the t ime of tender by the Engineer, shop set-up set-up and delivered assembled assembled where practicable. practicable. Cast iron shall be allowed to age for four weeks weeks before machining. Stress relieving shall shall be carried out after welding of fabricated baseplates. The number and size of fixing bolts for the baseplates shall be capable of withstanding all normal operating peak surge loads, be specified by the Contractor and approved by the Engineer.
4.6.20
Crawlers: shall be designed to permit ready inspection and replacement to wearing surfaces. They shall also be designed designed with jacking jacking steps at each end end of the crawler for ready installation of jack footing for removal of major components, including main equalisers, without having to excavate below the track pads. Lifting beams shall shall be provided for lifting the the crawler frame in two stages. stages. Support pads at at each side of the crawlers shall also be provided adjacent to the jacking point at each end of the crawler frame.
AA_SPEC_25400100.DOC
APPROVED
12 February 2008
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4.6.21 4.6.21
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Bog ie wheel(s): loads including operating wind loads and impact factors, but excluding lateral and vertical inertial forces from boom luffing shall be specified by the Contractor in tons/wheel together with the maximum rail loading in kg/m and be approved by the Engineer. The following shall shall also be specified by the Contractor Contractor and approved by by the Engineer. •
Sleeper centres
•
Laying tolerance
•
Maintenance tolerance
Structural stops shall be provided on each bogie such that in the event of a shaft failure the bogie cannot drop more than 45mm. Indication of failure shall be provided at the control cabin (see Clause Clause 4.11) to indicate wheel wheel and shaft failure. Rail scrapers which which embrace the rail crown shall be provided on both sides of each rail bogie. Balance beam pivots shall be provided with grading points to the high pressure sides. Buffers shall be provided to contact machine stops and shall be capable of bringing the machine to rest without exceeding the specified machine long travel deceleration rates with all the travel drives operating. Power required at each bogie shall be related to the most unfavourable distribution of bogie loads, including including wind effects. Reduction gearboxes gearboxes shall not be used without without the approval of the Engineer. Wheels of multiple wheel systems shall be carried in fabricated steel pivoted frames with all shafts equidistant and parallel to ensure equal load distribution to each wheel. Driving wheels shall be sufficiently numerous to allow acceleration, travel and braking without skidding under all specified operating conditions and configuration of the machine. The geometry and drive configuration shall be arranged to prevent crabbing on both high speed and low speed operation. Maximum lateral wheel loads due to skewing shall be submitted at time of tender for approval. 4.6.22
Wheels: shall be steel, double flange parallel tread type conforming to the requirements of BS 3037. Tread hardness hardness shall be 320 Brinell Brinell minimum. minimum. Coefficient of friction to be used in calculations shall not be less than t he following: •
Static friction between drive wheel and rail 0.2
•
Sliding friction between locked wheel and rail 0.12
•
Rolling friction between idler wheel and rail 0.02 (including the effects of bearings bearings and seals).
AA_SPEC_25400100.DOC
APPROVED
12 February 2008
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4.6.23
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Brakes: all travelling equipment shall be equipped with service brakes capable of operating in both directions, designed to stop and hold the machine on an incline of 1 : 10 in all climatic conditions with the wind blowing down the incline in the direction of travel at the specified velocity and with the machine slewed (where applicable) to present the maximum profile to the wind. The specified velocity shall be the maximum regional basic wind speed in the area of deployment deployment for a 50-year mean return period (See Clause 4.3.2). The brake system shall be capable of stopping the machine in the event of failure of the traverse drive, i.e. the brake system shall be designed as a stopping brake system without any electrical retardation via the drive unit. Brakes shall be of the drum or disc type and shall be rated at a minimum of 200% of full load motor torque. torque. Brake actuation shall shall be by spring or counterweight counterweight compression compression and hydraulic or electromagnetic electromagnetic release such that that the brake fails 'on'. Brake shoes shall shall be self-aligning, self-aligning, non binding and easily replaceable. Crawler mounted equipment shall be provided with holding brakes and all rail mounted machines shall be provided with rail clamps. Rail clamps shall be activated automatically by the cup anemometer when the wind speed exceeds that for the local local 50-year mean return period. period. Clamps shall apply apply a balanced, balanced, horizontal pressure to the rail head.
4.6.24 4.6.24
Conveyor dri ves: shall consist of an electric motor driving through a fluid coupling and totally enclosed reduction gear boxes mounted horizontally and directly coupled to the conveyor pulley by a flexible coupling. The whole assembly shall be mounted on a common base plate. plate. Bevel helical helical type type gearboxes gearboxes shall shall be used. Hold-backs shall be be installed on all inclined inclined conveyors conveyors and rated 150% 150% of full load motor motor torque. Electric motors shall be capable of starting at 125% of fully loaded belt capacity and six starts per hour. Speed reducer service service factor shall be be not less than 1.25.
4.6.25 4.6.25
Conveyor pul leys: shall be fabricated in accordance with AA Specification 371001. Eccentricity of the pulleys pulleys shall not exceed exceed 4mm TIR. Pulleys shall not not be welded or thermally shrunk onto the the shaft. Pulley surface shall have a crowned crowned profile. Pulley diameter shall be compatible with the belt construction, thickness and shall be approved by the Engineer. Drive pulleys shall shall be lagged with an approved approved lagging.
4.6.26 4.6.26
Conveyor belti ng: shall be either textile reinforced in accordance with the requirements of SANS 1173 or steelcord in accordance accordance with the requirements requirements of SANS 1366. The belt width, rating, construction, cover material and top and bottom cover thickness shall be suitable for the application and environment, specified by the Contractor and approved by the Engineer. Belt stretch under full load condition shall be guaranteed at not more than 2% of belt length for textile reinforced reinforced belt. Belt stretch for steelcord steelcord belt shall be guaranteed guaranteed at not not more than 0.25%.
AA_SPEC_25400100.DOC
APPROVED
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4.6. 4.6.27 27
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Conveyor troug hing idlers: shall be one or both of the following: Rigid type: shall conform to SANS 1313-1 and to AA Specification 373001. 373001. Idler rolls shall be mounted on metric series deep grove ball bearings sealed with labyrinth type seals applicable to the working working environment. environment. Bearings shall shall be grease grease packed 'lubricated for life' assemblies. assemblies. The same type of bearing shall be fitted to all rolls. Suspended type: the rolls shall be in accordance with requirements of SANS 1313-2 and AA Specification 373001. The type of suspension arrangement arrangement shall be submitted by the Contractor for approval at time of tender.
4.6.28 4.6.28
Conveyor belt take-ups: take-up devices shall be gravity, hydraulic type or electric winch with load cells. Gravity take-ups shall be provided with a means to restrict travel in order to arrest the assembly in the event of belt breakage. Hydraulic take-ups shall be provided with load measuring devices to ensure a constant tension in the belt. The minimum take-up distance provided shall be 2.5% of the conveyor belt length between head and tail pulley centres plus 500mm.
4.6.29 4.6.29
Conveyor belt tr aining : tilted carrying idlers may be fitted on belts which run in one direction only. On short reversible belts crowned crowned head take-up pul pulleys leys shall be used. Belt training may be aided by special training idlers, swivel idlers are not permitted. Acceptable idlers are 'V' form, negatively troughed idlers on return side of belt sited immediately prior to the tail pulley.
4.6.30 4.6.30
Conveyor belt cleaners: belt cleaners of an approved design shall be provided at the head pulley. Ploughs shall be provided on the return belt to prevent material entering pulley nip points.
4.6.31 4.6.31
Conveyor win d boards : shall be provided on both sides of the conveyor belt where required.
4.6. 4.6.32 32
Transfer Transfer chutes and and skirts : chutes shall be designed to accommodate material trajectory and build up. up. The transfer points shall shall have a material flow flow at the receiving belt belt in the same direction direction as that of the belt travel and and fed at a low angle angle of trajectory. Chutes shall incorporate an easily replaceable impact plate in the position dictated by the material trajectory. Chute liner plates plates shall be secured secured by bolting the chute structure, securing securing bolts shall be counter-sunk counter-sunk to a depth equal equal to the maximum permissible permissible wear. Chute volume shall be be adequate to accommodate accommodate run-down run-down capacity. Skirt length shall shall allow material to settle on the belt without spillage, be specified by the Contractor and approved by the Engineer. Chutes and skirt plates shall shall be of 8mm thick mild steel steel plate suitably reinforced and lined with a minimum of 10mm thick abrasion resistant steel plate (500 HBN) or approved equivalent at points in direct contact with the main stream of materials and with 4mm thick polished Grade 314 stainless steel for dribble chutes from pulley scrapers. Details of wear plates shall be included included in the tender.
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4.6. 4.6.33 33
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Winch and wire rope systems: where a control cab is supported by wire ropes the equipment and wire ropes shall conform to the requirements of the South African Mines and Works Act. Wire ropes shall be 'over lay', fibre core and galvanised with provision for external lubrication and cleaning. cleaning. Ropes shall not be ultra-high ultra-high tensile and shall not have reverse reverse bends. Thimbles for wire ropes shall shall conform to the requirements of EN 13411-1. 13411-1. Rope termination design shall be submitted by the Contractor at time of tender for approval. Winch drums shall be spiral grooved and have capacity to spool the maximum required rope length in one layer, have a wrapper plate and a minimum of six dead turns. Where two ropes are wound on one winch drum it shall have right and left hand spiral grooving and ropes layed to suit. suit. Winch drum bearing bearing details shall be submitted submitted by the Contractor Contractor at time of tender for approval. Wire rope sockets shall be in accordance with the requirements of AA Specification 288002. Brakes shall have the required thermal thermal capacity. Brakes shall be capable of stopping stopping in overspeed conditions and 150% maximum torque (including plugged chute) and be capable of halting the associated movement to a smooth stop from all loads and speeds. Safety circuits shall be provided to achieve fail safe conditions and stop the machine in the event of brake or rope failure. The emergency brake operations shall be interlocked through an adjustable timer such that the emergency brake shall be applied after a given time from application of the service brake. When an overspeed overspeed condition is detected in excess excess of 125% of normal speed, both operating operating and emergency emergency brakes shall apply apply simultaneously. simultaneously. Brakes shall operate to ensure that there are never less than six full turns of rope on the winch drum. Safety circuits shall be provided to achieve fail safe conditions and stop the machine in the event of brake or rope failure. Winches shall be mounted on rigid steel frames capable of withstanding all forces which may occur. Each winch shall be provided provided with a dual braking system as follows: follows: Emergency brake operating on the low torque side of the reducing gear. Normal service brake operating operating directly on the winch winch drum. It shall be capable of being being manually applied and released at the winch. Winches shall have drum anchorages suitable for reverse winding. Sheave wheels shall be generally in accordance with the requirements of AA Specification 281011. Sheaves shall be standard sizes to facilitate replacement and shall have adequately sealed rolling element bearings. The sheave design and bearing data shall be submitted for approval.
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4.6.34 4.6.34
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Hydrauli c sys tem: pressures shall be a maximum of 13.7MPa and be fitted with trip control pressure gauges. gauges. The use of flexible lines shall shall be kept to a minimum and shall conform to the requirements requirements of EN 853 or EN 856. Adequate safety provisions provisions shall be provided for the event event of component or reticulation reticulation element element failure. Components Components which carry a sustained load load shall be of zero zero leak design. Hydraulic piston piston motor systems on hoists shall be arranged so that the motor cannot be starved of oil even with the electrical power cut off for prolonged periods. periods. A mechanical brake shall shall be included in this type of system. Cylinders shall be designed designed to hold or release release under control control for all loads which may occur in either direction. direction. Hydraulic systems systems for hoisting or luffing shall shall be equipped with lock valves. Overhung loads carried on shafts of hydraulic motors or pumps shall be included when computing the allowable working working pressure difference. Motor and pump pump units shall be mounted on a common bedplate, in turn be mounted on anti-vibration mounts and have drainable drip trays. The hydraulic reservoir, electric motor and pump shall be housed in a separate, ventilated room or enclosure. Oil reservoirs shall be protected from the effects of moisture condensation condensatio n and corrosion within the tank. Reservoirs shall be positioned to provide a positive head feed feed to hydraulic pumps. pumps. Fluid level switches, switches, over temperature temperature switches, heaters or desiccants and a means for completely draining the reservoir and the system shall be provided. provided. Reservoir breathers breathers shall either be closed closed circuit or shall be be equipped with replaceable replaceable desiccant type filters of adequate capacity. capacity. Means of air bleeding of the system shall be provided provided where necessary. necessary. Bleeding points points shall be readily accessible. accessible. Bleeding sequences shall be fully specified in instruction documents and approved by the Engineer. Oil filters shall be of the 'tell tale' type, accessible accessible and readily readily replaceable. replaceable. Oil shall be filtered in accordance with the component manufacturers' requirements and all make up oil shall be filtered into into the reservoir. Oil temperature measured measured at the hottest area in the oil reservoir shall not exceed 50°C. The oil type and viscosity to Anglo American code shall be clearly and permanently marked on a plate and and secured to the reservoir. reservoir. Valves shall be fitted fitted to manifold blocks. blocks. Pipe connections connections shall be welded. The use of breakable fittings shall shall be compatible with the hydraulic fluid specified.
4.6.35 4.6.35
Flexibl e hos e assembl ies: shall have swaged end fittings with female running nuts at each end and shall be in accordance with accepted international standards and installed in accordance with manufacturer's recommendations giving particular attention to the following: Motion shall be in one plane plane and torsional torsional stresses avoided. avoided. Rubbing against against other hoses, machinery machinery or structures shall shall be avoided. Minimum recommended recommended radii radii shall be used. Support in thrust and compression compression shall be provided and and flexing distance shall be considered. Pipework shall be as specified by the Contractor Contractor at time of tender tender for approval. Pipework shall be adequately supported and securely fixed immediately before and after a bend or off set. Pipework shall conform conform to the requirements of the following following standards:
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
•
BS 778
Steel pipes and joint for hydraulic purposes
•
EN 10220
Seamless and welded steel tubes. Dimensions and masses per unit length
•
BS 1710
Identification of pipelines
•
BS 4368-1
Metallic tube connectors for fluid power and general use. Split collet compression fittings.
Pipe supports shall incorporate suitable vibration damping material and the support assembly shall shall not damage the pipe. Accumulators shall shall have provision provision to: positively positively isolate the hydraulic system from banks of accumulators, automatically vent on system shutdown except except where power conservation conservation or standby supply is required. Ready access to filling points and for component maintenance maintenance and replacement shall be provided. 4.6. 4.6.36 36
Lubric ants: shall confo rm to the applicable Anglo American Specifi Specifi cations. Oil lubricated machinery shall be delivered to site without oil and the interior surface of all oil containers painted painted with approved oil corrosion corrosion and heat resistance coatings. coatings. These units shall be cleaned with an initial charge of the correct grade of lubricating oil, drained and refilled with the correct grade of lubricating oil by the Contractor on site. Oil pumps shall incorporate a replaceable oil filter and oil pressure gauge to measure the pressure drop across the filter and shall include include a fill plug and oil level indicator. indicator. Vents to atmosphere shall be covered by a replaceable filter of adequate capacity. Hand lubrication lubrication shall be restricted to those points which require require infrequent greasing. greasing. All points where frequent lubrication is required shall be connected to an automatic system. Lubrication pumps, control equipment and lubricant reservoirs for this system shall be housed in dust proof enclosures and equipped with adjustable timing devices and malfunction alarm systems. Distributors shall be standardised, in a visible position and replaceable without removing other components. The number of points to be lubricated automatically or by hand shall be nominated by the Contractor. Attention shall be given to minimising the number of different types and brands of lubricants to be used.
4.6.37
Maintenance: Moving parts of the machine shall be readily accessible for inspection, maintenance and and replacement. Heavy items (motors, gearboxes, gearboxes, winches, sheaves etc.) etc.) shall have adequate lifting equipment and winches, or monorails suitable for use with manual hoists. The reach of monorails or fixed lifting equipment shall enable components to be lowered on to platforms or ground in a position accessible to mobile cranes operating at ground level. For small, elevated elevated items cantilever cantilever frames shall be provided. provided. Jacking points shall be provided provided where appropriate. appropriate. Attention shall be paid paid to the lateral access to equipment for dismantling and re-assembly.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Special service tools required shall be provided and clipped into a lock-up tool store located on the machine. Switched power outlets for welding and hand equipment shall be provided at rail track bogie and at machinery levels. Maintenance schedule recommendations shall be provided by the Contractor at the time of tender for approval. 4.6.38
Spares: recommended Spares: recommended spares and material lists covering the following categories shall be provided by the Contractor. Commissioning: spares and engineering materials required or consumed during commissioning commissioning of each machine. Consumables: spares and engineering materials which it is predicted will be required or consumed in the first two years of operation of the machine(s) assuming a production rate equal to the full specified production production capacity of each machine. This data shall be based based on experience of the Contractor of similar equipment in similar environments. Insurance: spares which it is recommended should be held (in addition to above) in order to minimise long delivery delivery of spares. Manufacturers or suppliers suppliers shall be identified identified by the Contractor for each insured spare. Local suppliers shall be identified at time of tender for approval.
4.7
STRUCTURAL
4.7.1 4.7.1
Struc tur e desig n: n: the structure and components shall be designed in accordance with the requirements of ISO 5049-1 Part 1. The following clauses of ISO 5049-1 Part 1 shall be amended as follows: Section 3.1.2.1.1b) second paragraph to read – the cross-sectional area shall be determined assuming the belt loaded to overflowing with material at maximum surcharge angle. Section 3.1.6.2 – the third paragraph to be deleted (i.e. the inertia forces always to be taken into account, irrespective of the number of cycles). Section 3.1.8 first paragraph to read – Metal flooring, stairways, ladders, platforms and hand railing shall be designed according to the SA Steel Construction Handbook. In countries other than South Africa the applicable local standards shall apply. Section 3.2.1 the following shall be added – The in-service (operating) design wind speed shall be as agreed with the client. The out-of-service design wind speed shall be the regional basic wind speed V in Figure 3, under Section 5.5.2.2 of SANS 10160. Figure 3 in SANS 10160 gives values of V for a 50-year mean return period, and the minimum value is 40 m/s. In countries other than South Africa the applicable local data shall apply. Section 9.1 - for the purposes of structural and stability calculations the calculated inertia forces shall be scaled by a factor 1.5, and the out of service wind speed shall be used.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Special Loads as specified in Section 3.3 of ISO 5049-1 Part 1 shall include the following additional cases. •
•
•
End-on collision of boom. Loss of bucket wheel. Consider Consider loads 3.1.1 (excluding the bucket bucket wheel), 3.1.2 (excluding the material load normally in the bucket wheel), 3.1.3, 3.1.5, 3.1.6 (relevant components) 3.1.7 and 3.2.1. Loads during maintenance. maintenance. Loads to be considered are those those imposed imposed on the machine during maintenance when parts of the structure or machinery might be removed or their support might be altered.
The overall design and that of all critical or sensitive structural areas shall be submitted to the Engineer for review. review. The Contractor shall shall give every assistance assistance but any survey survey shall not relieve the Contractor of responsibility responsibility for the design. Structural details in the areas of fluctuating stresses shall be designed to minimise stress concentrations. Structural connections connections shall, wherever wherever practical, be positioned positioned away from highly stressed area. All main and critical components of the structure shall be assessed for their loaded and unloaded natural natural frequency to ensure ensure no resonance resonance problems occur. occur. This data shall be be supplied by the Contractor and approved by the Engineer. Access shall be provided for maintenance on major components and jacking points provided to assist in the maintenance of components subject to frequent replacement. The structure shall be designed to minimise dirt and water collection points. Equipment loads shall be transferred to the track through a number of three point support systems. 4.7. 4.7.2 2
Structur al fabrication: welder qualification, fabrication, inspection and acceptance criteria shall be in accordance with the requirements of AWS D1.1. Structural steel shall not be located closer to the edge of a conveyor belt than 150mm with the belt in the central position. Welding procedures shall be supplied by the Contractor at time of tender for f or approval. The welder qualifying authority shall be the SAIW or approved organisation and shall be included in the tender. Welds between the circular diaphragm and the rail pad of a slew bearing shall consist of full penetration butt welds welds with large fillets and ground ground to a smooth profile. These welds shall be 100% ultrasonically ultrasonically tested and test results shall be submitted for approval. approval. Weld spatter shall be cleaned off the platework and welds dressed to obtain a clean finish. Where joints occur or where liner plates are bolted on the welds shall be dressed level with the platework. A weld strikeplate shall be provided provided on the equipment. equipment.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Welds, joining components of thickness 75mm and greater, or of complex configuration, shall be the subject of large scale diagrams on the working drawings showing fit up and clearances. References shall be given given from such diagrams diagrams to approved weld procedures procedures in each case. The Contractor shall ensure that items being welded are earthed directly to avoid possible damage to equipment that is adversely affected by the passage of current, e.g. bearings. Where possible bearings and electrical equipment shall be installed after welding is complete. Site welding shall only be carried out with the approval of the Engineer and shall be done under supervision of a qualified welding supervisor provided by the Contractor. The Engineer may may elect to take radiographs radiographs of up to 10% of the length length of site welds. welds. If such radiographs show defects, the weld shall be ground out and the components rewelded and re-radiographed re-radiographed by the Contractor Contractor free of charge. The Contractor shall bear bear the cost of radiographs. Grinding, re-welding re-welding and radiography shall shall continue until a set of radiographs shows satisfactory welds welds throughout throughout the test lengths. Only two repairs shall be allowed in any any defective area. The Engineer may, may, if deemed necessary, call call for up to 100% radiography. Connection of monorail and crane runway beams to the machine structure shall be made with High Strength Strength Friction Grip Bolts. Where bolted joints joints are required required the bolt spacing spacing shall be a maximum of 16 times the thickness of the thinnest thinnest flange. If mounting holes are not in alignment alignment they shall be reamed reamed out. Flame cutting is not not permitted. The angle between the bolt axis and the surface under the rotating component (i.e. bolt head or nut) shall be 90°+ 90°+ or - 3°. For angles outside these these limits a tapered washer washer shall be correctly positioned. Handling of fabricated fabricated platework shall ensure that distortion distortion or damage is avoided. avoided. Use shall be made of lifting eyes or hooks where these are provided on the platework. Damaged surfaces shall be treated as per the corrosion protection section of this specification (see Clause 4.10). Alignment of all mechanical and structural components will be subject to the Engineer's inspection. At least seven days prior notification that inspection inspection is required shall shall be given in writing to the Engineer. Platework shall be tested for dust tightness to the satisfaction of t he Engineer.
4.8
C ASTINGS
4.8.1 4.8.1
Carbo Carbo n equiv alent: castings to which connections are welded shall have a carbon equivalent (C.E.) (C.E.) not greater than 0.44%. 0.44%. When calculated calculated as follows: C.E. = C + Mn + Cr + Mo + V + NiCu 6
AA_SPEC_25400100.DOC
5
5
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
4.8.2 4.8.2
Non-destru cti ve examinati on: all critical areas of castings, including abrupt changes in section and areas to be machined shall be magnetic particle tested using the procedures of EN 1369. In addition, the complete surface of each casting casting shall be examined visually visually to EN 12454, and shall be free from cracks, hot treats, gross porosity, shrinkage and sand inclusions. Machined areas shall be retested retested after rough machining. Magnetic particle inspection shall be carried out in accordance with the requirements of AAC Specification Specification 999000 on all all Critical and Major Major castings.
4.8.3 4.8.3
Defect Defect repair: shallow defects shall be ground out and blended into sound metal to a maximum depth of 10mm or 25% of section thickness, whichever is the smaller. Confirmation that the defect has been fully removed shall be made using magnetic particle or dye penetrant testing. Weld repairs of larger defects shall be made using an approved welding procedure and welders qualified qualified to ASTM A488. All weld repairs shall be subjected subjected to a stress relief heat treatment. Defects with depth greater greater than 15% of the section section thickness shall be be cause of rejection. No repair welding or stress stress relief shall be conducted after final machining. machining. The weld repair procedure shall be submitted for approval at time of tender. All weld repairs shall be surface crack crack tested in accordance with AA Specification Specification 999000. All indications greater than 5mm in length shall be ground out and blended into sound metal. Larger defects shall shall be re-welded re-welded subject to approval. approval.
4.8.4 4.8.4
Dimensio ns and tol erances: all dimensions of cast components after final machining shall be in accordance with the Contractor's drawing tolerances.
4.8.5 4.8.5
Loc al hardenin g: where wearing surfaces of sheaves and rope drums are locally hardened, limited limited surface crazing shall be permitted. permitted. The hardened surfaces surfaces shall attain the values specified by the Contractor.
4.9
FORGINGS
4.9. 4.9.1 1
Non destruct ive examination examination Critical items UT to be in accordance with the requirements of EN 10228-3 for volumetric examination, M.P.T. to be in accordance with the requirements of EN 10228-1 for surface examination. Acceptance criteria criteria to AA Spec 999000. 999000. Major Major items As critical items. Minor items M.P.T. to be in accordance with the requirements of EN 10228-2 and acceptance criteria to AA Specification 999000.
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4.9.2 4.9.2
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Defect Defect repair: No repair welding shall be permitted on forgings. Minor surface defects shall be dressed out by careful grinding and blending into sound metal. Repair welding welding of surface defects defects is generally not not permitted. Details of all defect repairs to be undertaken by the Contractor shall be submitted to the Engineer for prior approval.
4.9.3 4.9.3
Dimensio ns and tol erances: all forgings shall be visually and dimensionally inspected before machining.
4.10
CORROSION PROTECTION
4.10.1
General: surface preparation and corrosion protection of steelwork and equipment shall be in accordance with the requirements of AA Specification 164000 and AA Specification 164050. Galvanising shall be in accordance with the requirements of SANS 121. The finish coat colour schedules for the equipment shall be specified by the Engineer.
4.11
S AFETY
4.11.1
Controls: all controls shall be fail safe and in the event of a power interruption brakes and rail clamps shall set, all motions arrested and positions prior to power failure shall be retained. Hydraulically Hydraulically controlled equipment shall maintain maintain position position in the event of pressure failure. failure. Manual restart of of the system shall shall be required required on restoration restoration of the supply.
4.11.2
Guarding: guards capable of supporting 100kg mass shall be provided for all couplings, gears, pulleys, conveyor nip points, tensioning equipment and moving machinery. Guards shall be securely securely fixed in position. position. Fixing shall be such that that the use of a hand tool is required for their removal. removal. Removal and replacement replacement of individual individual sections sections of guards shall not require disturbance of other guards. Guards shall be either perforated or solid construction. If perforated it shall not be possible for a persons to pass a hand through the openings. Guards shall conform to EN 593. Conveyors shall be equipped with guards that also comply with AAC Specification 375001.
4.11.3 4.11.3
Rail Rail clamp s: shall be kept released released during normal normal operations. They shall set immediately immediately in the event of a power failure or the operation of the emergency emergency stop system. Rail clamp interlocks shall prevent power being supplied to the traverse drive while the rail clamps are engaged.
4.11.4
Access: to and from the ground to the operator’s position or cab shall be possible with the machine in all operational operational positions. positions. The maximum angle angle to horizontal of any stairway stairway shall be 40° and ladders shall be provided with back protection. Walkways shall be provided on both sides of conveyors and be accessible from ground level on both sides.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
Access shall conform conform to the following: following: Access to points that are essential for operation and maintenance shall be safely and conveniently reached 4.11.5 4.11.5
Aud ibl e alarms: an audible alarm shall be mounted in the machine and be operable from a push button on the control panel as well as being automatically actuated 10 seconds prior to start-up of the conveyors. conveyors. Each device that controls a conveyor conveyor shall operate operate into the warning system circuit in such a manner that the warning alarm shall actuate each time the conveyor starts. The alarm shall sound until until cancelled by the operator.
4.11.6 4.11.6
Emergency pul l-cor ds: an emergency stop pull-cord shall extend the full length of each conveyor on the accessible side side or sides. The associated switches shall latch latch in the off position, have indicating flags and be mounted so as to be readily accessible for resetting. These shall stop the the associated conveyors. conveyors. A similar emergency emergency stop pull-cord, pull-cord, readily readily accessible from ground level, shall extend the full length of each motorized rail bogie system. All emergency pull pull cords shall switch switch on the alarm. alarm.
4.11.7 4.11.7
Belt tear: a belt tear device shall be fitted to all conveyors with a means of indication in the control position.
4.11 4.11.8 .8
Fire detection and protecti on: a fire extinguisher shall be provided in the control cab and near the door of each each electrical equipment equipment room. The extinguisher shall shall be 9kg, dry powder type and conform to the requirement of SANS 1910 and AAC Specification 762005. A fire detection and alarm system shall be installed that conforms to SANS 50054.
4.11.9 4.11.9
Wheel Wheel and shaft failu re: means re: means of indication shall be provided in the control position to indicate wheel and shaft failure.
5
QUALITY QUAL ITY ASSURANCE ASSURA NCE PROVISIONS Shall be in accordance with the requirements of AA STD 100.
6
TEST AND INSPECTION METHODS
6.1
GENERAL All materials, structural, mechanical and electrical, shall be tested and inspected but not limited to the requirements of the applicable standards and specifications.
6.2
TESTS L OAD A ND OPERATING TESTS
The Contractor shall conduct the following load and operating tests and shall notify the Engineer when when the equipment equipment is ready for for such test. The Contractor shall submit submit the results of all tests to the Engineer. The cost of these tests shall be for the Contractor’s Contractor’s account. If the equipment fails any of the tests specified, the test shall be repeated at the Contractor’s expense until the equipment meets the requirements of this specification and the requirements of the contract document.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
The Contractor’s work shall be considered acceptable upon demonstration of the following, as applicable to the equipment. 6.2.1
Inspect: and adjust the movements of all mechanical and electrical parts and equipment.
6.2.2
Test: all protective devices. devices .
6.2.3
Balance: the Balance: the equipment to determine the centre of gravity and the ballast weight.
6.2.4 6.2.4
Posit ion and operate: the material handling system for at least three consecutive shifts and establish, to the satisfaction of the Engineer, that the material handling system is capable of operating under load.
6.3
TRUCTURAL STRUCTURAL
6.3.1 6.3.1
Static test: load the boom with the following:
TESTS
Conveyor load: equivalent equivalent to belt filled to overflowing with material. Encrustation load at the boom tip equal to the weight of a 120 mm thick layer of material on the boom and if applicable the centre of the bucket wheel, considered as a solid disc up to the cutting circle. If applicable, live loads in 80% of the total number of buckets being 100% full with material. If applicable, encrustation load on the drum equal to a weight of a 12 mm thick layer of material. If applicable, live load in the reclaim discharge chute equivalent equivalent to the chute being filled to the brim with material. If applicable, simulated vertical digging force equal to the maximum digging force (theoretical) obtained from the rating of the bucket wheel or drum drive motor, the efficiency of the transmitting gear and the speed of the cutting edge. 6.3.2 6.3.2
Dynamic test : with the static test loads acting carry out the following: Lower and raise the boom through the t he full luffing range. Increase and decrease the shuttle conveyor run to its full limits. Slew the boom through the full slewing range. If applicable rotate the drum through more than 360°. Assess the equipment’s equipment’s ability to travel travel at creep speed. speed.
6.3.3 6.3.3
Wheel Wheel load measurement: during the dynamic test (see Clause 6.3.2) the wheel loads shall be measured and recorded. The boom(s) shall be in positions that cause maximum and minimum wheel loads. The Engineer shall supply material for the execution of these tests. The Contractor shall supply sandbags for the additional loads.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
6.3.4 6.3.4
Jacki ng to determi ne the mass and balance of the structure supported by the slew ring shall be carried out in one operation under dead load only after erection is complete .
6.4
GEAR REDUCERS Test runs for the gear reducers shall be conducted under no load conditions for a period of 24 hours, using recommended oil and supplied by the Contractor for in-service running. During the test runs, the Contractor shall record the ambient temperature, bulk oil temperature and high speed shaft bearing temperature. The Engineer may at his discretion require that the high speed bearing temperatures be measured by transducers in direct contact with the side of the stationary races of the rolling bearings. The costs of any tests tests shall be borne borne by the Contractor. Contractor. The Contractor shall also bear bear the costs of any dismantling required to establish that permissible contact patterns and backlash have been obtained. Noise levels shall be measured (and the results approved by the Engineer) with gearboxes operating under load.
7
PACKING AND MARKING
7.1
P ACK ING The method of packing shall protect all the equipment against damage and the effects of climatic conditions during transportation and storage. All parts shall be transported in as large a unit as practicable practicable but within the limits specified by Provincial Road regulations. Components shall be adequately labelled and boxed in crates of closed wooden construction, lined with with waterproof material. material. The crates shall be reinforced reinforced and bound on all sides. Machined surfaces shall be protected from corrosion and damage during transportation and storage. Spare parts shall be packed separately separately in containers for long term storage. They shall be boxed individually individually or in kits to be used in one single renewal renewal or overhaul operation. operation. Other spare parts or kits shall not be disturbed disturbed when using one set set or kit. For the convenience of export shipping more than one set of spare parts may be packed in one single crate or case. Prior to the first shipment the Contractor shall send to the Engineer a complete packing list for the equipment to be shipped. shipped. This packing list shall contain contain but not be limited to the part or equipment reference, drawing number number and quantity.
AA_SPEC_25400100.DOC
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7.2
AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
M ARK ING Spare parts shall be plainly marked ‘Spare Parts Only’ and clearly identified by stamped markings on screwed screwed on metal plates. Each part of the equipment equipment shall be legibly marked marked to show the unit of which it is part and match marked to show its relative position in the unit for easy assembly. Specific lifting points shall be clearly marked on the crates. All wording on on labels and crate markings shall be be in English. A packing list indicating the contents of each container shall be furnished in a moisture proof envelope securely securely fastened to the outside of the container. container. A copy of this packing list shall be included in the operation and maintenance instructions.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
APPENDIX A : RELATED RELA TED DOCUMENTS DOCUMENTS Unless otherwise specified the latest issue of the following documents are deemed to form part of this specification. AA STD STD 100
:
Quality Quality Manag Managemen ementt Systems. Systems.
AA Specifi Specificatio cation n 64000 64000
:
Users guide guide for corrosion corrosion preventio prevention: n: System System select selection. ion.
AA Specifi Specificatio cation n 371001 371001
:
Conveyor Conveyor pulleys pulleys and and shafts. shafts.
AAC Speci Specificati fication on 164050 164050
:
Corrosio Corrosion n protecti protection on of steelwork steelwork with coatings coatings
AAC Speci Specificati fication on 281011 281011
:
Elevator Elevator equip equipment: ment: Cast steel sheave sheave wheels wheels
AAC Speci Specificati fication on 28800 288002 2
:
Wire rope sockets sockets for draglines. draglines.
AAC Speci Specificati fication on 373001 373001
:
Belt conveyor conveyor idlers idlers and rolls. rolls.
AAC Speci Specificati fication on 375001 375001
:
Guarding Guarding of belt belt conveyo conveyors rs
AAC Speci Specificati fication on 762005 762005
:
Fire extinguish extinguishers ers
AAC Speci Specificati fication on 999000 999000
:
Non-destr Non-destructiv uctive e testing. testing.
AGMA 908-B89 908-B89
:
Geometry Geometry Factors Factors for Determini Determining ng the Pitting Pitting Resistanc Resistance e and Bending Strength of Spur, Helical and Herringbone Gear Teeth
AGMA 2001-D04 2001-D04
:
Fundamen Fundamental tal Rating Rating Factors Factors and Calculati Calculation on Methods Methods for Involute Involute Spur and Helical Gear Teeth
ASTM E45
:
Standard Standard test methods methods for the determining determining of the inclusion inclusion content content of steel.
ASTM A275M-06 A275M-06
:
Standard Standard Test Method Method for Magnetic Magnetic Particle Particle Examinati Examination on of Steel Steel Forgings
ASTM A488
:
Standard Standard Practice Practice for Steel Castings, Castings, Welding, Welding, Qualificat Qualifications ions of Procedures and Personnel
AWS D1.1 D1.1
:
Structural Structural welding welding code code – Steel. Steel.
BS 778
:
Steel pipes and joints for hydraulic purposes.
BS 970 Part 2: 1970
:
Wrought steels in the form of booms, billets bars and forgings.
BS 1134
:
Assessment of surface texture.
BS 1710
:
Identification of pipelines.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
BS 2772 Part 2:1989
:
Colliery haulage and winding equipment. Specification for wrought steel
BS 3037
:
Double-flanged Double-flanged parallel tread tyres.
BS 4368-1:1998
:
Metallic tube connectors for fluid power and general use. Split collet compression fittings.
BS 4480 Part 1:1992
:
Plain bearings, metric series.
EN 593:1998
:
Safety of machines. Guards. General requirements for the design and construction of fixed and movable guards.
EN 853:1996
:
Rubber hoses and hose assemblies. Wire braid reinforced hydraulic type. Specification
EN 856:1996
:
Rubber hoses and hose assemblies. Rubber-covered Rubber-covered spiral wire reinforced hydraulic type. Specification
EN 1369:1996
:
Founding. Magnetic particle inspection
EN 1371-1:1997
:
Founding. Liquid penetrant inspection. Sand, gravity die and low pressure die castings
EN 10220:2002
:
Seamless and welded steel tubes. Dimensions and masses per unit length
EN 10228-1:1999
:
Non-destructive inspection
EN 10228-2:1998
:
Non-destructive testing of steel forgings. Penetrant testing
EN 10228-3:1998
:
Non-destructive testing of steel forgings. Ultrasonic testing of ferritic or martensitic steel forgings
EN 12454:1998
:
Founding. Visual examination of surface discontinuities. Steel sand castings
EN 12680-1:2003
:
Founding. Ultrasonic examination. Steel castings for general purposes
EN 12680-2:2003
:
Founding. Ultrasonic examination. Steel castings for highly stressed components
EN 12680-3:2003
:
Founding. Ultrasonic examination. Spheroidal graphite cast iron castings
EN 12681:2003
:
Founding. Radiographic Radiographic examination
AA_SPEC_25400100.DOC
APPROVED
testing
of
steel
12 February 2008
forgings.
Magnetic
particle
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
EN 1559-2:2000
:
Founding. Technical conditions of delivery. Additional requirements for steel castings
ISO 4992-2:2006
:
Steel castings. Ultrasonic examination. Steel castings for highly stressed components
EN 1011-8:2004
:
Welding. Recommendations Recommendations for welding of metallic materials. Welding of cast irons
EN 10293:2005
:
Steel castings for general engineering uses
EN 13411-1:2002
:
Terminations for steel wire ropes. Safety. Thimbles for steel wire rope slings
FEM 2.131/2.132
:
Rules of the design of mobile equipment for continuous handling of bulk materials
ISO 281:2007
:
Rolling bearings – Dynamic load ratings and rating life.
ISO 5049-1-1994
:
Mobile equipment for continuous bulk materials – Part 1 : Rules for the design of steel structures.
SANS 121
:
Hot dip galvanized coatings on fabricated iron and steel articles – Specifications and test methods
SANS 1173
:
General purpose textile-reinforced conveyor belting.
SANS 1366
:
Steel cord reinforced conveyor belting
SANS 1313-1
:
Conveyor belt idlers Part 1: Troughed belt conveyor idlers (metallic and non-metallic) for belt speeds of up to 5,0 m/s
SANS 1313-2
:
Conveyor belt idlers Part 2: Link suspended idlers and fixed-form fixed-f orm suspended idlers
SANS 1431:2007
:
Weldable structural steels
SANS 1910:2006
:
Portable refillable fire extinguishers
SANS 10160
:
General procedures and loadings to be adopted for the design of buildings.
SANS 50054
:
Fire detection and alarm systems.
Mine Health and Safety Act and Regulations of the Republic of South Africa. Occupational Health and Safety Act and Regulations of the Republic of South Africa.
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AA SPECIFICATION
SPEC 254001
STACKING A ND RECLAIMING EQUIPMENT: EQUIPMENT: MECHANICAL MECHANICAL & STRUCTURAL STRUCTURAL
ISSUE 0 COPYRIGHT
APPENDIX B : RECORD OF AMENDMENTS AMENDMENTS Issue 0
:
Based upon AAC Specification Specificat ion 254001 (Issue 4) with the following amendments: • • •
Para 4.11.2 updated to include EN 593 and AAC Specification 375001; Para 4.11.8 updated to include AAC Specification Specificat ion 762005 and SANS 50054; Appendix A updated.
Allan Lill (February (February 2008)
AA_SPEC_25400100.DOC
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