Bucket Wheel Excavator VABE 400 Typical Tec

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Technical Specification Bucket Wheel Excavator VABE 400

TECHNICAL SPECIFICATION BUCKET WHEEL EXCAVATOR Type VABE 400

VOEST-ALPINE Materials Handling G.m.b.H.&Co.KG P.O. Box 2 Alpinestraße 1 A-8740 Zeltweg AUSTRIA Phone: +433577755-Ext. Fax: + 43 3577 756 339 e-mail : [email protected]

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VAMH

Technical Specification Bucket Wheel Excavator VABE 400

Part

1

General

Part

2

Technical Description of Mechanical & Structural Assemblies

Part

3

Technical Data

Part

4

Technical Specification of Electrical Equipment

Part

5

General Layout Drawing

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VAMH

Technical Specification Bucket Wheel Excavator VABE 400

Part

1

General

Part

2

Technical Description of Mechanical & Structural Assemblies

Part

3

Technical Data

Part

4

Technical Specification of Electrical Equipment

Part

5

General Layout Drawing

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Technical Specification Bucket Wheel Excavator VABE 400

Table of Contents 1.1

General

6

1.2

General Design Data

7

2.1

Bucket wheel with Drive

10

2.2

Undercarriage and Crawlers

11

2.3

Superstructure and Turntable

12

2.4

Bucketwheel Boom

13

2.5

Discharge Boom

14

2.6

Operator's Cabin, Control Desk and Transformers

15

2.7

Power Transmission, Electric’s, Control

16

3.1

General

18

3.2

Bucketwheel with Drive

19

3.3

Superstructure and Bucketwheel Boom

21

3.4

Bucketwheel Boom

23

3.5

Luffing Arrangement for Bucketwheel Boom

23

3.6

Discharge Boom

23

3.8

Conveying Line

25

3.9

Crawlers and Undercarriage

28

3.10

Lubrication

28

3.11

Miscellaneous

29

3.12

Power Supply

29

3.13

Motors, Quantity and Rated Power:

30

4.1

General Information

32

4.2

Power Supply and Distribution

34

4.3

Drives

35

4.4

Power Transformer

37

4.5

High-Voltage Switchgear

37

4.6

Resistance Banks

38

4.7

Low-Voltage Switchgear

38

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Technical Specification Bucket Wheel Excavator VABE 400

4.8

Local Devices

38

4.9

Signalling System

38

4.10

Operator's Cab Equipment

40

4.11

Miscellaneous Equipment

41

4.12

Lighting

43

4.13

Communication

43

4.14

Slipring Assembly

43

4.15

Cables and Installation Material

44

4.16

Automatic Control System

44

5.

General Arrangement Drawing

47

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Technical Specification Bucket Wheel Excavator VABE 400

Part 1

General

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Technical Specification Bucket Wheel Excavator VABE 400

1.1

General

(a)

The bucket wheel excavator will be used to unload copper ore from leaching pads discharging to a crawler mounted horizontal conveyor (supplied by others). The machine will excavate copper ore at an theoretical capacity of 2000 lm³/h (3000 t/h) or 1450 m³/h (2200 t/h) effective rate (max. density = 1.5 ton/m³ for power calculations). The resulting peak capacity will be kept to a minimum.

(b)

The bucket wheel excavator will excavate the copper ore in piles of 7 m in height on a leach pad system.

(c)

The machine design includes automatic functions wherever possible / feasible. Automation is documented in sufficient detail for evaluation of the operational advantages of the offered features.

(d)

The equipment is designed to obtain the highest possible degree of standardisation and interchangeability with respect to the other equipment specified. It is our target that such standardisation cover the complete electrical equipment including motors, couplings, brakes, brake actuators, bearings, plummer blocks and slewing rings. Particulars and feasibility of the above will be elaborated and agreed upon in Contract meetings.

(e)

A sketch of the bucket wheel excavator is attached in Part 5

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Technical Specification Bucket Wheel Excavator VABE 400

1.2

General Design Data

(a)

The BWE runs on crawlers. It mainly consist of the complete undercarriage and travel gear, the slewing assemblies, the superstructure, the bucket wheel boom with bucket wheel, the discharge conveyor, the luffing equipment, the counterweight boom and the complete electrical installation.

(b)

Bucket wheel and discharge booms have separate slewing and luffing action. The height adjustment of the discharge boom will be designed to suit the transfer parameters of the horizontal conveyor and the following grasshoppers.

(c)

Transfer points will be designed in such a way that material transfer with minimised spillage will be ensured and plugging under normal conditions is prevented. (d) The entire machine will be easily accessible through staircases and walkways so that supervision and maintenance as well as necessary repairs can be easily executed. All parts of the structure including platforms are to be provided with sufficient and effective drainage facilities. The BWE will be supplied with electric power by hook-up connection from the cable reel of the cable reel car running on the horizontal conveyor.

(e)

The maximum operational wind speed will be 72 km/hour, serving as the basis for structural design. A wind velocity of 130 km/hour has been considered for the out-ofoperation load case. Earthquake activity is considered for equipment design as far as applicable.

(f)

As a minimum the following design parameters will apply: Copper leach pad height Side slope Face slope Deep-cut below level Outreach of bucket wheel boom Length of discharge boom Grade ability in operation in transit

7m 60 -65 degrees 65 degrees - 0.5 m 8.5 m 15 m 1:20 1:10

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Technical Specification Bucket Wheel Excavator VABE 400

Average ground pressure based on operating weight Slewing range of superstructure related to undercarriage Slewing range of discharge boom related to superstructure (g)

100 kpa 360 ° +/- 105 °

Lighting as specified in this specification for the bucket cutting area will be provided to permit adequate illumination during night operation.

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Technical Specification Bucket Wheel Excavator VABE 400

Part

2

Technical Description of Mechanical & Structural Assemblies

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Technical Specification Bucket Wheel Excavator VABE 400

2.1

Bucket wheel with Drive

(a)

The bucket wheel will be designed as a cell-less type with suitably connected shaft arrangement. The bucket wheel shaft will be supported by spherical roller bearings.

(b)

The drive of the bucket wheel will be effected by electric motor, gearbox arrangement. A safety coupling (a turbo coupling and an electric overload protector) will be provided between gearbox and motor to prevent overstrain of the bucket wheel gear and separate the flux of forces from the motor to the gear if 1.4 motor momentum is exceeded.

(c)

The buckets will be designed with exchangeable cutting tools.

(d)

The digging teeth are fastened to the buckets in a way which will permit easy and rapid replacement and which will not loosen during operation. The external rims of the bucket wheel body will be protected by exchangeable wear bars and the bucketwheel chute and ring chute by exchangeable wear places.

(e)

The bucket design will provide for continuous cleaning of the buckets during wheel rotation.

(f)

Considering the material properties, the peripheral speed at the cutting circle of the bucket wheel will not exceed 75 percent of the critical peripheral speed.

(g)

The bucket wheel ring chute will prevent preliminary discharge and undue spillage of the material and will cover a minimum part of about 1/3 of the full bucket wheel running circle from fill to discharge points of the buckets.

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Technical Specification Bucket Wheel Excavator VABE 400

2.2

Undercarriage and Crawlers

(a)

The undercarriage of the BWE will be sufficiently strong and of rigid design. The machine will be supported by a two-crawler travel arrangement. The actual bearing surface of the crawler chain, related to the operational machine mass, permits sufficient area contact to ensure that the specified permissible ground pressure of 120 kpa will not be exceeded. The crawlers are to be equipped with a number of travel rollers in accordance with the load requirements and at chain support saddles in the upper part. The travel rollers are mounted in two wheel bogies to permit some flexibility and equal load distribution. The crawler frames will be straight, torsion free structures. The crawlers are equipped with a suitable take-up for the crawler chain.

(b)

The tension device for the crawler chain will be dimensioned in such a way that in case of wear in the links of the crawler chain one link can be removed.

(c)

Lubrication of the crawlers will be effected by central lubrication and life-time lubrication.

(d)

Each crawler is equipped with a drive arrangement. The crawler drives will be protected against spillage by covers. Dismantling of bogies and wear elements will be possible by simple means.

(e)

For travelling on inclined surface, safe braking of the crawlers must be provided. A ground clearance of at least 600 mm will be maintained. A turning radius of 10 m will not be exceeded.

(f)

Travel speed will be 8 m/min. Interlocking between the BWE and hopper car will ensure synchronised travel of the various equipment combinations.

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Technical Specification Bucket Wheel Excavator VABE 400

2.3

Superstructure and Turntable

(a)

The superstructure will be of a strong plate design and rigidly stiffened. The basic part will be the main turntable with firmly connected frame and counterweight boom. The turntable will be supported on the undercarriage by a slewing ring assembly. The slewing drive will consist of two (2) independent drive units. The slewing gear drives are mounted on the superstructure with pinions meshing into the gear rim mounted on the undercarriage.

(b)

The slewing gear drives will be equipped with a safety coupling or equivalent which stops all drives if inadmissible high lateral forces occur. The slewing speed will be indefinitely variable. The slewing ring assembly will be designed for equipment life and suitable lubrication arrangement. Effective protection against contamination will be provided.

(c)

The control of the slewing drive will be via AC motor with VVVF control.

(d)

A separate slewing arrangement for the discharge boom is arranged on top of the main turntable to permit independent movement of this unit.

(e)

The counterweight boom will have a rigid connection to the rear end of the turntable. It will consist of the structure, carrying the counterweight box, electric compartments and transformer. Free movement against the discharge is insured.

(f)

The frame, providing the support of the bucketwheel boom, the transfer chute and the suspension for the discharge boom will be mounted to the front end of the turntable. It will be of a torsion-strong design.

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Technical Specification Bucket Wheel Excavator VABE 400

2.4

Bucketwheel Boom

(a)

The bucketwheel boom will be of rigid design with suitable cross bracings to prevent torsioning. The boom is mounted by shaft connection and hinge bearings to the machine frame. Mounting provisions for the bucketwheel, the bucketwheel drive and the chute arrangements at the front end of the boom are provided. The bucketwheel boom has a hydraulic luffing arrangement. The hydraulic system is equipped with check valves or other suitable safety features to prevent a sudden drop of the boom in case of pressure loss or oil leakage. The transfer end of the conveyor will be provided with a sufficiently strong baffle plate in order to direct the material stream with minimum spillage to the discharge conveyor.

(b)

All chutes will be equipped with exchangeable wear plates.

(c)

The conveyor will have suitable drive arrangements with fluid couplings and brakes or holdbacks. The drives will be preferably motor-gearbox arrangements mounted on a common base with torque arrester. Flange couplings are used to connect pulleys to gearboxes.

(d)

A primary and secondary scraper will be provided at the discharge pulley. A plough scraper will be installed in front of the return pulley.

(e)

An electric driven conveyor belt aligner will be provided. The control of the devise will be from the operator’s cab.

(f)

Strong overflow guards will be provided along the bucket wheel boom conveyor.

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Technical Specification Bucket Wheel Excavator VABE 400

2.5

Discharge Boom

(a)

The discharge boom will be supported by the discharge boom slewing arrangement. Luffing will be by hydraulic cylinder. The boom is designed as a torsion-strong steel structure. Safety features have to be provided to prevent the discharge boom from accidentally dropping. Slewing movement against the bucketwheel boom will be controlled by limit switches to avoid collision. The receiving chute of the boom will be provided with an impact table. The chute will have exchangeable wear plates.

(b)

Sufficient tensioning distance will be ensured. The discharge end of the conveyor will be provided with a sufficiently strong baffle plate in order to direct the material stream with minimum spillage to the following equipment.

(c)

Transfer points are designed in such a way that plugging will be prevented under normal operating conditions.

(d)

The conveyor will have suitable drive arrangements with fluid couplings and brakes. The drives are shaft mounted motor-gearbox arrangements on a common base with torque arrester. Flange couplings are used to connect the pulley to gear box output shaft.

(e)

A primary and secondary scraper will be provided at the discharge pulley. A plough scraper will be installed in front of the return pulley.

(f)

An electric driven conveyor belt aligner will be provided. The control of the devise will be from the operator’s cab.

(g)

Strong overflow guards will be provided along the discharge boom conveyor.

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Technical Specification Bucket Wheel Excavator VABE 400

2.6

Operator's Cabin, Control Desk and Transformers

(a)

The operator's cabin will be arranged in such a way that the operator has the best possible visibility over the entire machine. The cabin is equipped with air conditioning, and ventilation.

(b)

The windows will be of tinted safety glass with windshield wipers and washers. One operator will be able to operate the entire machine on his own. From the control desk it will be possible to control all activities of the bucketwheel excavator and the hopper/cable reel car when the beltwagon is not in use.

(c)

The BWE will be controlled from the control desk of the machine, but the discharge boom is also controllable by remote and automated control from the beltwagon.

(d)

The cabin will be equipped with a suitable chair incorporating arm rests. Enough space will be provided to allow the operator free movement around the control desk.

(e)

A slewing angle indicator for the height and position of the bucketwheel and an indicator monitoring the crawler travel direction (and the corresponding advance steps of a cut as well as the total covered distance) will be in the operator's cabin.

(f)

The electric compartment containing the switchgear for the BWE is provided for on the counterweight boom.

(g)

Resistance sets are placed separately next to the switchgear house and are weatherprotected.

(h)

The transformers are placed on open platforms. Below the transformer, oil collecting troughs with syphons are to be provided.

(i)

Shelters are to be arranged above the transformers. The shelters will protect the transformers from being damaged by spillage.

(j)

A compartment for he storage of spare / wear parts is provided in the vicinity of the electrical house.

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Technical Specification Bucket Wheel Excavator VABE 400

2.7

Power Transmission, Electric’s, Control

(a)

For the power transmission from the superstructure to the undercarriage a slipring arrangement is to be provided which permits a slewing movement of 360 degrees. The room for the slipring is to be absolutely water proof, dustproof and protected against vermin.

(b)

For electrical interface, refer to Part 4: Technical Specification of electrical Equipment

(c)

Electrical components are to be designed in accordance with the applicable international standards.

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Technical Specification Bucket Wheel Excavator VABE 400

Part

3

Technical Data

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Technical Specification Bucket Wheel Excavator VABE 400

3.1

General Type of bucketwheel excavator

Compact Type Heavy Duty Version

Effective capacity

1450 lm³/hr 2200 t/h

Theoretical capacity

2000 lm³/hr 3000 t/h

Leach pad height Deep-cut above level

max. + 7 m - 0.5 m

Side slope Face slope

60 -65 degrees 65 degrees

Travelling speed Minimum turning radius related to crawler outer edge

8 m/min. 12 m

Gradeability - in operation - in transit

1:20 1:10

Average ground pressure based on operation weight

120 kpa

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Technical Specification Bucket Wheel Excavator VABE 400

3.2

Bucketwheel with Drive Bucketwheel Type of bucketwheel Diameter (related to cutting circle) Number of buckets Discharges per minute high speed Cutting speed Revolutions per minute - maximum - minimum (maintenance) Bucket capacity (I1) Ring space capacity (I2) Rated bucket capacity (In) Rated output at the above number of bucket discharges with buckets filled 100% Max. Cutting force Tilt of bucketwheel - related to horizontal plane - related to vertical plane

cell-less 5.6 m 10 66 per min 1.94 m/sec 6.6 rpm approx 0.3 rpm 0.325 m³ 0.150 m³ 0.400 m³ 1,880 lm³/h 171 N/cm² 8 degrees 0 degrees

Bucketwheel Shaft Type/design Material Bearings - Type/Number - Lubrication

hollow shaft 42CrMo4V spherical roller bearing grease-central lubrication

Bucket Wheel Drive Motors - Type - Number - Capacity of each motor - nominal (Nn) Rated Speed

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Squirrel cage 1 110 kW 1500 rpm

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Technical Specification Bucket Wheel Excavator VABE 400

Bucketwheel Reduction Unit Type Number Number of oil pumps

planetary gear 1 1

Overload Safety Device Mechanical Type Overload Electrical Type Overload

fluid coupling 1.5 -fold electronic / PLC 1.4 -fold

Chutes Inclination of chutes Type of wear protection - Thickness for ring chute - Thickness for fixed chute

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55-60 degrees high resistant wear plates 16 mm 12 mm

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Technical Specification Bucket Wheel Excavator VABE 400

3.3

Superstructure and Bucketwheel Boom Main Slewing Assembly Slewing angle of superstructure to undercarriage Maximum slewing speed related to centre of bucketwheel Type of slew bearing - Material specification Fastening - with superstructure - with undercarriage Type of sealing Lubrication Type of rolls for slewing race

infinite 36 m/min slew bearing 42CrMo4V bolted bolted V-type grease, central lubr. cylindrical rollers

Slewing Drive Units Number of slewing drives Type of slewing drive Type of motors Voltage Rated power of each motor Pinions per unit Type of safety clutch Overload factor Type of brake Number of brakes on each slewing drive Acceleration in operation Deceleration - in operating - at emergency stop

2 frequency controlled electrical 400 V 11 kW 1 magnetically 1.3 double shoe brake 2 0,05 m/sec² 0,05 m/sec² 0,15 m/sec²

Safety Devices Type of gripping device - Quantity - Location

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double shoe brake 2 slew drive

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Technical Specification Bucket Wheel Excavator VABE 400

Slewing Assembly for Discharge Boom Slewing angle of discharge boom related to the superstructure Slewing speed related to centre of discharge pulley

+/- 105 degrees 15 m/min

Type of slewing race - Material specification - Type of sealing - Lubrication

slew bearing 42CrMo4V V-type grease, central lubr.

Type of slewing drive Power of slewing drive

electrical 2 x 11 kW

Type of slewing gear - Lubrication

planetary gear oil

Type of brake

brake motor

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Technical Specification Bucket Wheel Excavator VABE 400

3.4

3.5

3.6

Bucketwheel Boom Length of system from slewing centre to centre of bucketwheel

8500 mm

Conveying angle - in highest position - in lowest position

+18 degrees -15 degrees

Adjusting speed, related to centre of bucketwheel - raising - lowering

approx. 5 m/min approx. 5 m/min

Luffing Arrangement for Bucketwheel Boom Number of hydraulic cylinders

1

Pressure of each cylinder - Operating pressure - Maximum pressure

220 bar 280 bar

Type of luffing drive Power of luffing drive

hydraulical 45 kW

Discharge Boom Dimensions Length in horizontal position from the slewing centre to the centre of material discharge

16 m

Length from centre of drive pulley to centre of discharge pulley

approx. 17 m

Height of centre discharge pulley related to travelling level - in highest position - in lowest position

7.6 m 3.2 m

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Technical Specification Bucket Wheel Excavator VABE 400

Conveying angle, maximum

+ 12 degrees - 5 degrees

Lifting and lowering speed of discharge boom

3 m/min

Luffing Arrangement Number of hydraulic cylinders Pressure of each cylinder Operating pressure Type of luffing drive Power of luffing drive

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180 bar 250 bar hydraulical 45 kW ( same as BW hoist )

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Technical Specification Bucket Wheel Excavator VABE 400

3.8

Conveying Line Bucketwheel Boom Belt speed Belt width

4.2 m/sec (820 fpm) 1200 mm (48”)

Troughing angle - Upper belt - Lower belt

35 degrees 15 degrees

Length measured from centre of return (take-up) pulley to centre of discharge pulley - minimum - maximum

10.000 mm 10.500 mm

Belt clearance to steel structure on each side

100 mm

Number of pulleys Diameter of pulley (wo. lagging) Face width of pulley Type of lagging Thickness of lagging Drive pulley Tail pulley Type of bearing Make of drive Type of drive Number of drives Drive power Type of brakes

2 630 mm min. 1450 mm herringbone rubber

Type of take-up Take-up length

hydraulic cylinder 500 mm

Type of carrying idlers Number of idlers per set Spacing of idler sets Diameter Type of bearing Type of sealing

3-roller garlands 3 max. 1200 mm 127 mm ball bearing labyrinth + V-type

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min. 20 mm (3/4”) min. 15 mm (~1/2”) spherical roller bearing electrical via gear box 1 75 kW double shoe brake

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Technical Specification Bucket Wheel Excavator VABE 400

Type of return idlers Number of idlers per set Spacing of idlers sets Diameter of idler tube Type of bearing Type of sealing

2-roller garlands 2 max. 3000 mm 127 mm ball bearing labyrinth + V-ring

Type of impact idlers Number of idlers per set Troughing Number of idler sets at transfer point Spacing of idler sets Diameter of idler tube Type of bearing Type of sealing

garlands 3 35 degrees 8 max. 380 mm 152 mm ball bearing labyrinth + V-ring

Type and number of belt cleaners

1 primary belt scraper 1 secondary belt scraper 1 plough scraper

Bucket wheel chute Type of wear protection Thickness of wear protection

wear resistant steel plates 12 mm

Discharge Boom Belt speed Belt width

4.2 m/sec (820 fpm) 1200 mm (48”)

Troughing angle - Carrying belt - Return belt Length of discharge boom between pulley centres - minimum - maximum Belt clearance on each side

16 m 16.5 m 100 mm

Number of pulleys

2

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35 degrees 15 degrees

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Technical Specification Bucket Wheel Excavator VABE 400

Diameter of pulley (wo. lagging) Face width of pulley Type of lining Thickness of lining Drive pulley Tail pulley Type of bearing

630 mm min. 1450 mm herringbone rubber

Type of drive Voltage Number of drives Type of brakes Drive power

electrical via gear box 400 V 1 double shoe brake 75 kW

Type of take-up Take-up length

hydraulic cylinder 500 mm

Spacing of idler sets Diameter of idler tube Type of bearing Type of sealing

max. 1200 mm 127 mm ball bearing labyrinth + V-ring

Type of return idlers Number of idlers per set Spacing of idlers sets Diameter of idler tube Type of bearing Type of sealing

2 max. 3000 mm 127 mm ball bearing labyrinth + V-type

Type of impact idlers Number of idlers per set Troughing Number of idler sets at transfer point Spacing of idler sets Diameter of idler tube Type of bearing Type of sealing

garlands 3 35 degrees 8 400 mm 159 mm (6 in.) ball bearing labyrinth + V-ring

Type of belt cleaners

1 belt scrapers 1 plough scraper

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min. 20 mm (3/4”) min. 15 mm (1/2”) spherical roller bearing

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Technical Specification Bucket Wheel Excavator VABE 400

Number of belt cleaners Angle of chute walls Type of wear protection Thickness of wear protection

3.9

2 55 – 60 degrees wear resistance plates 16 mm

Crawlers and Undercarriage Number of crawlers Track gauge Type of support Ground clearance Average ground pressure at service weight

2 6000 mm 4-point 500 mm 120 kpa

Length of crawler measured from centre of drive tumbler to centre of return tumbler

5,980 mm

Take-up distance

300 mm

Width of crawler plate Load bearing surface Number of track wheels per crawler Lubrication Number of drives per crawler Drive power per crawler

1,700 mm 20.4 m² 8 grease-central lubr. 2 45 kW

3.10 Lubrication Automatic grease lubrication -Type

dual line system

-Location - Number of grease pumps - Number of points of lubrication

platform 2 appr. 108

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Technical Specification Bucket Wheel Excavator VABE 400

3.11 Miscellaneous Walkways - Type of flooring - Inside width, minimum

grating 500 mm

Stairs - Type of flooring - Inside width, minimum

grating 500 mm

3.12 Power Supply Power supply from: Supply voltage HV - Motor voltage LV - Motor voltage Control voltage Lighting voltage

4.16 kV 4.16 kV 400 V 24 V 230 V

Frequency

50 Hz

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Technical Specification Bucket Wheel Excavator VABE 400

3.13 Motors, Quantity and Rated Power:

Qty

Installed Power (KW) (each)

Average Consumption each (KW)

- Travelling gears

2

45

15

- Bucketwheel drive Bucket Wheel Gear - oil pump

1 1

110 2.2

72 2

- Bucketwheel boom Slewing drive Hoisting unit (Hydraulic Power Pack) Conveyor belt

2 1 1

11 45 75

13 15 62

- Discharge boom Slewing drive Hoisting unit Conveyor belt

Others - Grease pumps - Air Conditioning - Others

electrically hydraulically (same as BW Hoist) 1 75 62

2 0.7 2 7 lighting, fans...

Total Installed Power

appr.

Average Power Consumption

appr.

1 5 3

450 KW 255 KW

*Average Estimated Consumption = Average Load X Duty Cycle (% of time)

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Technical Specification Bucket Wheel Excavator VABE 400

Part

4

Technical Specification of Electrical Equipment

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Technical Specification Bucket Wheel Excavator VABE 400

4.1

General Information

4.1.1

Operation Conditions Ambient Temperature

min. +0°C outdoor max. +35°C

Altitude:

900 m

4.1.2 Standards Design, manufacture and testing of the electrical equipment will be in accordance with the international codes and standards

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Technical Specification Bucket Wheel Excavator VABE 400

4.1.3

General Data of Electrical Equipment

Supply voltage:

4.16 kV, 3-phase

Frequency:

50 Hz

Allowable range of rated voltage:

±10%

Motor voltage:

4.16 kV,, 3-phase 400 V, 3-phase

Control voltage, general:

24 V, 1-phase

PLC voltage:

24 V, DC

Indications lamp voltage:

24 V, DC

Grounding: - 4.16 kV-Network ungrounded, with earth-leakage monitoring located in substation of the open pit mine - 400 V Main distribution network ungrounded, with earth-leakage monitoring - 400 V Auxiliary network B ungrounded, with ear-leakage monitoring - 230/400 V Auxiliary network A grounded neutral

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Technical Specification Bucket Wheel Excavator VABE 400

4.2

Power Supply and Distribution The 4.16 kV power supply of the BWE will come from the belonging belt wagon or directly from the cable reel car via the cable loop at the discharge boom to the 4.16 kV-Switchgear in the superstructure E-House. The 4.16 kV-power supply and switchgear can be isolated by switching-off the 4.16 kVLoadbreak switch on the cable reel car. For the power distribution on the BWE a - main distribution network - auxiliary network A - auxiliary network B will be provided. The auxiliary network A will comprise all the consumers (such as lighting, heating, main control and monitoring voltages, but not drives) which will remain powered after emergency-off. The auxiliary network B will comprise the consumers which are necessary for repair purposes, such as cranes and oil pumps, etc. In case of necessity, these consumers can be disconnected.

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Technical Specification Bucket Wheel Excavator VABE 400

4.3

Drives The drive motors with their data are specified in the motor list. This list also contains information about the control details as well as associated brake thrustors. The superstructure slew drive will be furnished with A.C. Motors. The motors are parallel-connected and fed by a frequency converter. The actual speed values are measured by one tacho-generator, which is attached to one motor. All squirrel cage rotor motors will be started directly, the slipring motors will be started by time-delayed gradual variation of the rotor resistance. Unintentional starts of drives after power voltage failure and recovered is prevented by suitable design of the control system. The drives of bucket wheel, the conveyors 1 and 2 are electrically interlocked among each other and with the associated conveyor route, that they allow being started in a segment only in a sense reverse to the direction of conveyance. Should anyone of these drives fail, all other feeding conveyors will be cut out immediately. In case of locally switch-on the conveyors by means of interlocking release, the drives cannot be started from operator's cabin. In addition, an interlocking will be provided for normal operation to allow connection of the excavator drives, hoist, slew and travel and only then will the bucket wheel drive be connected. For transportation of the excavator, the interlocking can be by-passed in the main operator's cabin by means of an unlocking switch. In this case, the bucket wheel drive cannot be started. Oil pump and grease pumps will be started in accordance with the main drives. The starting of the conveyor route from the operator's cabin is only possible, when the according conveyor system is running. This will be indicated by a signal-lamp on the operator's cabin. The main breaker will be opened with time lag with regard on the slew converter (also be emergency-off).

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Technical Specification Bucket Wheel Excavator VABE 400

The following protection and monitoring equipment will be provided: - Short circuit and overload protection, - Insulation monitoring, - Overcurrent monitoring. - Speed monitoring devices for some drives, - Slip monitoring device and Belt deviation monitoring for conveyor drives. The heater for the bucket wheel drive gear will be interlocked with the oil pump. The heater will be disconnected in case the oil pump is disconnected. The thermostat-controlled heaters will remain in operation. A.C. motors will be employed for the slewing drive. The slewing speeds will be controlled according to the function of l/cos alpha in the automatic mode.

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Technical Specification Bucket Wheel Excavator VABE 400

4.4

Power Transformer The bucket wheel excavator will be equipped with a vibration-proof power transformer suitable for vibration and inclination applications. The transformer tank will be of a welded plate design and resistant to pressure. Supply of the transformer will include the first oil filling. Bushing insulators and port insulators will be outdoor types of the relevant voltage class. Cable Terminal Boxes will be of protection IP 54. Voltage Tap-changing will be provided in variation of the voltage tap changer: ±2.5%, ±5%, Voltage tap-changing be of off-load type. Oil conservator with oil level gauge and air dryer (silicagel filling) will be provided as well as thermometer pocket and drainage valve.

4.5

High-Voltage Switchgear A high-voltage switchgear will be provided in the superstructure E-House with a - Transformer feeder consisting of a fused load-break switch - Motor feeder for bucket wheel main drive consisting of a - fused load break switch with motor drive and under voltage trip (switched off in case of emergency-off) - Contactor - Current transformers with overload relay and ammeter - Power capacitor for compensation of lower factor, located locally The power capacitor will be parallel connected with the B.W. motor so that it is switched on and off by the stator contactor together with the B.W. motor. The reactive power of the capacitors will be approximately 90% of the no-load reactive power consumption of the motor. The power capacitors will be anti-vibration and suitable for outdoor operation.

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Technical Specification Bucket Wheel Excavator VABE 400

4.6

Resistance Banks The resistance banks consist of cast iron elements or wire grids enclosed in standard sheet metal boxes in protection class IP 12.

4.7

Low-Voltage Switchgear A low-voltage switchgear will be provided consisting of different cubicles with circuit breakers, contactors, auxiliary relays, PLC, special relays, instruments etc., details are shown on the single line diagrams.

4.8

Local Devices The safety-and limit-switches and the supervising devices are compiled in the list of local control devices as well as by-pass switches, proximity switches, shaft encoders etc.

4.9

Signalling System A signalling system will be provided for transmitting all required information concerning malfunction and operating conditions of the machine. All detected malfunctions and operating conditions will be displayed on a monitor in the operator's cab as single or collective indication. The control signals between BWE and central control station will be transmitted via the nearest belt conveyor control substation (switch station at head drive station). (1)

Signals from BWE to the central control station: - Ready for operation; - BWE in operation; - BWE malfunction; - BWE out of operation.

(2)

Signals from central control station to BWE: - Ready for operation; - Running signal, conveyor; - Stop excavation.

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Technical Specification Bucket Wheel Excavator VABE 400

Among others, the following indications are envisaged: - Circuit breaker on/off - Control voltage on/off - Operational limit switch - Safety limit switch - Emergency stop - Fuse supervision (conveyor route) - Oil pressure supervision - Ground connection - Wind warning The rest indications are mentioned in the list of local control devices. A PLC (Programmable controller) for control and processing of annunciation signals, with all necessary components, interface, I/O racks, special cables, remote I/O adapters for remote I/O in operator's cab and/or control rooms, etc. will be provided. The PLC will perform all necessary operations as timing, counting, arithmetic operations, comparisation, data manipulation etc. The PLC will be provided with required power source and battery back-up to maintain memory contents during power loss. The required special relays of proximity switches, ground fault relays, lubricating system malfunction relays, selsyn indication units, inclination monitoring devices, will be provided.

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Technical Specification Bucket Wheel Excavator VABE 400

4.10 Operator's Cab Equipment Operator's Desks 1 Control desk for operator's cabin, consisting of left and right side panel and driver's chair, containing: Control and master control-switches for the drives of the excavator. Further controls are: • • • • • • • •

1 Interlock release switch 1 Key switch for control voltage 1 Push button for warning signal 1 Emergency stop button 1 Switch for air conditioning 1 Switch for lighting 1 Microphone Operating devices for communication equipment

Indication- and Instrument Panels 1 Monitor panel, containing: 1 Monitor • also for indications of • - crawler position • - slew position • - hoist position • - total distance travelled • - step advance • - slew speed • - wind speed • 1 Voltmeter for 6 kV • 1 Ammeter for bucket wheel drive • 1 Clock • 1 Loudspeaker for communication equipment •

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Technical Specification Bucket Wheel Excavator VABE 400

4.11 Miscellaneous Equipment The main items are specified in the list of local control devices. Among other the following items will be provided: Lever-type limit switches, heavy duty design. Inclination measuring device, with indication in the operator's cab, alarm and stop at inclinations of 1:10 (change of location) and 1:20 (operation). Anemometer indicating wind velocity, with alarm and stop at max. wind velocities (visible and audible alarm at a wind pressure of approx. 20kg/m², max. wind pressure at 80 kg/m² with equipment at standstill), anemometer transducer with heating, make: Lamprecht or equal; stop is effected when the maximum wind pressure persists for a period in excess of 6 seconds. Air-conditioning units for the cab, including intake filter and accessories. Miscellaneous emergency stop buttons with red mushroom-type button, to be unlatched by turning, type of enclosure IP 56, heavy iron-clad design, to be distributed over the machines. Required heating elements for gearing, cab, electrical room, etc. including the necessary accessories, such as thermostats, switches etc. Miscellaneous power plugging devices for connecting of vulcanising equipment, welding equipment and tools. Several high-power floodlights, suitable for outdoor use, also for illuminating of the BWE digging area of the bucket wheel. Several lighting fixtures with fluorescent lamps, complete with reflector, ballasts, starter, as required for adequate illumination of the walkways, stairways, suitable for outdoor installation. Several plastic fittings for fluorescent lamps, complete with glass well, reflector, ballasts, starter etc., for adequate illumination of the cab and E-house and collector ring room, workshops. Miscellaneous items for lighting and heating circuits, such as switches, push-buttons Several signal horns for outdoor installation, also for start-up alarm.

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Technical Specification Bucket Wheel Excavator VABE 400

Several fans and filters for the electrical room. Magnetic powder couplings for BWE superstructure slew drive, approx. 60 v, Amp., D.C. Slewing angle indicator with accessories for BWE slew drive, indication in operator's cab. Boom hoist height indicators mounted at pivot points, with indication of height from the ground to the bottom of bucket wheel, indication in operator's cab. BWE travel indication, indicating the travel distances and advance steps of the cuts and the total covered distances, indication in operator's cab. All necessary control valves, 24 V, DC (for hydraulic systems) Pull cord switches, 2 per conveyor and for cable tension monitoring of cable to other machine, including necessary ropes and accessories. Proximity limit switches for speed control and position limitation. Belt alignment switches.

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Technical Specification Bucket Wheel Excavator VABE 400

4.12 Lighting Outdoor lighting will be divided into general and operational lighting. Quick ignition floodlights will be used for illumination of the boom and crawler areas. The operational lighting will be provided for the important working areas, such as on the surface areas around the machine and the belt conveyor transfer point, etc. The general lighting will only be provided for the walkways, platforms and stairs etc., so that safety conditions will be guaranteed for operations and inspections. The E-house and operator's cab will be equipped with lighting installations according to the respective illumination requirements.

4.13 Communication The following communication equipment will be provided for the BWE: - Telephone systems for internal communications - One loudspeaker calling system - Space will be reserved for radio communication system between BWE and central control station.

4.14 Slipring Assembly A slipring assembly will be provided in the slewing centre of the BWE. All cables running between the superstructure and substructure are connected to the rings and brush holders of this slipring assembly.

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Technical Specification Bucket Wheel Excavator VABE 400

4.15 Cables and Installation Material Cables 4.16 kV power cables type NTSCgEwöu will be used for the infeeding primary side of power transformer and B.W. main drive motor. For LV power transmission rubber sheathed flexible cable will be used. Control cables will also be rubber sheathed flexible cable with a conductor cross Part of at least 2,5mm² as well as special cable, also shielded cables. Installation Material Fastenings and small installation material including terminal boxes, cable trays, conduits, cable grips, cable shoes, switches for lighting and heating, will be provided.

4.16 Automatic Control System An automatic control system will be provided for a)

Automatic operation Consisting of automatic control of bucket wheel main drive, conveyor drives, hydraulic pump, oil pumps, grease pumps, slew drive frequency converter.

b)

Automatically adjusting of bucket wheel height

c)

Automatic control system of slewing angle

d)

Automatic control of slewing speed

e)

Automatic cutting depth control

The detail principles of the automatic height adjustment and slewing angle control are as follows:

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Technical Specification Bucket Wheel Excavator VABE 400

Automation of Wheel Height Adjustment The wheel boom luffing angle relative to the excavator superstructure is determined digitally with a shaft encoder. The determined angle value can be corrected digitally in order to fix the grade level as zero reference for the boom lift. The angle value is converted to elevation values which indicate the difference in elevation between the lowest peripheral point of the bucket wheel and grade level. The desired luffing height is adjusting by hand on a digital setpoint station. Signal lamps indicate when the pre-stop position is reached.

Automatic Slewing Angle Control System The wheel boom slewing angle relative to the crawler is determined digitally with an absolute angle coder or similar device. The angle obtained is recorded in order to represent the slewing angle alpha T and alpha S as defined. The zero point can be adjusted digitally within reasonable limits. When a predetermined pre-stop position is reached, the slewing speed is reduced, and the slewing mechanism is stopped when the setpoint stop position is reached. The momentary slewing angle is indicated. Setpoint adjustment can be effected by making the first slewing pass through the slice by manual control. The actual limiting slewing angle values are used as setpoint input by pressing a key when the slewing mechanism is at a standstill. The boom movement will then stop when the stored set point values are reached.

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Technical Specification Bucket Wheel Excavator VABE 400

Part

5

General Layout Drawing

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