Belt Conveyors This is a Controlled Document that complies with Wesfarmers Chemicals, Energy & Fertilisers formatting f ormatting and Quality Control standards. Please check that this is the latest available version before use. Title:
BELT CONVEYORS
Number:
ES-14-403-03
Version Number:
8.0
Date Revised:
30 January 2015
Owner:
Harish Chopra
Authoriser:
Manoj Thakur
Reasons for Creating or Amending Document
Full Review of Document
Actual Change Details:
Full Review of Document. No changes to content. Control block updated to new template.
TABLE OF CONTENTS 1.
SCOPE ...................................................... ............................................................ ..................................... 4
2.
PURPOSE .......................................................... ........................................................... ............................ 4
3.
RESPONSIBILITY RESPONSIBILIT Y ..................................................... ........................................................... .................. 4
4.
DEFINITION OF TERMS ................................................... ........................................................... ........ 4
5.
STANDARDS ..................................................... ........................................................... ............................ 5
6.
BASIS OF DESIGN ..................................................... ........................................................... .................. 9
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 7.
BELT CONVEYOR DESIGN PROCESS .................................................... ..................................... 9 BELT SPEED ........................................................ ........................................................... .................. 9 BELT WIDTH ....................................................... ........................................................... .................. 9 DRIVE CAPACITY ........................................................ ........................................................... ...... 10 GENERAL .................................................. ........................................................... .......................... 10 DESIGN COMPUTATIONS .................................................... ....................................................... 10 FOUNDATIONS AND SUPPORTS ............................................................ ................................... 10 TECHNICAL DATA ...................................................... ........................................................... ...... 10 DESIGN REVIEWS ........................................................ ........................................................... ...... 10
DRAWINGS................ ........................................................... ........................................................... ...... 11
7.1
GENERAL REQUIREMENTS ........................................................... ............................................. 11
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Belt Conveyors 7.2
SPECIFIC REQUIREMENTS ............................................................ ............................................. 11
8.
CONVEYOR BELTING ....................................................... ........................................................... ...... 13
9.
PULLEYS.................... ........................................................... ........................................................... ...... 13
9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 10.
CONSTRUCTION .......................................................... ........................................................... ...... 13 DIAMETERS ........................................................ ........................................................... ................ 13 OVERALL WIDTH AND BEARING CENTRES .......................................................... ................ 13 TOLERANCES ..................................................... ........................................................... ................ 14 PULLEY LAGGING....................................................... ........................................................... ...... 14 BALANCING.................................................................. ........................................................... ...... 15 PULLEY SHAFTS .......................................................... ........................................................... ...... 15 PULLEY SHAFT BEARINGS ........................................................... ............................................. 16 CONVEYOR IDLERS ....................................................... ........................................................... ...... 16
10.1 10.2 10.3 10.4 10.5 10.6 10.7
GENERAL .................................................. ........................................................... .......................... 16 TROUGH IDLERS ......................................................... ........................................................... ...... 17 TROUGH IMPACT IDLERS (IF REQUIRED) .................................................... .......................... 17 TROUGH TRAINING IDLERS ......................................................... ............................................. 17 RETURN IDLERS .......................................................... ........................................................... ...... 18 RETURN TRAINING IDLERS .......................................................... ............................................. 18 AMMONIUM NITRATE CONVEYORS ................................................... .................................... 18
11.
GEARBOXES ........................................................... ........................................................... ................ 19
12.
BELT TAKE-UP ...................................................... ........................................................... ................ 19
12.1 12.2
GRAVITY TAKE-UP ..................................................... ........................................................... ...... 19 SCREW TAKE-UP ......................................................... ........................................................... ...... 19
13.
BELT SCRAPERS ................................................... ........................................................... ................ 20
14.
RUBBER SKIRTING ........................................................ ........................................................... ...... 20
15.
CHUTES AND HOODS .................................................... ........................................................... ...... 20
15.1 15.2 15.3
DESIGN ...................................................... ........................................................... .......................... 20 DUST SUPPRESSION.............................................................. ....................................................... 21 CONSTRUCTION .......................................................... ........................................................... ...... 22
16.
CLEARANCES ........................................................ ........................................................... ................ 22
17.
ACCESS AND MAINTENANCE MAINTENA NCE FACILITIES .................................................... .......................... 22
18.
SAFETY EQUIPMENT .................................................... ........................................................... ...... 23
18.1 18.2 18.3 18.4 18.5 19.
IDENTIFICATION IDENTIFICA TION ............................................................ ........................................................... ...... 24
19.1 19.2 19.3 20.
CONVEYOR GUARDS........................................................... ........................................................ 23 ANTI-ROLL BACK ........................................................ ........................................................... ...... 23 EMERGENCY LANYARD SWITCHES .................................................... .................................... 24 MONITORING DEVICES....................................................... ........................................................ 24 NOISE ......................................................... ........................................................... .......................... 24
EQUIPMENT NUMBERS ....................................................... ........................................................ 24 MOTOR IDENTIFICATION TAG .................................................... .............................................. 25 EQUIPMENT LABELS ........................................................... ........................................................ 25
MATERIALS ........................................................... ........................................................... ................ 25
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Belt Conveyors 7.2
SPECIFIC REQUIREMENTS ............................................................ ............................................. 11
8.
CONVEYOR BELTING ....................................................... ........................................................... ...... 13
9.
PULLEYS.................... ........................................................... ........................................................... ...... 13
9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 10.
CONSTRUCTION .......................................................... ........................................................... ...... 13 DIAMETERS ........................................................ ........................................................... ................ 13 OVERALL WIDTH AND BEARING CENTRES .......................................................... ................ 13 TOLERANCES ..................................................... ........................................................... ................ 14 PULLEY LAGGING....................................................... ........................................................... ...... 14 BALANCING.................................................................. ........................................................... ...... 15 PULLEY SHAFTS .......................................................... ........................................................... ...... 15 PULLEY SHAFT BEARINGS ........................................................... ............................................. 16 CONVEYOR IDLERS ....................................................... ........................................................... ...... 16
10.1 10.2 10.3 10.4 10.5 10.6 10.7
GENERAL .................................................. ........................................................... .......................... 16 TROUGH IDLERS ......................................................... ........................................................... ...... 17 TROUGH IMPACT IDLERS (IF REQUIRED) .................................................... .......................... 17 TROUGH TRAINING IDLERS ......................................................... ............................................. 17 RETURN IDLERS .......................................................... ........................................................... ...... 18 RETURN TRAINING IDLERS .......................................................... ............................................. 18 AMMONIUM NITRATE CONVEYORS ................................................... .................................... 18
11.
GEARBOXES ........................................................... ........................................................... ................ 19
12.
BELT TAKE-UP ...................................................... ........................................................... ................ 19
12.1 12.2
GRAVITY TAKE-UP ..................................................... ........................................................... ...... 19 SCREW TAKE-UP ......................................................... ........................................................... ...... 19
13.
BELT SCRAPERS ................................................... ........................................................... ................ 20
14.
RUBBER SKIRTING ........................................................ ........................................................... ...... 20
15.
CHUTES AND HOODS .................................................... ........................................................... ...... 20
15.1 15.2 15.3
DESIGN ...................................................... ........................................................... .......................... 20 DUST SUPPRESSION.............................................................. ....................................................... 21 CONSTRUCTION .......................................................... ........................................................... ...... 22
16.
CLEARANCES ........................................................ ........................................................... ................ 22
17.
ACCESS AND MAINTENANCE MAINTENA NCE FACILITIES .................................................... .......................... 22
18.
SAFETY EQUIPMENT .................................................... ........................................................... ...... 23
18.1 18.2 18.3 18.4 18.5 19.
IDENTIFICATION IDENTIFICA TION ............................................................ ........................................................... ...... 24
19.1 19.2 19.3 20.
CONVEYOR GUARDS........................................................... ........................................................ 23 ANTI-ROLL BACK ........................................................ ........................................................... ...... 23 EMERGENCY LANYARD SWITCHES .................................................... .................................... 24 MONITORING DEVICES....................................................... ........................................................ 24 NOISE ......................................................... ........................................................... .......................... 24
EQUIPMENT NUMBERS ....................................................... ........................................................ 24 MOTOR IDENTIFICATION TAG .................................................... .............................................. 25 EQUIPMENT LABELS ........................................................... ........................................................ 25
MATERIALS ........................................................... ........................................................... ................ 25
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Belt Conveyors 21.
HANDLING OF STEELWORK AND EQUIPMENT .................................................... ................ 25
22.
FABRICATION ....................................................... ........................................................... ................ 25
23.
WELDING ...................................................... ........................................................... .......................... 25
24.
BOLTING ....................................................... ........................................................... .......................... 26
25.
PROTECTIVE COATINGS ....................................................... ....................................................... 26
25.1 25.2 25.3 25.4 26.
INSTALLATION ..................................................... ........................................................... ................ 26
26.1 26.2 27.
STAGE 1 - PRE-COMMISSIONING ........................................................... ................................... 28 STAGE 2 – “DRY” “DRY” COMMISSIONING ...................................................... ................................... 29 STAGE 3 – “WET” “WET” COMMISSIONING COMMISSIONING ...................................................... ................................... 30
OPERATIONAL PHASE ............................................................ ....................................................... 30
29.1 29.2 30.
INSPECTION AND TEST PLAN ...................................................... ............................................. 27 WELD INSPECTION AND TESTING ........................................................ ................................... 27 FABRICATED STEELWORK INSPECTION ...................................................... .......................... 28 INSPECTION DURING INSTALLATION .......................................................... .......................... 28
COMMISSIONING ........................................................... ........................................................... ...... 28
28.1 28.2 28.3 29.
MECHANICAL/STRUCTURAL ....................................................... ............................................. 26 ELECTRICAL ....................................................... ........................................................... ................ 27
INSPECTION AND TESTING ................................................... ....................................................... 27
27.1 27.2 27.3 27.4 28.
STEELWORK ....................................................... ........................................................... ................ 26 MECHANICAL AND ELECTRICAL COMPONENTS ........................................................... ...... 26 BOLTS ........................................................ ........................................................... .......................... 26 FLOOR GRATING AND AND STAIR TREADS.......................................................... .......................... 26
MAINTENANCE STRATEGY .......................................................... ............................................. 30 INSPECTION DURING OPERATIONAL PHASE ........................................................ ................ 31
RECORDS MANAGEMENT ..................................................... ....................................................... 32
30.1 30.2 30.3
AS - BUILT DRAWINGS ........................................................ ....................................................... 32 ENGINEERING PROJECT FILES ..................................................... ............................................. 32 MAINTENANCE WORK ORDERS ............................................................ ................................... 32
TABLES Table 1
Pulley Width ................................................................... ................................................................................................................. .............................................. 14
FIGURES Figure 1
Belt Conveyor Conveyor Maintenance Process Flow Diagram ..................................................... 33
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Belt Conveyors
1.
SCOPE
This Standard establishes the minimum technical requirements for the design, fabrication, installation, testing, commissioning, preventative maintenance and inspection of belt conveyors.
2.
PURPOSE
To ensure that all belt conveyors in CSBP facilities are in compliance with WorkSafe WA regulations and other relevant codes and practices and that the company’s requirements for operability, safety and reliability are assured at all times.
3.
RESPONSIBILITY
During the development phase it is the responsibility of the Superintendent to ensure that the requirements of this Standard are adhered to. Following completion of project handover, it is the responsibility of each business unit to ensure that their belt conveyors remain compliant with this Standard and are safe to use.
4.
DEFINITION OF TERMS
Contractor/Vendor The company that provides the equipment and services needed. Sub-Contractor A third party to be employed by the Contractor/Vendor, who has been approved by the Superintendent. Superintendent CSBP Limited or authorised representative. For internal works, the Superintendent shall be the Responsible Officer. CSBP CSBP Limited. Works The scope of works that a Contractor is or may be required to execute under an agreement including variations and remedial work.
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Belt Conveyors Idler An assembly for supporting a conveyor belt. An idler is comprised of one or more rolls and the mounting frame or brackets for the rolls. Roll An individual rotating element of an idler (i.e. roller). Pulley An assembly comprising an enclosed cylinder fitted with a shaft, used to change the direction of a conveyor belt. Pulleys are located at drive, head and tail ends and gravity take-ups. Also referred to as a drum.
5.
STANDARDS
The Contractor shall perform the Works in accordance with this Standard, the latest issue of reference standards and Contractor regulations for on-site work. Should there be a conflict between the Works, Statutory Requirements and the Standards the Contractor shall notify the Superintendent in writing for resolution. In general, the most stringent requirements will prevail. CSBP Engineering Standards ES-14-101-02
Drawing Management
ES-14-101-03
Drawing Preparation
ES-14-101-04
Drawing Numbering
ES-14-101-06
Equipment Numbering System
ES-14-102-09
Labels and Signs: Plant and Equipment
ES-14-102-12
Protective Coatings
ES-14-202-14
Grouting
ES-14-301-05
Fixed Platforms, Walkways, Stairways and Ladders
ES-14-302-01
Fabrication of Structural Steel
ES-14-302-02
Erection of Structural Steel
ES-14-401-01
Mechanical Preferred Equipment
ES-14-402-01
Mechanical Equipment Design, Supply and Installation
ES-14-402-02
Testing and Commissioning of Mechanical Installations
ES-14-403-20
Monorails
ES-14-701-01
Electrical/Instrument Preferred Equipment
ES-14-902-01
Materials and Workmanship for Electrical Installations
ES-14-902-02
Testing and Commissioning of Electrical Installations
ES-14-903-12
Electric Motors
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Belt Conveyors CSBP Guide Manuals GM-05-043-01
Technical Data Requirements for Plant and Equipment
GM-05-050-01
Engineering Modifications
GM-10-020-04
Contractor’s Site Instructions
GM-11-035-02
Basic Safety Rules
GM-11-038-02
Slings, Rigging and Lifting Equipment Safety
CSBP Procedures DP-05-011-03
Maintenance Daily Schedule
DP-05-013-01
Work Order Entry and Approval
DP-05-013-04
Closing Maintenance Work Orders
DP-05-013-05
Developing Maintenance Strategies
DP-05-014-01
Maintenance Breakdown Repairs
EP-08-030-05
Engineering Project Files
EP-08-030-19
Engineering Project Design Review
EP-08-030-38
Engineering Project Handover
CSBP Standard Forms ES-14-101-12
Technical Data Sheets – Mechanical, Electrical and Instrument
Stage 1 Commissioning Inspection Reports SF1811
M101
General Mechanical
SF1812
M102
Fabric Carcass Conveyor
SF1813
M103
Miscellaneous Conveyor Equipment
SF1814
M104
Conveyor Idlers
SF1815
M105
Conveyor Pulley
SF1816
M106
Belt Conveyor
SF1823
M113
V-Belt Drive
SF1824
M114
Base Mounted Gear Reducer
SF1825
M115
Shaft Mounted Gear Reducer
SF1850
M140
Chute
Stage 2 Commissioning Test Reports SF1911
M201
General Mechanical
SF1912
M202
Fabric Carcass Conveyor Belt
SF1916
M206
Belt Conveyor
SF1923
M213
V-Belt Drive
SF1924
M214
Base Mounted Gear Reducer
SF1925
M215
Shaft Mounted Gear Reducer
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Belt Conveyors CSBP Standard Drawings 9900-3-0001/001
Standard 75º Ladder and Safety Cage Details
9900-3-0001/002
Standard Vertical Ladder and Safety Cage Details
9900-3-0001/003
Standard Stairway Details
9900-3-0001/004
Standard Platform, Handrail and Floor Grating Details
9900-3-0001/006
Landing for Stairs and Ladders
9900-3-0005/001
Standard Beam and Bracing Connection Details
9900-3-0005/002
Standard Beam Connection Details and Member Schedule
9900-3-0005/003
Structural Base Plates
9900-3-0005/004
Standard Column and Beam Bolted Splice Connection Details
9900-3-0006/000
Low Level Clearance Dummy Gantry
9900-4-0053/001
Standard Access Door
9900-4-0200/004
Conveyor General Stringer Arrangement
9900-4-0210/000
Typical Conveyor General Arrangement
9900-4-0240/000
Typical Head End Arrangement
9900-4-0250/000
Screw Take-up Arrangement
9900-4-0250/001
Screw Take-up Details
9900-4-0251/000
Gravity Take-up Arrangement
9900-4-0260/000
Typical Skirt Details (Dry Materials)
9900-4-0260/001
Conveyor Skirting Details (Dry Granular Materials)
9900-4-0260/002
Typical Skirt Details (Wet Materials)
9900-4-0260/003
Typical Skirt Details (Dry Uncoated AN Prill)
9900-4-0500/000
Conveyor Transfer Design For Dry Granular Fertilisers
9900-4-0550/001
UMHWPE Fixing Details
9900-4-2400/001
Standard Lifting Lug
9900-9-7011/000
Pullwire and High Burden Switch Installation Details
9900-9-7012/000
Pullwire Switch Installation Details
9900-9-7013/000
Pullwire and Blocked Chute Installation Details
9900-9-7015/000
Belt Drift Switches Installation Details
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Belt Conveyors Standards Association of Australia AS 1111 AS 1112 AS 1163 AS 1214 AS 1237 AS 1252
ISO Metric Hexagon Commercial Bolts and Screws ISO Metric Hexagon Nuts including Thin Nuts, Slotted Nuts and Castle Nuts Structural Steel Hollow Sections Hot-dip Galvanised Coatings on Threaded Fasteners Flat Metal Washers for General Engineering Purposes High-Strength Steel Bolts with Associated Nuts and Washers for Structural Engineering Conveyor Belting – Textile Reinforced Conveyor Belting of Elastomeric and Steel Cord Construction Methods of Testing Conveyor and Elevator Belting Rotating Electrical Machines – General Requirements Steel Sheet and Strip - Hot Dipped Zinc Coated or Aluminium/Zinc Coated Design of Rotating Steel Shafts Carbon Steels and Carbon-Manganese Steels – Hot Rolled Bars and Semifinished Products Carbon Steels and Carbon-Manganese Steels – Cold Finished Bars Wrought Alloy Steels – Standard, Hardenability (H) Series and Hardened and Tempered to Designated Mechanical Properties Cold-Formed Steel Structures Code Covered Electrodes for Welding Welding of Steel Structures Hot Rolled Steel Flat Products Fixed Platforms, Walkways, Stairways and Ladders – Design, Construction and Installation Conveyors - Design, Construction, Installation and Operation - Safety Requirements Certification of Welding Supervisors – Structural Steel Welding Packaging Roller Bearings – Dynamic Load Ratings and Rating Life SAA Wiring Rules Structural Steel Hot Rolled Plates, Floor Plates and Slabs Structural Steel Hot Rolled Bars and Sections Structural Steel Welded I Sections Vibration and Shock – Balance Quality of Rotating Rigid Bodies. Mechanical Equipment - Steelwork Safe Guarding of Machinery – Part 1: General Principles Steel Structures The Storage and Handling of Oxidising Agents Hot – Dip Galvanised (Zinc) Coatings on Fabricated Ferrous Articles
AS 1332 AS 1333 AS 1334 AS 1359 AS 1397 AS 1403 AS 1442 AS 1443 AS 1444 AS 1538 AS 1553 AS 1554.1 AS 1594 AS 1657 AS 1755 AS 2214 AS 2400 AS 2729 AS 3000 AS 3678 AS 3679.1 AS 3679.2 AS 3709 AS 3990 AS 4024.1 AS 4100 AS 4326 AS 4680
Other Engineering Standards and Publications AS/NZS ISO 9002 NFPA 490
Version No. 8.0
Model for Quality Assurance in Production, Installation and Servicing National Fire Protection Association Incorporated - Code for the Storage of Ammonium Nitrate
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Belt Conveyors 6.
BASIS OF DESIGN
6.1
BELT CONVEYOR DESIGN PROCESS
The belt conveyor design process is a systematic process, aimed at developing an appropriate reliable engineering solution with optimised life cycle costs, without compromising on safety or quality. The design process shall include the following activities: Select belt speed in accordance with Section 6.2 Select belt width in accordance with Selection 6.3. Select drive capacity in accordance with Section 6.4. Carry out detail design in accordance with Sections 6.5 to 6.8 and 7 to 25. Carry out design reviews in accordance with Section 6.9.
WARNING
SPECIAL DESIGN CONSIDERATION SHALL BE GIVEN TO CONVEYORS IN AN AMMONIUM NITRATE SERVICE. LOCATIONS WHERE AMMONIUM NITRATE COULD COLLECT AND BE CONFINED UNDER HIGH PRESSURE ARE AN EXPLOSION HAZARD IN THE EVENT OF A FIRE. COMPONENTS SHALL BE DESIGNED SO THERE ARE NO “HOLLOW SPACES” IN AMMONIUM NITRATE CONVEYORS.
6.2
BELT SPEED
Belt speeds shall be selected as appropriate to the application and shall avoid the possibility of spillage and excessive power consumption. Unless otherwise specified, the following maximum belt speeds shall normally apply: For short in-plant connecting / feed belts For medium transfer belts For long interplant / storage bin belts
6.3
- one (1) m/s - two (2) m/s - three (3) m/s
BELT WIDTH
Unless otherwise specified in the Works, or agreed to by the Superintendent, the belt width shall be selected based on a design capacity of 200% (2 times), the maximum rated process capacity.
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Belt Conveyors 6.4
DRIVE CAPACITY
Unless otherwise specified in the Works, or agreed to by the Superintendent, the drive capacity shall be based on 120% (1.2 times); the maximum rated process capacity, with due allowance for skirt and scraper friction and the increased power requirements for belt feeders fitted under material hoppers.
6.5
GENERAL
Belt take-ups shall not be positioned under feed or transfer points or anywhere where there is any likelihood of spillage from other parts of the plant. Layouts shall be designed such that in plan transfer angles, from one conveyor to another shall not be less than 90°, wherever possible.
6.6
DESIGN COMPUTATIONS
The Contractor shall supply design computations of the conveyor system to the Superintendent for approval, if requested. These computations shall include belt tensions, accelerating and decelerating forces and drive horsepower, conveyor belt speed, belt type/design, fricti on forces and take-up weights.
6.7
FOUNDATIONS AND SUPPORTS
The Contractor shall provide all necessary equipment loading data, drawings of bolt layouts and details of components to be built into the foundations. All loads imposed on other structures by the conveyors shall be specified on drawings, so that the design of the support structure can be verified.
6.8
TECHNICAL DATA
Equipment manuals, recommended maintenance schedules and spares list for all maintainable items and technical data sheets for each item of equipment shall be prepared and supplied by the Contractor, in accordance with the requirements of CSBP Guide Manual Technical Data Requirements for Plant and Equipment (GM-05-043-01).
6.9
DESIGN REVIEWS
Design reviews shall be carried out in accordance with CSBP Engineering Procedure Engineering Project Design Review (EP-08-030-19) , to ensure that the design is consistent with the agreed project criteria and it is compliant with CSBP Standards, Statutory Requirements and other applicable codes and practices.
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Belt Conveyors 7.
DRAWINGS
7.1
GENERAL REQUIREMENTS
All conveyor layout drawings, head and tail end arrangements, take-ups, chute work, marking plans, stairways, mechanical equipment supporting steelwork, platework and fabricated equipment components shall be drawn, numbered and approved in accordance with CSBP Engineering Standards: ES-14-101-02
Drawing Management
ES-14-101-03
Drawing Preparation
ES-14-101-04
Drawing Numbering
Typically drawings shall provide complete information necessary for the fabrication and erection of the conveyor system. The Superintendent’s review, approval or acceptance of Contractor drawings, does not relieve the Contractor of responsibility for accuracy of shop or site connection detailing, conformance to this or referenced standards or contractual obligations.
Note:
7.2
SPECIFIC REQUIREMENTS
7.2.1
Conveyor General Arrangement
The Conveyor General Arrangement shall consist of an elevation, cross-sections at appropriate points along the conveyor and a design information table. For typical Conveyor General Arrangement layout refer to CSBP Standard Drawing 9900-4-0210/000. Dependant on the size and configuration of the conveyor system or as directed by the Superintendent, the Conveyor General Arrangement shall indicate the following where applicable: a. b. c. d. e. f. g. h. i. j. k. l. m. n.
location plan; belt line, idlers and pulleys, working points and set out dimensions, idler spacing and type; amount of take-up; conveyor support structure; location of run-off, under-speed and emergency stop swit ches; conveyor crossovers and splicing platforms; location of transfer station column lines and floor levels; locations of feed points and discharge conveyor work point; lengths of travel of trippers, where applicable; surrounding ground level; clearance over roads, rail tracks and access ways; location of conveyor accessories; diagram of running tensions; Design Information Table comprising a schedule of belts, gearboxes, motors, reducers, couplings, pulleys, bearings, brakes, idlers, accessories used on the conveyor system together with conveyor and drive data. •
Associated equipment drawing numbers shall be recorded wherever possible.
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Belt Conveyors o.
Item numbers for all components listed in the Design Information Table schedule. •
Item numbers shall be shown on the conveyor elevation and cross-sections adjacent to the conveyor components. Symbols for each idler type and conveyor accessories.
p.
•
Symbols shall be shown adjacent to the item number in the Design Information Table schedule and on the conveyor elevation and cross-sections indicating where the conveyor components are located.
In accordance with CSBP Engineering Standards, Equipment Numbering System (ES-14-101-06) and Drawing Numbering (ES-14-101-04) the primary drawing number shall match the conveyor equipment number. EXAMPLE:
Conveyor Equipment Number: X0821 Conveyor General Arrangement drawing number _ _ _ _ – 4 – 0821 / 000
If a Conveyor General Arrangement would become very complex and difficult to understand with the amount of information to be included on a single sheet, consideration shall be given to having additional sheets numbered 001, 002 etc. The Design Information Table and Conveyor Profile shall always be placed on sheet 000. If, on very long conveyors all of the profile cannot be shown on sheet 000, sheets 001, 002 etc shall also be used. Similarly, cross-sections and other details shall be on sheets 001, 002 etc if space dictates. 7.2.1.1
Reference Drawings
Reference drawings, to be listed on the Conveyor General Arrangement shall include: •
structural arrangements;
•
head and tail end arrangements;
•
take-ups;
•
chute work;
•
conveyor guarding;
•
standard drawings relevant to the facility;
•
cross-reference between the General Arrangement sheet 000 and associated sheets 001, 002 etc.
7.2.2
Structural Steelwork Drawings
Typically, drawings shall provide complete information necessary for the fabrication and erection of all structural steelwork including member size, weight and dimensions, location, type and size of bolts and welds, joints and splices, erection mark numbers and reference to the required steel specification(s) and protection coating system. Additionally, ref erence to associated design drawing and erection diagram drawing numbers should be made.
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Belt Conveyors
8.
CONVEYOR BELTING
The Superintendent shall approve the fabric, tensile strength, number of plies and cover of the conveyor belting against each specific application. The preferred selections are as follows: Fabric Strength No of plies
-
PN 150kN/m/ply 3
Top Cover Bottom Cover -
5mm 1.5mm
Conveyor belting shall comply with the requirements of AS1332, or AS1333 if steel cord belting is used. Jointing of all conveyor belts shall be by hot vulcanising carried out in accordance with the belting manufacturer’s instructions. Mechanical splicing is not ac ceptable.
9.
PULLEYS
9.1
CONSTRUCTION
Pulleys shall be welded mild steel construction with ample strength for the loads imposed by the belt tension forces. Welding procedure shall take into consideration restraint between pulley shell and end plates. All welds shall be 100% visual and ultrasonic examined and permissible levels of imperfections shall be in accordance with AS 1554.1 If post weld heat treatment (PWHT) is specified, final non-destructive examination (NDE) shall take place after PWHT has been performed. Crowned pulleys shall be used when no other belt tracking devices can be used or when specified by the Superintendent. All shafts shall normally be fitted to pulleys with “Compression style locking elements” e.g. “Ringfeder”, except for ammonium nitrate conveyors. Refer to Sections 9.7.3 and 9.7.4 f or details.
9.2
DIAMETERS
Pulley diameters shall be to suit the belting being used and the desired belt speed. The thickness of the lagging on pulleys is to be disregarded in determining the diameter of pulleys. Where practicable, pulley diameters shall be restricted to 480mm and 630mm.
9.3
OVERALL WIDTH AND BEARING CENTRES
Unless otherwise specified or directed by the Superintendent, pulley face widths for dry areas shall be wider than the belt width in accordance with normal conveyor design practice.
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Belt Conveyors Unless otherwise specified, pulley face widths for wet areas (ie. the superphosphate manufacturing and granulation plants at CSBP Kwinana) shall be less than the width of the belt as per Table 1, so that no spillage will fall onto the pulley.
Belt Width – B in mm 300 450 500 600 750 900 1000 1200 1600 1800 2000 Table 1 Note:
9.4
Pulley Width in mm B minus 75 B minus 75 B minus 75 B minus 100 B minus 100 B minus 150 B minus 150 B minus 150 B minus 150 B minus 200 B minus 200 Pulley Width
The bearing centres of non-driving head pulleys and snub pulleys at drives shall be the same as for drive pulleys.
TOLERANCES
Pulley diameters shall be machined to a maximum tolerance of nominal diameter ±3mm. Concentricity with shaft centres measured as total movement on a dial type indicator, to be within 0.8mm for non-lagged pulleys and 1.5mm for lagged pulleys. The difference in diameters as measured at opposite ends of the shell shall not exceed 0.8mm per linear metre. The shell thickness of the finished pulley shall be not less than the minimum calculated thickness or 5mm, whichever is greater and shall not vary from place to place by more than 0.8mm. Shell thickness shall be measured ultrasonically.
9.5
PULLEY LAGGING
In general all conveyor pulleys shall be rubber-lagged. 9.5.1
Rubber Lagging
Rubber lagging of pulleys shall be hot vulcanised to the pulley shells. The lagging shall be 12mm thick, free of spiral wrap marks with hardness in the range of 50 – 60 Shore A Durometer hardness. After fixing the lagging, it shall be ground to the correct size and concentricity if required to comply with manufacturer’s tolerances.
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Belt Conveyors Rubber lagging on head pulleys shall be grooved in a diamond pattern. 9.5.2
Ceramic Lagging
Head pulleys in the Compound Fertiliser areas shall be ceramic lagged. Fixing to the pulley shells shall be in accordance with the manufacturer’s instructions.
9.6
BALANCING
All pulleys shall be statically balanced. Additionally, when specified by the Superintendent, they shall be dynamically balanced.
9.7
PULLEY SHAFTS
9.7.1
General
Shafts shall be designed in accordance with the requirements of AS1403. Unless otherwise specified, shafts shall normally be manufactured from K1045 material as nominated in AS1442, AS1443 and AS1444. Higher grade 4140 material shall be used if shaft loads dictate. 9.7.2
Diameter Reduction
All diameter reductions must be carefully machined, all corners rounded and shoulders blended with swept radii free of tool marks. Where the major diameter reduction is machined using a fillet, the radius of this fillet shall be not less than D/10 and preferably at least D/5, where ‘D’ is the reduced diameter of the shaft. 9.7.3
Compression Type Locking Element Pulley Shaft Assembly
All shafts shall be fitted to the pulley with Superintendent approved compression type locking elements such as Ringfeder 7012, Mav 2005 or Mav 1061’s or equivalent, except for ammonium nitrate conveyors or elsewhere where it is specified that a fully welded pulley/shaft assembly is required. They shall be supported by plummer block type anti-friction bearings. Refer to Section 9.7.4 for welded assembly details. Note:
9.7.4
Use of plummer blocks does not apply to screw take up arrangement and may not apply to head pulleys on small to medium sized conveyors. Welded Pulley Shaft Assembly
To prevent ingress of ammonium nitrate into the pulleys, thus reducing any potential explosion risk, pulley and shaft assemblies for this service shall be fully welded, i.e. the shafts shall be fully welded to the end plates, which in turn are to be fully welded to the pulley shell.
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Belt Conveyors 9.8
PULLEY SHAFT BEARINGS
All pulley shaft bearings shall be of the ball or roller type with a minimum B10 life of 60,000 hours or higher if specified by the Superintendent Unless otherwise specified, bearing housing shall be: a.
SKF, SNH series or equivalent from CSBP approved supplier, two bolt mounting plummer blocks, fitted with Taconite seals for shafts up to 150mm diameter and
b.
SKF, series SD31 or equivalent from CSBP approved supplier, four bolt mounting plummer blocks, fitted with Taconite seals for shafts over 150mm diameter.
10.
CONVEYOR IDLERS
10.1
GENERAL
Width of idlers shall be consistent with and based on pulley width, as required for wet or dry areas (see Section 9.3). 10.1.1 Balance All idler rolls shall be suitably balanced for operation at speeds 25% in excess of the speed shown in the drawings, to have a maximum out of balance of 0.056Nm. Weigh idlers shall be balanced within 0.014Nm. Maximum peripheral runout of idler shells when rotated on their own shafts shall be not more than 0.5mm movement for rubber surface idlers, measured on the periphery of the rubber. In general, idlers fitted to belt scrapers shall be precision balanced types. Additional precision balanced idlers shall be installed adjacent to the weigh idler in accordance with the weigh idler manufacturer’s requirements. 10.1.2 Bearings All bearings in idler rolls shall be of ball roller type. They shall be designed in accordance with the bearing manufacturer’s catalogue ratings for a B10 life of 60,000 hours service, or higher if specified by the Superintendent and at a continuous loading equivalent to the maximum loading imposed by the conveyor rated load. Idler roll bearings shall be of an approved sealed-for-life type. 10.1.3 Idler Profile The horizontal and vertical deviations from design values shall be limited to ±3mm. Idlers installed on belt conveyors that incorporate weighing idlers shall have a profile tolerance as specified by the weighing equipment manufacturer.
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Belt Conveyors 10.2
TROUGH IDLERS
The Superintendent shall approve trough idlers, which shall be three-roll offset type. All rolls are to be of equal length and interchangeable. Preferred troughing angle is 35°. Where necessary, adjustable trough transition idlers shall be provided over the transition length of conveyor head and tail ends and shall be arranged to uniformly effect transition with minimal increase in belt edge tension zone. Longitudinal buckling of the belt in the transition zone will not be accepted. The angle of the outer roll of transition idlers shall be adjustable through a range of 10° to 35°. Trough idler rolls shall be 127mm diameter, lagged with 6mm thick, 50-60 shore A Durometer hardness rubber, unless otherwise specified. All types of trough idlers, for each particular belt size, shall have the same profile dimensions and are to be interchangeable. Spacing of trough idlers shall be to suit loading requirements of individual conveyors and shall be spaced to give a maximum of 1.5% sag for all conveyors Closer spacing shall be used on convex vertical curves. Graded zone spacing may be used where approved.
10.3
TROUGH IMPACT IDLERS (IF REQUIRED)
Trough impact idlers shall be three roll offset type, heavy-duty rubber disc. All rolls are to be interchangeable. All impact rolls shall be positively locked into their frames and fitted under all loading points, for sufficient distance, to ensure that all impacts on the belt are taken over the impact idlers. The spacing of impact idlers shall not exceed 300mm centres. Provision shall be made to install and withdraw any idler assembly without disturbing adjacent idlers.
10.4
TROUGH TRAINING IDLERS
Trough training idlers shall be fitted with rolls interchangeable with those of normal trough idlers. Side guide rolls shall have ball or roller bearings and shall not be less than 50mm diameter. Trough training idlers shall be fitted to all conveyors that are twenty (20) metres or greater in length and shall be located in the following locations where possible: a.
Six (6) metres from head and tail pulleys.
b.
At 35 metre centres for conveyors up to 125 metres in length.
c.
At 60 metre centres for conveyors in excess of 125 metres long.
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Belt Conveyors When fitted to Reversing Conveyors, trough-training idlers shall be capable of operating in both directions.
10.5
RETURN IDLERS
Unless otherwise specified, return idlers shall be 127mm diameter, “flat roll” (rubber) for fabric belts and “vee roll” for steel cord belts. Flat roll, return idler rolls shall be lagged with 6mm thick, 50-60 shore A Durometer hardness rubber. Unless otherwise approved by the Superintendents, spacing of return idlers shall not exceed three (3) metres.
10.6
RETURN TRAINING IDLERS
Return training idlers shall be flat self-training idlers with rolls interchangeable with those of normal return idlers. Side guide rolls shall have ball or roller bearings and shall be 50mm minimum diameter. Spacing of return training idlers shall be as per trough training idlers. Refer to Section 10.4 for details. When fitted to Reversing Conveyors, return training idlers shall be capable of operating in both directions.
10.7
AMMONIUM NITRATE CONVEYORS
To minimise potential explosion risk, construction of ammonium nitrate prill conveyors have the following special requirements. 10.7.1 Return Idlers Return idlers shall be solid shafts with rubber discs. Shafts shall be fixed to the conveyor stringers in such a way that there are no locations where ammonium nitrate can accumulate. 10.7.2 Carrying Idlers Carrying idler rolls shall be filled with expanded closed cell polyurethane foam, or another material approved by the Superintendent. 10.7.3 Conveyor Belting All conveyor belting shall be of fire retardant type. Conveyor belting to be used for coated ammonium nitrate prill shall be polyvinyl chloride (PVC) coated to resist the effects of the coating agent on normal rubber belt covers.
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Belt Conveyors Conveyor belting for inclined conveyors, used for coated prill, shall incorporate a anti-slip texture such as scallops or a similar texture approved by the Superintendent.
11.
GEARBOXES
Gearboxes shall be shaft-mounted and supplied in accordance with CSBP Engineering Standard Mechanical Preferred Equipment (ES-14-401-01).
12.
BELT TAKE-UP
Unless otherwise specified, gravity take-ups shall be used on all conveyors except for short conveyors up to forty (40) metres in length, which shall use a screw take-up system. Short conveyors incorporating a weightometer (belt scale) shall have some type of gravity take-up to ensure the accuracy and consistency of the weightometer. Refer to the following CSBP Standard Drawings for typical arrangement details: 9900-4-0250/000
Screw Take-up Arrangement
9900-4-0251/000
Gravity Take-up Arrangement
Take-ups shall be sized for the required belt tension and take-up travel based on the belting manufacturer’s recommendations. All conveyor gravity take-up pulleys shall be fitted with shedder plates above them to prevent spillage wedging between the pulleys and conveyor belts.
12.1
GRAVITY TAKE-UP
Take-up side guides shall be equipped with wooden or plastic guide blocks. Gravity take-up weights shall be constructed from steel plate filled with concrete and shall be fitted with shedder plates to prevent accumulation of spillage from the belt. Provision shall be made for adding or removing weight. The assembly shall be weighed by the Contractor to verify the correct design mass. The Superintendent shall witness the weighing of the take-up and the certified mass in kilograms shall be painted on the take-up frame in 50mm high black letters. Lifting lugs shall be provided on the top of the structure and on the gravity take-up weight, to facilitate lifting. For lifting lug details refer to CSBP Standard Drawing 9900-4-2400/001. For general arrangement and details of typical gravity take-ups refer to CSBP Standard Drawing 9900-4-0251/000. The Superintendent shall specify the preferred type of gravity take-up for relevant conveyors.
12.2
SCREW TAKE-UP
Unless otherwise specified, take-up housings shall be SKF THM 500 series or equivalent from a CSBP approved supplier, fitted with Taconite seals for shafts up to 140mm diameter.
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Belt Conveyors Exposed thread on take-up screws shall be wrapped with Denso tape or approved equivalent in accordance with manufacturer’s instructions after final adjustment of the belt tension has been completed. For screw take-up arrangement and details refer to CSBP Standard Drawings 9900-4-0250/000 and 9900-4-0250/001.
13.
BELT SCRAPERS
A primary belt scraper shall be provided at the head pulley of each conveyor to clean the carrying side of the belt. Discharge chutes shall be arranged so that material scraped from belts will discharge into chutes. Secondary scrapers shall be fitted where specified and shall scrape into chutes too. Primary scraper blades shall be replaceable polymer sectional type and secondary scraper blades shall be non-metallic unless otherwise specified. Special scraper requirements exist in the wet areas of the SMP and some ammonium nitrate prill areas. Additional information will be provided for individual projects in these areas. Where specified, belt cleaning brushes shall be fitted. Brushes shall be used in lieu of blade type scrapers for textured belts (eg scalloped belts), where blade type scrapers cannot be used. Brushes shall be located to ensure all material brushed off belts falls into the associated head chute. Where specified a plough type scraper shall be located on the inside of the return side of all belts, close to the tail pulley. Blades of plough type scrapers shall be non-metallic to minimise the wear inside the belt. The proposed type and position of scrapers shall be submitted to the Superintendent and approval obtained, before any item is fabricated or purchased.
14.
RUBBER SKIRTING
Rubber skirting shall be provided at all transfer and loading points and wherever there is any likelihood of material spillage from the belt. Unless specified otherwise or directed by the Superintendent, skirts and clamps shall be as shown on CSBP Standard Drawings 9900-4-0260/000, 9900-4-0260/001, 9900-4-0260/002 or 9900-40260/003 for the relevant type of material. In ammonium nitrate despatch areas where prill is dry and at or near ambient temperature, the skirt design on 9900-4-0260/000 shall be used. In ammonium nitrate manufacturing areas where uncoated prill is wet and/or at elevated temperature, the skirt design on 9900-4-0260/003 shall be used. Approval of proprietary skirting systems shall be at the sole discretion of the Superintendent.
15.
CHUTES AND HOODS
15.1
DESIGN
Chutes and hoods shall be provided at all transfer points. For dry granular fertilisers, typical conveyor transfer design details shown on CSBP Standard Drawing 9900-4-0500/000 shall be used.
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Belt Conveyors Chutes shall be designed so that adequate space is available below the head pulley and conveyor to accommodate belt scrapers, magnetic head drums with waste disposal chutes and product samplers if used and to allow for operational headroom and maintenance service access as required. Designs shall be such that the extremities of the material trajectory fall evenly each side of the conveyor centre line, based on the Dunlop Methodology for Conveyor Design or a similar method. Due to the significant potential for product build-up on surfaces and the resultant cleaning burden, designs incorporating impact plates will not be acceptable unless approved by the Superintendent. Where possible, chute designs shall prevent direct impact of product onto chute surfaces. Inspection doors shall be provided in all transfer hoods and chutes, to facilitate access for cleaning and maintenance purposes. The openings shall be as large as practicable and constructed in accordance with CSBP Standard Drawing 9900-4-0053/001. Where maintenance and inspection openings are intended to be used while the equipment is in operation, a guard mesh shall be bolted into the opening to allow observation without exposing personnel to an unsafe opening. Where chutes are provided with outlet gates, the gates shall be of arc or clamshell types. Horizontal slide gates are not generally acceptable but may be approved by the Superintendent for particular applications. Chute valley angles and configurations shall be made to suit the material being handled but in general shall not be less than 60 °. Where possible, chutes shall be vertical to minimise the potential for product build-up on surfaces.
15.2
DUST SUPPRESSION
All hoods and chutes shall be designed to minimise dust movement during plant operation. The following principles shall be observed: a.
Material drop shall be reduced to the practical minimum.
b.
The free falling column of material shall be maintained where possible in the “compressed” condition, to minimise air entrapment.
c.
Transfer points shall be fully enclosed and sealed with rubber strip curtains to prevent entry of outside air.
d.
The downstream conveyor shall be enclosed at the outlet of the transfer point with a cover of minimum length two (2) times the belt width and 500mm or 250% of material lump size (whichever is the greater), above the belt at the conveyor centre-line. The whole length of the cover shall be provided with standard rubber skirting. Refer to CSBP Standard Drawing 9900-4-0500/000 for details.
e.
Dust collection points, when installed, shall be positioned downstream of transfer points, to maximise dust settling inside the skirted transfer point.
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Belt Conveyors 15.3
CONSTRUCTION
Unless otherwise specified, chutes shall be of skeletal steel frame construction with 6mm (minimum) thick rubber panels and hoods fabricated from 6mm (minimum) thick steel, stiffened and supported as required. All chutes and hoods shall be designed and constructed so that they are readily removable for maintenance purposes. Standard lifting lugs as per CSBP Standard Drawing 9900-4-2400/001 shall be provided. Note:
16.
Where material is likely to impact the chutes, they shall be lined with UHMW polyethylene in accordance with CSBP Standard Drawing 9900-4-0550/001.
CLEARANCES
All conveyors shall have a minimum clearance between the underside of the return belt and the ground surface or floor of one (1) metre. Where required by design constraints, this clearance may be reduced, with the approval of the Superintendent. Conveyor stringer supports and transfer structures shall give clear access below the belt and bracing. Transfer structures shall be clear to a height of three (3) metres above ground level. To achieve this, the use of portal type structures is recommended and the use of diagonal cross bracing shall be kept to a minimum. Where crane or vehicle access is required under elevated conveyors, the minimum height clearance shall be six (6) metres and the minimum width clearance shall be ten (10) metres. Note:
Where the minimum height cannot be achieved, a low-level clearance-warning gantry shall be installed. Refer to CSBP Standard Drawing 9900-3-0001/006 for typical details.
The minimum head clearance between a conveyor walkway, platform and any structures over the conveyor walkway, shall be 2.2 metres. Note:
17.
Where the minimum height cannot be achieved, low clearance warning signs shall be clearly displayed and any low overhead structure shall be locally painted with hazard warning 100 mm wide black and yellow diagonal stripes.
ACCESS AND MAINTENANCE FACILITIES
All walkways, platforms and stairways on conveyor structures shall be in accordance with CSBP Engineering Standard Fixed Platforms, Walkways, Stairways and Ladders (ES-14-301-05) and CSBP Standard Drawings 9900-3-0001/003, 9900-3-0001/004 and 9900-3-0001/006. Wherever possible, all conveyor structures shall be designed with clear space on both sides of the belt for idler removal, replacement and belt splicing access. The belt splicing area shall be identified on the conveyor framework using black lettering on a yellow background, stating “Belt Splicing Area”.
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Belt Conveyors When designing walkways around conveyors, a minimum walkway width of 600mm (preferably 750mm) shall be maintained, measured from the outermost part of the conveyor. If pull wires and /or pull wire switch boxes are outside the conveyor frame then t he walkway widths shall be outside the pull wires and pull wire switch boxes. Particular attention should be made to the walkway design around transfer points where the guarding and pull wires can be several hundred millimeters outside the conveyor frame. Elevated conveyors shall be provided with walkways on both sides of the conveyor. The main walkway shall be at least 750mm wide and the maintenance walkway shall be at least 600mm wide. These widths shall be measured as described above Crossovers shall be provided at 100 metre intervals along the belt. Adequate lifting beams and monorails shall be built into the conveyor structures at drive and transfer points for handling heavy components during maintenance operations. Refer to CSBP Engineering Standard Monorails (ES-14-403-20) and CSBP Standard Drawing 9900-4-2400/001 for lifting lug details. No pipes or cables shall be run parallel to and immediately below any belt conveyor. Where conveyor structures are used to support pipe racks or cable ladders, the pipe racks and cable ladders shall be positioned so they do no obstruct any conveyor maintenance operation, especially belt changing and splicing, changing of idler assemblies and spillage clean up.
18.
SAFETY REQUIREMENTS
Conveyor components shall be designed in accordance with the safety requirements of Statutory Authorities, AS 1755 - Conveyor Safety Code and CSBP’s relevant Engineering Standards and Standard Drawings.
18.1
CONVEYOR GUARDS
Conveyor guards shall be designed to remove any foreseeable risk of personal injury by accidental contact with equipment. They shall be designed to enable routine visual inspection to be carried out on the equipment without removing the guards. Guards around transfer points and areas where adjustments are made, shall be designed where possible to be able to be handled by one person to provide quick access to items such as idlers, skirting and take-up adjustments. Where possible, guards at these locations should be made of light weight material such as aluminium or plastic and not weigh more than 15kg. In these locations guards should not have a width, length or height greater than 1000mm, to ensure they are relatively simple to handle by one person. It shall be possible to remove guards without having to disconnect pull wires. It is suggested that where a guard extends vertically both above and below the pull wire by more than 300mm, the guard be split into two separate sections with the split being directly behind the pull wire.
18.2
ANTI-ROLL BACK
All inclined conveyors shall be fitted with an anti-roll back device on the reduction gearbox shaft.
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Belt Conveyors Fitting of brakes may also be required on other conveyor types or for specific purposes eg to prevent “run on”. In particular, inclined reversing conveyors shall be fitted with a brake instead of a gearbox mounted anti-roll back device.
18.3
EMERGENCY LANYARD SWITCHES
All conveyors shall be fitted with continuous pull wires and pull wire switches in accordance with CSBP Standard Drawings 9900-9-7011/000, 9900-9-7012/000 and 9900-9-7013/000. On elevated conveyors with walkways on both sides of the belt, pull wires shall be provided on both sides. Pull wires shall be installed outside of guarding and where possible at least 100 mm clearance shall be provided between the pull wire and the guard or any other solid object. Other than where pull wires pass through eye bolts or other guides, the clearance shall not be less than 50 mm.
18.4
MONITORING DEVICES
All conveyors shall be fitted with belt-drift detection tilt switches, or a Superintendent approved equivalent, fitted in accordance with standard drawing 9900-9-7015/000 and as follows: a.
On belts ten (10) metres or larger in length, four (4) switches shall be fitted. One each side of the trough and return belt leading onto the head and tail pulleys.
b.
On belts less than ten (10) metres in length, two (2) switches shall be fitted at the head end only.
All conveyors shall be fitted with an under-speed sensing switch. This device shall be fitted to the tail pulley. Where specified, conveyor discharge chutes shall be fitted with a “blocked chute” probe in accordance with CSBP Standard Drawing 9900-9-7013/000. All gravity take-up weights shall be provided with end travel, limit detection switches. All monitoring devices shall be as specified in CSBP Engineering Standard Electrical/Instrument Preferred Equipment (ES-14-701-01) .
18.5
NOISE
No part of the conveyor system shall emit noise levels exceeding 85dB(A), at a distance of one (1) metre from the source.
19.
IDENTIFICATION
19.1
EQUIPMENT NUMBERS
All equipment shall be assigned an identification number in accordance with CSBP Engineering Standard Equipment Numbering System (ES-14-101-06).
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Belt Conveyors 19.2
MOTOR IDENTIFICATION TAG
All electric motors shall be fitted with an identification tag in accordance with CSBP Engineering Standard Electric Motors (ES-14-903-12).
19.3
EQUIPMENT LABELS
Equipment labels shall be manufactured and installed in accordance with CSBP Engineering Standard Labels and Signs: Plant and Equipment (ES-14-102-09).
20.
MATERIALS
Unless otherwise specified or approved by the Superintendent all materials shall be new and comply with the following CSBP Engineering Standards: ES-14-302-01
Fabrication of Structural Steelwork
ES-14-401-01
Mechanical Preferred Equipment
ES-14-701-01
Electrical/Instrument Preferred Equipment
ES-14-902-01
Materials and Workmanship for Electrical Installations
21.
HANDLING OF STEELWORK AND EQUIPMENT
Care shall be taken at all times to prevent damage to steelwork, equipment and their protective coatings. Equipment shall be carefully packed for transportation to protect it from dust, moisture, climatic conditions and vibration which may occur during loading and transport. Heavy and bulky equipment shall have provision for lifting, slinging and handling during transit, erection and maintenance periods. Any parts normally lifted during maintenance periods and weighing one (1) tonne or more shall be marked with their weight. If spreaders are required for slinging, a label stating the requirements shall be fitted near each lifting point. Damaged materials and coatings shall be repaired in accordance with applicable standards and manufacturer’s instructions, to the satisfaction of the Superintendent or they shall be replaced.
22.
FABRICATION
Unless otherwise specified fabrication of conveyor system steelwork and components shall be in accordance with CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01).
23.
WELDING
Unless otherwise specified all welding shall conform with CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01) and: a.
AS 1554.1 Category SP (Special Purpose), for all structural welding and conveyor supporting steelwork
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Belt Conveyors b.
AS 1554.1 Category GP (General Purpose), for welding of all chutework and other conveyor ancillary steelwork items.
24.
BOLTING
Unless otherwise specified all bolting shall conform with CSBP Engineering Standard Erection of Structural Steelwork (ES-14-302-02) and: a.
AS 1252 Grade 8.8/TB bolts for structural bolted connections
b.
AS 1252 Grade 8.8/S for general bolted connections.
25.
PROTECTIVE COATINGS
25.1
STEELWORK
Surface preparation and protective coating shall be in accordance with CSBP Engineering Standard Protective Coatings (ES-14-102-12). Coating system and colour shall be as specified for the particular area in which the conveyor is installed.
25.2
MECHANICAL AND ELECTRICAL COMPONENTS
Protective coating and finish of mechanical and electric components shall be to the manufacturer’s standard except those components covered by CSBP Engineering Standard Protective Coatings (ES-14-102-12).
25.3
BOLTS
Unless otherwise specified, all bolts nuts and washes shall be hot-dip galvanised in accordance with AS1214.
25.4
FLOOR GRATING AND STAIR TREADS
Floor grating and stair treads shall be hot dipped galvanised in accordance with AS 4680. Unless otherwise specified, floor grating shall be welded in place and stair treads shall be bolted to stairway stringers.
26.
INSTALLATION
26.1
MECHANICAL/STRUCTURAL
All mechanical and structural installation activities including setting out, erection, bolting, field welding and, grouting of steelwork and machinery base plates shall be carried out in accordance with: a.
the drawings;
b.
Superintendent approved Contractor erection procedures;
c.
CSBP Engineering Standards: •
ES-14-202-14
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Belt Conveyors • • •
d. Note:
26.2
ES-14-302-02 ES-14-403-20 ES-14-301-05
Erection of Structural Steelwork Monorails Fixed Platforms, Walkways, Stairs & Ladders
Statutory Authorities having jurisdiction over the work site. Prior to installation, bolt holes in chute flanges and those in equipment flanges and supporting steelwork shall be checked for alignment accuracy. Discrepancies shall be reported to the Superintendent and rectification work carried out to the satisfaction of the Superintendent.
ELECTRICAL
All electrical installation activities shall be in accordance with: a.
the drawings;
b.
Superintendent approved Contractor installation procedures;
c.
CSBP Engineering Standard Materials and Workmanship for Electrical Installations (ES-14-902-01);
d.
Statutory Authorities having jurisdiction over the work site.
27.
INSPECTION AND TESTING
27.1
INSPECTION AND TEST PLAN
The Contractor shall submit Inspection and Test Plans (ITP), for all aspects of the work, to the Superintendent for approval, at least 14 days prior to commencement of any work, which may be affected. The Contractor shall not proceed with any related work until the Superintendent has approved the ITP. The ITP shall identify: a.
The inspection, tests and verifying procedures to be performed, including those specified in this Standard and any others in the Works.
b.
The acceptance criteria for each procedure and the standard or process under which they are to be performed.
c.
The point, during the execution of the Works, at which the procedure is to be performed.
d.
Who is to perform the procedure.
e.
The procedures to be witnessed by the Superintendent and whether or not subsequent work is to be held pending the Superintendent’s approval of the procedures and t heir results.
27.2
WELD INSPECTION AND TESTING
Weld inspection and testing shall be in accordance with AS 1554.1 and CSBP Engineering Standards: ES-14-302-01 Fabrication of Structural Steelwork ES-14-302-02 Erection of Structural Steelwork.
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Belt Conveyors
27.3
FABRICATED STEELWORK INSPECTION
All fabricated structural steelwork shall be inspected in accordance with CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01).
27.4
INSPECTION DURING INSTALLATION
The following areas shall be inspected and approved by the Superintendent: a.
Surface preparation of concrete footing prior to erection of structural support steelwork.
b.
Setting out and alignment tolerances.
c.
Cutting, drilling and welding of existing steelwork.
d.
Surface preparation and protective coating of remedial works and field welds.
e.
Cleaning and surface preparation, of the underside of support column and machinery base plates, holding down bolts and concrete foundations prior to grouting.
Inspection shall be carried out in accordance with relevant Australian Standards and CSBP Engineering Standards: •
ES-14-102-12
Protective Coatings
•
ES-14-202-14
Grouting
•
ES-14-302-02
Erection of Structural Steelwork
•
ES-14-403-20
Monorails
28.
COMMISSIONING
Prior to being placed into service the conveyor system shall be subject to the following commissioning activities.
28.1
STAGE 1 - PRE-COMMISSIONING / CONSTRUCTION VERIFICATION
All components within the conveyor system shall be inspected to verify that they have been fabricated / manufactured, supplied, installed, aligned and lubricated in accordance with: •
contract drawings and documentation;
•
Standards and Codes specified in this Standard;
•
Statutory Regulations;
•
Manufacturer’s requirements.
Tests and calibrations shall be carried out to prove that all systems are operational, including protective and measuring devices. Testing and commissioning of all belt conveyor electrical and instrument equipment shall be carried out in accordance with CSBP Engineering Standard Testing and Commissioning of Electrical and Instrumentation Installations (ES-14-902-02).
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Belt Conveyors The following Stage 1 Mechanical Commissioning Inspection Reports shall be used to verify equipment details: •
SF1811 M101
General Mechanical
•
SF1812 M102
Fabric Carcass Conveyor
•
SF1813 M103
Miscellaneous Conveyor Equipment
•
SF1814 M104
Conveyor Idlers
•
SF1815 M105
Conveyor Pulley
•
SF1816 M106
Belt Conveyor
•
SF1823 M113
V-Belt Drive
•
SF1824 M114
Base Mounted Gear Reducer
•
SF1825 M115
Shaft Mounted Gear Reducer
•
SF1850 M140
Chute
Note:
28.2
Stage 2 Commissioning of an item of equipment shall not commence until the Superintendent has accepted and signed off all the Stage 1 Commissioning Inspection Reports for the item of equipment, as being successfully completed.
STAGE 2 – “DRY” COMMISSIONING
This stage involves actual running of equipment under ‘no-load’ conditions, except where manufacturer’s instructions state this would be detrimental to the equipment. Mechanical testing shall only commence after motor rotational tests and electrical control and safety checks have been carried out. Refer to CSBP Engineering Standard Testing and Commissioning of Electrical and Instrumentation Installations (ES-14-902-02) for details. No-load running testing shall include: a.
checking and recording the motor amps;
b.
checking the correct operation of the equipment;
c.
checking for evidence of misalignment, overheating or abnormal wear;
d.
measurement of bearings and gear vibrations;
e.
adjustments and correction of all faults
The plant shall be run for a sufficient length of time to establish that it is in a reliable and serviceable condition. The following Stage 2 Commissioning Test Reports shall be used to test equipment under ‘no-load’ condition: •
SF1911 M201
General Mechanical
•
SF1912 M202
Fabric Carcass Conveyor Belt
•
SF1916 M206
Belt Conveyor
•
SF1923 M213
V-Belt Drive
•
SF1924 M214
Base Mounted Gear Reducer
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Belt Conveyors •
SF1925 M215
Stage 3 Commissioning an item of equipment shall not commence until the Superintendent has accepted and signed off all the applicable Stage 2 Commissioning Inspection Reports for the equipment, as being successfully completed. Only suitably qualified and experienced personnel shall carry out testing activities.
Note:
28.3
Shaft Mounted Gear Reducer
STAGE 3 – “WET” COMMISSIONING
This stage involves testing and adjusting equipment, with the conveyor system operating under ‘load’ condition, i.e. running material through the process equipment. The Contractor, under the direction of the Superintendent shall carry out this work.
29.
OPERATIONAL PHASE
Flow diagram Figure 1 shows the high level activities involved in the management of a commissioned, belt conveyor systems during the operational phase. Reference to relevant clauses in this Standard and other CSBP documents are made.
29.1
MAINTENANCE STRATEGY
A maintenance strategy, in accordance with CSBP Departmental Procedure Developing Maintenance Strategies (DP-05-013-05), shall be established and full details covering the belt conveyor system, inspection and preventative maintenance requirements recorded in the JDE Maintenance Information Management System. 29.1.1 Ammonium Nitrate Conveyors Special consideration shall be given when developing a strategy for conveyor preventative maintenance and replacement of equipment, in an ammonium nitrate service. Any location where ammonium nitrate could collect and be confined under pressure is an explosion hazard in the event of a fire. 29.1.1.1
Inspection
Frequent visual inspection shall be included in the maintenance inspection plan, to ensure that any location that has an ammonium nitrate build-up is identified quickly and appropriate remedial action taken. 29.1.1.2
Equipment Replacement
Pulley and shaft assembly shall be a fully welded configuration. Refer to Section 9.7.4 for details. Return idlers shall have solid shafts and carrying idlers shall be filled with polyurethane or other approved material. Refer to Section 10.7 for details.
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Belt Conveyors 29.2
INSPECTION DURING OPERATIONAL PHASE
Inspections shall be carried out in accordance with the Preventative Maintenance Inspection Plan and results recorded, to establish whether any remedial work is required. Areas of inspection shall include, but not be limited to the following: a.
Locations of ammonium nitrate build-up, in ammonium nitrate conveyor systems.
b.
Extent of corrosion and condition of protective coating on conveyor system steelwork including; conveyor support structures, take-up structures, walkways, platforms, stairways, platework, fabricated equipment components and connection bolts.
c.
Extent of corrosion and condition of protective coating on mechanical and electrical components.
d.
Tightness of bolted connections especially in areas subject to vibration.
e.
Wear clearances and alignment on all moveable components being within manufacturer’s limits.
f.
Condition of chains, wire ropes and slings where fitted. Refer to CSBP Guide Manual Slings, Rigging and Lifting Equipment Safely (GM-11-038-02) and CSBP Engineering Standard Monorails (ES-14-403-20) for requirements.
g.
Condition of electric motors, cabling, controls, lights, horns, lanyards, under speed switches, proximity switches, electromechanical brakes, belt drift switches, blocked chute switches, weigh frames/load cells, etc.
h.
Functioning of emergency stop and control devices.
Based on inspection findings, maintenance work shall be carried out in accordance with work priority or if an engineering modification is required, changes shall be implemented in accordance with CSBP Guide Manual Engineering Modifications (GM-05-050-01). All closeout details shall be recorded in the JDE System.
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Belt Conveyors
30.
RECORDS MANAGEMENT
30.1
AS - BUILT DRAWINGS
On completion of installation, testing and commissioning activities, drawings shall be upgraded to reflect any as-built design deviations. Drawings recording the as-built details shall be prepared/revised, numbered, approved and handed over in accordance with CSBP Engineering Standards: •
ES-14-101-02
Drawing Management
•
ES-14-101-03
Drawing Preparation
•
ES-14-101-04
Drawing Numbering
30.2
ENGINEERING PROJECT FILES
On completion of the project and handover to the Business Unit, in accordance with CSBP Engineering Procedure Engineering Project Handover (EP-08-030-38), all relevant hard-copy documentation shall be archived in the designated work area in numbered project files. Records in electronic format (such as drawings and JDE data) shall be stored in the appropriate databases and designated work area. Refer to CSBP Guide Engineering Modifications (GM-05-050-01) and CSBP Engineering Procedure Engineering Project Files (EP-08-030-05) for type of documents to be retained for historical purposes.
30.3
MAINTENANCE WORK ORDERS
On completion of the maintenance work order, details shall be recorded in accordance with CSBP Departmental Procedure Closing Maintenance Work Orders (DP-05-013-04).
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