DC-002 MECHANICAL DESIGN CRITERIA

SINO IRON PROJECT

DC-002 MECHANICAL DESIGN CRITERIA Doc No:

DI-024726

Revision:

03 Status:

AFD Rev Date:

17 Sept 2008

Uncontrolled when printed Mechanical Design Criteria No: DI-024726 Page: 2 of 82

CONTENT 1 SCOPE ............................................................................................................................. 8 2 REFERENCED DOCUMENTS ........................................................................................ 8

2.1 Acts and Regulations ................................................................................................ 8 2.2 Design Criteria .......................................................................................................... 8 2.3 Engineering Specifications ....................................................................................... 9

2.3.1 General / Multidiscipline .................................................................................... 9 2.3.2 Civil, Structural and Architectural ...................................................................... 9 2.3.3 Mechanical ........................................................................................................ 9 2.3.4 Pumping and Piping .......................................................................................... 9 2.3.5 Electrical ............................................................................................................ 9 2.3.6 Instrumentation and Control .............................................................................. 9 2.3.7 Communication ............................................................................................... 10 2.3.8 Drawing Standard ........................................................................................... 10

2.4 Australian Standards .............................................................................................. 10 2.5 International Standards........................................................................................... 12 2.6 National Occupational Health and Safety Council .................................................. 13 2.7 Environmental ......................................................................................................... 13

3 GENERAL ...................................................................................................................... 14 3.1 Deliverables ............................................................................................................ 14 3.2 Operating Hours ..................................................................................................... 14 3.3 Design Basis ........................................................................................................... 14 3.4 Units for Design ...................................................................................................... 15 3.5 General project information and plant design criteria ............................................. 15 3.6 Specific requirements ............................................................................................. 16 3.7 Layout requirements ............................................................................................... 16 3.8 Equipment selection – General criteria ................................................................... 17 3.9 Equipment Handling ............................................................................................... 17 3.10 Quality ..................................................................................................................... 18 3.11 Capacity Design Allowances .................................................................................. 18 3.12 Corrosion Allowances ............................................................................................. 18 3.13 Design Loads .......................................................................................................... 18

3.13.1 Fatigue Loads ................................................................................................. 18 3.13.2 Static Loads .................................................................................................... 19 3.13.3 Pressure Vessel Design Loads ....................................................................... 19 3.13.4 Service Factors ............................................................................................... 19

3.14 Standardization ....................................................................................................... 20 3.15 Unitized Equipment ................................................................................................. 20 3.16 Lubrication Points ................................................................................................... 20 3.17 Interlocks ................................................................................................................ 20 3.18 Lifting facilities ........................................................................................................ 20 3.19 Painting ................................................................................................................... 21 3.20 Rubber lining ........................................................................................................... 21 3.21 Health, safety and environment .............................................................................. 21 3.22 Noise and vibration ................................................................................................. 21

3.22.1 Noise ............................................................................................................... 21 3.22.2 Vibration .......................................................................................................... 22

4 GENERAL MECHANICAL EQUIPMENT ....................................................................... 23 4.1 Environmental Cooling ............................................................................................ 23 4.2 Fitting ...................................................................................................................... 23

4.2.1 Limits and Fits ................................................................................................. 23

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4.2.2 Surface Finish ................................................................................................. 23 4.3 Bolted connections ................................................................................................. 23

4.3.1 General ........................................................................................................... 23 4.3.2 Bolted connection design ................................................................................ 23 4.3.3 Bolting type and size ....................................................................................... 24 4.3.4 Bolt length ....................................................................................................... 24 4.3.5 Bolt anti-seize .................................................................................................. 24 4.3.6 Bolt locking ...................................................................................................... 24 4.3.7 Fitted bolts and dowel pins ............................................................................. 24 4.3.8 Bolt holing ....................................................................................................... 25 4.3.9 Bolt tightening ................................................................................................. 25

4.4 Bearing and shafting assemblies ............................................................................ 25 4.4.1 Bearings .......................................................................................................... 25 4.4.2 Bearing mounting ............................................................................................ 26 4.4.3 Plummer block type bearing housings ............................................................ 26 4.4.4 Shafting (custom designed) ............................................................................ 27 4.4.5 Shrink disc shaft couplings ............................................................................. 28 4.4.6 Keys and Keyways .......................................................................................... 29

4.5 Castings .................................................................................................................. 29 4.5.1 General ........................................................................................................... 29 4.5.2 Grey cast iron castings .................................................................................... 29 4.5.3 Ductile iron/spheroidal graphite (SG) cast iron castings ................................. 29 4.5.4 Steel castings .................................................................................................. 29

4.6 Steel fabrications .................................................................................................... 30 4.6.1 General ........................................................................................................... 30 4.6.2 Design ............................................................................................................. 30 4.6.3 Fabrication ...................................................................................................... 30 4.6.4 Sealing of crevices and sandwiched faces ..................................................... 30 4.6.5 Minimization of distortion................................................................................. 30 4.6.6 Post weld heat treatment (stress relieving) ..................................................... 30

4.7 Machine and drive base frames ............................................................................. 31 4.7.1 General ........................................................................................................... 31 4.7.2 Light machine base frames and hold-down .................................................... 31 4.7.3 Large/heavily loaded machine frames and hold-down ................................... 32 4.7.4 Bolted connections .......................................................................................... 33 4.7.5 Machining ........................................................................................................ 33 4.7.6 Equipment location on base frames or sole plates ......................................... 33 4.7.7 Lifting facilities ................................................................................................. 33

4.8 Machines without separate base frames ................................................................ 33 4.9 Shims/packers ........................................................................................................ 34

4.9.1 Material ........................................................................................................... 34 4.9.2 Installation ....................................................................................................... 34

4.10 Grease lubrication equipment ................................................................................. 34 4.10.1 Manual greasing .............................................................................................. 34 4.10.2 Automatic grease spray lubrication ................................................................. 34 4.10.3 Automatic grease lubrication ........................................................................... 35 4.10.4 Tubing and fittings ........................................................................................... 35

4.11 Oil lubrication/hydraulic systems ............................................................................ 35 4.11.1 General ........................................................................................................... 35 4.11.2 Design ............................................................................................................. 35 4.11.3 Oil Filters ......................................................................................................... 36 4.11.4 Pumps ............................................................................................................. 36 4.11.5 Reservoirs ....................................................................................................... 37 4.11.6 Oil coolers ....................................................................................................... 37

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4.11.7 Accumulators .................................................................................................. 38 4.11.8 Hydraulic/oil piping, tubing and fittings ............................................................ 38

4.12 Gearboxes .............................................................................................................. 38 4.12.1 General ........................................................................................................... 38 4.12.2 Continuous gearbox rating .............................................................................. 39 4.12.3 Thermal rating ................................................................................................. 39 4.12.4 Intermittent rating ............................................................................................ 39 4.12.5 Gearing classification ...................................................................................... 39 4.12.6 Case construction ........................................................................................... 39 4.12.7 Lubrication ....................................................................................................... 39 4.12.8 Seals ............................................................................................................... 39 4.12.9 Cooling ............................................................................................................ 39

4.13 Vee belt drives ........................................................................................................ 40 4.13.1 General ........................................................................................................... 40 4.13.2 Design ............................................................................................................. 40 4.13.3 Pulleys ............................................................................................................. 40 4.13.4 Matched belt sets ............................................................................................ 41

4.14 Chain drives ............................................................................................................ 41 4.14.1 General ........................................................................................................... 41 4.14.2 Design ............................................................................................................. 41 4.14.3 Sprockets ........................................................................................................ 41 4.14.4 Lubrication ....................................................................................................... 41

4.15 Shaft couplings ....................................................................................................... 41 4.15.1 General ........................................................................................................... 41 4.15.2 Design ............................................................................................................. 42 4.15.3 Rigid couplings ................................................................................................ 42 4.15.4 Shaft attachment ............................................................................................. 42

4.16 Fluid couplings ........................................................................................................ 42 4.16.1 General ........................................................................................................... 42 4.16.2 Starting torque ................................................................................................. 43 4.16.3 Stall torque ...................................................................................................... 43 4.16.4 Slip .................................................................................................................. 43 4.16.5 Use with conveyor drives - Starting frequency ............................................... 43 4.16.6 Thermal overload protection ........................................................................... 43

4.17 Brakes ..................................................................................................................... 43 4.17.1 General ........................................................................................................... 43 4.17.2 Brake construction .......................................................................................... 44

4.18 Holdbacks ............................................................................................................... 44 4.18.1 General ........................................................................................................... 44 4.18.2 Lubrication ....................................................................................................... 44

4.19 Variable speed (VVVF) drives ................................................................................ 44 4.20 Pneumatic systems ................................................................................................. 44 4.21 Hydraulic power systems and equipment ............................................................... 44

4.21.1 General ........................................................................................................... 44 4.21.2 Hydraulic pumps ............................................................................................. 45 4.21.3 Oil filtration ...................................................................................................... 45

4.22 Lifting equipment and reeved systems ................................................................... 45 4.22.1 General ........................................................................................................... 45 4.22.2 Cranes and hoists ........................................................................................... 45 4.22.3 Wire ropes ....................................................................................................... 45 4.22.4 Wire rope slings .............................................................................................. 45 4.22.5 Eyebolts .......................................................................................................... 45 4.22.6 Chain and shackles ......................................................................................... 45

4.23 Guards .................................................................................................................... 46

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4.23.1 General ........................................................................................................... 46 4.23.2 Personnel clearance ....................................................................................... 46 4.23.3 Painting ........................................................................................................... 46 4.23.4 Guard design ................................................................................................... 46

4.24 Balance quality requirements for rotating equipment ............................................. 47 5 GRINDING MILLS .......................................................................................................... 47

5.1 General ................................................................................................................... 47 5.2 Structural Design Criteria........................................................................................ 48 5.3 Mill Shells, Heads and Trunnions ........................................................................... 49 5.4 Mill Support Bearings .............................................................................................. 49 5.5 Lubrication Systems ............................................................................................... 51

5.5.1 General ........................................................................................................... 51 5.5.2 Piping and Valves ........................................................................................... 52 5.5.3 Electrical and Instrumentation ......................................................................... 53

5.6 Mill Lining Systems ................................................................................................. 54 5.7 Trunnion Liners ....................................................................................................... 54 5.8 Feed Chute, Spout & Removal Trolley ................................................................... 54 5.9 Discharge Trommel ................................................................................................ 55 5.10 Baseplates, Soleplates, Sub-Soleplates and Embedments ................................... 55 5.11 Jacking Systems ..................................................................................................... 55 5.12 Temporary Lubrication System ............................................................................... 56 5.13 Lifting Lugs ............................................................................................................. 56 5.14 Guards .................................................................................................................... 56 5.15 Fasteners ................................................................................................................ 56 5.16 Torque Wrenches and Elongation Meters .............................................................. 57 5.17 Bearings .................................................................................................................. 57 5.18 Ring Gear Drive ...................................................................................................... 57

5.18.1 General ........................................................................................................... 57 5.18.2 Ring Gear ........................................................................................................ 57 5.18.3 Pinion Gears ................................................................................................... 58 5.18.4 Pinion Shaft Bearings ...................................................................................... 59 5.18.5 Main Drive Gear Reducers.............................................................................. 59 5.18.6 Couplings ........................................................................................................ 60 5.18.7 Main Drive Motors and Liquid Resistance Starters ......................................... 60 5.18.8 Inching Drives ................................................................................................. 60 5.18.9 Gear Lubrication System................................................................................. 60 5.18.10 Gear Guard ..................................................................................................... 61 5.18.11 Vibration Monitoring System ........................................................................... 61 5.18.12 Infra-red Pinion Temperature Monitoring System ........................................... 61 5.18.13 Dropped Charge Protection System ............................................................... 61

6 BELT CONVEYORS ...................................................................................................... 62 6.1 General ................................................................................................................... 62

7 BELT FEEDERS ............................................................................................................ 62 7.1 Belt Feeder Components ........................................................................................ 62 7.2 Maintenance ........................................................................................................... 62

8 PRIMARY CRUSHING APRON FEEDER ..................................................................... 62 9 VIBRATING FEEDERS AND SCREENS ....................................................................... 63 10 AIR EMISSIONS ............................................................................................................ 63

10.1 Dust Suppression ................................................................................................... 63 10.1.1 Conveyor Covers ............................................................................................ 64 10.1.2 Dust Control Equipment .................................................................................. 64 10.1.3 Ductwork ......................................................................................................... 64

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10.1.4 Chutes, Enclosures & Skirting ........................................................................ 64 10.2 Dust Collection Baghouses And Collection Systems ............................................. 64 10.3 Bunding ................................................................................................................... 64 10.4 Hazardous Area Storage ........................................................................................ 65

11 SCREW CONVEYORS .................................................................................................. 65 12 CHUTES ......................................................................................................................... 65

12.1 General design requirements ................................................................................. 65 12.2 Minimum chute angles ............................................................................................ 66 12.3 Feed Openings Under Hoppers .............................................................................. 66 12.4 Transfer Chutes, Hoppers & Bins ........................................................................... 66 12.5 Liners ...................................................................................................................... 67

13 SLURRY HANDLING EQUIPMENT ............................................................................... 67 13.1 Pumps ..................................................................................................................... 67 13.2 Pump Control .......................................................................................................... 68 13.3 Sumps and Hoppers ............................................................................................... 68 13.4 Launders ................................................................................................................. 68

14 PUMPING AND PIPING ................................................................................................. 68 15 CRANES AND HOISTS ................................................................................................. 69 16 AGITATORS ................................................................................................................... 69

16.1 General ................................................................................................................... 69 16.2 Agitator gearbox ..................................................................................................... 69 16.3 Agitator shaft ........................................................................................................... 69 16.4 Materials ................................................................................................................. 70 16.5 Fabrication .............................................................................................................. 70

16.5.1 Welding, testing and inspection ...................................................................... 70 16.5.2 Stress relieving ................................................................................................ 70

17 LAUNDERS .................................................................................................................... 70 17.1 Design ..................................................................................................................... 70 17.2 Open launders ........................................................................................................ 71 17.3 Closed launders / gravity flow lines ........................................................................ 71 17.4 Flotation concentrate launders ............................................................................... 71 17.5 Junction boxes and distributors .............................................................................. 71

18 TANKS............................................................................................................................ 72 18.1 Capacity .................................................................................................................. 72 18.2 Required pump suction nozzle submergence ........................................................ 72 18.3 Steel tanks .............................................................................................................. 72

18.3.1 API 650 Coded tanks ...................................................................................... 72 18.3.2 Uncoded tanks ................................................................................................ 72 18.3.3 Common requirements .................................................................................... 72

18.4 Fibre reinforced plastic (FRP) tanks and fabrications ............................................ 73 18.5 Flanges ................................................................................................................... 73

19 LININGS & WEAR BARS ............................................................................................... 73 20 PUMP HOPPERS .......................................................................................................... 74

20.1 Capacity .................................................................................................................. 74 20.2 Hopper design ........................................................................................................ 74

21 TANK AND PUMP HOPPER OVERFLOWS ................................................................. 74 21.1 Arrangement ........................................................................................................... 74 21.2 Design – tank and hopper overflows ...................................................................... 74

22 PROCESS AIR BLOWERS AND COMPRESSED AIR EQUIPMENT ........................... 75

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22.1 Plant and instrument air systems ........................................................................... 75 22.1.1 Plant air systems ............................................................................................. 75 22.1.2 Instrument air systems .................................................................................... 76 22.1.3 Plant and instrument air compressors ............................................................ 76 22.1.4 Instrument air dryers ....................................................................................... 76 22.1.5 Air receivers .................................................................................................... 76

22.2 Process air blowers ................................................................................................ 76 23 HAZARDOUS CHEMICALS ........................................................................................... 76

23.1 ADG Code and TGA classifications ........................................................................ 76 23.2 Material Safety Data Sheets ................................................................................... 78 23.3 Storage and handling .............................................................................................. 78

24 FIRE PROTECTION ....................................................................................................... 79 24.1 General plant .......................................................................................................... 79 24.2 Flammable storage facilities ................................................................................... 80 24.3 Service buildings ..................................................................................................... 80

25 ORE RECLAIM ACCESS TUNNEL ............................................................................... 80 26 LABELLING AND SIGNAGE .......................................................................................... 80

26.1 Requirements for labels, nameplates and signage ................................................ 80 26.2 Dual language requirements .................................................................................. 81 26.3 Suitable materials and lettering application ............................................................ 81 26.4 Pipeline labels ......................................................................................................... 81 26.5 General plant signage ............................................................................................. 81

27 SHOP ASSEMBLY AND TESTING ............................................................................... 81 27.1 Mechanical .............................................................................................................. 81 27.2 Instrumentation and control .................................................................................... 82

27.2.1 Factory Acceptance Testing ........................................................................... 82 27.2.2 Hardware testing ............................................................................................. 82 27.2.3 Configuration testing ....................................................................................... 82

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1 SCOPE This Design Criteria applies to the general and technical requirements for the design, construction and installation of Concentrate Plant, Crusher Plant, Pellet Plant, Stockyard and related infrastructure for the Sino Iron Project.

It is internal project criteria for use by MCC and CPMM mechanical engineers and designers for use throughout the Project and is to be read in conjunction with the other project design criteria documents and Australian standard referenced.

2 REFERENCED DOCUMENTS All work covered by this Design Criteria shall be in accordance with the applicable Australian and International Standards and Codes and Statutory Acts and associated Regulations applicable to the project site.

The following list of Acts and Regulations, Design Criteria and Engineering Specifications are applicable to the project. The Australian and International Standards and Codes listed are specifically referenced by this document.

2.1 Acts and Regulations

Refer to Design Criteria DC-001 (DI-024725): Site Information and General Plant

2.2 Design Criteria

DC-001(DI-024725) Site Information and General Plant

DC-002 (DI-024726) Mechanical

DC-007 (DI-024731) Instrumentation, Control and Communication

DC-008 (DI-024732) Electrical

DC-004 (DI-024728) Plant Layout

DC-005 (DI-024729) Civil

DC-006 (DI-024730) Structural

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2.3 Engineering Specifications

2.3.1 General / Multidiscipline

ES-001 (DI-024735) Protective Coating Systems

ES-007 (DI-024742) Insulation

ES-002 (DI-024736) Packaging and Transportation of Goods

ES-003 (DI-024737) Grouting

ES-004 (DI-024738) Noise and Vibration

ES-005 (DI-000500) Labeling and Signage

ES-006 (DI-000498) Equipment Numbering System

ES-008 (DI-024741) Welding and NDE

2.3.2 Civil, Structural and Architectural

ES-014 (DI-024748) Steelwork Fabrication and Erection

2.3.3 Mechanical

ES-027 (DI-024761) Installation of Mechanical Equipment

ES-028 (DI-024762) Pre-commissioning of Mechanical Equipment

ES-033 (DI-024767) Stainless Steel Fabrication

ES-029 (DI-024763) FRP Fabrication

ES-030 (DI-024764) Rubber Lining

ES-031 (DI-024765) Mechanical Equipment

2.3.4 Pumping and Piping

ES-041 (DI-024775) Piping Fabrication and Installation

ES-042 (DI-024776) Piping Material & Valve Specification

ES-044 (DI-024778) Piping pressure test

2.3.5 Electrical

ES-061 (DI-024795) 220 KV and 33KV Powerline

ES-062 (DI-024796) installation and cabling specification

ES-063 (DI-024797) Testing and Commissioning specification

ES-064 (DI-024798) HV and LV Cables

ES-065 (DI-024799) Lightning Protection

ES-060 (DI-000923) Electrical drawing format specifications

ES-068 (DI-024799) Lightning

2.3.6 Instrumentation and Control

ES-051 (DI-024785) PLC and SCADA functional Specification

ES-052 (DI-024786) PLC and SCADA Programming Specification

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ES-053 (DI-024787) Process Control Philosophy

ES-054 (DI-024788) Plant Network Specification

2.3.7 Communication

ES-073 (DI-021966) Communications System Hardware Specification

2.3.8 Drawing Standard

ES-083 (DI-024781) Drawing Standard and Specification

2.4 Australian Standards

AS 1065 Methods for Ultrasonic Testing of Ferritic Steel Forgings

AS/NZS 1110 ISO Metric Hexagon Bolts & Screws – Product Grades A and B

AS/NZS 1111 ISO Metric Hexagon Bolts & Screws – Product Grade C

AS 1112 ISO Metric Hexagon Nuts

AS 1138 Thimbles for Wire Rope

AS 1210 Pressure Vessels

AS 1214 Hot dipped galvanised coatings on threaded fasteners (ISO metric coarse thread series)

AS 1237 Plain Washers for Metric Bolts, Screws and Nuts for General Purposes

AS/NZS 1252 High Strength Steel Bolts with Associated Nuts and Washers for Structural Engineering

AS 1275 Metric Screw Threads for Fasteners

AS 1318 Use of colour for the marking of physical hazards and the identification of certain equipment in industry (known as the SAA Industrial Safety Colour Code)

AS 1319 Safety signs for the occupational environment

AS 1332 Conveyor belting - Textile reinforced

AS 1334 Methods of testing conveyor and elevator belting

AS 1345 Identification of the contents of pipes, conduits and ducts

AS 1353 Flat Synthetic - Webbing Slings

AS 1375 Industrial fuel-fired appliances (known as the SAA Industrial Fuel-fired Appliances Code)

AS 1403 Design of Rotating Steel Shafts

AS 1418 Cranes (including hoists and winches)

AS 1442 Carbon Steels and Carbon Manganese Steels – Hot Rolled Bars and Semi-Finished Products

AS 1443 Carbon Steels and Carbon Manganese Steels - Cold Finished Bars

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AS 1444 Wrought alloy steels - Standard, hardenability (H) series and hardened and tempered to designated mechanical properties

AS 1448 Carbon and Carbon Manganese Steels - Forgings (Ruling Section 300 mm Maximum)

AS/NZS 1554.1 Structural Steel Welding – Part 1: Welding of Steel Structures

AS/NZS 1554.5 Structural steel welding - Welding of steel structures subject to high levels of fatigue loading

AS/NZS 1596 The Storage and Handling of LP Gas

AS 1654 Limits & Fits for Engineering

AS 1666 Wire Rope Slings

AS 1697 Installation and maintenance of steel pipe systems for gas

AS 1742 Manual of uniform traffic control devices

AS 1743 Road signs - Specifications

AS 1744 Forms of letters and numerals for road signs (known as Standard alphabets for road signs)

AS 1755 Conveyors – Safety Requirements

AS 1830 Grey Cast Iron

AS 1831 Ductile Cast Iron

AS 1940 The Storage and Handling of Flammable and Combustible Liquids

AS 1988 Welding of Steel Castings

AS 2074 Steel Castings

AS 2129 Flanges for Pipes, Valves and Fittings

AS 2177 Non-destructive testing - Radiography of welded butt joints in metal

AS 2207 Non-destructive testing - Ultrasonic testing of fusion welded joints in carbon and low alloy steel

AS 2293 Emergency escape lighting and exit signs

AS 2317 Collared Eyebolts

AS 2321 Short-link Chain for Lifting Purposes

AS 2382 Surface Roughness Comparison Specimens

AS 2419.1 Fire hydrant installations - System design, installation and commissioning

AS/NZS 2430.3.3 Classification of hazardous areas - Examples of area classification - Flammable liquids

AS/NZS 2430.3.4 Classification of hazardous areas - Examples of area classification - Flammable gases

AS/NZS 2430.3.5 Classification of hazardous areas - Examples of area classification - Refineries and major processing plants

AS 2528 Bolts, studbolts and nuts for flanges and other high and low temperature applications

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AS 2625 Rotating and Reciprocating Machinery - Mechanical Vibration

AS 2634 Chemical plant equipment made from glass-fibre reinforced plastics (GRP) based on thermosetting resins

AS 2670 Evaluation of Human Exposure to Whole Body Vibration

AS 2671 Hydraulic Fluid Power – General Requirements for Systems

AS 2714 The storage and handling of hazardous chemical materials – Class 5.2 substances (organic peroxides)

AS 2729 Rolling Bearings - Dynamic Load Ratings and Rating Life

AS 2741 Shackles

AS 2759 Steel Wire Rope - Application Guide

AS 2788 Pneumatic Fluid Power – General Requirements for Systems

AS 2941 Fixed fire protection installations - Pumpset systems

AS/NZS 3000 Electrical installations (known as the Australian/New Zealand Wiring Rules)

AS 3569 Steel Wire Ropes

AS/NZS 3678 Structural steel – Hot-rolled plates, floorplates and slabs.

AS/NZS 3679 Structural steel - hot rolled bars and sections

AS 3709 Vibration and shock - Balance quality of rotating rigid bodies

AS 3721 Vibration and shock - Balancing machines - Description and evaluation

AS 3780 The Storage and Handling of Corrosive Substances

AS 4024.1 Safe Guarding of Machinery - General Principles

AS 4041 Pressure Piping

AS 4100 Steel Structures

AS 4326 The storage and handling of oxidising agents

AS/NZS 4452 The storage and handling of toxic substances

AS 4458 Pressure Equipment – Manufacture

AS 5601 Gas installations

AS/NZS/ISO 9001 Quality Management Systems – Requirements

Australian Dangerous Goods Code (ADG): 6th Edition; Volumes 1 & 2

Australian Government – Department of Health and Aged Care - Therapeutic Goods Administration (TPG) – “Standard for the Uniform Scheduling of Drugs and Poisons No. 21”

2.5 International Standards

AGMA 915-1 Inspection practices – Part 1 Cylindrical gears – Tangential measurements

AGMA 915-2 Inspection practices – Part 2 Cylindrical gears – Radial measurements

AGMA 2000 Gear Classification and Inspection Handbook

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AGMA 2015 Accuracy classification system – Tangential measurements for cylindrical gears

AGMA 2101 Fundamental rating factors and calculation methods for involute spur and helical gear teeth (Metric Edition)

AGMA 6004 Gear power rating for cylindrical grinding mills, kilns, coolers and dryers

AGMA 6110 Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives (Metric Edition)

AGMA 9005 Industrial Gear Lubrication

ANSI B29.10 Heavy Duty Offset Sidebar Power Transmission Roller Chains and Sprocket Teeth

API 650 Welded Steel Tanks for Oil Storage

ANSI B16.5 Steel Pipe Flanges, Flanged Valves and Fittings

BS 6374.5 Lining of Equipment with Polymeric Materials for the Process Industries; Part 5. Specification for Lining with Rubbers

BS 4235 Metric Keys & Keyways

BS 4994 Design and construction of vessels and tanks in reinforced plastics

BS 6374.5 Lining of Equipment with Polymeric Materials for the Process Industries; Part 5. Specification for Lining with Rubbers

BS 7608 Code of practice for fatigue design and assessment of steel structures

DIN 2391 Seamless Precision Steel Tubes

ISO 4406 Hydraulic Fluid Power Fluids - Method for Coding Level of Contamination by Solid Particles

ISO 281 Rolling bearings - Dynamic load ratings and rating life

ISO 5048 Continuous mechanical handling equipment - Belt conveyors with carrying idlers - Calculation of operating power and tensile forces

TEMA Tubular Exchanger Manufacturer’s Association

CEMA Conveyor Equipment Manufacturers Association

ISO 16889 Hydraulic fluid power filters -- Multi-pass method for evaluating filtration performance of a filter element

VDI 2230 Systematic calculation of high duty bolted joints

2.6 National Occupational Health and Safety Council

NOHSC:2005 National Code of Practice for Manual Handling

NOHSC:1003 Exposure Standards for Atmospheric Contaminants in the Occupational Environment (1995).

2.7 Environmental Environmental and Social Impact Assessment (Vol. II) prepared by Knight Piésold and Co. June 2006

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3 GENERAL

3.1 Deliverables

Engineering for the project comprises the following facilities

Semi-mobile crushing plants

Conveyors system

Stockpile and delivery equipment.

Mill plant and magnetic separation plant

Classification equipment

Concentrate thickener

Tailing thickener

Concentrate filter

For the concentrate pipeline:

Agitated storage tanks at mine site

Outdoor mine site centrifugal pump station with two trains, one operating, and one standby.

Slurry pipeline

Return water pump station

Return water pipeline

Other related equipments and piping

3.2 Operating Hours

All equipment shall be designed for continuous 24 hour per day operation. There are 365 working days in the year, 3 shifts per day, 8 hours per shift; the availability of crusher is 56.5% equivalent to 4950 working hours per year. The availability of mill and magnetic separation equipment is 90.4% equivalent to 7920 working hours per year.

Selection of equipment shall be based on operating and design conditions and on information as specified on the Process Design Criteria and relevant Process Data Sheets.

3.3 Design Basis

Refer to Process Mass Balance and Process Equipment Data Sheets for the primary source of data for throughputs for the following systems:

Primary process stage equipment including thickeners, service water, and compressed air.

All plant and materials shall be suitable for the specified operating conditions and for such other conditions of outdoor installation, exposure to temperature, temperature variations, dusty and or wet, moist and humid environment.

The plant shall be designed with operator safety, ease of operation and maintenance. Access for operation and regular maintenance shall be by platforms, and stairways of safe design. Moving parts and/or hot surfaces accessible to the operators shall be guarded for safety.

The Process Engineer is responsible for equipment duty sizing and selection for the design envelope for new equipment such as pumps.

These data shall be specified on the relevant process data sheets for each item of the equipment.

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3.4 Units for Design

Units used for the project shall be metric as per standard practice for use of the International System of Units (SI) and Australian Standards.

3.5 General project information and plant design criteria

Refer to Design Criteria DI-024725 Site Information and General Plant which has been drafted for the purpose of issue with the Contract Enquiries to provide a source of quick reference, general site information and plant design criteria to the Supplier/Contractors.

It includes the following;

(a) Project introduction

(b) Site location

(c) Site access

(d) Units / Survey and datum

(e) Site conditions

(f) Plant areas (Work breakdown structure)

(g) General process information

(i) Process description

(ii) Equipment Data Sheet definitions

(iii) Cooling water quality

(iv) Compressed air quality

(h) General civil/structural design criteria

(i) Wind load

(ii) Seismic loading

(i) General mechanical design criteria

(i) Design life and availability

(ii) Design operating environment

(iii) Design loads

(iv) Operability, maintainability and lifting facilities

(v) Isolation of equipment

(vi) Insulation for personnel protection

(vii) Guarding of mechanical equipment

(viii) Hazardous area classification

(ix) Standardisation of equipment

(x) Hazardous areas and substances

(j) General electrical design criteria

(i) General

(ii) Power supply

(iii) Hazardous area classification

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(k) General instrumentation and control design criteria

(i) Instrument and control signals

(ii) Instrument power supplies

(l) Site Map

(Note: - Information provided by Design Criteria DC-001 (DI-024725) Site Information and General Plant is not duplicated in this document.)

3.6 Specific requirements

The following issues have been identified to be included in the design of the plant:

• Inspection ports/doors to be vertically hinged so they open horizontally

• Doors to be clamped/latched and not fasted by bolts and nuts

• Guards to be light and vertically split

• Stairs are to be provided rather than vertical ladders to locations requiring frequent access

• Stairs ways are to terminate at a landing rather than directly to the target structure

• The underside of conveyors (where accessible to personnel) are to be sufficiently guarded to prevent access to pinch points and moving equipment. This includes elevated conveyors and conveyors passing over access ways/roads. Guards should be designed so that they do not allow the build-up of material.

• Conveyor pull cord switch boxes to be of metallic construction

• Door handles (for operation of the latching mechanism on building personnel doors) to have extended length shanks to prevent hand/finger injury.

• In addition to standard earthing requirements, additional motors grounding is required via the motor foot mounts

• Conveyor tail pulleys are to be provided with sufficient clearances to allow for safe housekeeping and maintenance access.

• Tank access hatches are to be fitted with davit type facilities for handling cover plates over 32 kg where frequent access is required.

• Tanks are to be fitted with stepped drain nozzles that permit a 100% tank emptying capability.

• Safety cables are to be run at crane rail locations to ensure harnesses can be attached when needed for emergency crane access.

• Design to provide for specific safety belt attachment points required where work at heights is unavoidable for infrequent maintenance and operations personnel use.

3.7 Layout requirements

Refer to Design Criteria DC-001 (DI-024725) Plant Layout for plant layout requirements.

Layout of all new facilities will allow for safe access for operation, housekeeping and maintenance. Provision shall be made for operation, inspection, sampling, cleaning, servicing and safe removal and replacement of machinery and components.

Where an overhead crane is required, maintainable equipment shall be positioned so it can be removed with a direct vertical lift by the overhead crane.

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Where manual handling is required, sufficient room shall be allowed to access equipment with suitable lifting/handling machines.

3.8 Equipment selection – General criteria

Equipment selection shall, in general, be based on mass balance design capacities, plant operating criteria, the conditions specified in the Equipment Datasheet and the requirements listed herein.

Equipment selection shall also take into consideration all the environmental obligations of the project as defined in the EMP’s.

The key criteria for equipment selection are safety in operation, suitability for duty, cost, reliability and ease of operation and maintenance whilst minimizing the construction foot print.

All equipment, material and components shall be new unless specifically advised otherwise.

All equipment and components shall be Suppliers/Contractors/Manufacturer's standard proven design for the service specified with readily available replacement parts located in Australia unless otherwise specifically varied by The Engineer.

Equipment selection shall in general be based on mass balance design capacities, plant operating criteria, the conditions specified in the Equipment Data Sheet and the requirements listed herein and the other referenced Design Criteria documents.

Equipment selection shall also take into consideration, all the environmental obligations of the project.

The key criteria for equipment selection include;

(a) Safety in operation

(b) Suitability for duty

(c) Cost

(d) Reliability

(e) Ease of operation and maintenance

3.9 Equipment Handling

Where practicable, equipment shall be removed to a centralized maintenance facility either within the plant or offsite rather than being maintained in-situ.

The plant shall therefore be designed to enable ready removal and re-installation of equipment without the necessity of dismantling structural steelwork or mechanical equipment not related to the equipment being removed.

Where items of equipment and consumables are to be manually handled during construction of the plant or in the due course of plant operation, the Australian Workplace Health and Safety Act, Code of Practice – ‘Manual Handling in the Building Industry’ shall be followed.

All items of equipment weighing 15kg and greater, shall be furnished with lifting lugs for mechanical handling.

Equipment components weighing 15kg and greater shall have provisions for mechanical lifting.

Items of equipment or subassemblies weighing less than 15kg may require mechanical handling assistance due to accessibility constraints, size or shape of the components.

Permanently installed davits shall be used for man-ways and vessel covers weighing more than 32kg were frequent access is required. Vertical hinges may be fitted where davits are not practical subject to Owner’s approval.

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Equipment requiring regular maintenance (once a year or more), and weighing more than 32kg shall be readily retrieved from their installed position by wheeled trolley, forklift, hoist or crane (either installed or mobile) onto road transport at grade level or to a designated position where maintenance can be performed.

Monorail hoists and cranes of more than 2 tonnes capacity shall have electrically motorised lift and travel motions.

3.10 Quality

Equipment and materials will only be obtained from Vendors that can demonstrate they have safety and quality systems appropriate to the scope of work. Selection of appropriate levels of quality assurance shall be in accordance with the Engineers procedures.

3.11 Capacity Design Allowances

Continuous operating equipment and piping shall be designed and sized in accordance with the capacity allowances included in the Process Mass Balance and Design Criteria and the Equipment Datasheets.

Electric motor sizing shall be such that the motor is not overloaded over the full design operating conditions.

Where practical, motor size may be increased to the next standard size.

3.12 Corrosion Allowances

The design of vessels, tanks, heat exchangers and the like shall include corrosion allowances as required by relevant codes, as a minimum, with additional allowances as appropriate to the service conditions.

3.13 Design Loads

Design loads for mechanical equipment shall be the most adverse combination of loading and shall include, but may not necessarily be limited to the following:

• Dead live and wind loads as specified in AS1170 Parts 0, 1, and 2;

• Earthquake loads in accordance with AS1170.4 and 11120-101-C0705 or other standards as approved by the Owner;

• Pressure induced loads;

• Loads applied by machine action (eg torque);

• Acceleration or deceleration/inertia loading (eg braking forces);

• Impact loads;

• Loading produced by expansion or contraction of materials of construction;

• Loading produced by material spillage or abnormal operation (eg conveyor spillage onto adjacent walkways, blocked chutes); and

• Loading produced during the course of plant maintenance (eg resting equipment on adjacent platforms).

3.13.1 Fatigue Loads

Equipment shall be designed for a fatigue life of at least 15 years unless otherwise specified or approved by the Owner. Ferrous materials subject to fatigue loads shall be designed for an infinite life.

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Design loads for fatigue analysis shall be determined from those loads applied to, or produced by, a machine whilst operating at its maximum rated capacity assuming the machine’s prime mover(s) are operating at their maximum continuous rating unless otherwise specified or approved by the Owner.

3.13.2 Static Loads

Equipment shall be designed to accommodate the maximum possible static loading(s) to which it may be reasonably subjected during the design life, without the risk of equipment damage or risk of injury to personnel.

Where equipment is driven by a prime mover such as an electric motor, it shall be designed to accommodate the maximum torque that the prime mover can produce. This requirement applies to all equipment power transmission items.

Where equipment is driven by a hydraulic or pneumatic prime mover, it shall be designed to accommodate the maximum possible torque or force the prime mover can produce at the pressure relief setting providing this setting is considered to be tamper-proof by the Owner.

3.13.3 Pressure Vessel Design Loads

Design loads for horizontal and vertical pressure vessels (including reactors, towers, heat exchangers and filters) shall be the most adverse combination of loading under the following four load cases:

• Normal Operation Case: Combined load under the condition of common action of the following loads:

‐ Inner or outer pressure at design temperature;

‐ Operating weight;

‐ Thermal force, if any;

‐ Wind load and seismic load (if code requires); and

‐ Additional load (piping etc).

• Erection Case: Combined load under the condition that the following loads act simultaneously:

‐ Erection load; and

‐ Wind load or seismic load.

• Shut-down Case: Combined load under the condition that the following loads act simultaneously:

‐ Operating weight; and

‐ Wind load or earth-quake load.

• Test Case: Combined load under the condition that the following loads act simultaneously:

‐ Operating weight with water inventory;

‐ Wind load; and

‐ Test pressure.

3.13.4 Service Factors

As a minimum the service factor shall not be less than 1.5 times the installed nameplate continuously rated power. The service factor shall take into account:

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The duration of the load, eg intermittent, 12 hourly, etc; and the nature of the loading, eg steady, surge, reversing, shock, etc.

3.14 Standardization

Equipment standardization shall be employed to minimize spares inventory. This philosophy shall be followed for both engineered and vendor supplied items.

Only equipment with a proven record of reliable service in similar installations shall be considered for the project.

Special attention shall be given to select and use proven equipment that is the same or similar as existing equipment.

For all equipment, regard shall be given to rationalization of individual components such as drives, pulleys, shafts, idlers, belting, pumps etc.

3.15 Unitized Equipment

Unitized Equipment will be designed as follows:

Pre-assembled and aligned on common base plate where possible;

Major components or sub-assemblies shall be match marked prior to shipment;

Items and components shall be standardized where possible to ensure a minimum stockholding for items of equipment and interchangeability of identical parts;

All components shall be suitably marked to facilitate assembly;

When similar but not identical components are used they shall also be suitably marked to obviate incorrect assembly; and

Vendor supervisory attendance and commissioning assistance should be provided as and where regarded necessary by the vendor and approved by the Owner.

3.16 Lubrication Points

All application points for lubrication shall be readily and safely accessible. Grease fittings shall be the standard button-head type with British Standard Pipe Thread, orientated such that ready and convenient access for grease gun attachment is provided.

Where lubrication and seal purging points are not readily accessible or would require the removal of guarding for access, the grease nipples shall be installed on a rigidly mounted bulkhead in a position which is readily accessible and does not require the removal of safety guards.

For equipment requiring multiple lubrication points or purging points, the lubrication fittings shall be piped to a common bulkhead and readily and safely accessible. All grease nipple bulkheads shall include a hinged dust cover to protect the nipples.

Grease canisters may be used in critical applications where daily application is required.

3.17 Interlocks

Personnel and equipment safety interlocks and safety lockouts shall ensure that maintenance can be accomplished without danger to personnel or equipment. Personnel and equipment interlocks shall be hard wired.

3.18 Lifting facilities

All cranes, hoists, monorails, davits and other lifting equipment, including all permanent lifting lugs provided on equipment, shall be design registered with The Engineer.

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Lifting facilities shall be in accordance with DC-001 (DI-024725) Site Information and General Plant.

All equipment and/or subassemblies shall be provided with lifting lugs or lifting points to facilitate transportation, installation and maintenance. Lifting capacity shall be clearly indicated on the lifting facility.

Any one lifting lug shall have the strength to support the entire unit to be lifted. Item masses shall be identified externally on all major lifting items.

3.19 Painting

Unless otherwise specified, proprietary equipment may be supplied with Supplier’s/Contractor’s/Manufacturer’s standard surface treatment and colors, provided it is suitable for the specified service conditions.

Fabricated plate work and structural steel shall be prepared and coated with the paint system specified in accordance with Engineering Specification ES-001 (DI-024735) Protective Coating Systems.

3.20 Rubber lining

Rubber linings shall be selected and applied in accordance with Engineering SpecificationES-030 (DI-024764) Rubber Lining and BS 6374.5 by applicators with experience and qualifications subject to review and acceptance by The Engineer.

3.21 Health, safety and environment

The project design shall be such as to;

(a) Prevent injury or illness to employees, contractors, customers and the public,

(b) Identify, access and control the environmental aspects during the project execution and

(c) Deliver plant and facilities which will permit the Operator to achieve outstanding HS&E performance.

(d) Be generally in accordance with the Environmental Impact Statement and consent documents.

3.22 Noise and vibration

3.22.1 Noise

3.22.1.1 Occupied rooms and buildings

The noise levels within rooms due to intruding noise, including HVAC systems and externally located equipment, shall not exceed the following:

• Supervisors Offices and Conference Rooms: 40 dB(A)

• General Offices, Plant Control Rooms: 40 dB(A)

• Passageways and Foyers: 45 dB(A)

• Mess Rooms and Facilities Areas: 50 dB(A)

• Workshops, Warehouses and Plant Gatehouse: 70 dB(A)

• Plant Rooms: 80 dB(A)

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3.22.1.2 Plant areas

(a) General noise limit

Equipment shall be selected and installed so that the noise level (Sound Pressure Level) in all normal operating modes within the General Plant, shall be less than 85 dB(A) at one meter from the nearest operator access point for equipment in areas where virtually continuous presence of Plant Personnel is required when equipment is operating.

(b) Multiple noise sources – Overall noise limit

For some items of equipment, noise level limits may prove impractical and for others a lower noise level limit may be imposed to minimize the resultant noise level within the operating plant and at defined external environmental boundaries.

If equipment consists of components from different suppliers e.g., a driver and a driven part or two or three machines side by side in close proximity, the individual equipment noise limit shall be reduced to ensure that the assembled equipment meets the general noise limit of 85 dBA.

For such equipment, a more stringent noise limit shall be as specified in Table 3.10.1.2(1).

Table 3.10.1.2 (1)

Combined equipment noise limits (sound pressure level)

Return Period Free

Standing dB(A)

Closely Spaced Like MachinesdB(A)

Whole Train 85 82 Separate Items of a 2

Component Train 82 79

Separate Items of a 3 Component Train 80 77

(c) Emergency conditions – Noise limit

For emergency conditions, unless otherwise specified, the absolute noise limit of 115 dB(A) shall not be exceeded.

3.22.1.3 Equipment located outside the work area – Noise limit

For equipment located outside the work area, at positions inaccessible to personnel, the maximum sound pressure level at 1 m from the equipment may be higher than for that specified in Section 3.10.1.2 expressed as a function of distance.

The allowable increase shall be:

10 log (x) Where 'x' is shortest distance from noise emitting equipment under consideration to the nearest work area, expressed in meters with a Logarithm Base 10

3.22.2 Vibration

Maximum vibration levels (in rms ν mm/s) under normal conditions of operation shall be as specified by AS 2625.1 Table A1 Quality A for Class 1, 2, 3 and 4 equipment.

Measurement and evaluation of vibration severity shall be in accordance with AS 2625 Parts 2, 3 and 4 as applicable.

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Transmission of vibration levels to a foundation or building structure shall not exceed those levels recommended by AS 2670 for human comfort.

4 GENERAL MECHANICAL EQUIPMENT

4.1 Environmental Cooling

The design of bearing, gearboxes and other air cooled equipment shall use the maximum ambient dry bulb temperature.

Evaporative air coolers shall not be used due to the environments high wet bulb temperature, Other closed loop evaporative system coolers and fans can be used, however worst case ambient conditions must be considered.

4.2 Fitting

4.2.1 Limits and Fits

Limits and fits shall be in accordance with AS 1654.

4.2.2 Surface Finish

The principal parameter used for describing and quantifying surface roughness (finish) shall be the Arithmetic Mean Deviation (Ra) expressed in microns (µm).

Verification of the specified Ra value shall be by the use of a visual roughness comparator in accordance with AS 2382.

4.3 Bolted connections

4.3.1 General

All bolted connections used for mechanical equipment shall be designed and manufactured in accordance with AS 4100.

All screw threads shall be metric size, ISO coarse pitch series in accordance with AS 1275.

Unless otherwise specified, all bolts and nuts shall conform to AS/NZS 1110, AS/NZS 1111, AS 1112, AS/NZS 1252 or AS 2528 as applicable and shall be hot-dipped galvanized in accordance with AS 1214.

Unless otherwise specified, flat washers shall be in accordance with AS 1237 and shall be hot-dipped galvanized in accordance with AS/NZS 4680. Taper washers shall be provided on bolted sections whenever required by the shape of the sections being connected.

4.3.2 Bolted connection design

Where possible, connections shall be through bolted. Tapped holes shall only be used where it is not practicable to use through bolted connections.

Friction grip joints shall only be used where it is the proven industry standard for the equipment provided.

For non-friction grip bolted joints, all significant shear loads shall be taken by biscuit keys, dowel pins and/or location (jacking) bolts.

Dowel pins shall be in Grade 316 stainless steel.

All bolting shall be readily accessible considering the method of bolt tightening employed.

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Bolting up to and including M30 size used in the assembly of mechanical equipment, plate and framing fabrications shall be readily accessible for tightening with air impact wrench tooling.

Equipment design shall be such that bolting larger than M30 can be tightened using either pneumatic or hydraulic power assisted bolt tightening tools.

The use of flogging spanners to sledge hammer tighten large diameter bolts is not an acceptable practice.

4.3.3 Bolting type and size

Bolting shall generally be in accordance with Section 4.2.1 of this document unless specified as being hydraulically tensioned. In this case, bolting shall have a minimum length of 5 x bolt diameter with tensioning provided by fully portable, hydraulic bolt tensioning kits.

Further alternative bolt tensioning methods may be used subject to review and acceptance by The Engineer.

Bolt tensioning shall be to 65% of proof load.

Minimum bolt size used to make significantly loaded connections shall be M20.

Minimum bolt size shall be M10.

4.3.4 Bolt length

Tightened bolts shall project not less than two full threads through nuts and not more than half of the bolt diameter. Bolt length shall be based on the design grip thickness plus one (1) flat washer and one (1) full hexagon nut only unless otherwise specified or reviewed and accepted by The Engineer. Bolt length shall be selected from the commercially available range to meet this requirement.

Cutting of bolts shall be avoided and shall only be undertaken in the case where it is not practicable to obtain suitable bolts of suitable commercial length and where reviewed and accepted by The Engineer.

4.3.5 Bolt anti-seize

All bolts used in the assembly of mechanical equipment, plate and machine fabrications which may require disassembly for maintenance shall be coated with “Loctite” Nickel 771 anti-seize or equivalent.

4.3.6 Bolt locking

Bolting in joints subject to reverse cyclic movement and vibration shall be locked using a full nut acting as a lock nut or other method reviewed and accepted by The Engineer.

Tack welding, helical spring lock washers and tooth lock washers shall not be used.

“Nylok” lock nuts may be used on lightly loaded joints subject to review and acceptance by The Engineer.

4.3.7 Fitted bolts and dowel pins

Fitted bolts and dowel pins shall be in Grade 316 stainless steel and shall have an AS 1654 - H7h6 transition fit unless otherwise specified.

All holes for fitted bolts shall be reamed on trial workshop assembly. The mating components, including the bolts or pins, shall be match marked by metal stamping.

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4.3.8 Bolt holing

All shop and site drilled bolt holes shall be drilled. Holes may be punched where indicated by the drawings. Oxy acetylene torch burning of holes is not permitted.

4.3.9 Bolt tightening

All bolting shall be tightened to 65% of specified bolt proof load in accordance with standard Ajax bolting procedure for the “Snug tight/part turn” bolt tightening method unless otherwise specified.

4.4 Bearing and shafting assemblies

4.4.1 Bearings

4.4.1.1 General

SKF bearings and bearing housings are the preferred brand.

All bearings shall be of standard types and sizes readily available in Australia. The number of different sizes and types used shall be minimized.

Bearings for all mechanical equipment shall be ball or roller anti friction type.

In special applications such as oscillating pivot linkages and highly loaded, high speed shafting, plain or journal bearings may be used subject to review by The Engineer.

All bearing selections and operating parameters (temperature etc.,) shall be in accordance with the bearing manufacturer’s recommendations for the given application, load and operating conditions and Section 4.3.1.2 of this document.

Bearings in plummer block type housings shall be spherical self-aligning type.

Where exterior bearings are applied, bearing seals shall be selected to protect the bearings from dirty environment and water intrusion.

Unless otherwise specified, externally mounted bearing shall be housed in cast, split type housings for shafts up to and including 300mm diameter

4.4.1.2 Required bearing life

Unless otherwise reviewed and accepted by The Engineer, the fully adjusted L10 life of ball/roller bearings used in specific equipment types supplied to the project shall as specified by the following unless specified otherwise by the Equipment Data Sheet:

• Trolleys and hoists 3,000 hours

• Tank agitators 80,000 hours

• Pumps, blowers 65,000 hours

• Conveyor pulley bearings 80,000 hours

• Conveyor idlers 65,000 hours

• Screens 80,000 hours

• Compressors and centrifugal fans 100,000 hours

• Gear drives and reducers 80,000 hours

• Other equipment (Refer to Technical Specification and Equipment Data Sheet)

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The fully adjusted “L10 Life” shall be derived using the procedures laid down in ISO 281 or AS 2729 (with life adjustment factors for reliability A1, materials A2, and application A3 taken as unity).

4.4.1.3 Bearings in plummer block type housings

Unless otherwise specified, bearings in plummer block type housings shall be spherical self aligning type or CARB type with W33 grease grooves.

Non-driving shaft ends shall not protrude through housings and shall be blanked with a closure plate. Where zero speed sensing is required, the shaft shall extend through the bearing.

4.4.2 Bearing mounting

4.4.2.1 General

All bearings shall be mounted in accordance with the bearing manufacturer's recommendations.

4.4.2.2 Bearings in plummer block type housings

All bearings shall be mounted on tapered adaptor or withdrawal sleeves unless otherwise approved by the Owner.

Adaptor sleeves shall be provided for shaft sizes up to and including 140 mm nominal shaft size with oil injection withdrawal sleeves being provided for shafting above 140 mm.

4.4.3 Plummer block type bearing housings

4.4.3.1 General

All bearing housings shall be of standard types and sizes readily available in Australia. The number of different sizes and types used shall be minimized.

4.4.3.2 Housing type

Externally mounted bearings shall be housed in cast, split type housings.

SNL 5 or 6 series split housings shall be used on shafts up to and including 140 mm diameter. Large SNL housings shall be used for shafts of 150 mm and above.

SNL 5 or 6 series housings shall be provided with 2 hold-down bolt holes for shafts nominally up to 50 mm size and 4 hold-down bolt holes for shafting nominally above 50 mm size as per standard SKF SNL 5 and 6 series supply.

Lifting eye bolts shall be fitted to SNL housings size 520 and above.

All grease lubricated bearing housings shall be provided with two (2) drilled and tapped holes in the housing cap plus a grease escape hole as per standard SKF SNL bearing supply.

Both holes shall be tapped 1/4” BSP and be plugged with a readily removable metallic plug.

4.4.3.3 Bearing mounting surfaces

Bearing housings shall be mounted on a flat surface to eliminate the risk of housing overstressing upon hold down bolt tightening.

Out of flatness between any pair of hold down bolt holes shall not exceed that recommended by SKF.

Bearing housings for shaft sizes 125 mm and greater shall be mounted on a machined surface.

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4.4.3.4 Bearing seals

Grease lubricated bearings shall be fitted with Taconite seals with grease purged, radial labyrinth seals with a V-ring seal fitted onto the shaft as per standard SKF supply. Where seal face velocity precludes the use of Taconite seals, seal provisions shall be as recommended by the bearing seal and bearing manufacturer subject to review and acceptance by The Engineer.

Each labyrinth seal shall have a grease injection point into the annular space between the labyrinth and the V-ring seal.

This grease injection point shall be tapped 1/8” BSP and the housing shall be supplied with the grease point plugged.

Oil lubricated bearings shall be fitted with standard SKF TURU seals.

4.4.3.5 Housing location

Galvanized jacking screws complete with lock nuts shall be used for the adjustment and positive location of externally mounted split type bearing housings. The jacking screws are to be located at each end of the bearing housing base.

Two (2) jacking screws, in accordance with Section 4.6.6 of this document, shall be used for bearings housings on shafting up to and including 120 mm diameter. Four (4) jacking screws shall be used for bearing housings on shafting larger than 120 mm diameter.

Housings shall be set square to the shaft such that the radial gap measured between the labyrinth seals at any two diametrically opposite points in the plane parallel to the housing base does not vary by more than 0.5 mm.

4.4.3.6 Shaft location

The bearing housing closest to the drive shall incorporate a locating ring which axially locates the bearing and shafting. The non-drive end bearing shall be free to axially float within the housing.

Un-powered shaft assemblies shall also incorporate one located and one free bearing arrangement.

4.4.3.7 Non-drive shaft ends

Non driving shaft ends shall not protrude through housings and shall be blanked with a closure plate.

Where zero speed sensing is required, the shaft shall extend through the bearing.

4.4.3.8 Condition monitoring sensor attachment

Bearing housings shall be provided with flat areas in 3 axis positions as per standard SKF supply to enable the use of magnetically attached SKF CMP sensors for condition monitoring purposes.

4.4.4 Shafting (custom designed)

4.4.4.1 General

The following Sections of this document are applicable to large custom designed shafting.

Shafts shall be designed in accordance with AS 1403 with a minimum safety factor of 1.5 using the equation applicable to shafting subjected to more than 600 starts per year.

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4.4.4.2 Stress concentration factors

Unless otherwise specified, the stress concentration factor (K) as defined and used in AS 1403 shall not exceed 1.5 excepting for those stress concentration factors attributable to contact pressures produced by shrink disc type couplings. In this case, the minimum stress concentration factor shall be taken as 2.5.

Shrink disc type couplings shall be mounted on a raised shaft landing, or alternatively, a relief groove shall be machined in the shafting directly under the contact edge of the shrink disc.

4.4.4.3 Shaft materials

Shafting shall preferably be manufactured from plain carbon steel having a maximum carbon content of 0.5% in accordance with AS 1442 or AS 1443.

Where higher strength/hardenable shafting is required (e.g., integral shafting/gear pinions), shafting shall be forged alloy steel in accordance with AS 1444.

Shaft forgings shall be manufactured in accordance with AS 1448 with “Procedure 2” tensile, impact and hardness testing. Test and compliance certificates shall be provided.

As a minimum, all forged shafting shall be ultrasonically tested in accordance with AS 1065 “Level 1” for the outer 80% zone and “Level 2” for the inner 20% zone unless otherwise specified.

4.4.5 Shrink disc shaft couplings

4.4.5.1 Acceptable brands

Shrink disc couplings shall be supplied by a well established manufacturer such as Ringfeder or Imtec.

4.4.5.2 Design capacity

Shrink disc type couplings shall have a rated torque capacity of at least twice that applied to the coupling under the worst case loading conditions where one shrink disc is transmitting all the torque of a particular drive or brake.

Where 2 shrink discs are employed on a shaft with a drive on one end such as on a conveyor drive pulley, each shrink disc shall have a rated torque capacity of at least 1.25 times that produced under the worst case loading conditions. Both shrink discs shall be the same.

Where there is a brake on one end and a drive on the other end of a shaft, again such as on a conveyor drive pulley, both shrink discs shall have a rated torque capacity of at least 1.5 times that worst case maximum produced by either the brake or the drive, whichever is the greater.

Bending moments applied to shrink disc couplings shall be calculated for the worst case shaft loading assuming the coupling housing is fixed and completely rigid. Shrink disc couplings shall have a bending moment capacity of at least 1.5 times that applied.

4.4.5.3 Housings

Minimum housing dimensions shall be in accordance with the shrink disc coupling manufacturer’s recommendations.

Shaft and housing contact stresses generated by the shrink disc shall not exceed the shrink disc manufacturer’s recommendations for the particular shaft and hub material.

Housings shall be stress relieved prior to machining.

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4.4.5.4 Installation

Shrink discs shall be installed strictly in accordance with the manufacturer’s recommendations.

Shrink disc cavities shall be coated with Shell Ensis 1014 and sealed against external contamination by a fastener attached cover plate having a close clearance fit to the shaft that is sealed with neutral pH silicon sealant following cleaning of sealant contact surfaces with a suitable solvent.

4.4.6 Keys and Keyways

4.4.6.1 4.3.6.1 General

Unless otherwise specified, all keys and keyways shall be designed and manufactured in accordance with BS 4235.

The BS 4235 class of fit for all keys shall be “close fit”.

4.4.6.2 Key material

Keys for shafting conforming to Section 4.3.4.3 of this document shall be manufactured from plain carbon steel having a maximum carbon content of 0.5% in accordance with AS 1442 or AS 1443.

4.5 Castings

4.5.1 General

All castings shall conform with the applicable Australian Standards.

All test work shall be carried out by an independent NATA (National Association of Testing Authorities) registered testing authority.

Certificates of compliance with the relevant standard shall be supplied for all castings custom produced for the project.

4.5.2 Grey cast iron castings

Grey cast iron shall not be used except for lightly loaded bearing housings and castings not subject to shock loading (e.g., conveyor bearings, etc.,).

In all cases, the use of grey cast iron shall be subject to review and acceptance by The Engineer.

Where approved, grey cast iron castings shall conform to AS 1830 and shall be of minimum grade T-220.

4.5.3 Ductile iron/spheroidal graphite (SG) cast iron castings

All ductile iron/spheroidal graphite (SG) cast iron shall conform with AS 1831 and shall be of minimum grade 350-22.

Ductile/SG iron casting weld repair is not acceptable.

4.5.4 Steel castings

All cast steel shall conform with AS 2074 and shall be of minimum grade C4-1.

Steel castings shall be repaired in accordance with AS 1988.

All casting repair work and procedures shall be subject to review and acceptance by The Engineer.

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4.6 Steel fabrications

4.6.1 General

All steel plate and section fabrication associated with mechanical equipment (i.e., steel fabrication that appears on mechanical drawings) such as chute and hopper platework, machine and drive base fabrications, support frames for conveyors, pump bases etc., shall be designed and fabricated in accordance with this Section.

4.6.2 Design

Assessment as to whether or not a steel fabrication is to be designed as a steel fabrication subject to fatigue loading shall be in accordance with AS 4100.

Fabrications exempt from fatigue assessment shall be designed in accordance with AS 4100 (limit states design method) or AS 3990 (working stress design method).

Fabrications subject to fatigue loading shall be designed in accordance with AS 4100.

4.6.3 Fabrication

Steel fabrication not subject to fatigue loading shall be in accordance with AS 4100 or AS 3990 with welding in accordance with AS 1554.1 Cat SP.

Fabrications subject to fatigue loading shall be welded in accordance with AS 1554.5.

Steel shall comply with AS 3678 and/or AS 3679 or equivalent international standard.

These requirements shall also apply to welding and fabrication works associated with site installation.

4.6.4 Sealing of crevices and sandwiched faces

Unless otherwise specified, all welds shall be continuous welds to ensure that crevices and sandwiched faces are effectively sealed to prevent corrosion.

4.6.5 Minimization of distortion

The Supplier/Contractor shall select material thickness and fabrication procedures to minimise the extent of welding and distortion.

For example, the practice of selecting thin material requiring extensive gusset or stiffener addition in lieu of using thicker material in the first place shall be avoided. Also, platework flanging as typically provided to join sub-assemblies of chutework, bins, hoppers etc., shall be made of 10 mm minimum thickness angles and not flat bar unless the bar size and thickness is sufficiently substantial to resist distortion.

4.6.6 Post weld heat treatment (stress relieving)

Unless otherwise specified, all steel fabrications subject to fatigue loading (as assessed according to AS 4100) shall be stress relieved prior to machining.

Typically, this shall include all machine and drive base frames subjected to heavy loading or vibration.

All post weld heat treatment or stress relieving shall be undertaken following the completion of all welding/fabrication in accordance with AS 4458 prior to finish machining.

A heat treatment certificate shall be provided giving details of the heat treatment including;

(a) holding temperature

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(b) holding time

(c) cooling rate and

(d) a copy of the time/temperature heat treatment chart.

4.7 Machine and drive base frames

4.7.1 General

Machine and drive base frames may be of either fabricated, cast ductile/SG or cast steel construction. Grey cast iron shall not be used unless subject to review and acceptance by The Engineer.

All machine and drive base frames shall be designed such that deflections due to all design loading conditions, both produced internally (dead loads, thermal expansion etc.,) and externally (piping loads etc.,), does not result in potentially detrimental effects such as the misalignment of the machine or drive components beyond those limits specified by the drive coupling, drive or driven equipment manufacturer or applicable standard.

Design loadings exerted on the equipment by piping shall be those allowable loads indicated by the American Petroleum Institute (API) standard applicable to the machine under consideration and shall be subject to review and acceptance by The Engineer.

Bases shall preferably be designed to be rapidly free draining to enable easy hose out of accumulated dust and spilled fluids and materials. Where this is not practicable, bases may be fully enclosed to prevent the entry of fluids and solids subject to review and acceptance by The Engineer.

All machine and drive base frames subjected to fatigue loading or vibration (Refer to Section 4.5.2 of this document) shall be stress relieved in accordance with Section 4.5.6 of this document prior to machining.

4.7.2 Light machine base frames and hold-down

4.7.2.1 Design

Light machine base frames to be used under lightly loaded machines where included in the scope of supply shall be provided with pads of 13 mm minimum finished thickness on the top of base frames at all locations interfacing with machined equipment feet.

Pad size shall be at least 20 mm longer and 20 mm wider than the corresponding equipment feet.

Pads shall not project beyond the outer edges of the base frame in such a way that they become a hazard and cause leg injury.

The underside of all machine and drive base frames shall have pads of 25 mm minimum finished thickness located at the hold-down bolts. (Refer to Mechanical Standards Drawings)

4.7.2.2 Base support on concrete foundations

Light duty machine and drive base frames mounted on concrete foundations shall be installed directly onto epoxy grout pads cast into position around the hold down bolting following base frame levelling upon installation in accordance with Engineering Specifications ES-027: Installation of Mechanical Equipment(DI-024761) and ES-003: Grouting(DI-024737)

Grouting allowance shall be 30 mm unless otherwise specified.

Packers shall not be used unless otherwise specified.

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4.7.3 Large/heavily loaded machine frames and hold-down

4.7.3.1 Design

Base frames for large/heavily loaded machines (e.g., ball or crushing mill) shall be of heavy duty construction, machined on the underside and at all location interfaces as per the Supplier/Contractor’s standard supply for the equipment and duty subject to review and acceptance by The Engineer.

4.7.3.2 Base support on concrete foundations

(a) Hold down bolting

Hold down of large, heavily loaded machines shall preferably be achieved by the use of hydraulically tensioned, stud type bolts.

These bolts shall be located in pockets that provide ready access to both the top and bottom nuts for hydraulic bolt installation and removal if required.

Bolt pockets may be provided by either sacrificial in-concrete mouldings or permanent heavy duty fabricated steel plate / bolt tube embedments cast into the concrete foundations.

(b) Packers

Epoxy grouted packers shall be provided as the main bearing support for heavily loaded machine hold down. (Refer to Mechanical Standards Drawings)

Unless otherwise specified, packers shall have the following features;

• be provided typically as thick, heavy duty, rectangular AS/NZS 3679 steel bar strips picking up hold down bolting groups typically across the centre line axis of the supported frame or sole plate

• be drilled to match the machine frame hold down bolting location and size

• machined on top and provided with 3 recessed, socket cone levelling grub screws to enable accurate adjustment of height and flatness

Packers shall be set to level and grouted, with sufficient accuracy (as a minimum, to within +/- 0.5 mm of level) such that the machine frame or sole plate can be bolted down directly without detrimental distortion without the use of shimming.

(c) Sole plates

Where horizontal adjustment or concrete foundation shear keying is required, sole plates shall be provided.

These sole plates shall be heavy duty, machined top side and provided with grouting holes where necessary, heavy duty jacking screws to enable horizontal adjustment of the equipments and underneath shear keys as necessary to accommodate equipment shear loading.

Fine vertical adjustment between the underside of equipment and the sole plate shall be provided by shimming. The necessity for shimming shall be avoided if possible.

Final location of the equipment base or base frame on the sole plate shall be by the use of site match drilled, reamed and fitted dowels in accordance with Section 4.2.7 of this document.

4.7.3.3 Grouting

Following the installation of sole plates (or equipment base frames) on top of packers, the sole plates or equipment base frames shall be completely grouted such that the packers are completely sealed in grout to ensure the exclusion of corrosive fluids.

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Grouting specifications and grouting allowance shall be as per Engineering Specification ES-003 Grouting(DI-024734) and the Supplier/Contractor’s standard subject to review and acceptance by The Engineer.

4.7.4 Bolted connections

All bolted connections shall be in accordance with Section 4.2 of this document.

4.7.5 Machining

All machine and drive base frame surfaces interfacing with proprietary equipment having machined surfaces shall be machined at these interface surfaces.

The load bearing surfaces at the hold-down bolt locations underneath all machine and drive base frames and bolt washers shall be machined after fabrication and stress relieving.

The machining of these pads shall be to a common level unless the machine design necessitates otherwise.

4.7.6 Equipment location on base frames or sole plates

Location of equipment on base frames or sole plates subject to lateral loading shall be such that relative movement is prevented without the reliance on friction between the joint surfaces.

Components bolted to a machine or drive base frame shall be shimmed where necessary in accordance with Section 4.8 of this document and laterally located by galvanised adjustment bolts complete with locking nuts. These bolts shall also act as adjustment jacking bolts to enable convenient alignment of the equipment in both the longitudinal and traverse directions.

Jacking screw ends shall be face machined flat and shall locate on the housing normal to the contact surface.

Jacking screws shall be heavy duty and sized to suit the application.

Where specified, equipment shall also be permanently located with 316 stainless steel dowel pins fitted into match drilled and reamed holes providing this is done on site after installation is complete and all alignments have been witnessed and accepted by The Engineer.

Shop dowelling may only be carried out where specified.

Where the base frame itself may be subjected to significant shear loadings, a means of positively locating the base frame on its support steelwork or concrete foundations shall be provided by shear keys.

Welding of the base frame to the steel support structure or sole plates shall not be permitted.

4.7.7 Lifting facilities

Unless otherwise specified, all equipment bases shall be fitted with a minimum of four (4) lifting lugs which are readily accessible from the outside of the base. Such lugs shall be designed for lifting the base plus the "wet" weight of all equipment attached thereto.

Lifting lugs shall be in accordance with Sections 3.6 and 4.21 of this document.

4.8 Machines without separate base frames

Machines without separate base frames which are located on structural steel or concrete foundations shall have underneath, machined pads or feet, at each hold-down bolt. The machining of these pads shall be to a common level unless the machine design necessitates the use of multi-level pads.

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Where the machine is relatively light and is to be located on a concrete foundation, epoxy grout pads under each machine foot pad as specified in Section 4.6.2 of this document shall be provided.

Where the machine is large/heavily loaded and is to be located on a concrete foundation, base support shall be in accordance with Section 4.6.3 of this document.

4.9 Shims/packers

4.9.1 Material

All shims shall be cut from stainless steel shim material and shall sit flat with no raised areas such as kinks or lips.

Packers shall be made from 316 stainless steel sheet or plate and shall have a minimum thickness of 5 mm.

All shim and packer corners and edges shall be radiused, and free of burrs.

Holing dimensions shall be the same as the base the shims or packers are under and shall be punched, drilled or machined.

Shims and packers shall be the same size as the base they are under and shall not protrude out from the mating surfaces being shimmed.

4.9.2 Installation

The total number of shims plus packers used shall be minimized and shall not exceed 5.

The total thickness of shims plus packers shall not exceed 10 mm.

4.10 Grease lubrication equipment

4.10.1 Manual greasing

Individual nipple greasing shall only be acceptable for where there is a very small number of readily accessible lubrication points spaced far enough apart to make it un-economic to install a manual hand pump dispensed, central lubrication unit.

Even for these situations, the use of self dispensing, single point mechanical lubricators shall be considered.

Where grease nipples are installed, they shall be Tecalemit 4788/1 (for use where grease nipple tappings are 1/8” BSP) or 4785/13 (for use where grease nipple tappings are 1/4“ BSP), orientated such that ready and convenient access for grease gun attachment is provided.

Where there is more than six (6) lubrication points in reasonable proximity to one another, a hand pump dispensed, centralised lubrication system (such as Lincoln Quicklube) shall be provided with the master grease gun nipple being provided in a readily accessible location.

4.10.2 Automatic grease spray lubrication

Open gear and chain drives shall be lubricated with automatic spray grease lubrication systems.

Open gear lubrication systems shall be a 200 litre grease drum pump based system, fully automatic, pneumatically activated, grease spray type such as Lincoln SAF (or equivalent) supplied as a complete system.

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4.10.3 Automatic grease lubrication

Automatic grease lubrications systems shall be provided on critical items of equipment where it is not practicable to provide manual lubrication due to regularity of lubrication requirements and/or there is a large number of lubrication points.

Automatic grease lubrication systems shall preferably be of the air actuated grease pump type utilising a conventional 60 litre grease drum based system with injectors and/or divider metered supply for each lubrication point.

Installations requiring high grease usage rates such as for grinding mill lubrication applications, may utilise a 200 litre grease drum pump based system.

4.10.4 Tubing and fittings

All grease lines shall be cold drawn seamless precision plain carbon steel metric tubing, cleaned, annealed, normalised, free of scale, phosphated and oiled conforming to DIN 2391 material St 37.4 or equivalent.

Minimum grease line size shall be 6 mm nominal. Plastic tubing shall not be used.

All grease line tube fittings shall be plain carbon steel “Swagelok” compression type fittings or equivalent.

All tubing joins shall be made by connection fittings. Grease lubrication tubing shall not be welded.

Tube thickness shall not be less than 1.6 mm.

4.11 Oil lubrication/hydraulic systems

4.11.1 General

Oil lubrication/hydraulic systems shall be designed and supplied by a well established and reputable AS/NZS/ISO 9001 certified Supplier/Contractor specialist in the field of hydraulic/oil lubrication systems and equipment design and supply such as Bosch Rexroth.

All systems shall be designed such that lubricated equipment receives sufficient oil at sufficient pressure to enable the machine to come to rest safely and without equipment damage under emergency shut down or loss of power conditions.

The lubrication systems shall be located remotely from the lubricated equipment to maximize maintenance access around the typically large equipment that requires this type of lubrication.

Hydraulic lines shall be cold drawn seamless tubing. Flexible lines shall be avoided, except for connections where there shall be relative movement between the connected components. Lines requiring special cleaning shall be done in the shop environment where practical.

4.11.2 Design

Oil lubrication systems that may be subject to severe contamination such as grinding mill lubrications systems, shall incorporate a three (3) compartment (return/dirty/clean) oil reservoir with a conditioning/oil transfer circuit as per the standard Rexroth grinding mill lubrication system supply of this type.

Critical oil lubrication systems that are not subject to the possibility of severe contamination such as grinding mill gearbox and main motor journal lubrication systems shall incorporate a two (2) compartment oil reservoir with a conditioning/oil transfer circuit.

Under conditions of continuous operation, pump inlet temperature of the hydraulic fluid shall not exceed 45°C or 50°C elsewhere in the circuit.

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Oil coolers, where necessary, shall be provided in the conditioning circuit.

The conditioning circuit shall be cleaned via “absolute” rated oil filtration.

Nominal filtration shall be provided on each pump duty discharge and on the discharge of all flow dividers.

“Clean” oil supply shall have a maximum ISO 4406 oil cleanliness as per the recommendations of the hydraulic equipment and bearing suppliers/manufacturers.

As a maximum, the ISO 4406 “clean side” oil cleanliness shall not be worse than 17/14 but in all cases shall not be worse than that recommended by system component and lubricated equipment suppliers/manufacturers.

4.11.3 Oil Filters

4.11.3.1 General

All filters shall be shall be Hydac (or equivalent) and of the full flow, duplex type with integral condition indicators and shall be located so as to be readily accessible for inspection and service.

All filters shall be sized in accordance with the filter manufacturer’s recommendations for the particular application. However, as a minimum, oil filters shall be selected on the basis of no more than a 0.4 bar pressure drop at the oil viscosity reference temperature of 40 °C.

4.11.3.2 Absolute rated oil filters

Where absolute filtration circuits requiring an ISO 4406 oil cleanliness rating of 17/14 are specified, filters shall have a rating of no greater than 10 µm.

Where absolute filtration circuits requiring an ISO 4406 oil cleanliness rating of 15/12 are specified, filters shall have a rating no greater than 3 µm.

All absolute rated filters shall have a minimum ISO 16889 ß rating of 200 or better as necessary to achieve the required ISO 4406 oil cleanliness.

4.11.3.3 Nominal Filtration

Where nominal filtration is specified, filters shall have a rating of 20 µm unless a smaller rating is recommended by the lubricated equipment manufacturer to protect system components.

4.11.4 Pumps

4.11.4.1 General

Pump speeds shall not exceed 1500 rpm.

Pumps and motors shall be capable of continuous operation at their rated pressure/power when operating at a maximum casing temperature of 120°C.

Preferably, fixed capacity units will be gear type.

All pumps shall be direct coupled to the drive motor via a bell housing and flexible coupling in accordance with the pump and motor manufacturer’s recommendations.

4.11.4.2 Installation

Pumps shall be flange mounted external to the hydraulic fluid reservoir such that bolting is readily accessible.

Pump suction lines shall be as direct as possible with all fittings being conducive to minimum pressure drop.

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Flexible hosing shall be installed between the pump and delivery piping to minimize vibration transmission to the piping.

Where duty/standby pump arrangements are provided, each pump shall be mounted in such a way that vibration is not transmitted to the adjacent standby pump sufficiently to cause brinelling of that pump’s bearings.

4.11.5 Reservoirs

4.11.5.1 Design

For three (3) compartment (return/dirty/clean) oil reservoirs, the dirty oil compartment shall have an oil capacity of not less than 6 x conditioning circuit flow rate (litres from litres/minute) with the return and clean oil compartments having a capacity of not less than 15% and 60% of the dirty side compartment respectively.

Oil reservoirs shall be provided with bolted inspection/cleaning access doors designed for ease of internal inspection and cleaning and a full under tray to prevent leaks or spills from running onto the surrounding floor.

Minimum plate thickness used for reservoir construction shall be 6mm. Thicker plate and reinforcing shall be utilized as required for pump and equipment support to ensure negligible vibration and deflection during operation.

The reservoir bottom shall be slanted towards the drain(s) for collection of contaminants. Minimum drain size shall be DN40 complete with ball valve isolation.

The reservoir assembly shall be supported on legs above the catchment tray to enable the drainage points to be a minimum of 400 mm above the tray level and that there is sufficient space to clean up spills lying in the tray under the reservoir.

Accessible oil fill points of DN40 minimum shall be provided.

The oil reservoir shall be provided with a 10 µm (nominal rating) filter in the tank filling line and a 10 µm (nominal rating) breather.

4.11.6 Oil coolers

4.11.6.1 Type and location

Oil coolers using water as the cooling medium shall be provided if necessary to maintain oil temperature below the specified maximum.

Air blast coolers shall not be provided.

The coolers shall be preferably located on the on the low pressure (conditioning) side of the circuit on the lubrication skid.

The oil cooler(s) shall be shell and tube type with pressure containing components in compliance with AS 1210 (or international equivalent) and TEMA with removable end covers to enable cleaning of the water side (tube internal) heat exchange surfaces.

Preference will be given to shell and tube cooler designs that also enable the oil side surfaces to be cleaned.

4.11.6.2 Capacity

The oil cooler(s) shall have sufficient capacity to enable prolonged periods of operation under worst case ambient and maximum demand operating conditions without the need for regular cleaning of the heat transfer surfaces assuming a minimum fouling resistance of 0.0002 m2. °C/Watt.

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Refer to Design Criteria DI-024725 Site Information and General Plant for cooling water supply temperature and quality document.

4.11.7 Accumulators Hydro-pneumatic accumulators shall be bladder type. Accumulators shall be designed such that it is not possible to dismantle them before relieving accumulator gas and liquid pressure. Warning signage shall be provided in accordance with AS 2671. Accumulators shall be charged with nitrogen and shall be designed, constructed and tested in accordance with AS 1210 or equivalent international standard.

4.11.8 Hydraulic/oil piping, tubing and fittings

Minimum hydraulic/oil line size shall be 6mm nominal.

All hydraulic lines shall be cold drawn seamless precision plain carbon steel metric tubing, cleaned, annealed, normalized, free of scale, phosphated and oiled conforming to DIN 2391 material St 37.4 or equivalent unless otherwise specified.

All hydraulic line tube fittings shall employ elastomeric seals.

All tubing joins shall preferably be made by connection fittings rather than welding. Where welding is required, it shall be undertaken in accordance with AS 4041 for Class 2 piping (or equivalent international standard).

Minimum tubing thickness shall comply with AS 4041 for the specified pressure conditions allowing for a 1 mm minimum corrosion allowance. Tube thickness shall not be less than 1.6 mm.

4.12 Gearboxes

4.12.1 General

Gearbox shall be totally enclosed, of standard manufacture, designed, rated and fabricated in accordance with the latest applicable Standards. Gearbox shall be supplied complete with inspection covers, labyrinth seals with double lip seals incorporated, oil drains, oil sight glasses giving indication when running, breather, magnetic drain plug, cast in lifting lugs, drip tray, and oil dip sticks. If necessary, additional piping shall be provided to enable gearboxes to be filled and drained easily from local platforms.

Motor to gearbox configuration with motors up to and including 11 kW capacity may incorporate a flanged motor bolted directly onto a bevel or parallel, helical gearbox having an input shaft bell housing and shrink disc hollow output shaft.

Motor to gearbox configuration with motors greater than 11 kW capacities shall incorporate a foot mounted motor coupled to the solid input shaft of the gearbox.

The gearbox shall preferably be a parallel helical type having a shrink disc coupled hollow shaft output unless otherwise specified. Where access around the gearbox is limited, a bevel, helical type gearbox would be preferred.

Gearboxes exposed to wet or corrosive conditions (e.g., agitator gearboxes) shall have a solid output shaft coupled to the driven shaft using a solid coupling unless otherwise specified.

For special circumstances where space is limited (e.g., on a tripper drive), a shrink disc type, hollow shaft gearbox may be direct coupled to the driven machine shaft subject to review and acceptance by The Engineer. In this case, the shaft interface surfaces shall be oiled in accordance with the shrink disc/gearbox manufacturer’s recommendations and the external interface entry thoroughly cleaned by a suitable solvent and then sealed with neutral pH Silastic.

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Flange mounted motors on drives greater than 11 kW shall only be considered for specialist proprietary equipment which has been specifically designed for flanged motors.

Vee belt drives from the motor to the input shaft of the gearbox or chain drives from the gearbox output shaft to the driven equipment shall only be utilized subject to review and acceptance by The Engineer.

Worm type reducers shall not be used.

All gearing or gearboxes shall be capable of being driven in either direction.

4.12.2 Continuous gearbox rating

The design torque rating of the gearbox shall be equal to, or greater than the full motor load torque multiplied by the gearbox service factor as recommended by AGMA 6110 for the particular application, specified AGMA gear classification and required gear life of the gearing offered, or 1.5, whichever is the greater.

4.12.3 Thermal rating

The thermal rating of the gearbox shall not be less than the full load power rating of the drive motor and the gearbox operating oil temperature shall not exceed the oil manufacturer’s recommendations.

4.12.4 Intermittent rating

All gearing and gearboxes shall be designed to accommodate those maximum short term loads generated under motor stall conditions or under worst case braking conditions.

4.12.5 Gearing classification

All gearing shall be manufactured to a minimum Class 12 quality classification in accordance with AGMA 2000.Minimum service factors for strength and durability shall be the greater of 2.0 times motor power or 2.0 times the required brake power.

4.12.6 Case construction

Gear casings shall be to the manufacturer’s standard design and shall be robust, oil tight, water tight, and dust proof.

Casings shall be of ductile/spheroidal graphite cast iron or fabricated mild steel construction and shall comply with the minimum requirements of this document.

4.12.7 Lubrication

Mineral based oils without EP additives are preferred.

Splash lubrication is preferred to forced circulation oil lubrication.

Splash lubrication systems shall meet the requirements of AGMA 9005.

4.12.8 Seals

As a minimum, gearing and gearboxes shall be fitted with grease purged triple labyrinth taconite type seals.

4.12.9 Cooling

Under conditions of continuous operation with maximum ambient temperature and solar heat gain, the maximum oil temperature shall not exceed the gearbox and lubricant manufacturer’s recommendations. The maximum oil temperature shall not exceed 70°C.

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4.13 Vee belt drives

4.13.1 General

Vee belt drives shall be designed to transmit the design torque and motor starting torque without slip.

Vee belt drive design and service factors shall be in accordance with the manufacturer's recommendations with due regard to application, drive duty, operational period, pulley centre distance, minimum pulley diameter and belt speed.

All vee belt drives shall be designed for the SPA, SPB or SPC range of belts with preference being given to the SPB range.

Shaves shall be made of cast iron or steel and machined to the tolerances described in above mentioned standard. Sheaves shall be equipped with de-mountable, compression type hubs (taper lock), except where used on auxiliary equipment drives of less than 0.75kw.

For belt speeds up to 10m/s, sheaves and hubs shall be statically balanced to ISO1940 Class G6.3*

For belt speeds over 10m/s, dynamically balance sheaves shall be provided to ISO1940 Class G6.3*

Note: *ISO1940 Balance Quality Requirements. Rotors in a constant (rigid) state – Part 1: Specification and Verification of Balance Tolerance or AS 3709 Vibration and Shock – Balance Quality of Rotating Rigid Bodies.

4.13.2 Design

The minimum vee belt drive service factor shall be 1.5.

The belt speed range for belt drives shall be between 2.5 and 25 m/sec.

The minimum and maximum number of belts per drive shall be 2 and 5 respectively.

The drive ratio for belt drives shall not exceed the following:

(a) general application 3:1

(b) for pump drives 2:1

Wherever possible, drive ratios shall be selected such that standard stock pulleys are used.

Centre spacing and drive ratio shall be selected to ensure that the minimum angle of wrap is not less than 120 degrees.

Centre distance shall be adjustable to maintain the belt tension as recommended by the vee belt manufacturer.

Installation and take-up allowance shall be strictly in accordance with the vee belt manufacturer’s recommendations.

4.13.3 Pulleys

Minimum pulley diameter shall be in accordance with the belt manufacturer's recommendations or 125 mm, whichever is the greater.

Unless otherwise specified, all belt pulleys shall be attached to their shafts with “Taper Lock” (or equivalent) tapered bushes and BS 4235 rectangular parallel keys.

Fitting and removal of the pulleys to and from the shafts shall be in accordance with the manufacturer’s recommendation.

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4.13.4 Matched belt sets

Belts for multi-belt drives will be supplied in matched sets.

Belts shall be supplied sealed in weatherproof containers.

4.14 Chain drives

4.14.1 General

Chain drives shall only be used for low speed, high torque applications where it is not practicable to use direct mount, high torque capacity, planetary gearbox drives.

All chain and sprockets shall conform to ANSI B29.10.

Chain shall be cranked link type.

4.14.2 Design

The minimum safety factor for high torque, low speed chain drives shall be equal to the average tensile strength of the chain divided by the applied chain tension produced at the drive sprocket torque at full motor load shall be 12.

The drive ratio for chain drives shall not exceed 3:1.

Centre spacing and drive ratio shall be selected to ensure that the minimum angle of chain wrap is not less than 120 degrees.

Chain drives shall be arranged such that the tension side of the chain is on the bottom and both the tension and slack sides of the chain are at no more than 45° from horizontal.

Installation and take-up allowance shall be strictly in accordance with the chain manufacturer’s recommendations but shall not be less than 2 chain pitches.

4.14.3 Sprockets

All drive sprockets shall be manufactured for AS/NZS 3678 Gr 250 plate and shall be fully machined unless otherwise specified.

The number of teeth on the drive sprocket shall not be less than 13.

Driven sprockets may have flame or abrasive sand cut teeth subject to the review and acceptance of The Engineer.

Unless otherwise specified, all sprockets shall be attached to shafting using shrink disc type couplings.

4.14.4 Lubrication

Low speed, high torque chain drives shall be lubricated by spray lubrication.

An enclosure shall be provided for the complete drive. This enclosure shall be completely leakproof and designed to prevent the ingress of dust and water from hosing.

4.15 Shaft couplings

4.15.1 General

All shaft couplings shall be supplied by a well established reputable supplier such as Flender, Tsubaki, etc., and shall preferably be of the non-lubricated type.

Coupling selection and service factors shall be in accordance with the coupling manufacturer's recommendations with due regard to application and drive duty unless otherwise specified.

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The component parts of couplings of the same manufacturer type and size shall be fully interchangeable and shall be readily available in Australia.

All couplings shall be shrouded to prevent bolts from protruding and shall be fitted with guards.

4.15.2 Design

Couplings shall be selected to transmit the full load motor torque multiplied by the service factor as recommended by the coupling manufacturer unless otherwise specified.

The minimum service factor shall be 1.5 at full motor load.

Rigid couplings shall have a minimum service factor of 1.5 at full load motor torque and 2.0 on the worst case bending moment.

All couplings shall be manufactured from ductile/SG cast iron, cast or fabricated steel.

4.15.3 Rigid couplings

Rigid couplings used for the attachment of shaft mounted drives shall have coupling halves centralised by a machined spigot with a tapered lead.

4.15.4 Shaft attachment

Unless otherwise specified, couplings shall be installed in accordance with the coupling and coupled machine manufacturer’s recommendations.

Couplings fitted with flexible elements shall have these removable from the coupling without requiring disassembly or removal of other drive components.

Couplings shall be mounted to their respective shafts using Taper-Lock bushes and BS 4235 rectangular parallel keys for drives up to and including 150 kW.

For larger drives, couplings shall be attached to their shafts using a light interference fit equal to AS 1654 - H7 p6 and BS 4235 rectangular parallel keys. Keeper end plates shall be used where end thrust may result in a coupling half moving on its shaft. Alternatively, couplings large couplings may be installed on a taper fit utilizing aided oil injection for fit up and removal.

In special applications, other methods of coupling attachment may be used subject to review and acceptance by The Engineer.

4.16 Fluid couplings

4.16.1 General

Fluid couplings shall be capable of bi-directional rotation and shall be of the delay-fill type with extended start and adjustable acceleration.

The outer wheel incorporating the delay-fill chamber shall be connected to the prime mover.

Fluid couplings shall be designed such that their removal and replacement will not require displacement of either the motor or the gearbox.

An oil sump shall be provided directly below the coupling to accommodate oil drained from the coupling. This sump shall be equipped with a drain pipe with a valve.

The oil specification and oil quantity shall be in accordance with the manufacturer's specification for the particular duty.

The coupling shall be designed such that the input side of the coupling is mounted directly onto the drive motor shaft. The output side of the fluid coupling shall incorporate a flexible coupling if not provided with a vee belt output.

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The input and output bores of the fluid and flexible couplings shall be bored to suit the specified motor and driven equipment shaft in accordance with the fluid coupling manufacturer’s recommendations.

4.16.2 Starting torque

Unless otherwise specified, the maximum torque transmitted shall not exceed 150% of the motor full load torque.

4.16.3 Stall torque

In the event of the driven machine or equipment stalling, the maximum torque transmitted shall not exceed 200% of the motor full load torque unless otherwise specified.

4.16.4 Slip

When running at full load conditions with the specified oil level, the coupling slip shall not exceed 3%.

4.16.5 Use with conveyor drives - Starting frequency

All couplings shall be selected so that they will be capable of starting the fully loaded conveyor, twice in direct succession then followed by 6 evenly spaced starts per hour.

For the above conditions, it shall be assumed that the coupling has been running at full load and has attained its operating temperature.

4.16.6 Thermal overload protection

All couplings shall be fitted with a thermal control element. In the event of the coupling oil reaching a predetermined temperature, this thermal control element shall trip a base mounted sensor which will be connected to the plant control system to provide alarm and trip functions. A non-contact type element is preferred.

In addition to this thermal control element, all couplings shall be fitted with a built in fusible plug. This plug shall be designed to melt at 20 °C above the setting of the thermal control element.

4.17 Brakes

4.17.1 General

Unless otherwise specified, brakes shall be calliper disc type with spring actuation and electro hydraulic thruster release.

All brakes shall be selected to suit the application, specified brake torque, duty cycle and ambient conditions and shall be:

(a) Adequately sized for the load characteristics and heat dissipation

(b) Rated for a torque at least 150% of specified braking torque

(c) Fitted to the high speed input shaft of the speed reducers and on the reducer side of the coupling,

(d) Fail safe,

(e) Provided with a facility for automatic wear compensation which incorporates an adjusting mechanism.

(f) Provided with a facility for the adjustment of brake torque and the rate of application of brake torque.

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4.17.2 Brake construction

Shafting and bearings shall be checked to ensure compliance with this document for the worst case brake reactions produced.

Disc callipers shall be mounted on rigid supports attached to the same base frame as the drive.

All adjustment bolting and screws shall be in Grade 316 stainless steel.

Brakes shall be provided with self-lubricating bushes and Grade 316 stainless steel pins on all pivoting joints.

4.18 Holdbacks

4.18.1 General

The selection of holdbacks shall be based on at least 1.5 x the maximum stalled or pull-out torque of the driving motor referred to the holdback unless otherwise specified.

Unless otherwise specified, holdbacks shall be designed for a life of 100,000 hours of operation.

Holdbacks integral with the gear reducer shall be located on an extension of the high speed shaft or the highest speed intermediate shaft of the reducer.

Holdbacks that are not integral with the gear reducer shall be mounted on the driven shaft of the equipment (e.g: on the non-drive end shaft extension of a conveyor head pulley).

4.18.2 Lubrication

Holdbacks used for slow speed applications may be grease or oil lubricated.

Holdbacks mounted integral with the drive gearbox shall be lubricated by the gearbox lubrication system.

4.19 Variable speed (VVVF) drives

Electro/mechanical variable speed drives incorporating Variable Voltage Variable Frequency (VVVF) control shall be selected to meet the specified torque performance across the full specified speed range at maximum ambient temperature conditions.

Performance shall be based on the specific drive components incorporated (i.e., for the particular VVVF, motor and gearbox).

4.20 Pneumatic systems

Pneumatic systems shall comply with AS 2788 and shall be designed to operate on an available air pressure as specified in Design Criteria DI-024725 Site Information and General Plant.

4.21 Hydraulic power systems and equipment

4.21.1 General

All hydraulic systems shall be designed to conform to the recommendations and preferences of AS 2671.

Hydraulic system operating pressure shall not exceed 15,000 kPag, unless otherwise specified.

Under conditions of continuous operation and worst case ambient conditions, oil temperature anywhere in the circuit shall not exceed that recommended by the lubricant and hydraulic component supplier. This maximum oil temperature shall not exceed 65°C.

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4.21.2 Hydraulic pumps

Pump speeds shall not exceed 1500 rpm.

Pumps and motors shall be capable of continuous operation at their rated pressure when operating at a maximum casing temperature of 120°C.

Preferably, fixed capacity units will be gear type.

All pumps shall be direct coupled to the drive motor via a bell housing and flexible coupling in accordance with the pump and motor manufacturer’s recommendations.

4.21.3 Oil filtration

Oil filtration requirements shall be as specified by Section 4.10.3 of this document.

4.22 Lifting equipment and reeved systems

4.22.1 General

All equipment used for lifting or in reeved systems shall be designed and manufactured in accordance with AS 4100, AS 1418 and AS 1666 as applicable.

4.22.2 Cranes and hoists

Cranes and hoists shall be designed in accordance with AS 1418 and amendments.

Overhead travelling type cranes (OHTC) shall incorporate the following features:

(a) AS 1418 M5/C5 hoist/crane classification

(b) 2 speed long travel and hoisting

(c) Caternary power supply

(d) Pendant control

(e) Hoist and long travel limit switches

4.22.3 Wire ropes

Wire rope selection shall be in accordance with AS 2759.

Wire ropes shall conform to AS 3569.

4.22.4 Wire rope slings

Wire slings shall conform to AS 1666. Flat synthetic webbing slings shall conform to AS 1353.

Thimbles shall conform to AS 1138.

4.22.5 Eyebolts

Eyebolts shall be of drop forged construction and shall conform to AS 2317.

All eyebolts shall be hot dipped galvanized.

4.22.6 Chain and shackles

All chain and shackles shall conform to AS 2321 and AS 2741 respectively, and shall be hot dipped galvanized.

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4.23 Guards

4.23.1 General

Identification of hazards and risks and the principles of guarding shall be in accordance with AS 4024.1.

All guards shall be designed in accordance with AS 1755.

Guards should be an integral part of the design of the machine or machinery.

All exposed rotating or moving parts shall be provided with light weight guards or vertically split guards or other features necessary to safeguard operational and maintenance staff. All guards shall be easily removable for access.

All guards to be designed and installed in compliance with West Australia Safety codes. As a minimum, guards shall be supplied at the following areas:

• All conveyor drives, skirted areas, take ups, tail-ends and head ends shall be guarded;

• Where return idler nip points are accessible or within reach from ground, then guards shall be provided to cover all nip points;

• All v-drives, chain-drives, shaft-ends and key-ways shall be guarded;

• All drive couplings, v-belts, chains, etc shall be guarded;

• All ore passes shall have safety nets;

• Grinding mills to be fully guarded around the full perimeter of the shell, guards shall be 1.8m high, shall use 50mm square weld mesh, shall be removable and the maximum weight of a single guard section is shall be 32kg;

• All rotating machinery parts shall be guarded;

• Other potential pinch points with the exception of carry idler nip points (transitions and convex curves).

4.23.2 Personnel clearance

Where there is the possibility of personnel becoming trapped between moving equipment and any fixed object, stops or travel restrainst shall be provided such that the minimum possible clearance between the equipment and the fixed object is 600 mm.

Where there is less than 600 mm clearance, personnel access to the offending area shall be prevented by suitable hand railing and the posting of warning signs.

4.23.3 Painting

All guards shall be fully painted in Safety Yellow.

4.23.4 Guard design

Material used for the construction of guards shall be an appropriate thickness to ensure that the level of protection required is obtained and that the guards are mechanically sound.

Where necessary, sheet guards shall be provided with a mesh panel to enable inspection of the guarded components.

Mesh guards shall have a skeletal frame fabricated from either angle or tubular members. All mesh ends shall be welded to the frame.

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Guards shall be designed so that they are capable of supporting 100 kg (i.e., the weight of a person).

Where guarding is required to be regularly removed, wedge or other suitable quick release type fixings shall be provided. Alternatively, hinged inspection doors may be provided. These doors shall be hinged in such a way that there will not be a tendency for the door to be left in the open position.

Where removal of the guard will be infrequent, it shall be fixed in position so that it cannot be removed without the use of tools.

Guards for vee belt drives shall have adequate ventilation and shall have provision for tachometer access.

Lifting handles or lugs shall be provided where required for the safe removal or opening of guards.

Large guards with any dimensions in excess of 1800 mm shall not be fabricated in one piece.

Guards shall be easily assembled from component parts that do not exceed 32 kg mass.

All component parts of the guard shall be bolted together with a minimum number of bolts to form a rigid and safe assembly.

The mass of all separable guard panels shall be clearly indicated by signage attached to the panel. This signage shall be subject to review and acceptance by The Engineer.

4.24 Balance quality requirements for rotating equipment

As per the recommendations of API standards for rotating equipment used in the petrochemical industry, the out of balance of all rotating equipment as determined in accordance with AS 3709 shall not exceed the following as measured at each shaft journal bearing;

Umax = 6350 x W / N

Where:

Umax = the maximum allowable unbalance per plane in gram-mm

W = static journal load in kg

N = the maximum continuous rotating speed in rpm

The correction of rotating equipment out of balance shall be in accordance with AS 3721.

5 GRINDING MILLS

5.1 General

(a) All work shall be to the requirements of this document.

(b) The mill shall be of robust and well-proven design, fit for operation in the service specified and suitable for continuous operation in arduous mining conditions.

(c) The mill and accessories shall be designed for a 35-year life expectancy for the duty specified.

(d) The mill shall be bi-directional. Liner design may be unidirectional.

(e) The Contractor shall design all mill components such that they may be pre-assembled off site and shipped in the least number of sub-components possible. The size and weight limitations of shipment will be defined later. As a minimum, it is expected that all shells will be pre-assembled prior to shipment.

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(f) The Contractor shall provide all safeguards for human protection (except where specifically excluded) and shall satisfy the minimum requirements of the governing body for the destination country and good industry practice.

(g) Compliance with this specification shall not relieve the Contractor of the responsibility to supply equipment suited to meet the specified service conditions, requirements of the ultimate user and applicable regulations.

(h) The drive system and drive train shall be designed to account for load sharing during operation, start up, closing of LRS contactors and shutdown. Particular attention shall be given to the magnitude, duration and frequency content of transients. The design of all components shall consider the cumulative life incorporating normal operating conditions and all transients. Simulations of the drive system and drive train shall include the motor and LRS characteristics shall be developed to determine the design of all components.

(i) The Contractor shall design the drive train to accommodate influences from the grinding mill including deflections due to mill load variations and expansion/contraction due to ambient conditions and solar radiation. The Contractor shall provide analysis demonstrating that there will be no detrimental effect on pinion alignment or mill performance under such variable operating conditions.

(j) The Contractor shall provide a system for protecting the grinding mill from “dropped charge” events. The system shall be capable of detecting a “locked charge” and preventing potential damage during a mill start. The Contractor shall provide a description of their proposed system in their tender.

(k) The drive train shall be designed and located such that all components are installed on approximately the same level as the mill operating floor.

5.2 Structural Design Criteria

(a) The Contractor shall nominate design loadings including seismic and dynamic loads (and frequencies) on mill foundation drawings

(b) The mill structural design shall consider seismic conditions as required by relevant Australian standards.

(c) Stiffening ribs shall not be allowed on shells, heads, trunnions and their flanges.

(d) The design stress ranges for the mill shall be chosen by the mill vendor to ensure a 35-year fatigue life under the nominated design load. These shall be stated in the Technical Schedule. No increases to the stress range levels in the Technical Schedule shall be accepted for weld enhancement such as stress relief, peening etc.

(e) Weld Design:

• The Contractor’s choice of welding standards shall satisfy the requirements of the design with respect to the allowable size of flaws at the design stress range. The Contractor shall demonstrate in their tender how allowable flaw sizes specified in the chosen manufacturing welding standards will satisfy these design requirements.

• All welding shall be full penetration.

• As a minimum, the following welds shall be ground

i. All internal welds shall be ground flush.

ii. Any further grinding of flange welds including longitudinal flange welds as determined by CPMM’s auditor (following submission of the Contractor’s FEA).

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iii. Weld face grinding shall not reduce the weld size below the Contractor’s specified minimum.

• Grinding procedures shall be provided for review and approval of CPMM as part of the Contractor’s tender.

5.3 Mill Shells, Heads and Trunnions

(a) All circumferential flanges shall be spigoted to ensure alignment in the field. Fitted bolts shall be provided in all longitudinal and radial flanges in shells and heads respectively.

(b) Mating flange surfaces, and the opposite side of all flanges where assembly fasteners will be in contact with flange surfaces on the mill shell, heads and trunnions shall be accurately machined to ensure proper fit.

(c) Trunnions shall be fully machined. Mill support and thrust bearing surfaces shall be machined accurately and polished.

(d) Castings shall be fully machined on all cope side surfaces. Appropriate machining allowances shall be provided to ensure that all casting dross and other unacceptable material is removed during the machining operations resulting in a smooth surface for seating of liners after rubber lining.

(e) All liner-bolt holes shall be located to provide clear maintenance access to all liner bolts without fouling with the ring motor and head/shell fasteners. It is the intention that no special tools other than those specified shall be required for the removal of liner-bolt holes and nuts.

(f) It is a requirement of this specification that liner-bolt holes for the shell shall be drilled after the shell is rolled and stress relieving is completed. Repair of misdrilled holes shall be subject to CPMM approval.

(g) “Knock-out” holes shall be provided for each liner, in addition to the boltholes required for liner attachment, to facilitate liner removal. Rubber plugs (including 5% extra) shall be provided for each mill by the Contractor to prevent leakage through the liner “knock-out” holes.

(h) The mill brake flange shall be machined so that it is step-free.

(i) Slinger rings or similar shall be provided to prevent slurry contact from leaking liner-bolt holes onto bearing seals and brake flange surfaces.

(j) Mill shells shall be fitted with two ball ports located at either end of the mill and circumferentially oriented at 180°. Ball port size shall be the minimum possible size required to discharge balls at the nominated maximum size without bridging.

5.4 Mill Support Bearings

(a) The mill shall be supported by multi-pad bearings and axially constrained with thrust bearings. Mill bearing surfaces shall be manufactured of standard babbit.

(b) Mill radial bearings shall be of the self-aligning type and allow for mill deflection, and longitudinal expansion and contraction of the mill without damage to the bearing surfaces.

(c) Mill bearings shall be designed to lift the mill structural design load, as defined in the Technical Schedule based on 80% of the nominal bearing lubrication system delivery capacity. The vendor shall determine the minimum oil film thickness by analysis. This analysis shall include both the bearing and mill deformations. The analysis will subject to CPMM audit.

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(d) Self-aligning pad bearings shall include hydraulic adjustment mechanisms. Individual pads shall be readily removable without the need to raise the mill and the Contractor shall provide any special tools or structures required to remove pad assemblies.

(e) The load on individual pad bearings shall be measured and provided as a signal to the plant DCS. These signals together with the load cell measurements shall be employed in the Contractor’s control philosophy to protect the mill against overload and to detect mismatches in loads between individual bearings. The maximum allowable difference between individual bearing loads shall be consistent with the Contractor’s design assumptions used in the structural analysis of the mill. This difference shall be specified in the Contractor’s tender.

(f) Mill bearings shall include oil-tight housings that totally enclose the bearing surfaces on the mill rotating element assembly. Housings shall be complete with access doors, removable inspection/maintenance panels and grease purged contact seals. All access doors and inspection/maintenance panels shall be attached by quick release fasteners. Where access doors cannot be safely accessed from the operating floor, steps shall be provided on the bearing housings.

(g) Seals shall be designed for grease purging to prevent dust ingress and shall include provisions to inhibit excessive grease passing into the housing interior. A distributed, automatic grease purge system shall be provided. Housing seals shall be robust, readily adjustable, prevent dirt ingress or oil egress, provide full 360° seal contact under all operating conditions, and avoid excessive heat generation on the bearing surface when correctly adjusted. The seal shall be automatically preloading. It shall be designed such that it does not cause the wear on the trunnion surface. The Contractor shall provide sketches and details of their chosen seal type with their bid proposal. Removable covers shall be provided on the bearing housings to prevent direct impact of slurry on the seal area.

(h) Machined steel baseplates with shear keys shall be provided to support each bearing pedestal mounted directly on the concrete foundation. Baseplates for bearing pedestal support shall also include jacking pads for accurate field alignment of the bearing pedestal and provisions to hold the aligned bearing pedestal in place. Longitudinal and transverse axis centrelines shall be permanently scribed or machined to facilitate ease of installation and maintenance.

(i) Resistance type temperature detectors (RTD’s) shall be installed in each bearing or bearing housing to measure temperature across the support and thrust bearing surfaces. RTD’s shall be 100 ohm platinum three-wire type and be wired to junction boxes mounted on each bearing pedestal or housing to enable connection to CPMM’s DCS.

(j) Mill bearing pedestal design shall ensure that deformations under normal operating, start-up, extreme motor eccentricity and seismic design conditions will not have detrimental effects on bearing or mill operation. Bearing pedestal deformations, stresses and stress ranges (in plates and welds) shall be determined by finite element analysis.

(k) Bearings shall be supported on angled bottomed housings.

(l) Bearings shall be electrically insulated to prevent stray currents passing into the bearings.

(m) The Contractor shall provide all lubrication piping, hose, valves and fittings integral to the bearings and bearing housings.

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5.5 Lubrication Systems

5.5.1 General

(a) The lubrication systems shall comprise of:

i. A single lubrication system for the main support and thrust bearings,

ii. A single lubrication system for the pinion bearings and main drive gear reducers,

iii. A single lubrication system for the main drive motor bearings.

(b) All oil lubrication systems shall comprise of, as a minimum, skid-mounted, self contained, modular lubrication units complete with:

i. baffled reservoirs,

ii. immersion heaters,

iii. level gauges,

iv. return oil strainers,

v. duty and standby heat exchangers,

vi. duplex filters,

vii. complete duty and standby pumps with motors,

viii. integral piping, hose and fittings,

ix. valves,

x. rotary (gear type) flow dividers,

xi. air actuated valves for controlling water; and

xii. all necessary field mounting brackets/frames.

(c) All lubrication systems shall be preferably from a single sub-supplier.

(d) The heat exchangers shall be water-cooled. A standby cooler shall be provided to allow for on line maintenance. Heat exchangers shall be designed to allow regular cleaning of both oil and water sides.

(e) The cooling capacity of any lubrication system shall be adequate to dissipate the heat rejected from the system under the extremes of climatic and operational conditions and include suitable allowances for internal and external fouling of the cooler. The mill, drive and lube system shall be housed indoors.

(f) The delivery side of all oil delivery pumps (i.e. main bearing high pressure, main thrust bearing pumps, gearbox pumps, pinion bearing pumps and main drive motor pumps) shall include high-pressure duplex filters to protect downstream equipment from damage.

(g) Lubrication skids shall be designed to contain oil spills within the skid and self-drain the oil to discharge outlets complete with valves.

(h) Oil reservoirs shall be fully sealed to prevent dirt and moisture ingress. Filtered breathers and oil fill points shall be provided. Baffles shall preferably be full depth with non-return valves. Access to each baffled section shall be provided with a suitably sealed and removable cover plate. Reservoirs shall have their internal surfaces cleaned and surface protected prior to receiving oil. Oil-level site-glasses and drain valves with magnetic plugs shall be provided in each compartment.

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(i) Duty and standby equipment shall be provided with lockable manual isolation valves and check valves to allow for isolation and maintenance of equipment, with the mill still operating. Valves shall be provided with stainless steel labels to clearly indicate the correct operating positions for the duty and standby pumps.

(j) The Contractor shall design the bearings and lubrication system so that the bearings and other equipment are fully protected from damage during a complete loss of oil delivery (power or other failure). Where an accumulator circuit is required, the circuit shall be provided with, as a minimum, duty and standby pumps with motors, control valve for accumulator charging and discharging, sufficient accumulators for mill “rundown” time with a minimum of one standby unit, individual accumulator oil isolation and bleed valves, nitrogen charging kit complete with all necessary hoses, gauges and fittings, all integral piping and valves and registration/certification relevant to the state/country of installation. Redundant valves shall be supplied for accumulator discharge to ensure oil supply integrity under power loss.

(k) Main bearing lubrication systems shall incorporate a low pressure conditioning circuit taking return oil from the dirty side of the reservoir and pumping through coolers and 12 micron filters into the clean side of the reservoir. All delivery pumps shall draw from the clean side of the reservoir.

(l) Where forced lubrication is necessary, thrust shoes shall be provided complete with duty and standby pumps, motors, and all integral piping, valves and rotary flow dividers.

(m) Where hydrostatic or hydrodynamic shoe type bearings are used, a means of adjusting the height of each bearing via an integral hydraulic cylinder shall be provided. Hydraulic pressure shall be provided via a high-pressure pump including all necessary integral piping, valves and flow dividers.

(n) The systems shall be sized to deliver a minimum of 25% excess oil flow over the design requirement as provided in the Contractor’s Fluid Film Analysis.

(o) External lubrication system oil-supply piping connections shall be flanged. Gravity return piping connections on bearing pedestals preferably shall be flanged, but may be grooved for Victaulic couplings to be provided by others if space limitations negate flanged connections.

(p) Oil filters shall be sized such that the differential pressure across a single operating filter shall be less than the Filter-Suppliers maximum nominated clean oil pressure drop with the oil at its minimum allowable temperature (low temperature alarm setting). The duplex filters shall allow on-line changeover and safe replacement without stopping the mill.

(q) Mill support and thrust bearing lubrication systems shall incorporate high-pressure pumps for adjustment of the bearing pads.

5.5.2 Piping and Valves

(a) The Contractor shall provide all lubrication piping, hose, valves and fittings as follows:

(b) Piping integral to lubrication skids.

(c) Piping integral to field mounting panels or bearing housings.

(d) The Contractor shall size all oil delivery and return lines based on extreme ambient conditions and layout drawings provided by CPMM. The Contractor shall provide line sizing calculations if requested by CPMM. The Contractor shall also recommend whether lines shall be trace-heated to prevent oil supply and return difficulties at minimum ambient conditions.

(e) Piping systems shall be carbon steel and supplied in accordance with ASME B31.3 unless noted otherwise. The Contractor shall use high quality pipe, tubing, hose, fittings and

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valves. The use of threaded joints shall be minimised and flanges shall be used to the maximum extent possible for pipe joints in pressure service. Piping shall be welded using full penetration butt welds and socket weld fittings shall not be used. Barrel unions shall not be used.

(f) All piping shall conform to the following standards: (3) i. ASME B1.20.1

ii. SAE Code 61, SAE Code 62,

iii. DIN Code 41 or

(3) iv. ASME 16.5

(g) All hoses shall have swaged ends

(h) All piping shall be cleaned by pickling following fabrication. Piping shall be then pressure tested in accordance with the relevant Code and the system flushed. The Contractor shall submit their procedures for cleaning and pickling, pressure testing and flushing for review and approval by CPMM.

5.5.3 Electrical and Instrumentation

(a) Sufficient instrumentation and controls shall be provided to allow control, performance monitoring, safe, and reliable operation of the lubrication systems and associated equipment. As a minimum, the Contractor shall provide:

i. Low level switches for alarm and shutdown conditions in each section of the oil reservoir.

ii. Sufficient analogue temperature transmitters to allow temperature control of the oil, as well as high and low alarm and shutdown conditions.

iii. Analogue flow transmitters (or tachometers where rotary flow dividers are used) to allow monitoring of oil flow to all bearings in operation, providing alarm and shutdown set points. An analogue flowmeter shall also be provided for the low pressure pump flow in the mill support bearing lubrication system.

iv. Sufficient analogue pressure transmitters to: allow monitoring of high pressure pump discharge pressures or main bearing pad pressures; allow fill and discharge of accumulators, and provide low pressure alarm and shutdown conditions.

v. Differential pressure transmitters for filters to allow blocked filter detection.

vi. Level, pressure and temperature gauges for field monitoring of operating conditions.

vii. Moisture sensors mounted prior to tank return inlet to indicate water or slurry content.

(b) The lubrication skids and any field instrumentation skids shall be provided with all integral wiring and conduit terminated at terminal blocks contained in a local marshalling panel.

(c) Control and monitoring of the lubrication systems shall be provided by CPMM’s PLC or DCS. The Contractor shall provide P & ID’s and logic diagrams for approval by CPMM.

(d) Electrical and instrumentation equipment shall be supplied in accordance with CPMM’s Standard Specifications.

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5.6 Mill Lining Systems

(a) The Contractor shall be responsible for liner design, preparation of liner drawings, specifications, and co-ordination with the liner supplier over all issues. CPMM will participate in liner design and selection and therefore liners shall be priced as a Provisional Sum ($/kg plus fixed costs). Final liner design shall be approved by CPMM prior to procurement. The Contractor shall submit design and manufacturing details in their tender along with the nominated sub-suppliers.

(b) Prior to the liner design meeting the Contractor shall submit a trajectory analysis or similar to demonstrate their liner design is optimized for the given operating conditions. This analysis shall have considered a number of combinations of liner spacing, lifter height and face angle.

(c) The mill internal surface shall be provided with a permanent rubber backing liner. Rubber lining shall be in accordance with CPMM’s standard specification.

(d) Liner configurations shall be designed to eliminate continuous circumferential joints or other areas in which pulp raceways may form. The liners shall not span shell joints. The number of different types and sizes of mill liners shall be minimized.

(e) Liner bolts shall be a minimum of 48 mm diameter. Liner hardware shall include sealing washers and “Nylok” type nuts complete with 5% extra of each item.

(f) All mill liners shall be sized to be passed through the mill feed end opening with a mill liner handler, to be provided by others. The liners shall also be designed to suit the lifting attachments supplied with the mill liner handler. The Contractor shall be responsible for co-ordinating with CPMM’s nominated mill liner-handler supplier.

5.7 Trunnion Liners

(a) Replaceable liners shall be provided in both feed and discharge ends of the mills. Trunnion liners shall be adequately sealed to their trunnion to prevent leakage of slurry between the liner and trunnion.

(b) The discharge trunnion liner wear lining material shall be of replaceable modular rubber liners, and shall be readily replaceable without removing the trommel. Minimum rubber lining thickness shall be 100 mm.

5.8 Feed Chute, Spout & Removal Trolley

(a) The ball mill feed chute shall be of fabricated steel construction and provide a “rock box” for material discharging from CPMM’s conveyor. The feed chute shall be lined with easily removable liners. Liners shall be provided with lifting provisions for installation.

(b) An integral feed chute transportation cart shall be provided and include hydraulic drive motors and lift cylinders for 2-axis all-wheel-drive travel along embedded rails provided by the CPMM. Supply shall also include all piping, hoses and “quick connect” connections for hydraulic oil supply from a portable hydraulic power pack.

(c) The portable hydraulic power pack shall include; all necessary instrumentation, hydraulic controls, control panel, electric motor starter, flexible power cable with plug connector and flexible hoses for quick connection.

(d) The mill feed chute/spout shall be provided with simple and effective interface with CPMM’s flanged conveyor head chute. An effective seal with the mill shall also be provided to prevent slurry egress.

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(e) The feed spout shall be fitted with a locking mechanism to hold it in place when the mill is in operation.

(f) The feed chute shall be supplied with packers and shims to allow vertical alignment with the mills.

5.9 Discharge Trommel

(a) The Mill shall be provided with a discharge trommel adequately sized to separate scats from the discharge slurry at maximum capacity specified in the Data Sheet. The Ball mill trommel shall be provided with heavy duty and replaceable rubber or poly-urethane panels attached to the frame with a positive, but readily removable, locking system. Heavy duty and readily replaceable rubber or poly-urethane retention spirals or dams shall also be provided.

(b) The Ball mill trommel shall be provided with heavy duty and replaceable rubber or poly-urethane panels attached to the frame with a positive, but readily removable, locking system. Heavy duty and readily replaceable rubber or poly-uretne retention spirals or dams shall also be provided.

(c) The trommel structure shall be a heavy-duty steel frame with 12 mm rubber lining, preferably by vulcanising. All members that shall be lined with rubber shall have sharp edges ground to generous radii to facilitate application of the rubber lining. The bonding of thin sections of rubber along the thickness of plate sections shall not be permitted. The rubber lining shall conform to the Purchaser’s standard specification for rubber lining.

(d) A drip ring shall be provided to interface with the Purchaser’s trommel cover seal.

(e) The trommel design life shall be 10 years. The Supplier shall nominate their design loading conditions and design method in their tender.

(f) Details of the design of the trommel and the application of the rubber lining shall be submitted to the Purchaser for approval and provided with the Supplier’s tender.

5.10 Baseplates, Soleplates, Sub-Soleplates and Embedments

(a) The Contractor shall supply all baseplates, soleplates, sub-soleplates, packers, stainless steel shims and embedments for all mill bearings, brake pedestals and drive components including electric motors. Shear keys shall be provided where necessary.

(b) Horizontal alignment adjustment shall be achieved utilizing pillars and setscrews with their heads against the bearing housing and one nut either side of the jacking pillar. Wedges or similar shall be supplied to lock the main bearings into position.

(c) The holding down bolts shall be specified and supplied by the Contractor and clearly shown and indicated on the mill foundation drawings. The design of these items shall be subject to approval of by CPMM. The schedule of manufacture of these items shall satisfy CPMM's schedule requirements.

(d) Longitudinal and transverse axis centrelines shall be permanently scribed or machined on baseplates and soleplates to facilitate ease of installation and maintenance.

(e) Baseplates and soleplates shall be thermally stress relieved after all welding is completed and prior to machining.

5.11 Jacking Systems

(a) Complete mill jacking systems shall be provided, each including two (2) jacking cradles, four (4) hydraulic jacks, a portable hydraulic power pack and all necessary hoses, fittings,

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valves and controls. The cradles and hydraulic jacking systems shall be capable of lifting and supporting either end of a fully loaded mill (with structural design weight specified herein).

(b) The hydraulic power pack shall be supplied fully functional and factory tested including as a minimum, motor starters, 30-metre power cable and all necessary gauges, instruments and controls for safe and accurate raising and lowering of the mill.

(c) Jacking cradles shall completely support mills from the ground floor slab without need for temporary steelwork or dunnage.

5.12 Temporary Lubrication System

(a) The temporary lubrication system shall be used to facilitate turning of the mill during initial installation prior to commissioning of the main lubrication system.

(b) The temporary lubrication system shall be capable of being used to rotate a mill fully assembled with liners and rotor poles.

(c) The temporary lubrication system shall be supplied fully functional and factory tested including, as a minimum, electric motor, motor starter, instrumentation, controls, 30 m long power cable with plug, and 30 m long supply and return oil hoses and fittings.

5.13 Lifting Lugs

(a) All heavy components (e.g. shell, heads, trunnions, etc) shall be supplied with removable lifting lugs for crane handling. Each lug shall be designed to carry a minimum of twice the lifting load. The gross weight of the lift shall be stencilled or painted in a conspicuous location and identified as the gross lifting weight.

(b) Lugs shall be bolted to each component in the shop prior to shipment.

(c) The Contractor shall provide lifting diagrams to show how these items are lifted from transport facilities and lifted into position during installation.

(d) For remaining equipment, suitable lifting points shall be provided on all equipment or assemblies that exceed 20 kg in weight.

(e) All lifting lugs shall be certified by the relevant authority.

5.14 Guards

(a) All guards shall conform to the safety requirements of the duly constituted Local Authority and to the relevant local country design codes.

(b) All guards shall be segmented in such as manner so as they sections can be safely removed and replaced by one person.

(c) The Contractor shall provide all guards for human protection (except where specifically excluded).

5.15 Fasteners

(a) Rotating element fasteners shall be machined for use with an ultrasonic bolt-elongation measuring device. Both ends of the bolt/studs shall be machined parallel and flat to allow true and accurate readings and verification using a micrometer where necessary.

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(b) Maximum and minimum fastener elongations shall be included in the Contractor’s installation instructions.

(c) All external threads on rotating elements fasteners shall be rolled.

(d) Bearing surfaces on all externally threaded assembly fasteners shall be machined to ensure they are perpendicular to the fastener centreline and to provide smooth, flat surfaces without any die seams.

(e) Bearing surface total runout on all fasteners shall not exceed 1.0 mm.

(f) All nuts shall be assembled on to bolts for shipping. Nuts shall turn freely.

5.16 Torque Wrenches and Elongation Meters

(a) The two hydraulic torque wrenches shall be supplied complete with power pack, torque wrench and all sockets (4 of each size), adapters and accessories necessary to tighten all mill rotating element fasteners.

(b) The hydraulic torque wrench shall be supplied by Hy-Torc.

(c) The two ultrasonic bolt elongation meters shall be supplied with all accessories including leads, calibration equipment, software and a carry case. A total of eight spare ultrasonic probes and eight temperature probes shall be provided (including cables) with the equipment.

(d) The Contractor shall include a 3 day on-site training and calibration session performed by the elongation meter supplier.

5.17 Bearings

Minimum L-10 life for antifriction bearings in auxiliary systems shall be 80,000 hours for the maximum design duty

5.18 Ring Gear Drive

5.18.1 General

(a) All gear drive components shall be rated, designed and manufactured to the requirements of the Technical Schedule.

(b) The design hardness range for fully hardened gears shall not exceed 30 points on the Brinell hardness scale. The design hardness range for case hardened gears shall not exceed 5 points on the Rockwell “C” scale.

(c) Induction hardening of gears shall not be allowed.

5.18.2 Ring Gear

(a) Ring gears shall be designed for bi-directional rotation.

(b) Ring gear segment joint splits and flanges shall be oriented parallel to the gear helix angle.

(c) The tooth number shall be stamped permanently on the top land of every fifth ring gear tooth and on one tooth on each side of each ring gear segment joint split.

(d) All changes in ring gear section thickness shall be radiused. Rough edges in areas of gear section thickness changes shall be removed by grinding.

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(e) Pulp slinger rings shall be shop fabricated, match marked and predrilled for bolting to predrilled and tapped holes in the ring gears.

(f) Ring gear castings shall be heat treated and identified by permanent serial number. A record of chemical and mechanical properties for each ring gear casting shall be maintained for review by the Buyer’s quality surveillance representative.

(g) The tensile properties of each casting shall be confirmed by testing of specimens representative of the thickest casting section. Cast test coupons shall undergo heat treatment with the castings they represent.

(h) Mechanical bolt tensioners, such as Superbolt® products, shall be provided for installation of all externally threaded fasteners for ring gear segment assembly.

(i) A reference band for checking ring gear radial runout when mounted on the mill shall be machined on the inside diameter of each ring gear near the rim face or on the top land of the gear teeth. Location of the reference band on the inside diameter is preferred. The reference band shall be readily accessible when the ring gear is mounted on the mill. Reference band surface finish shall not exceed 3.2 micrometres (125 microinches).

(j) All critical ring gear final dimensions and tooth quality attributes except lead shall be checked and recorded. As a minimum, the pitch shall be measured on both flanks of all teeth at midface, the absolute profile shall be measured on both flanks at midface of one tooth on each gear segment and the comparative profile shall be measured on both flanks at midface of at least 15 percent of the teeth. The 15 percent shall include one tooth before and one tooth after each final cut tool change and an equal number of teeth on each side of each gear segment joint split and midway between the gear segment joint splits.

(k) “Spring tests” shall be carried out when the ring gear is split after preliminary and final machining to ensure there is no relative movement between the split faces due to residual stress.

(l) No weld repairs shall be allowed in the tooth area of cast steel blanks. Weld repairs in other than in the tooth area, shall be documented fully and submitted to the Purchaser for approval.

5.18.3 Pinion Gears

(a) Pinion gears shall be made of heat-treated alloy steel forgings with integral shafts. Pinion gears shall be designed for bidirectional rotation.

(b) Pinion forgings shall be heat-treated.

(c) Pinion teeth shall be carburised case hardened and ground.

(d) Pinions centres shall be bored axially to relieve residual stresses.

(e) Fully hardened pinion gear mechanical test coupons shall undergo the same heat treatment as the final forgings they represent. Case hardened pinion gear test coupons shall accompany the pinions they represent during the carburizing process. Test coupons for case hardened pinions shall then be sectioned and surface hardness and the depth of the hardened layer shall be measured and recorded.

(f) Pinion gear finish machining and profile grinding shall be done after all heat treatment and hardening is complete.

(g) Prior to the start of pinion fabrication, the pinion supplier shall define how the applicable AGMA tolerances will be applied to the tooth profile or lead modifications to insure compliance with the AGMA quality levels specified in this specification.

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(h) All critical pinion gear final dimensions and tooth quality attributes shall be checked and recorded using a Klingelnberg PFSU 2500, or a Purchaser approved equivalent measuring equipment. As a minimum, the pitch shall be measured on both flanks of all teeth at mid-face, the profile shall be measured at mid-face on both flanks of four teeth located approximately 90 degrees apart, and the lead shall be measured at mid-tooth height on both flanks of four teeth located approximately 90 degrees apart.

5.18.4 Pinion Shaft Bearings

(a) Pinion shaft bearings shall be heavy-duty antifriction pillow block assemblies with split housings and taconite-type seals.

(b) Pillow block assemblies shall provide ample hold-down bolt head access for the use of hydraulic torque wrenches during installation and maintenance alignments. Hold-down bolt bearing surfaces and the corresponding pillow block contact surfaces shall be fully machined to ensure proper contact.

(c) Pillow block hold-down bolt washers shall be hardened to prevent galling during installation and maintenance.

(d) A means of providing accurate referencing of pillow block movement shall be provided.

(e) Each pinion shaft bearing shall be provided with resistance temperature detectors (RTDs) for connection to the Purchaser’s Plant PLC/DCS and connections for a circulating oil lubrication system.

(f) All bearings shall be fitted with vibration monitoring sensors. Details to be supplied with Tender.

5.18.5 Main Drive Gear Reducers

(a) The reducer gears shall be helical type. Gearing shall be finish cut after heat treating to the required mechanical properties. Not more than one driving gear and one driven gear shall be mounted on each shaft.

(b) Reducer housings shall be split through shaft centerlines to allow replacement of major components. Inspection openings shall be provided complete with quick release fasteners and shall allow for inspection of high and low speed gearing.

(c) Reducer housings shall be of welded steel or cast iron construction. Inspection openings with bolted and gasketed covers, complete with lifting handles, shall be provided in the housing covers to allow for inspection of high and low speed gearing without removal of major housing sections. The upper half of the housings also shall be removable to allow for gear replacement. The split between the upper and lower housing halves shall pass through the centre of all shafts and bearings. Expanded metal, or equivalent, footsteps shall be provided on the housings where necessary to facilitate maintenance.

(d) Reducer housings shall be provided with an oil sight glass, sump oil temperature RTD, magnetic drain plug and drain valve, filtered oil fill point, filtered breather and flanged connections for circulating oil.

(e) All bearing temperatures and the sump oil temperatures shall be monitored by RTD.

(f) All bearings shall be fitted with vibration monitoring sensors as part of the system detailed in Paragraph 5.18.11. Taconite-type seals shall be provided wherever shafts project through the housings.

(g) Gear reducers shall include high-speed shaft extensions with half couplings for connection of the inching drive.

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5.18.6 Couplings

(a) Flexible couplings shall be furnished for low and high-speed shafts.

(b) The main drive motor couplings shall accommodate longitudinal motor shaft movements in accordance with limits set by the Purchaser’s motor manufacturer.

(c) All half couplings shall be shop mounted prior to shipment. Motor-mounted half couplings shall be rough bored and delivered to the motor manufacturer on a timely basis for mounting. Mounting instructions for motor-mounted half couplings also shall be supplied to the motor manufacturer on a timely basis by the Supplier.

(d) Pinion, main gear reducer and main motor couplings shall include “hydraulic assist” provisions for easy removal.

5.18.7 Main Drive Motors and Liquid Resistance Starters

(a) See separate electrical specification.

(b) LRS starters shall be CSE Uniserve.

5.18.8 Inching Drives

(a) The inching drive shall be supplied with a hydraulic motor, hydraulic brake, drive coupling, gear reducer and shiftable coupling.

(b) The hydraulic inching drive shall be a packaged unit connected to the high-speed shaft extension of the main drive gear reducer. The inching drive shall drive both pinions to minimise drive train loads imposed during inching. The inching drive and brake shall be designed to rotate and hold the eccentric load of a fully loaded mill to at least 40o (from bottom dead centre) and operate in either direction of rotation.

(c) The inching drive shall provide a simple, easy and safe engagement and disengagement. The shiftable coupling shall be hydraulically driven and fitted with limit switches and “Castell” type lock, with spare keys, to ensure that the main motor cannot be started with the inching drive engaged.

(d) Pressure transducers shall be provided to monitor hydraulic pressures at the hydraulic motors.

(e) Two (2) inching hydraulic power packs shall be provided to service the mills. The hydraulic power packs shall be supplied as skid mounted units complete with reservoir, pumps, motors, valves, instrumentation and hydraulic controls.

(f) The Contractor shall supply one complete control panel with the inching drive to enable local operation, monitoring and protection during the installation period. The control panel shall also include all motor starters and electrical equipment necessary for independent operation of the inching drive during installation.

5.18.9 Gear Lubrication System

(a) An automatic grease lubrication system shall be provided for lubricating the ring gear and pinion mesh. The system shall be supplied fully functional and include, as a minimum, grease pump, drum heater, valves, metering blocks, nozzles, pressure gauges, relief valves, and all grease and air piping/tubing/hoses between the control panel, grease drum and nozzle header. The Contractor shall provide trace heating where required.

(b) The lubrication system shall be a stand-alone system with all necessary instrumentation, controls (PLC), panels and junction boxes. As a minimum, alarm and shutdown conditions shall be provided for low air pressure, low grease pressure, drum low-level, low

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temperatures, system fault, and blocked nozzles. Voltage free contacts shall be provided for connection to the Plant PLC or DCS.

(c) The grease application to the gear mesh shall be accomplished within the gear enclosure guard, and sufficient nozzles shall be provided to ensure uniform and adequate lubrication across the full-face width of the gear.

(d) The Contractor shall provide all details of their nominated gear lubrication system in their tender for review by CPMM.

5.18.10 Gear Guard

(a) The ring gear and pinion shall be provided with a rigid 360° guard. The guard shall be multi-piece with lifting lugs for easy removal of individual segments. A seal system to exclude dust, water and slurry shall be provided around the full circumference on both sides of the ring gear. A seal around the pinion shaft openings shall also be provided.

(b) The gear guard shall be provided with a flanged spent grease drain to allow disposal in empty drums. The gear guard shall be provided with thermostatically controlled heaters to prevent build up of spent grease.

(c) A hinged inspection hatch, complete with lockable handles and rubber seals, shall be provided at the pinion mesh to allow on line monitoring of temperatures. Removable hatches shall also be provided to access the gear mesh for alignment (backlash) checking.

(d) The gear guard shall be designed so as to prevent the build-up of grease with adequate clearances between the ring gear and the guard walls.

5.18.11 Vibration Monitoring System

(a) A vibration monitoring system for each mill shall be supplied to provide analogue RMS output of bearing vibration to the plant PLC/DCS system for alarm and trending, of the following:

(b) Main drive gear reducer bearings

(c) Pinion bearings

(d) Main drive motor bearings

(e) The Contractor shall provide details of their proposed system with their tender.

5.18.12 Infra-red Pinion Temperature Monitoring System

(a) An infra-red pinion temperature monitoring system for each mill shall be supplied to provide pinion temperature at three places across the pinion face to the plant PCS system for alarm, interlock and trending.

(b) The system shall include an automatic air purging system to ensure sensors do not get blocked with grease.

5.18.13 Dropped Charge Protection System

The Contractor shall provide details of their proposed system with their tender. It is expected that measurement of torque from the twin hydraulic inching drives will be used as part of this system.

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6 BELT CONVEYORS

6.1 General

Belt conveyors shall be designed in accordance with ISO 5048 or Conveyor Equipment Manufacturers Association (CEMA) recommendations as a minimum. Adherence to the requirements of CITIC Pacific mining Management’s document “ES 032 Engineering Specification for Belt Conveyors” is specifically required.

7 BELT FEEDERS The discharge opening of the associated belt feeder hopper shall be large enough to ensure passage of the material at the required maximum discharge rate which shall be throttled by the feeder.

To maintain uniform flow from the hopper, the discharge opening shall have a horizontal taper in the direction of belt travel and the hopper bottom shall have vertical relief. The vertical skirt boards shall be continuous and parallel with the feeder centre line.

The minimum material depth at the hopper outlet shall be the greater of the following two cases;

• Two times the largest lump size; or

• One third of the hopper opening width.

Design of stockpile outlets including chutes and belt feeder shall be in accordance with relevant test work and recommendations. The belt feeder shall have a variable speed drive to accommodate the recommended speed range.

Belt Feeders shall be capable of pulling out a fully loaded belt from the feeder. Power required shall be calculated to start the Feeder belt under occasional larger feed loads due to filling.

7.1 Belt Feeder Components

All belt feeders and their component parts shall be suitable for operation in a dust laden or moist atmosphere and shall be resistant to the action of high pressure water jets used for clean up.

Belt feeders shall be fitted with hydraulic belt tensioners.

7.2 Maintenance

All feeders shall be designed and positioned for ease of belt replacement. A monorail beam and trolley with a ‘points’ system (subject to detail design) to assist with equipment removal shall be provided in each feeder tail and drive area for lifting of components.

8 PRIMARY CRUSHING APRON FEEDER Apron feeders shall be heavy duty design suitable for ore material containing large, sticky, heavy and sharp lumps incorporating the following features:

(a) Head shaft centreline located downstream of the feed opening by a minimum distance of 1.5 x times the maximum lump size beyond the toe of the material repose angle

(b) Feed slot to be at least 2.5 x maximum lump size of 900 mm

(c) Pans shall be impact resistant manganese steel

(d) Caterpillar (or equiv.) SALT type tractor-type feeder chain with I-Loc master links having a minimum safety factor of 5 on maximum chain pull calculated for worst case pull out conditions

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(e) Standard Caterpillar (or equiv.) segmented-type head and tail sprockets made of manganese steel

(f) Electro/mechanical VVVF controlled drive designed for 0 to 0.25 m/s maximum speed under worst case loading and ambient conditions

(g) Manually operated hydraulic jacks to tension the apron feeder chains to the design tension including stainless steel screws to lock the take-up at the generated force.

(h) Feeder skirtboards at least 150 mm higher than material bed depth and spaced equal to the pan width less 100 mm

(i) Heavily reinforced and lined discharge chute completely enclosing the head sprockets, chain and pans, with a minimum clearance of 50 mm between chute or liner and pans

(j) Dribble chute will be provided under the return run along full length of the feeder to catch all material drippings and discharge them to the receiving belt conveyor

(k) Emergency pull cord switches on both sides of the feeders

9 VIBRATING FEEDERS AND SCREENS Vibrating feeders and screens will be electromechanical type, heavy duty design, with natural frequency based coil spring drive, adjustable eccentric weights, and rotating weights guards.

Feeder pan and frames shall be welded construction, stress relieved and designed for maximum strength and reliability.

All surfaces subject to abrasive wear or corrosion shall be lined or protected.

Liners on the pan and skirts shall be readily replaceable Bisalloy 500 or as otherwise recommended by the machine Supplier/Manufacturer.

A minimum 50mm clearance between the vibrating frame and all discharge chutes or hoppers should be maintained.

(Note:- Reclaim feeder selection and spacing will be subject to Tunra testwork being currently undertaken.)

10 AIR EMISSIONS Ambient air quality within the workplace shall be maintained within the limits prescribed (Ambient Air Quality) for the mine site.

Ambient air quality outside the workplace boundary shall also be maintained within limits prescribed by the Environmental Management plan.

10.1 Dust Suppression

Where practical, the emission of dust shall be controlled by fogging water sprays. Air atomized resonating nozzles are preferred because of high efficiency without use of surfactants.

Where dust is not airborne, water deluge systems shall be considered before the materials discharges off the conveyor head pulley or materials handling equipment.

Where dust collection systems are required at conveyor and crusher discharge points, a dust bag filter assembly or wet dust collection system shall be used. The dust collection systems shall ensure that the very fine dust produced is effectively contained. The collected dust shall be mixed to form a slurry and pumped to a point in the process plant where it can be discharged.

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10.1.1 Conveyor Covers

Consideration shall be given to the requirement for covering conveyors to minimize dust emissions to the local environment and prevent ingress of rain onto the conveyor.

The requirement for covers shall be nominated in the equipment datasheet.

Covers shall be hinged for access to the conveyor. Covers are to be designed to prevent rain access on the conveyor belt in tropical conditions.

10.1.2 Dust Control Equipment

Dust and ventilation control equipment shall be manufactured in accordance with statutory requirements and specifications. Reference shall be made to the publication “Industrial Ventilation’ of the American Conference of Government Industrial Hygienists (latest edition) as a guide to recommended practice. All dust control equipment, including ductwork design and layout shall be engineered with full consideration given to environmental conditions, plant process, ease of maintenance, safety of operation and accessibility of equipment.

10.1.3 Ductwork

Enclosures, chutes and covers shall be located to ensure that dust is contained and collected with the minimum exhaust volume. Openings shall be located in the minimum number of areas required to effectively collect dust.

Ductwork should be avoided where possible but if required, shall be as short as possible with the minimum number of bends. Easily accessible test points, clean outs hatches and blast gates shall be located in each branch duct and main duct where required. Ducts shall be adequately supported and be designed to carry the system fully plugged. Minimum clearance between ducts and ceilings, walls or floors shall be 150mm.

10.1.4 Chutes, Enclosures & Skirting

Material handling chutes, conveyor enclosures and conveyor skirting shall be designed to minimize the release of dust. Joints shall be welded or flanged and gasketed. Conveyor enclosure heights shall be a minimum of one half belt width of the conveyor in order to provide sufficient particulate settling capacity. Fitted rubber curtains shall be provided at the entrance and exit of all conveyor enclosures. Exhaust points or hood locations shall be situated to develop cross flows and to preclude obstructions due to material accumulation including dust build up.

10.2 Dust Collection Baghouses And Collection Systems

Dust baghouse filters shall be selected with an air to cloth ratio of 0.20 to 0.30 L/s/m2.

Dust control air volumes and velocities shall be as per standard materials handling criteria and formulae for given conditions and shall match or exceed the best practice recommended in the ACGIH Manual of Industrial Ventilation.

Reference shall be made to the publication “Industrial Ventilation’ of the American Conference of Government Industrial Hygienists (latest edition) as a guide to recommended practice.

10.3 Bunding

The Plant layout included in the Development Plan Report and the Site Water Management Plan shall been used as the basis for bunding requirements.

Bunding shall be provided around all storage tanks. Bunding shall be based on the largest tank volume multiplied by a capacity factor. The floor inside a bund shall facilitate drainage to a common sump.

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Area bunding shall allow for a:

• Capacity factor, based on largest tank in bund is 110% largest vessel;

• Minimum floor slope of 1 in 100;

• Minimum floor slope in materials handling equipment areas of 1 in 25.

As the design progresses and safety reviews are completed, other storage areas may be identified to comply with Hazardous Area Storage guidelines.

10.4 Hazardous Area Storage

Reagents and process slurries shall be safely handled and stored on site. Where the classification of a material is such that it falls under the category of a Dangerous Good or Hazardous Substance, then storage and handling of the substance on site shall comply with the latest issue of following Government Regulations and Standards:

• Occupational Heath and Safety (Hazardous Substances) Regulations;

• Dangerous Goods Act;

• AS4452 The Storage and Handling of Toxic Substances;

• AS3780 The Storage and Handling of Corrosive Substances; and

• WA Department of Mines Cyanide Handling Practice.

The above Standards and Regulations set out the minimum requirements and recommendations for the safe storage and handling of the hazardous substance and dangerous goods.

Where it is unclear as to the minimum requirements for storage and handling of a particular substance, the relevant code, EPM and EIS shall be referred to, to ensure compliance.

11 SCREW CONVEYORS Design capacity of screw conveyors shall be based on 45% loading of trough cross sectional area for non-abrasive material, 30% for moderately abrasive material and 15% for highly abrasive material.

Flights for screw conveyors handling highly abrasive material shall be hardfaced.

Intermediate bearings shall not be used.

12 CHUTES

12.1 General design requirements

Chutes shall be designed to/have/be;

• A throat and outlet dimensions preferably at least 3 times the largest nominal rock size but no less than twice the largest nominal rock size

• A minimum cross sectional area of 5 x cross sectional feed load

• have a minimum volume not less than 1.5 x dump volume following normal or emergency stop

• Heavy duty welded construction with bolted connections for installation and loose flanges where necessary for field fitting and adjustment

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• Fabricated from mild steel plate and sections to AS 3678 / AS 3679 Grade 350. Plate thickness and section size shall be such that plastic deformation does not occur as a result of material impact or pressure

• Enclose the head pulleys, snub pulleys, and belt scrapers

• Collect and shed all carryover and fines dropping from the head pulley, snub pulley, and the belt, and deposit it onto the receiving belt

• No leakage or spillage of the conveyed material

• Load material centrally on the receiving belt with the first point of impact of ore on the receiving belt being midway between two impact idlers

• Free flow of material without arching, rat-holing, bridging, plugging, or otherwise constricting the flow of material

• Material impacts and flows on areas protected by liner plates, rock boxes, heavy chains, or grizzly bars only

• Support the weight of the chute with liners, attachments, and the weight of ore equal to that of the plugged chute volume

• Inspection doors mounted on fabricated hinges and fitted with latches and dust-tight gaskets

• Equipped with rubber dust curtains at the chute entrance

• Flanged joints to facilitate installation, and maintenance of all conveyor equipment and plate work with minimum disturbance to surrounding equipment, structures, and plate work

• Plugged chute detector.

12.2 Minimum chute angles

Unless specified in the material test reports, the following minimum chute angles shall apply;

• Minimum chute wall angle (deg.) 70

• Minimum chute and hopper valley angle (deg.) 60

• Minimum dynamic angle of repose for rock boxes (deg.) 60

• Screen undersize chute wall angle (deg.) 60

12.3 Feed Openings Under Hoppers

Draw-down holes shall be as large as possible, with chute or rock box configurations designed to minimize direct static load on the feeder.

The minimum dimension for a feed slot over a feeder shall be greater than 3 times the maximum lump size.

Edges shall be protected by wear bars, provision made for blocking off the opening with spile bars, timber or a gate.

12.4 Transfer Chutes, Hoppers & Bins

Except with sticky materials (eg clay like or clay containing materials), rock boxes shall be incorporated at transfer points where excessive wear is anticipated. All wear surfaces shall be lined with approved liner materials. Chutes handling cons. Should not have rockboxes.

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Chute widths shall be standardized insofar as possible for uniform liner sizes. Inside width of head chutes shall be no less than pulley width plus 75mm each side. For sticky materials chutes and transfer points shall be made sufficiently large to avoid blockages and lined with low friction materials.

Chute throat dimensions and hopper outlet dimensions shall at least 3 times the largest nominal rock size, but where this cannot be achieved, shall be no less than twice the largest nominal rock size.

At loading points, belt conveyors shall be provided with lined steel plate skirt boards complete with adjustable rubber skirts. Skirt boards shall be set at ⅔ of belt width and provided with top cover plate unless noted otherwise.

Bins with draw-down openings near the bin walls require local abrasion protection.

12.5 Liners

All areas subject to wear shall be lined with plate liners.

Standard liner plates of 20 mm thick shall be used in areas of heavy abrasion as typically applicable to chute work handling crushed ore.

In general wear liner materials shall be Bisalloy 500 or equivalent plate for dry application.

Where the service conditions do not suit the application for Bisalloy 500, other materials such as dual-layer composite metal carbide plate (e.g. Duoplate), rubber, ceramic, or UHMW polyethylene lining material may be used in specific applications.

In general, hard iron wear bars will be used in applications involving run of mine or coarse crushed rock.

Liner plates shall be of a size and design that can be readily handled and installed.

13 SLURRY HANDLING EQUIPMENT The following criteria apply to the following equipment classes which will handle ore concentrate and tailings

• Slurries:

• Pumps;

• Sumps;

• Launders;

• Junction boxes, sampling boxes and distributors.

Priorities for space allocation in slurry system layout shall be:

• Gravity launders; then

• Pressure slurry lines.

All pedestals shall be designed to assist clean-up operations.

Pipe sizes and launder sizes shall be determined by the Process Engineer.

13.1 Pumps

All concentrator pumps in slurry service shall be supplied in accordance with the requirements of the Equipment Datasheet. The Process Engineer is responsible for sizing and selection of all pumps.

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Standard vendor equipment is preferred.

Particular attention shall be given to the following:

• Pump design i.e. prefer standard vendor design for service;

• Seal selection i.e. variable speed pumps shall have water flushed gland seals unless expeller seals can be demonstrated to be adequate;

• Froth/aeration pumping and conical hopper design; and

• Pumps shall be selected to avoid the pump duty point being at the limit of it performance curve.

Sump pumps will preferably be of the vertical spindle type with rubber lining and flexible hose attachments.

Pumps shall be mounted such that shaft bearings are not immersed when the sump is full.

13.2 Pump Control

For the applicable process control philosophy refer to the Instrumentation and Control Design Criteria.

13.3 Sumps and Hoppers

Adequate retention time shall be provided in all sumps to accommodate fluctuations in sump feed and to allow proper level control.

Sump and hopper capacities shall be determined by the Process engineer.

Pump sumps and hoppers shall be designed to maximise de-aeration prior to the slurry entering the pump.

Sumps and hoppers to be designed so that solids don’t block alternative pump suction nozzle when it is not in use.

Sump and hopper capacity shall be measured as the volume between 300mm above the top of the pump suction nozzle and the lip of the sump overflow weir.

Above ground sumps and hoppers shall have a piped overflow to floor level (grade). The overflow pipe shall discharge through an elbow in the direction of the floor gradient towards the sump.

Floor sumps shall be concrete and have removable screens to protect the pump and restrict the size of material entering the sump. The openings in the grating shall be 5mm smaller than the top size of material that can be handled by the pump.

13.4 Launders

Open launders shall be used where applicable for cyclone overflow transfer launders, flotation froth transfer launders, and wherever splashing and spilling is likely to occur.

• High sided open launders shall be used for froth transfer.

• Launder sizes and slopes shall be determined by the Process Engineer.

14 PUMPING AND PIPING Refer to Design Criteria DI-024727 Pumping and Piping.

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15 CRANES AND HOISTS Cranes and hoists shall be designed in accordance with AS1418 and amendments. The requirement for cranes and hoists shall be in the Technical Datasheet.

Gantry type cranes shall be fitted with facilities to prevent uncontrolled travel and over turning during abnormal wind conditions. Crane rails shall be fitted with stop blocks.

Unless otherwise approved, maintenance cranes and hoists which work intermittently shall be classified as follows:

• Workshop cranes Class 2;

• Plant maintenance cranes Class 2;

• Manual cranes and hoists Class 1.

16 AGITATORS

16.1 General

Agitators shall be of heavy industrial construction and shall be to the Supplier’s/Contractor’s standard proven design for the duties and applications indicated by the Equipment Data Sheets, except where otherwise reviewed and accepted by The Engineer.

All motors shall be capable of starting DOL under the conditions specified by the Equipment Data Sheets.

16.2 Agitator gearbox

Agitator gearboxes shall be designed specifically for agitator duty.

This duty requires that the overhung load capacity of the gearbox is substantially greater than that provided by a standard gearbox not specifically designed for heavy minerals processing plant slurry duty and that the retention of lubricating oil in the gearbox does not rely on the integrity of the output shaft seal arrangement.

The output shaft of the gearbox shall be of solid, keyed shaft type.

Gearboxes having a hollow output shaft, shrink disc type coupling arrangement are not acceptable.

16.3 Agitator shaft

A rigid, bolted coupling shall be provided to couple the agitator gearbox output shaft to the agitator shaft.

Where the agitator shaft is a solid shaft, the lower gearbox coupling half shall be attached to the agitator shaft by bored and keyed flanged hub complete with a retaining cap plate bolted onto the end of the shaft.

Where the agitator shaft is a hollow, pipe type shaft, the lower gearbox coupling half shall be of a forged “weld neck” type flange construction attached to the agitator shaft by a full penetration butt weld.

Flat plate, slip-on type flange, double fillet weld construction is not acceptable.

Coupling design for fatigue and maximum static loads shall comply with Design Criteria 1598-DC-001 – Site Information and General Plant.

The first critical speed of the shaft (complete with specified scale build-up), impeller and coupling assembly shall be at least 25% above the maximum operating speed of the agitator.

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16.4 Materials

All agitator components shall be constructed of materials that will enable the specified design life of the agitator to be achieved whilst performing the duty specified by the Equipment Data Sheets without any deterioration of material properties or component strength.

16.5 Fabrication

16.5.1 Welding, testing and inspection

All welding shall be in accordance with AS 1554.5.

Where the agitator shaft is a pipe type shaft, the gearbox coupling half to agitator shaft weld shall be a full penetration butt weld, ground and polished smooth on both the outside and inside. This weld shall be subject to 100% radiographic examination in accordance with AS 2177.

Weld joints that attach agitator blades onto the agitator shaft hub (either directly or via the blades being bolted onto “ears” which are welded onto the hub) shall be:

(a) Reinforced, full penetration butt welds

(b) Ground smooth with all corner fillet welds radiused to minimize stress concentrations and

(c) Subject to 100% radiographic or ultrasonic examination in accordance with AS 2177 or AS 2207 respectively.

16.5.2 Stress relieving

All fabricated components shall be stress relieved following the completion of fabrication in accordance with AS 4458.

17 LAUNDERS

17.1 Design

Launder hydraulic design is normally determined iteratively using the Manning formulae as follows:

14.1(1) R

23

Where:

A = Cross sectional area of the flow (m2)

R = Hydraulic radius (m) = A / Wetted perimeter

S = Launder slope (m/m)

QAn× S

12

× 3600×:=

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N = Friction factor (assume rough surface and use 0.012)

Required slopes shall be as follows:

Mill discharge/cyclone underflow 10 deg.

Cyclone overflow 1 deg.

Wet screen underpan 15 deg.

Slurry (grinding) 8 deg.

17.2 Open launders

Open launders may be with rectangular or rounded bottom.

Rectangular bottom launders are preferred for course materials and semi-circular bottom launders for fine materials.

Open launders should be designed so that the level of slurry does not exceed 25 percent of the overall launder depth at Normal Flow operating conditions or 50 percent at Maximum Flow conditions.

17.3 Closed launders / gravity flow lines

Closed launders should be designed so that the level of slurry does not exceed 50 percent of the pipe diameter at normal operating conditions or 65 percent at Maximum Flow conditions using the Manning formula provided in Section 14.1 of this document.

The required slope of the launder shall be determined using the Durand’s method to calculate the limiting settling velocity for the particular slurry being handled. Refer to Design Criteria DI-024727 Pumping and Piping.

17.4 Flotation concentrate launders

Flotation concentrate launder arrangement and design shall be to suit the particular froth and characteristics of the particular slurry being conveyed. However, launder sizing for froth flow, particularly concentrate froth, is usually determined empirically as the required launder shape (pipe or rectangular open launder) sizing, slope, wall height etc., depends very much on froth characteristics.

17.5 Junction boxes and distributors

Junction boxes with step-downs shall be used in preference to 90 degree direction changes in open launders.

Junction boxes shall be sized with enough volume to absorb and dissipate excessive kinetic energy in the entering streams while maintaining the slurry solids in suspension.

Freeboard above maximum flow condition should be a minimum of 300 mm.

A distributor may be used where it is necessary to divide a process slurry stream into two or more streams of specified proportions having the same solids concentration, sizing and composition as the original stream.

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18 TANKS

18.1 Capacity

Generally, unless otherwise indicated by the Equipment Data Sheet, tank working capacity shall be based on that capacity between the LAL (Level Alarm Low) and the LAH (Level Alarm High) point.

Generally the capacity between LAH and LAHH (Level Alarm High/High - Shut down of flows into tank) and between LAL and LALL (Low Alarm Low/Low - level shut down of pump) shall be X% and Y% of the working capacity respectively.

The LAHH to overflow level and the LALL to pump suction outlet level shall be as indicated by the Equipment Data Sheet with the LALL level being sufficiently above the pump suction outlet that vortexing does not occur without a requirement for a vortex breaker.

18.2 Required pump suction nozzle submergence

Minimum submergence to prevent vortexing shall be determined by Equation 15.2(1) obtained from the American National Standard for Pump Intake Design, Hydraulic Institute ANSI / HI 9.8-1998 Section 9.8.7:

15.2(1) H s d 8218

Q

d1.5×+:=

Where:

Hs = required submergence (surface to suction CL (mm)

Q = flow rate (m3/h)

d = suction pipe size (mm)

18.3 Steel tanks

18.3.1 API 650 Coded tanks

Hazardous chemical storage tanks and large capacity storage tanks shall be designed, manufactured and installed strictly in accordance with API 650.

18.3.2 Uncoded tanks

Relatively low capacity, low risk tanks (e.g., process tanks) shall be generally designed, fabricated and installed in accordance with API 650 excepting AS 1554.1 Cat SP welding may be used for pressure retaining components which allows a lower level of NDE.

18.3.3 Common requirements

General requirements applicable to both API 650 Coded and Uncoded tanks unless otherwise specified by the Equipment Data Sheet will include;

(a) Plate material to be AS 3678 Grade 250 plate (or ASTM equivalent)

(b) An allowable membrane design stress of 160 MPa shall be applied

(c) Corrosion/abrasion allowance shall be 2 mm

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(d) Non pressure retaining and other structural components shall be designed and fabricated in accordance with AS 4100 and AS 1554.1 Cat SP

(e) Tank floors greater than 8 mm thick to be double V butt, full penetration welded

(f) Tanks to be hydrostatically tested

(g) Slurry tanks to be provided with a 600 mm “D” door fitted with a davit

(h) Solution tanks to be provided with a 600 mm diameter access opening fitted with a davit

(i) Minimum material thicknesses shall be as follows;

(i) 6 mm unless otherwise specified

(ii) 10 mm for all shop fabricated tank floors

18.4 Fibre reinforced plastic (FRP) tanks and fabrications

FRP fabrication design, manufacture and installation shall be in accordance with BS 4994, Category I for thermoplastic lined fabrications and AS 2634 for fabrications that are not thermoplastic lined.

Thermoplastic lined tanks to BS 4994 shall have a minimum overall design factor K of 12.

Unlined tanks to AS 2634 shall have a minimum overall design factor K of 10.

FRP fabrications shall be manufactured by either filament winding or contact moulding techniques.

18.5 Flanges

Flanges shall be generally be in accordance with ANSI B16.5 PN20 (Class 150) unless otherwise indicated by the Equipment Data Sheet.

19 LININGS & WEAR BARS Wear materials and liners shall be provided to minimize wear as well as being compatible with low initial cost.

Wherever possible standard items shall be used which have a known history of use in the application.

Wear plates shall be specified where required. However, the following general requirements are provided as guidance for Linings and Wear bar selection.

Wherever possible rock boxes shall be used to handle impact loads from ore being deposited from conveyor head pulleys, screen discharges and belt/apron feeder discharge chutes. Rock boxes shall not be used for concentrated or sticky materials.

Ease of replacement of liners shall be considered in high wear areas. Standard liner plates 20mm thick shall be used in areas of heavy abrasion prior to primary crushing. Liner plate’s 10mm thick shall be used after primary crushing in areas of heavy abrasion. These plates will have mild steel chute work as a backing plate. In general wear liner materials shall be manganese steel or equivalent plate for dry application. Manganese steel liner shall be spot welded, not bolted to parent metal. Where the service conditions do not suit the application for manganese steel, other materials such as dual-layer composite metal carbide plate (eg Duoplate), rubber, ceramic, or UHMW polyethylene lining material may be used in specific applications. In general, hard iron wear bars shall be used in applications involving run of mine or coarse crushed rock. Impact zones where slurries enter sumps shall have wear protection.

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Rubber linings shall be selected according to the specific application.

In general, pumps in slurry service shall be rubber lined unless the vendor recommends an alternative liner material based on the duty listed in the equipment datasheet. Brass shall not be used for wetted components.

20 PUMP HOPPERS

20.1 Capacity

Generally, unless otherwise indicated by the Equipment Data Sheet, pump hoppers shall be designed to provide 50 minutes of working capacity at the Maximum Flow pump out rate between the LAL (Level Alarm Low) and the LAH (Level Alarm High) point.

Generally the capacity between LAH and LAHH (Level Alarm High/High - Shut down of flows into hopper) and between LAL and LALL (Low Alarm Low/Low - level shut down of pump) shall be 10% and 20% of the working capacity respectively.

The LAHH to overflow level and the LALL to pump suction outlet level shall be as indicated by the Equipment Data Sheet with the LALL level being sufficiently above the pump suction outlet that vortexing does not occur without a requirement for a vortex breaker.

Minimum submergence for vortexing shall be determined by equation 15.2(1).

20.2 Hopper design

Generally, pump hoppers shall be designed with a floor slope of maximum 40 deg. unless otherwise indicated by the Equipment Data Sheet.

Generally, pump hoppers shall be cylindrical with a flat bottom floor sloping towards the pump suction with a generously sized rectangular to circular transition into the pump suction designed to facilitate de-aeration of the slurry as it enters the pump suction.

Hopper overflow design shall be as indicated in Section 17 of this document.

Hopper design and fabrication shall be as per that applicable to Uncoded tanks as indicated in Section 15.3.2 of this document.

21 TANK AND PUMP HOPPER OVERFLOWS

21.1 Arrangement

Above ground tanks and hoppers shall have a piped overflow to floor level (grade). The overflow pipe shall discharge through an elbow in the direction of the floor gradient towards the sump.

The arrangement of the overflow shall be such that air is not entrained upon entry into the overflow pipe and is readily vented during discharge. The arrangement shall also enable convenient inspection of the overflow opening from the tank top access provided.

Overflows shall be constructed integral with the tank/hopper without flanging and shall be provided with a Victaulic coupling attached elbow at the bottom to enable adjustment of discharge direction on-site and to enable the tank to sit flat for transport with this bottom elbow removed.

21.2 Design – tank and hopper overflows

Tank overflow capacity shall be based on the following equation:

For flow entry into overflow pipe:

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17.2(1)

dQ F 1× F 2×( )

12 1000×

K H

12

:=12

×

⎛ ⎞⎜ ⎟ ⎝ ⎠

Where:

d = required inside diameter of pipe at flow inlet (mm)

Q = flow rate (m3/h)

K = 10354

H = depth of flow over overflow outlet (m)

F1 = 1.1

F2 = aeration factor

= 1.0 for classifying screen underflow

= 1.2 for centrifuge effluent

= 1.25 for cyclone overflow

= 1.4 for cyclone overflow

= 2.0 for flotation concentrate

(Note:- Flow capacity of overflow is determined purely by the entry loss condition.)

22 PROCESS AIR BLOWERS AND COMPRESSED AIR EQUIPMENT

22.1 Plant and instrument air systems

22.1.1 Plant air systems

A detailed plant wide air demand investigation of all known, as well as anticipated air users will be performed in order to establish the necessary plant compressed air system capacity.

The air system will be designed to provide between 800 kPag at the compressor discharge and 600 kPag air at the furthest point from the compressor while supplying air for as many tools and equipment which may be in use at any one time.

The main air supply line should be sized to carry the average air demand of all users with a pressure drop through the main (including all fittings) not exceeding 20 kPa.

Branch lines from the main should be sized to carry the maximum air demand of the number of outlets in use at any one time for a particular branch line with a pressure drop through the branch lines not exceeding 20 kPa.

Feeder lines from the branch lines should be sized to carry the maximum air demand for as many tools which may be connected at any one time with a pressure drop through the feeder lines not exceeding 10 kPa.

Branch lines should be taken from the top of the mains and the feeder lines should be taken from the top of the branch lines.

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The mains and branches should be sloped toward low points.

All low points should be drained with drip legs using automatic moisture traps.

Each outlet for pneumatic tools will be provided with a regulator/lubricator/filter /pressure gauge unit.

22.1.2 Instrument air systems

Instrument air systems shall be designed to the same criteria as applicable to Plant air excepting each outlet will be provide with a regulator/filter/pressure gauge unit.

22.1.3 Plant and instrument air compressors

General purpose air compressors shall be rotary screw type air compressors.

Instrument air compressors shall also be oil free type.

Air compressors should be supplied as complete pre-assembled packages.

22.1.4 Instrument air dryers

Instrument air dryers shall be heatless, regenerative type, with twin towers allowing one to be regenerating while the other is on drying cycle.

22.1.5 Air receivers

Separate air receivers should be provided for each of the Plant and Instrument Air systems and shall be designed and constructed in accordance with AS 1210.

22.2 Process air blowers

The economics of positive displacement roots type process air blowers versus centrifugal units will be investigated.

Both the positive displacement and centrifugal type units will require acoustic enclosures, however acoustic and vibration treatment of centrifugal machines is less onerous.

The blowers will be located inside a dedicated room to further attenuate noise from the process building.

23 HAZARDOUS CHEMICALS

23.1 ADG Code and TGA classifications

Australian Dangerous Goods Code (ADG) and Australian Government – Department of Health and Aged Care - Therapeutic Goods Administration (TPG) – “Standard for the Uniform Scheduling of Drugs and Poisons No. 21” classifications for reagents used in the process are provided in Table 19.1(1).

(Refer to Australian Dangerous Goods Code for comprehensive description of codings.)

TABLE 19.1(1) ADG CODE & TGA CLASSIFICATIONS FOR REAGENTS

Service Description

Fluid Code

As Delivered Physical Form / (As used)

ADG Code Class1. (Applicable Storage and

Handling Australian Standard)

ADG Packing Group2.

ADG Haz- chem Code3.

TGA Poison Sch4.

Collector – Fatty Acid RFC Fluid 97% conc. (Used as

received) Not classified – But is a

Combustible fluid NC NC NC 5.

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Service Description

Fluid Code

As Delivered Physical Form / (As used)

ADG Code Class1. (Applicable Storage and

Handling Australian Standard)

ADG Packing Group2.

ADG Haz- chem Code3.

TGA Poison Sch4.

(FA-2) (AS 1940)

Collector (Xanthate - PAX) RXP Pellet/powder 90% conc.

– (Diluted to 10% w/w)

Class 4.2 – Flammable solid (flam. gases emitted when

mixed with water) (AS 1940, AS 2430.3.3)

II 1[Y] NC

Copper Sulphate RCU Crystal 99.5% conc. – (Diluted to 25% w/w)

Not classified (AS/NZS 4452) NC NC S6

Flocculant RFL Powder 99% conc. (Diluted to 0.25% w/w)

Not classified – But may form potentially explosive dust in storage bins (AS

2430.3.5)

NC NC NC

Frother (DF250) RFF Fluid 100% conc. (Used as received)

Not classified – But is a Combustible fluid

(AS 1940) NC NC NC

Frother (MIBC) RMI Fluid 100% conc. (Used as received)

Class 3 - Flammable fluid (AS 1940, AS 2430.3.3) III 3[Y] NC

Lime RLS Powder 70 to 90% conc. (Diluted to 15% w/w) NC NC NC NC

Oxidant (H2O2 Hydrogen Peroxide)

RHP Fluid 50% conc. – (Diluted to 10% w/w)

Class 5.1 – Oxidising substance (AS 4326) II 2P S6

Promotor (Aeropine 5100) RFP Fluid 100% conc. (Used

as received) Class 3 - Flammable fluid (AS 1940, AS 2430.3.3) III 2[Y] NC

Quebracho (Tannic Acid) RTA Powder 81% conc. –

(Diluted to 4% w/w) NC NC NC NC

Sodium Carbonate RCA Fluid 99% conc. – (Diluted to 10% w/w) NC NC NC S5

Sodium Chloride (NaCl) RCL Crystal 98% conc. –

(Diluted to 32% w/w) NC NC NC NC

Sodium Cyanide (NaCn) RCY Pellets 98% conc. –

(Diluted to 20% w/w) Class 6.1 – Toxic substance

(AS/NZS 4452) I 2X NC (S7)

Sodium Fluoride (NaF) RFL Crystal 98% conc. –

(Diluted to 4% w/w) Class 6.1 – Toxic substance

(AS/NZS 4452) III 2Z S6

Sodium Hydroxide (NaOH) RCA Flake 97% conc. –

(Diluted to 25% w/w) Class 8 – Corrosive

substance (AS 3780) II 2R S6

Sodium Silicate RSI Fluid 47.1% conc. (Used as received)

Class 8 – Corrosive substance (AS 3780) III 2X S5

Sodium Sulphite RSU Crystal 96% conc. – (Diluted to 15% w/w)

Class 8 – Corrosive substance (AS 3780) II 2R NC

Sulphuric Acid RSA Fluid 98% conc. (Used as received)

Class 8 – Corrosive substance (AS 3780) II 2P S6

NOTES:- 1. ADG Class 3 – flammable liquids, Class 4 – flammable solids, Class 5 – oxidising agents, Class 6 –

Toxic substances, Class 8 – Corrosive substances.

2. ADG Packing Group I – Great danger, Packing Group II – Medium danger, Packing Group III – Minor danger.

3. Refer to following Table 19.1(2) for Hazchem code definitions.

4. TGA code definitions: S5 = Caution – Substances with low potential to cause harm. S6 = Poison – Substances with moderate potential to cause harm. S7 = Dangerous poison – Substances with high potential to cause harm

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5. NC = Not classified. Refer to the manufacturer’s Material Safety Data Sheet (MSDS) for hazard description and precautions to be taken.

Hazchem letter codes indicate the precautions to be taken in the event of a fire or spillage. Full definition of Hazchem codes as indicated in Table 19.1(1) are provided as a table in Appendix 4 of the ADG Code. For quick reference, that part of the ADG Code Appendix 4 table applicable to the reagents listed is given by the following Table 19.1(2)

TABLE 19.1(2) HAZCHEM CODE DEFINITIONS

Letter Risk of Violent Reaction or Explosion

Recommended Personal Protective Equipment2. Appropriate Measures

P Yes Full protective clothing Dilute3. R No Full protective clothing Dilute X No Full protective clothing Contain4.

[Y] Yes Breathing apparatus for fire only Contain Z No Breathing apparatus Contain

[Z] No Breathing apparatus for fire only Contain

NOTES:- 1. The number for first part of the Hazchem code indicates equipment suitable for firefighting – 1 water

jets, 2 water fog, 3 foam, 4 dry agent

2. Full protective clothing is a minimum of breathing apparatus, protective gloves, appropriate boots and a chemical splash unit. Where breathing apparatus is indicated, chemically impervious protective gloves should be worn.

3. “Dilute” indicates the substance may be washed away with large quantities of water.

4. “Contain” indicates the need to prevent spillage from entering drains or water courses.

23.2 Material Safety Data Sheets

Refer to Appendix C of Design Criteria DI-024725 Site Information and General Plant for Material Safety Data Sheets (MSDS) for all chemical reagents used by the process.

23.3 Storage and handling

Where the classification of a material is such that it falls under the category of a Dangerous Good or Hazardous Substance, then storage, installations and handling of the substance on site shall comply with the latest issue of following statutory regulations and standards:

• Occupational Heath and Safety (Hazardous Substances) Regulations

• Dangerous Goods Act

• AS 1375 Industrial fuel-fired appliances (known as the SAA Industrial Fuel-fired Appliances Code)

• AS/NZS 1596 The storage and handling of LP Gas

• AS 1697 Installation and maintenance of steel pipe systems for gas

• AS 1940 The storage and handling of flammable and combustible liquids

• AS 2714 The storage and handling of hazardous chemical materials – Class 5.2 substances (organic peroxides)

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• AS 3780 The storage and handling of corrosive substances

• AS 4326 The storage and handling of oxidising agents

• AS/NZS 4452 The storage and handling of toxic substances

• AS 5601 Gas installations

The above Standards and Regulations set out the minimum requirements and recommendations for the safe storage and handling of the hazardous substance and dangerous goods.

Where it is unclear as to the minimum requirements for storage and handling of a particular substance, the relevant code, EPM and EIS shall be referred to, to ensure compliance.

General plant hazardous area classification shall be in accordance with AS/NZS 2430.3.5.

Hazardous area classification for AS 1940 flammable fluid storage areas (for Aeropine 5100 Promotor and MIBC reagent storage areas) shall be in accordance AS 2430.3.3.

Also note that in accordance with AS 1940 and consistent with the ADG Code Packing Group classifications provided in Table 19.1(1), flammable fluids are divided into 3 Packing Groups as follows:

PG I - high danger; initial boiling point ≤ 35ºC

PG II - medium danger; flash point (closed cup) < 23ºC; initial boiling point > 35ºC

PG III - low danger; flash point (closed cup) ≥ 23ºC ≤ 60.5; initial boiling point > 35ºC

Hazardous area classification for flammable gas storage areas (for LPG areas) shall be in accordance AS 2430.3.4.

24 FIRE PROTECTION

24.1 General plant

General plant areas and equipment will generally be protect with fire hydrants and wall mounted hose reels and fire extinguishers.

A hose house complete with equipment shall be provided for each hydrant.

The fine ore reclaim conveyor will be protected by an automatically/manually activated sprinkler system located over the centre line of the reclaim conveyor.

The fire water supply, pumping, hydrant system, fire hose reels and fire extinguishers installation shall be designed to comply with the following Australian Standards:

• AS 2419.1 Fire hydrant installations - System design, installation and commissioning

• AS 2941 Fixed fire protection installations - Pumpset systems

• AS 2118.6 Automatic fire sprinkler systems - Combined sprinkler and hydrant

• AS/NZS 1221 Fire hose reels

• AS 2441 Installation of fire hose reels

• AS 2444 Portable fire extinguishers and fire blankets - Selection and location

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24.2 Flammable storage facilities

Fire protection of flammable storage areas shall be in accordance with AS 1940.

24.3 Service buildings

Service buildings will be protected with fire hydrants and wall mounted hose reels and fire extinguishers.

25 ORE RECLAIM ACCESS TUNNEL The fine ore reclaim tunnel shall incorporate clear bobcat access down one side for cleanup and shall be provided with an additional emergency egress route.

The tunnel floor shall slope 1:100 to the main exit to ensure self drainage. Drainage shall be contained locally by a spoon type drain running down the length of the tunnel.

All equipment and structural column base plates shall be mounted on elevated concrete plinths nominally 200 mm above grade.

The tunnel shall be positively ventilated in accordance with standard industry practice.

Emergency exit light signage shall be provided along the emergency egress route.

Restrictive access signage shall be placed at the tunnel entrance.

26 LABELLING AND SIGNAGE

26.1 Requirements for labels, nameplates and signage

Labels shall be provided for the following:

• All equipment (including electrical equipment) allocated an equipment number in the Purchase Order by The Engineer shall be provided with a major equipment identification label.

• Identification of electrical and instrumentation equipment

• Equipment warning of hazards

• Identification of pipelines

Nameplates shall be provided for the following:

• All standard proprietary rotating equipment (gearboxes, fluid couplings, brakes, hydraulic motors etc.,), code designed tanks, pressure vessels and pressure relief valves shall be fitted with a permanent single nameplate as per the manufacturer’s standard, excepting materials of construction and method of nameplate attachment shall be suitable for the particular application and operating environment.

Signage shall be provided where;

• required or recommended by relevant codes, standards or statutory requirements and/or

• information/advice is to be provided to personnel that may be engaged in loading/unloading, transportation, installation, commissioning, operation and maintenance of the equipment and plant facilities where personnel engagement in these activities may result in exposure to a hazard and/or where there may be a requirement for a particular action to be followed to avoid potential equipment or plant facility damage or personnel injury

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26.2 Dual language requirements

All labels, tags and signage shall be provided in both the English and Chinese language.

Where practicable, both English and Chinese language lettering shall be provided on the one sign/label/tag.

Where this is not practicable due to space constraints, signs/labels/tags shall be “split” into two separate equal size and content signs/labels/tags.

In all cases, translations shall be provided by The Engineer as part of the Supplier/Contractor Data Submission process. This process will require the submission of native Autocad drawings of all signs/labels/tags to enable The Engineer to directly provide the equivalent and consistent Vietnamese equivalent translations.

26.3 Suitable materials and lettering application

Labels shall be made of either plastic (matt finish, 1.5 mm thick, 2 ply, Gravoglas 2-Plex laminated acrylic sheet) with lettering applied by engraving or stainless steel (1.5 mm thick, grade 316) with lettering applied by the black laser etching.

Labels shall be attached either by double sided self adhesive tape or stainless steel screws or both.

Selection of label material and method of attachment shall be selected to suit the application and environmental exposure.

26.4 Pipeline labels

Pipeline labels shall be provided for every pipeline installed in accordance with AS 1345.

Each label shall include;

(a) Contents description

(b) Line number

(c) Front supplementary band with flow direction arrows

(d) Rear supplementary band with colour coding

Color coding of pipe shall be in accordance with Standard Specification DI-024775 Piping Fabrication and Installation which is generally in accordance with AS 1345.

26.5 General plant signage

All general plant safety/warning signage shall be in accordance with the relevant Australian Standards, particularly AS 1318, AS 1319, AS 1742, AS 1743, AS 1744, AS 1755, AS 2293.1 and AS/NZS 3000 as applicable and shall be as per the Supplier/Contractor’s and signage manufacturer’s industry standard supply for the particular purpose, application and environment.

27 SHOP ASSEMBLY AND TESTING

27.1 Mechanical

All equipment shall be shop fabricated and assembled to the extent allowable by transportation logistics.

A transportation size and mass matrix will be prepared for the project. (TBC)

All critical dimensions shall be verified and recorded by the Supplier/Contractor before packing.

SINO IRON PROJECT


DI-024726

Revision:

03 Status:

AFD Rev Date:

17 Sept 2008

anical Design Criteria No: DI-024726 Page: 82 of 82 Uncontrolled when printed Mech

All gearboxes shall be shop tested under reduced load conditions for a minimum period of 8 hours.

Where practicable, equipment and systems shall be set up for testing such that the tested system simulates actual service operation as closely as possible.

Noise and vibration levels shall be shall be verified and recorded by the Supplier/Contractor during testing of the equipment.

All accessories and sub-assemblies shall be suitably match marked and disassembled only to the extent necessary for shipment and installation.

Where practicable, the equipment shall be shipped to site completely assembled.

27.2 Instrumentation and control

27.2.1 Factory Acceptance Testing

Configurable Systems shall be subjected to a series of Factory Acceptance Tests (FAT) prior to final shipment to site. The purpose of these tests is to prove correct operation of the equipment and systems prior to final shipment to site.

Any Factory Acceptance Testing shall be based upon a written set of Procedures and Witness Sign-off Sheets. These tests shall be witnessed by The Engineer.

Factory Acceptance and Testing shall be conducted for both hardware and configuration.

27.2.2 Hardware testing

Any hardware type Factory Acceptance Testing shall include testing of the following:

(a) All Programmable Electronic System subsystems

(b) At least one channel from each installed input/output module

27.2.3 Configuration testing

Any configuration type Factory Acceptance Testing shall be based upon –

(a) Simple closed loop simulation

(b) Any associated Functional Specification/s

DC-002 MECHANICAL DESIGN CRITERIA

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