Slurry Pipeline Design Criteria

8/10/2019 Slurry Pipeline Design Criteria

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Appendix E

Design Criteria


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Escarpment Mine Slurry Pipeline

Design Criteria

Doc N 0412-DC-GEN-001

Job N 2930412at Dennis ton Plateau

By Beca Carter Hollings & Ferner Ltd

11/06/2010

These Documents are intended to remain confidential to, and copyright in thembelongs to, the Principal/Employer. They shall not be passed to any third party, otherthan a prospective Subcontractor, without the written permission of thePrincipal/Employer.


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Escarpment Mine Coal Slurry Pipeline DESIGN CRITERIA Page 1

Beca Carter Hollings & Ferner Ltd Job N o 2930412 // 11/06/20102930412 NZ1-3002328-10 Rev B

INTRODUCTIONSCOPE

This document describes the key design criteria to be used as the basis for the feasibility study for theEscarpment Mine Coal Slurry Pipeline. The scope of these design criteria covers the following areas of the

plant:

General Site Condi tions, Location & Plant Data Design Life Operating Hours Throughput Redundancy

Process

Coal Slurry water (flow, contaminants, turbidity, temperature, pH etc) Treated water (flow, quality, etc) Chemicals (type, form, quantity) Waste streams (type, form, quantity)

Civil & Structural Geotechnical Drainage Roads Structural Design

Mechanical Equipment and Component Design

Electrical, Instrumentation & Controls Power supply & reliability, distribution Site electrical standards (motors, voltages, cables etc) Transformers, MCCs, VSDs & switchgear Motors Process control requirements E, I & C equipment supplied with mechanical packages


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SITE CONDITIONS, LOCATION AND PLANT DATA

Site conditions and plant data are as summarised in Tables 1 and 2 below:

Table 1 - General Characteris tics

Location Denniston Plateau, Westland, New Zealand

Plant Elevation Denniston Plateau 674m, Fairdown 12m

Climate Temperate

Operating schedule 24 h/d, 7 d/wk

Table 2 - Site Characterist ics

Site Conditions Units Value Source

Ambient temperature max. C TBA TBA

Ambient temperature min. C TBA TBA

Annual precipitation rain mm ~6,000 L&M Coal

Rainstorm event mm/h 6 L&M Coal

Relative humidity % TBA TBA

Prevailing wind direction SW L&M Coal

Maximum wind gust (*S.L.S.) m/s 37 AS/NZS 1170

Maximum wind gust (*U.L.S.) m/s 45 AS/NZS 1170

Snow Load kPa 1.8 AS/NZS 1170

Seismic Hazard Factor (NZS 1170.5) z 0.30 (Westport) AS/NZS 1170

*S.L.S. Serviceability Limit State*U.L.S. Ultimate Limit State


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PROJECT DESCRIPTION

The following are the key project scope items forming a basis for the study: A Coal Preparation Plant (CPP) will be located approximately 1km to the north east of the Escarpment

Mine Plan Area (MPA)

The coal slurry pipeline will commence at the CPP location, and generally follow an alignmentalongside a new pipeline to be constructed by Kawatiri Energy for a hydro power scheme. Thispipeline alignment runs towards the north-west.

A raw water supply pipeline, with an intake located around 6.5km north-east of the CPP on the upperWaimangaroa river.

The coal loadout facility will be at Fairdown, alongside the rail line and adjacent to SH67. This isapproximately 11km from the CPP location (in pipeline length terms).

Dewatering of coal will be by screening, coal is to be deposited from the screen into a concrete bunkerfrom where it will be stockpiled by mobile equipment for subsequent dispatch by rail.

Water used to transport the coal will be treated and discharged to a local stream through a watertreatment plant.

STANDARDS AND CODES

The specification and design of all new equipment and structures shall be in accordance with the latestrevision of the standards referred to in these Design Criteria. Where no specific requirement is stated, thedesign and construction shall meet or exceed the requirements of the latest edition codes and standardslisted in the following subsections. In case of conflict between standards and these Design Criteria, themost appropriate requirements shall apply.

UNITSThe SI System of Units shall be used throughout the project.

The following units will be used as required:

Length mm (millimetres) Area m 2 (square metres)Velocity m/s (meters per second)Weights t (tonnes) or kg (kilograms)Capacity t/h (tonnes per hour)Elevation m (metres)Forces kN (kilo-Newtons)

Stresses MPa (mega-pascals)Moment and Torsion kN-m (kilo-Newton metres)Uniform Live Loads kN/m 2 (kilo-Newtons per square meter)Site Co-Ordinates m (metres) relative to plant site datumFlow Liquid m3/h for main process flows, l/h for chemical dosing.Flow Gases Am 3/min or Nm 3/min (Actual or Normal cubic meters per minute)Pressure (Gauge) kPa, kPag or Bar, BargPressure (Absolute) kPaa or BaraTemperature C (degrees Celsius)


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GENERAL DESIGN CRITERIA

EQUIPMENT DUTY

Design LifeThe intended economic life of the Escarpment Mine is 7 years, however the equipment and facilities willlikely be required to operate with future new mine areas. Mechanical equipment will therefore be specifiedfor a design life of 20 years and foundations, building steelwork and concrete will be designed for 30 years.

Operating Hours

All equipment to be selected and designed for continuous operation, 24 hours per day, 365 days per year,with allowance for short planned outages for inspection and maintenance. The site is to be designed formanned operation 24 hours per day, 7 days per week.

Standardization of Components

All new components shall be standardized and rationalized with existing where practical to minimize newtypes spare parts inventory.

WATER DISCHARGE QUALITY STANDARDS

The discharge from the water treatment plant is to be designed to Class AE Water (being water managedfor aquatic ecosystem purposes).

The key requirements of this are:

(1) The natural temperature of the water shall not be changed by more than 3 Celcius.

(2) The following shall not be allowed if they have an adverse effect on aquatic life:(a) Any pH change:(b) Any increase in the deposition of matter on the bed of the water body or coastal water;(c) Any discharge of a contaminant into the water.

(3) The concentration of dissolved oxygen shall exceed 80% of saturation concentration

(4) There shall be no undesirable biological growths as a result of any discharge of a contaminant into thewater

(5) Activities that reduce pH of receiving waters must avoid, remedy or mitigate acidity effects and shouldachieve the natural pH level of the affected river wherever practicable; and

(6) Activities that increase dissolved iron concentrations or the concentration of any other metal or non-metal in the receiving water must avoid, remedy or mitigate adverse effects and the natural metal/non-metal concentration of the receiving water should be achieved wherever practicable.

(7) The following effects must be avoided: the production of any conspicuous oil or grease films, scums or foams or floatable or

suspended materials; any conspicuous change in the colour or visual clarity; any emission of objectionable odour; the rendering of fresh water unsuitable for consumption by farm animals; any significant adverse effects on aquatic life


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Operating Schedule Units Value Source

Transport rate (average) t/h 143 Calculated

Table 5 - Pipeline Characteris tic s

Data Units Value Source

Coal Slurry density (coking) Cw (%) 40 Weir

Coal Slurry density (thermal) Cw (%) 43 Weir

Transport water (coking design rate) m 3/hr 275 Weir

Transport water (design rate) m 3/hr 243 Weir

Minimum pipeline velocity m/s 1.6 Weir

Redundancy

Design capacities for individual units shall be selected to be mid-range of current industry practice.

Redundancy will not be provided on major process areas and in general the process will need to beshutdown to effect planned and unplanned maintenance. In the event of a major problem with thedewatering system and/or water treatment plant the contents of the slurry pipeline will need to be dumpedto the emergency receiving pond.

Buffer tanks between the raw water line and slurry pumps and between the dewatering screen and watertreatment plant shall have approximately 30 minutes capacity.

The philosophy for each of the major process equipment items is:

Raw water pump - one duty pump installed, one complete spare not installed

Slurry pumps - three duty, one standby

Dewatering screen - one duty only with spare parts

Coal solids removal (cyclone and dewatering screen) - spare parts only

Clarification - spare parts only (complete spare sludge pumps)

Filtration - spare parts only (complete spare backwash pumps)

Sludge Mechanical Dewatering - spare parts only

Chemical Dosing Systems - spare parts only (complete spare dosing pumps)

Treated Water Pump - one duty only with spare parts

NB: a more detailed analysis of individual unit vs. final plant availability will be carried out at subsequentdesign stages.

Chemical Storage

Chemical storage is to be designed to provide 30 days storage at average dose and maximum flow. Aminimum of 14 days storage is to remain at the time of delivery.

Chemical storage and distribution is to be located as close as practicable to the point of dosing.


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WATER TREATMENT PLANT PROCESS DESIGN CRITERIA

Item Units Value Source

COAL SLURRY WATER PARAMETERS

Design Raw Water Flow m 3/hr 275 Calculated

Turbidity NTU 2.90 Lab testing results

pH Unit 8.3 Lab testing results

Suspended Solids g/m 3 7.4 Lab testing results

DOC g/m 3 2.9 Lab testing results

UV254 cm -1 0.126 Lab testing results

TREATED WATER PARAMETERS

Treated Water Flow Design m 3/hr 275 Calculated

Treated Water Parameters - Refer above REM

Availability % 80 Marston

Allowable Plant Outages Days/yr 73 Marston

FLOCCULATION

Flocculent Chemical - Polyacrylate Beca

Bulk Storage - 25kg bags Beca

Dosing system - Skid mounted batch plant Beca

Flocculent Dose Rate g/m 3 0.5 (est.) Beca

LIME ADDITION

Lime Source - Hydrated Lime Beca

Bulk Storage - 25kg bags Beca

Dosing system - Skid mounted batch plant Beca

Lime Dose g/m 3 15 (est.) Beca

SOLIDS SYSTEMS

FINE COAL HANDLING

Cyclone cutoff size m 75 Beca

Dewatering technology Type: Screen Beca

Dewatering Capacity m 3/d TBA Beca

SLUDGE HANDLING

Sludge Thickener Capacity m 3/d 6,600 Calculated

Dewatering technology Type: Belt press filter Beca

Dewatering Capacity m 3/d 640 Beca

FILTRATION

Filtration technology - Sand filters Beca

Units No: 3 Beca

Unit size m 2 10 Beca


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Item Units Value Source

TREATED WATER TANK

Residence Time minutes 15 Beca

TREATED WATER PUMPS Pumps No: 1 Beca

Pump Flowrate m 3/s 0.08 Calculated


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MATERIALS HANDLING SYSTEM CRITERIA

DESIGN LIFE

All structures shall be designed for a 30 year service life. All mechanical components shall be designed fora 20 year service life.

COAL SLURRY PIPELINE FEED CONVEYOR

Single conveyor feeding slurry pipeline constant density tank. Loading hopper for front end loader reclaimfrom CPP product stockpiles.

Design capacity 200t/h (at 18% moisture content)

Operating hours 24h/d

STOCKYARD CONVEYOR AND STACKER

Single yard conveyor taking dewatering screen product for transfer to linear stacker.

Stockpile sizes: 2 x 15,000t (one thermal, one coking)

Conveyor and stacker design capacity 200t/h (at 15% moisture content)

Operating hours 24h/d

Stockpile formation aided by mobile equipment (dayshift only)

TRAIN LOADING

By front end loader to hopper cars.

Hopper cars 42t capacity each

Train parcel size 925t 22 cars per train

4 trains per day, 6 days per week

Design loading time (arrival to departure) 1.5 hours

Cycle time (Fairdown-Westport return, including loading) 3.5 hours

Average loading rate required over complete train 690t/h


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CIVIL/STRUCTURAL DESIGN CRITERIA

STANDARDS AND CODES

Refer to General Design Criteria Section for the projected design life of the project.

As a minimum, the Works shall comply with the current editions of relevant internationally recognisedCodes, Standards and Regulations, together with New Zealand Codes, Standards and Bylaws. Whereconflict between International Standards and the equivalent New Zealand Standards exist, the morestringent requirements shall prevail.

GEOTECHNICAL AND FOUNDATION DESIGN CRITERIA

No site specific geotechnical investigations or testing has been carried out to date. Golder Associates Ltd(Golder) have been retained as the project geotechnical engineers, and the following information is

indicative only and therefore subject to Golder verification and confirmation.Based on a 2002 Geological Map of the area, it can be inferred that

The slopes from the Dennison Plateau to the coastal plain are largely landslide debris from the coalmeasures above

The coastal plain is a mixture of alluvial and fan deposits with dune sands near the coast. Thesesoils are sand, gravel and swamp deposits (peat)

The slurry pipeline from the Denniston Plateau down to the Westport Flats may be subject to large andsmall scale instability. On the Westport Flats the pipeline and plant are likely to be founded on loosesaturated soils with potentially some peat layers. Settlement (total and differential) may be of concern andliquefaction is likely to be an issue. Any structure below ground level may need to consider the potential forflotation and vibrations from machinery could result in localised liquefaction, over and above that fromearthquakes.

DRAINAGE

Any new drainage that is proposed shall comply with the appropriate sections of the Regional Councilsdrainage requirements.

ROADS

TBA

STRUCTURAL DESIGN

All design will be in accordance with the relevant New Zealand standards where possible. All design codeslisted are to be used in conjunction with the latest approved amendments dated at the time of issue of thisdesign criteria report.

The following Australian and New Zealand loadings codes will be used:

AS/NZS 1170.0 - Structural Design Actions General Principles.

AS/NZS 1170.1 - Structural Design Actions Permanent, imposed and other actions. AS/NZS 1170.2 - Structural Design Actions Wind actions.


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AS/NZS 1170.3 - Structural Design Actions Snow & Ice actions.

NZS 1170.5 - Structural Design Actions Earthquake actions New Zealand.

NZS 3404 Steel Structures Standards.

AS/NZS 1170.0 Table C1 Suggested Serviceability Limit State Criteria.

NZS 3101 Code of Practice for the Design of Concrete Structures.

AS/NZS 4671 Steel Reinforcing Materials.

Structural Design Acti ons

Buildings will be designed to withstand a combination of loads due to gravity and lateral loads. Gravityloads are made up of permanent dead loads, superimposed dead loads and non-permanent live loads,including snow loads. Dead loads and superimposed dead loads result from the weight of the buildingelements and finishes (e.g. cladding materials, floor finishes, building services, self weight of structuralelements, etc), and live loads from the type of occupancy (i.e. number of people, shelving, computers, etc).Wind and earthquake loads are often collectively referred to as lateral loads as they tend to act horizontally.

Dead Loads

Dead load includes the self-weight of the structural floor system and underlying structural support framing.Structural toppings over precast floor systems are also included. Non-structural screeds and permanentpartitions, etc are categorised as superimposed dead loads and defined below. Dead loads are calculatedfor the structure based upon the proposed construction materials.

Superimposed Dead Load

Superimposed dead load (SDL) includes all permanent but non-structural elements of the building fabric.This includes screeds required to form falls and set downs, fixed partitions, suspended ceilings andservices, and floor finishes such as tiles or carpet. On roofs and exterior balconies drainage falls andwaterproofing systems are also included.

Live Load

Live load includes all gravity loads not described as dead or superimposed dead load and that are generallyconsidered to be transient or non-permanent (i.e. stored materials, movable partitions, equipment, furnitureand people).

The New Zealand loading standard AS/NZS 1170:2002 defines minimum live load allowances for particularoccupancies.

Lateral Design Actions

The structural frame will be designed to resist actions due to wind or earthquake loading. The magnitude ofthe calculated lateral loads are a function of the sites location (topography, exposure, ground conditions,seismicity and proximity to fault lines), the specified design life of the building, the importance level

selected, the overall weight of the building, and the anticipated behaviour and performance of the structurewhen subjected to lateral loading.

Factors pertaining to the site are as specified in the New Zealand Loading Standard AS/NZS 1170. Theminimum design life is mandated by the NZ Building Code and is 50 years for normal buildings.

Other factors influencing the overall lateral loads include the weight of internal partitions and claddingelements, location of heavy equipment, plant and tankage, weight and stiffness of the structural frame,structural frame spacing and building height. The distribution of these factors through the building alsoplays a significant role, as heavy equipment, building elements or heavy storage rooms located near the topof a building result in very high lateral forces being applied to the top of the structure. Thus, relocatingheavy elements or occupancies to the lower levels can reduce the required structural element sizes.

Earthquake

The earthquake loads are calculated in accordance with AS/NZS 1170 using the following assumedparameters. These will need to be confirmed by subsequent geotechnical investigation:


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Site subsoil category: C

Importance Level: 2

Risk Factor, Ru: 1

Hazard factor, Z: 0.3

Near-fault factor N(T,D): 1.0

Ductility, 1.25

Wind

Wind loads are calculated in accordance with AS/NZS 1170 assuming the following parameters:

Basic wind speed: 45m/s U.L.S.

Terrain category: 1.0

Wind directional multiplier: 1.0

Wind shielding multiplier: 1.0

Wind topographical multiplier: 1.0


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SHAFTS

Shafting shall be designed for a life in excess of the economic life of the equipment.

Stress concentrations at turned down shaft ends shall be considered in the design of shafts.

All keyways shall be in-line and square. Keys shall be supplied with shafts, shop fitted and taped in place

for shipping. Keyed shaft ends and keyways shall be in accordance with ISO standards.

Shafting over 100 mm in diameter and shafts in critical areas shall have their metallurgical composition andheat treatment procedures specified.

All commercial sized shafting shall be cold rolled steel (CRS). Shafts 150 mm in diameter and larger shallbe forged and ultrasonically tested before machining. All drive shaft ends shall be chamfered and providedwith threaded centre holes.

Turndown radii shall have a finish of 1.6 m or better and shall be at least 25% of the minor shaft diameter.Undercut at radius shall not be permitted. Repairs that involve welding shall not be carried out on shafts.

BOLTSBolts and nuts shall be metric thread sizes.

ADJUSTING SCREWS

Adjusting screws shall be stainless steel and metric thread sizes.

BEARINGS AND BEARING SEALS

Minimum L10 life of all bearings shall be 60,000 hours after taking into account all service factors.

Each shaft shall have one fixed and one floating type bearing, the fixed bearing being on the drive end ofany driven shaft.

Seals shall be taconite, grease purged, radial design, replaceable triple labyrinth type or accepted equal.Where a shaft terminates at a bearing, the shaft shall terminate within the bearing housing and the housingshall be equipped with a dust-tight end disc. Seals shall be designed taking account of fabrication andrunning alignment tolerance.

All pillow blocks for 50mm shaft diameter and larger shall have cast ductile iron, cast steel, or fabricatedsteel split housing. All pillow blocks shall be arranged such that the line of force acting through the pillowblock shall be perpendicular to the pillow block supports. Pillow blocks for shafts larger than 90mm shall befurnished with four bolt-bases.

Adjusting screws with locknuts and lugs shall be welded to supporting steel to facilitate alignment ofcomponents. Maximum angular misalignment between shaft and housing shall be 0.25.

Grease fittings shall be installed on all bearing housings. Housings shall be filled with grease beforeshipping.

DRIVE BASES

Base frames shall be sufficiently stiff to withstand any undue deflection due to both static and dynamicloading conditions.

Steel pads fabricated from a minimum of 25mm thick plate shall be welded to the base frame and machinedwhere the motor and gearbox mounts come in contact with the base.

Drive bases shall be stress relieved after welding but before machining.


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Each drive base shall be provided with adjusting screws and locknuts to assist radial and axial alignment ofthe motor. Four jacking screws and a minimum of 6mm shimming allowance shall be provided for themotor vertical alignment.

Minimum 25mm of non shrink grout shall be provided under bases.

FLEXIBLE COUPLINGSFlexible power transmission high-speed couplings shall be designed and constructed with a service factorof not less than 1.5 based on the nameplate motor power.

RIGID COUPLINGS

Rigid couplings shall be designed using a service factor of 1.5 on all applied loads including bendingmoment.

A spigot shall be provided in order to locate the coupling halves and centre them on their respective shafts.

The coupling shall be laid out so that removal of bolts is possible without removing the coupling or any ofthe adjacent drive components.

CHAIN DRIVES

Chain drives shall be avoided where it is practical. If approved, they shall be totally enclosed oil bath type,with oil pump and filter in larger sizes except for the shuttle chute drive that can be dry. Holes and coversshall be provided for insertion of a hand held tachometer.

LUBRICATION SYSTEMS

Manual lubrication will be applied for grease points that need to be serviced every 3 months or longer.

All manually serviced grease lines shall be grouped together to central distribution blocks that areaccessible from walkways and platforms.

Grease nipples shall be provided where appropriate and shall be 1/4 standard Alemite fittings.

Lubrication lines shall be fabricated in stainless steel S.S. 316 and located to permit servicing anddismantling of adjacent components. Brass or copper tubes shall not be used. Flexible lines, whererequired shall be minimum 6mm I.D. wire braid, grease resistant, rubber covered non-skive type hose.

Initial lubrication, including that required for adjustment and testing shall be by Contractor.

All lubrication points shall be accessible from, or piped out for ready access from walkways, platforms orstairs with extension tubing.

HOPPERS AND BINS

Hoppers shall be fabricated of a minimum 10 mm thick, grade 250 steel plate, adequately reinforced.

The minimum valley angle in hoppers shall be 50 from the horizontal and minimum hopper angle forwedge type hoppers shall be 55 .

All hopper and miscellaneous plate and steel work shall be designed and fitted for efficient dust sealing andshedding.


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GUARDS

All revolving parts such as belt drives, couplings, pulleys and exposed shafts shall be adequately guarded.

Non-lubricated drives shall have guards of flattened expanded mesh for visual inspection. All guards shallbe fabricated and mounted with provision for easy removal by one person. Lubrication capability, withoutrequiring removing of guard, shall be provided.

Guards shall be failsafe in that should the securing system fail or come loose, the guard will not fall off.

ZERO SPEED SWITCHES

The switches shall be of the non-contacting pulse counting type, consisting of sensing probe and remotemounted control unit. Switches shall be conveniently located and protected against spillage.

PAINTING

Vendor supplied & site fabricated mechanical equipment shall be painted in accordance with

TBC

Vendor supplied & site fabricated structural equipment shall be painted in accordance with

TBC

GENERAL CONVEYOR REQUIREMENTS

All conveyors and conveyor accessories shall be designed according to the requirements of the ConveyorEquipment Manufacturers Association (CEMA).

All conveyors shall be capable of starting under any and all operating conditions.

Design Capacity - is a peak capacity that all of the equipment can handle for extended periods of time,without any impact on the equipment performance.

The conveyor drive motor power shall be greater than 1.1 x the calculated absorbed power at the motorshaft, based on the conveyor design capacity.

Conveyor belt speed and the drive reduction ratio selection shall be based on the CEMA recommendedmaterial cross section, at the standard edge distance for a bulk density of 800 kg/m. A suitable automatictake-up shall be provided for all conveyors. Vertical gravity take-up is the preferred take-up design.

Elevated conveyors shall have a 900 mm wide operators walkway on one side of the conveyor.

All inclined conveyors shall be fitted with a backstop.

An area of each conveyor structure shall be identified for the belt splicing station. Belt splicing table supportshall be provided on the structure along with power outlets for belt vulcaniser and equipment.

SPEED REDUCERS

All speed reducers shall be of the manufacturers standard design.

Expected service life for gears (G1: 1% expected failure rate) and bearings (L10) shall not be less than60,000 hours. Reducers shall be rated in accordance with AGMA Standard 6010-F97, latest edition, forgear capacity, bearing capacity and strength of other components such as shafts, keys and bolting exceptwhere a higher requirement is specified elsewhere in these Design Criteria.


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LINERS

All interior surfaces of chutes and skirt boards which may become in contact with handled coal, shall belined with 20mm thick, abrasion resistant liner plates.

Liner sizes shall be coordinated with the chute design such that high wear areas of the chute can bereplaced as a complete panel and relined in the shop.

Protruding bolt heads or nuts are not acceptable on inside surfaces of liners.

Liner Plate sizes shall be standardized and the weight of each plate shall not exceed 40kg where linerplates must be replaced individually inside the chute.

Each chute section shall have uniform minimum gaps not to exceed 5mm between liners and these gapsshall be staggered between adjacent rows. No transition of liner plates shall be allowed from one section toanother, i.e., surface continuity shall be maintained.

CONVEYOR WEIGH SCALES

Load cell type system with steel weighbridge complete with 4 precision idlers shall be rated for a maintainedaccuracy of 0.5% over the full operating capacity range.

DUST CONTROL SYSTEM

A water spray dust suppression system shall be used in the coal stockyard for dust control at the stockpiles.

FIRE PROTECTION

A fire suppression system including hose cabinets with hose reels containing 40mm diameter, 30m longhoses shall be provided at nominated buildings and structures.


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ELECTRICAL AND INSTRUMENTATION DESIGN CRITERIA

GENERAL REQUIREMENTS

All equipment and systems supplied shall comply fully with the requirements of the local Regulations and allLocal Authorities at the place of installation having jurisdiction over any part of the works.

All equipment and systems shall conform to the latest editions, including amendments, of the relevant NewZealand, Australian or IEC Standards, unless specified otherwise.

SUPPLY VOLTAGES

Switchboard Power

11kV, 3 phase, resistance earthed, 50Hz.

400V, 3 phase, 4 wire, solidly earthed, neutral, 50Hz.

Controls

220V, 1 phase, 50 Hz.

24V DC

EQUIPMENT

Transformers

Distribution transformers (11kV/400VAC) shall be outdoor ONAN type unless otherwise specified.

Transformers shall be standardised regarding size, rating and type as much as practicable to provideinterchange ability. Primary and secondary terminations shall be made in cable boxes. Oil type transformersshall be located in a bund with oil water separator facility for drainage.

11kV Switchboards and MCCs

Switchboards shall be constructed to AS1025 standards and type tested.

Switchboards shall be fitted with surge protection.

Switchboards and MCCs shall be located in dedicated electrical rooms with adequate ventilation.

Switchboards and MCCs shall be designed with 20% spare capacity for future development.

400V Swi tchboards and MCCs

Switchboards shall be constructed to AS/NZS3439 standards and type tested.

Switchboards shall be fitted with surge protection.

Power factor correction equipment shall be fitted to main Switchboards to maintain a plant power factor of0.95.

Switchboards and MCCs shall be located in dedicated electrical rooms with adequate ventilation.

Switchboards and MCCs shall be designed with 20% spare capacity for future development.

Motor Starters shall be provided with a facility for means of lockable isolation and manual selection controls.Status indication shall include available, fault and running.


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Connectivity to Distributed Control System (DCS) or Programmable Logic Controller (PLC) system isrequired, typically via serial communication link.

Variable Speed Drives (VSDs) and Soft Starters

All VSDs shall be designed with a DV/DT filter or better, to limit harmonics.

Steps to minimise Radio Frequency Interference (RFI) shall be undertaken, such as fitting EMC filters.

VSDs are to be of a suitable construction for the environment where they are to be located.

Motors

The voltage rating of AC motors shall be 400VAC, 3 phase 50 Hz.

Motors larger than (TBC) kW shall have thermister protection. These motors are also shall have an integralanti-condensation heater, which is to be energised whilst the motor is stationary and de-energised whilst themotor is running.

Motors shall be designed for high efficiency and energy saving, service factor 1.15, insulation class F.

Motors larger than 95KW and are fed via a VSD, shall be of insulation class H. They are to have aninsulated bearing at the non-drive sided and a conductive brush at the drive side to reduce EDM. OtherEDM protection is to form the basis of the design for these motors.

Emergency stop facility shall be provided local to the motor.

Control Equipment

The general and sequential control shall be through agreed type Distributed Control System (DCS) orProgrammable Logic Controller (PLC) installed in stand-alone cabinets and located in dedicated air-

conditioned rooms.The SCADA or HMI equipment will be located in a clean air-conditioned room or be suitably rated for theenvironment in which it is located.

Power for all instruments, PLCs, HMIs and alarm systems shall be provided from separate power sources.The PLC shall be provided with power from an uninterruptible power supply (UPS).

In general, the instrumentation shall be electronic with 4 to 20mA DC signal range. Any control valves shallbe provided with electric or pneumatic actuators.

Electrical supply for instrumentation shall be 230V, 50 Hertz, or 24VDC.

Field instrumentation shall comply with latest industry standards and practices. This shall be suitable for theenvironment in which it is to be located.

Cabling

All electrical cables shall have copper or aluminium conductors.

Cables carrying low voltage and above, shall be armoured.

All cables which are situated between a VSD an the respective motor, shall be of the variolex type, orequivalent. This cable only applies where the length of the cable is inside the VSD manufacturers tolerance.If the length is beyond the VSD manufacturers recommendation, then an alternative shall be specifiedwithin the design.


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Transmission Lines

Electrical transmission lines shall have copper or aluminium conductors.

Emergency Power and Light ing

Where required, standby diesel power generation shall be provided, capable of meeting the full plantcapacity load requirements.

Al instrumentation and control systems are to be powered by an uninterruptable power supply (UPS), with aminimum 60 minute capacity.

Emergency lighting shall be provided where required and shall consist of self-charging units complete withlamps, storage battery, charger and automatic transfer relay.

Lightning Protection

All lightning protection systems shall comply with AS/NZS 1768:2007

E, I & C EQUIPMENT SUPPLIED WITH MECHANICAL PACKAGES

Electrical, instrumentation, and control equipment supplied as part of mechanical packages must complywith project standards, including:

All criteria defined within this document

Pre-installation, pre-wiring and pre-testing in the suppliers factory, as far as possible

Provision for remote control and monitoring

General intent of the operating and control requirements for the package.

Slurry Pipeline Design Criteria

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