Aa - Spec - 248002 Materials Handling Machines Structural Components Specification

AA SPEC 248002
MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION
VERSION 1 27 MARCH 2012 COPYRIGHT
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1 2 Scope Technical Requirements to be Specified by the Engineer 2.1 2.2 2.3 2.4 2.5 3 4 General Information Duty and Service Requirements for Machine Physical Characteristics of Product Operating Conditions Other Information 3 3 3 3 4 4 4 5 6 6 6 7 12 16 24 34 35 38
Definitions Requirements 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 General Design Risk Assessment Loading Analysis Design Construction Commissioning Procedures Monitoring Quality Assurance Provisions
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4.10
Documentation Requirements
40 46 46 47
Appendix A: Referenced documents Appendix B: Record of Amendments Appendix C: Submital Requirements
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AA SPEC 248002
SCOPE
This specification details the requirements for the design, construction monitoring and documentation of all structural components of materials handling machines supplied to Anglo American for operation at any Anglo American site. The following machines are specifically included in the scope of this specification: a) b) c) d) e) f) Stackers; Reclaimers; Stacker-reclaimers; Draglines; Ship loaders and Wagon tipplers.
TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

The following requirements shall be specified by the Purchaser on every invitation to tender, contract or order:
2.1
General Information
a) b) c) Title, reference number, issue and date of this specification; If required, drawings and design calculations and The name of the Quality Assurance Representative.
2.2
2.2.1
Duty and Service Requirements for Machine

Machine Duty a) b) c) Number of working shifts per day; Maximum operational hours per day and Operational hours per year.
2.2.2
Material Handling Rate a) b) c) Nominal rate (tons per hour); Design capacity rate (tons per hour) and Engineering availability required.
2.2.3
Service Life a) b) The minimum required economic life and The required design life for structural components.
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2.3
Physical Characteristics of Product

Wherever possible, design should be based on measured properties of the actual product to be handled. The following typical physical characteristics shall be provided by the Purchaser: a) b) c) d) e) Product to be handled; Solid density and bulk density; Product size grading, and maximum lump size; Moisture content and Angle of repose and surcharge angle.
2.4
Operating Conditions
Specific geographical operating conditions shall be defined, including where necessary: a) b) c) d) e) Location and elevation above sea level of site; Wind conditions and speed details, unless the national norms are appropriate; Seismic zone; Ambient temperatures, including maximum, minimum and daily range and Other relevant information.
2.5
Other Information
Provision of other information may be helpful for the project design. This may include, but is not limited to, the following: a) b) c) d) e) f) Suppliers of electrical and mechanical equipment; Stockpile capacities; Maximum shutdown time before production is effected; Collision detection; Level of automation and Self preservation / protection of equipment.
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AA SPEC 248002
DEFINITIONS
For the purposes of this specification the following definitions shall apply: AS AWS BS Competent person : : : : Australian Standard American Welding Society British Standards Having appropriate theoretical and practical training and having relevant experience in the specific work or tasks to be performed. In the context of this standard, competence refers specifically to competence in structural engineering. Competence in design may be demonstrated by professional registration in terms of local legislation, or by the MIStructE qualification. In any case where there is any doubt regarding the competence of any Structural Engineer or Contractor, this should be referred to Anglo American Engineering Standards and Governance for a decision. As defined by AA REQ 100 Alarm providing a warning only Alarm linked to automatic restriction of machine operation. Following activation of a Level 2 alarm, the control system shall disable all actions leading to a less safe state or a higher stress condition As defined by AA REQ 100 As defined by AA REQ 100 The company or store designated as the recipient of finished products or services. An inspection agency appointed by and approved by the Anglo American Engineer.
Critical Level 1 Alarm Level 2 Alarm
: : :
Major Minor Purchaser
: : :
Quality Assurance Representative Site
The area of any mine, plant or port at which the machine is intended to operate.
The following terms are defined in the General Conditions of Contract: a) Anglo American, Approved, Company, Contractor, Engineer
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4
4.1
REQUIREMENTS
General
The Contractor shall design, manufacture, supply and erect the structural components of the machine in accordance with the details specified in the Contract and Purchaser's Requirements.
4.1.1
Compliance with Legislation The design and construction of the machine shall comply with relevant local legislation and regulations, and shall be such as to facilitate operation and maintenance in compliance with relevant local legislation and regulations.
4.2
Design Risk Assessment

A design risk analysis shall be conducted to determine the specific loads, load combinations and special design requirements to be considered in the structural design of the machine. The risk analysis shall consider the various stages in the life of the machine, including at least design, construction, travelling or propel, operation, and maintenance. In each stage the structural design risk analysis shall consider at least, but not be limited to, the following: a) b) The implications of using design loads which are below the accepted industry norms, as well as means of informing operations personnel of these implications; The manner in which the machine, or its components are supported during construction and maintenance and what influence poor or uneven ground conditions may have on the structure; The manner in which any instability of any motion electrical control loop may influence structural loading, including the influence of electrical transients, etc; The possibility that the maximum full load torque or short circuit torque of the motors may be exerted on structural components and how structural components are protected against this; The manner in which any failure of mechanical equipment may influence structural loading, including the influence of rope or sheave failure and the failure of drive couplings to properly limit torque transfer; The manner in which major components are installed, or removed for maintenance; Whether upgrades are anticipated and how these may influence the structural components; Events outside of normal operations, including: collisions with stockpiles, fixed objects, ships or trains, or other machines; inundation of a boom in a stockpile; and unauthorised operator actions, as well as consideration of how electrical equipment is controlled, what limits are applied, and what measurements are recorded and The number of load cycles that must be applied for each fluctuating load in the fatigue analyses.
c) d)
e)
f) g) h)
i)
The documented risk analysis shall be completed prior to the commencement of any structural design.
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4.3
4.3.1
Loading
General The Contractor shall assume full responsibility for determination of all design loads in accordance with this specification and appropriate national standards. The design loads, load factors, load combination factors and load combinations which the Contractor proposes to use shall be submitted to the Anglo American Engineer for approval prior to commencement of design. The main loads to be considered in the design of the structural components are a function of the self weight of the structures, live loads due to operation of the machine and dynamic loads due to the capacity of installed hoists, drag and swing motors, conveyor drives, etc, which create acceleration loads. The loading or digging pattern, operator characteristics as well as the electrical motor control systems influence the loading on most structural components. Generally, three categories of loads shall be considered. These are nominal loads, special loads and accidental loads. Nominal loads are those loads occurring during normal operation of the machine. Special loads and accidental loads are those loads that are usually of short duration and significant magnitude, but are considered unlikely to occur under ideal operating conditions during the machine working life. Special loads are those loads which may be present during an event arising from unusual conditions such as overload or excessive digging condition of the machine, but which will not be followed by inspection of the machine. Accidental loads are those loads which may arise during an extreme event such as collision, seismic event, or other extreme event, and which will be followed by inspection of the machine for damage prior to continued use of the machine. The loads and load cases to be considered shall include at least, but not limited to, those listed below.
4.3.2
Nominal Loads The normal loads to be considered shall include at least, but not be limited to, the following: a) b) c) Permanent loads shall include the self weight of all structures, equipment, ropes, fuel and lubricants, ballast or counterweights, etc; Normal payload on conveyor belts, in buckets, etc. All chutes shall be assumed to be plugged and completely full when determining these loads; Nominal and dynamic operating equipment loads, including motor and gearbox torque, hydraulic cylinder forces, swing and luffing acceleration forces, etc. Provision shall be made for full load reversal where regenerative braking is employed; Nominal and dynamic travelling or propel equipment loads, including motor and gearbox torque, hydraulic cylinder forces, etc. Determination of these loads shall assume moving the machine from rest while supporting 100 % of permanent loads, 100% of product imposed loads and operating wind loads, and 25 % of imposed floor loads. The traction force for rail-mounted machines shall be increased by a factor of 1.25 to allow for construction tolerances and dirt on the rail surface; Nominal and dynamic rope tensions during operation, etc; Conveyor belt tensions shall make provision for a start-up factor of 1.5;
d)
e) f)
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g) h) i)
Imposed loads on platforms (5 kN/m2), walkways (3 kN/m2) and roof structures (0.5 kN/m2); Other floor areas shall be taken as the solid plan area and provision must be made for spillage to a minimum of 3 kN/m2 of this plan area; Operating wind loads, including wind excitation of structures. Where the fundamental natural frequency of vibration exceeds 1.0 Hz wind loading can be treated as a static load case. Where the fundamental natural frequency of vibration is less than 1.0 Hz wind loading shall be treated as a dynamic load case and a full dynamic analysis shall be carried out; Overhead crane loads; Construction and maintenance loads, based on actual construction and maintenance procedures to be adopted; Loads during maintenance, including jacking loads, rope tensions during boom lowering and lifting, equipment loads on floor areas, etc. A uniformly distributed load of not less than 3 kN/m2, or a concentrated load of not less than 5 kN shall be applied to all floors; Loads during construction, including rope tensions during initial lift of the boom, temporary support, etc; Proof test loads required for commissioning or routine monitoring; For draglines, overhand digging and underhand digging shall be considered as nominal loads; Equipment, including anti-friction bearing housings and structures, shall be adequately designed to withstand periodic wash down with water by fire hose at 1 MPa and Thermal loads shall be included except where adequate provision is made for free thermal expansion. The nominal temperature range shall be the difference between the lowest annual temperature and the highest annual temperature.
j) k) l)
m) n) o) p) q)
The increase in the maximum temperature on the exposed upper surface of steel components and concrete footings and the temperature differential between the exposed upper surface and the shaded underside of steel box structural components shall be determined in terms of national standards, but shall not be taken as less than 15 C. 4.3.3 Special Loads The special loads to be considered shall include at least, but not be limited to, the following: a) Conveyor belt tensions must consider the condition with the feed chute plugged leading to the belt tail end being inundated with product and the maximum inclination of any luffing boom, and shall apply an overload factor of 1.1; Loads arising assuming that the machine, or any components of the machine, are driven by only half of the drive motors provided. The motors causing the most severe condition shall be considered;
b)
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c)
Where safety couplings (whether fluid couplings or shear type couplings) are used to limit the nominal torque transfer, a special load case assuming overfilling of the fluid coupling or over-strength pin in a shear type coupling shall be considered. The peak torque transfer shall be taken as 1.4 times the motor full load torque during acceleration or the short circuit torque. The full rated torque of the specified motors shall be used, inclusive of any specified service factors and over-capacity of motors to achieve standardisation; Where loads applied to the machine structure are limited by means of limits set on hydraulic oil pressure, the current drawn by motors, or the like in the machine control system, a special load case based on failure to set these limits shall be considered. The peak torque transfer shall be taken as 1,4 times the motor full load torque during acceleration or the short circuit torque. The full rated torque of the specified motors shall be used, inclusive of any specified service factors and over-capacity of motors to achieve standardisation; Impact of the machine with structural stops. Stops may be provided at the ends of rails to prevent the machine running off the rails, at the extremity of swing motions to limit the extent of swing, or on bogies so that in the event of a shaft failure the bogie cannot drop an excessive amount; Train positioner pulling rail cars against tippler structures; Storm wind loads. Where the fundamental natural frequency of vibration exceeds 1,0 Hz wind loading can be treated as a static load case. Where the fundamental natural frequency of vibration is less than 1,0 Hz wind loading shall be treated as a dynamic load case and a full dynamic analysis shall be carried out; In assessing the storm wind load case, cognizance shall be taken of the rate of increase in wind speed. Where mature storms or hurricane type wind conditions prevail, the machine can be assumed to be shut down in its parked position under storm wind load conditions. Where thunderstorm wind conditions prevail, in which winds can reach extreme speeds very quickly, the machine shall be assumed to be in its normal operational condition under storm wind conditions; Loads arising from jamming or failure of load equalisation mechanisms and For draglines, chop cutting shall be considered as a special load.
d)
e)
f) g)
h)
i) j) 4.3.4
Accidental Loads The accidental conditions and loads to be considered shall be based on the risk analysis. The loads shall include at least, but not be limited to, the following: a) b) c) d) e) f) g) h) i) Bucket or bucket wheel collision with stockpile or fixed object during full speed slew; Boom lateral collision with stockpile, ship, or other fixed object during full speed slew; Boom in-line collision with stockpile during lowering of boom, or travelling; Jamming of bucket or rakes during full speed drag; Jamming of rail car or tippler during tippler rotation; Lifting of boom following inundation with product or rock; Collapse of product stockpile or high wall onto boom; Breaking of any rope; Control system failure;
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j) k) l)
Mechanical failure; Collision of earthmoving vehicles or rail cars with machine and Seismic loads, where applicable, shall be assessed in accordance with an approved national seismic design standard, but with the following modifications of the design procedures: 1. 2. 3. 4. 5. 6. 7. Seismic loads need not be considered in seismic zones 0, 1 and 2A; Simplified design methods shall not be used in seismic zones 3 or 4; Seismic accelerations shall be evaluated in accordance with the national seismic design standard; All conveyor belts, buckets, chutes, etc shall be taken to be carrying the full design material mass; All buckets, rakes, etc shall be assumed to be clear of the ground or stockpile, thus providing no support to the materials handling machine; Where a simplified design method is used in seismic zone 2B, the behaviour modification factor shall be taken as 1 and In seismic zones 3 and 4 a linear elastic analysis of the full materials handling machine shall be performed. The outcome of the elastic analysis shall be reviewed together with the Purchaser to determine whether a full non-linear analysis is required.
Accidental loads may be omitted from the specified design load conditions where: a) The accidental condition is protected by at least two independent controls, where activation of either one of these controls will prevent the drives from causing a more severe condition, or The safety of persons is not compromised and the incident is sufficiently unlikely that the financial loss is acceptable.
b)
However, the accidental condition shall be included in the risk register. In order to limit the impact load arising from possible failure of wheels or axles, stops shall be provided to prevent bogies dropping more than 15 mm in the event of a failure. Accidental loads shall be assessed accordingly.
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4.3.5
Load Factors and Load Combinations The load combinations used for the structural design shall be based on the structural risk analysis, but as a minimum the load combinations listed in Table 4.1 below shall be considered.
Load Combinations
Boom Construction
General Construction
Normal Travelling Accidental Travelling
Self weight Operating equipment nominal Operating equipment dynamic Propel or long travel equipment nominal Propel or long travel equipment dynamic Rope tension nominal Rope tension dynamic Imposed load Wind load Overhead crane load Seismic load Bucket collision with stockpile Boom collision with stockpile Jamming of bucket Breaking of rope
X X X X X
Normal Operation
Loads
X X X
X X X
X X X
X X X
X X X
Maintenance X X X X X X
Accidental Operation 1
Accidental Operation 3 X X X X
X X
X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X
X X X
X X X X
Table 4.1: Minimum Load Combinations for Structural Design
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4.4
Analysis
The structural analysis shall include static analysis, dynamic and fatigue analysis. The Purchaser wishes to minimise the need for future repair of damage and fatigue cracks and for future structural modifications, well beyond the contracted warranty period. The reliability of machines is a high priority for the Purchaser and the specified analysis will be used to assess and confirm the strength of the machine and its resistance to fatigue cracking and the acceptability of the design for the application.
4.4.1
Extent of Analysis A controls and systems simulation model of the complete machine shall be developed to quantify the interactions and bi-directional effects between the mechanical components, structural components, electrical- connections and components and control algorithms (hoist, drag, swing, etc.). This simulation must be used to aid the design process and to determine and verify the influence of various load cases. In the structural analysis of the machine the Contractor shall account for the effects of slack rope or conveyor belts, possible overloading or underloading of counterweights, and the variable skill levels of operators. Additionally, the Purchaser seeks innovative schemes to control the transient loads associated these possibilities.
4.4.2
Extent of Analytical Model A complete structural model of the machine shall be developed for the structural analysis. Components and, where applicable, assemblies of components shall be modelled as complete entities, to ensure correct representation of all load paths and load cases. The masses of all relevant non-structural components, such as motors, gearboxes, cabling, walkways and stairs, and ballast, shall be incorporated in the complete model. They shall be represented in a realistic manner, including accurate modelling of the centre of gravity.
4.4.3
Load and Boundary Conditions Loads from components adjacent to the one being modelled shall either be derived from first principles or from a stick model of the machine. Appropriate boundary conditions shall be used to generate realistic displacements and stresses at the edges of the model.
4.4.4
Geometry The geometry used for the model shall be the geometry of the contracted design. Any deviation from the contracted design in the model shall be communicated to the Purchaser at or before the completion of model construction. The completion of model construction shall be a hold point in the design review process analysis shall not proceed until the model geometry has been approved by the Purchaser representatives.
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In order to obtain good results for the fatigue life analysis, regions of high stress concentration shall be represented realistically. In particular the following shall be adhered to: a) b) All holes greater than 25mm diameter shall be represented in the regions of refined mesh; Doubler plate regions shall not be represented as locally thickened plate, but as a second offset plate with a representation (including appropriate stiffness) of the attaching fillet welds; Manhole insert plates shall be realistically represented, as shall any manholes (remaining in the design) with welded-in rings; Thick to thin plate transitions (abrupt, with 4:1 taper or otherwise) shall be realistically represented and Welds generally do not require to be represented. If however there are areas where one-sided or two-sided fillet welds have total throat thickness less than the thinner plate thickness in a structural connection, either the welds shall be represented or the thinner plate in the connection shall be ascribed a thickness equal to the total throat thickness.
c) d) e)
4.4.5
Support Conditions The static analysis shall give cognisance to different support conditions at different stages as per the structural design risk assessment. At least the following support conditions shall be considered, but not be limited to: a) b) The basic support condition is uniform support under the entire support area, or over all wheels. Under these conditions loads and pressures are determined by static analysis; For the normal travelling load combination uneven ground will lead to uneven support along the tracks of crawler-mounted machines, so the support shall be assumed to act on the front 30 % of one track, and the rear 30 % of the opposite track. For the normal travelling load combination rail alignment tolerances will lead to some unevenness of support where the machine supports are not fully articulated, so in this case it shall be assumed that wheel loads may increase or decrease by 20 %; For boom construction load combinations, the boom must be supported as it will be supported on Site and The shoe structure of walking draglines is sensitive to ground conditions and bridging angle whilst the dragline is walking. The loading profile of the shoe in terms of the relative percentages of uniform loading, centre supported loading and bridging should be considered. The design assumptions made shall be submitted to the Purchaser for review.
c) d)
4.4.6
Static Analysis The static structural analysis may be done component by component, or as a complete machine structure. Where the analysis considers only a single component, it is of critical importance that all reactions from other attached components are properly defined in the analysis.
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4.4.7
Special Analysis The risk analysis shall consider the need to provide inherent safeguards against unforeseen failure of structural components. Where failure of structural components has the potential for initiating catastrophic failure of major components of the machine, a special analysis of the machine structure in which such structural component is omitted shall be performed to determine the resulting structural loads.
4.4.8
Dynamic Analysis The structural analysis shall include a full dynamic analysis of the entire machine structure. Where operation of the machine involves significant accelerations of major components of the machine, such as is the case for draglines, the dynamic analysis shall incorporate the behaviour of mechanical components and shall simulate the drive motor torque fluctuations in a realistic manner.
4.4.9
Fatigue Life Analysis
4.4.9.1 Basis of fatigue life analysis Fatigue analysis shall be based on finite element analysis of agreed major structural components of the machine. 4.4.9.2 Components subject to fatigue life analysis The components to be analysed for fatigue life shall be based on risk assessment. The list of components for which fatigue life analysis is proposed shall be submitted to the Purchaser for approval prior to commencement of analysis. Typical components requiring fatigue life analysis include, but are not limited to, the following: a) b) c) d) e) For walking draglines: the revolving frame, the house frame, the boom and boom suspension structures, and the tub; For stackers: the slew ring and supports; For bucket reclaimers: the slew ring and supports, bucket wheel; For ship loaders: the slew ring and supports and For tipplers: the main beams and clamping structure.
4.4.9.3 Fatigue cycles and stress range A fatigue life analysis shall be done using the stress ranges resulting from application of the nominal loads and any relevant special loads identified from the risk assessment. The number of cycles shall be determined from the risk assessment. The loads, stress ranges and number of cycles shall include at least, but not be limited to, those shown in Table 4.2.
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Loads Digging Dragline: dynamic dump 100 % RSL at full reach and with full hoist acceleration and dynamic rebound Bucket wheel reclaimer: dynamic digging load, including side load into stockpile Swinging or slewing Full acceleration clockwise Full acceleration anticlockwise Dragline propel Machine self weight with the bucket on the ground Walking the high point during the walking cycle with 80 % of the machine self weight on the shoes and 20 % on the trailing edge of the tub Crawling machine self weight distributed to front 30 % of one track and rear 30 % of other track then reversing to traverse uneven ground
Stress range
Cycles
Number of Negative maximum to buckets for positive maximum design production
Number of Negative maximum to swing actions positive maximum for design production
Assess by Negative maximum to distance positive maximum travelled
Rope tensions Nominal and dynamic rope loads shall be applied.
0 to maximum
Number of applications for design production
Tippler Empty wagon moving off tippler and full wagon moving onto tippler Tippler rotation Reclaimer (rake and A frame type) Loads from rake motion Range due to rake motion One cycle per second Negative maximum to Number of positive maximum wagons
Table 4.2: Loads, Stress Ranges and Cycles for Fatigue Analysis 4.4.9.4 Fatigue life assessment method Miners summation shall be used to combine the effects of the different stress ranges, and determine the fatigue life.
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4.5
4.5.1
Design
Design Philosophy All structural design shall be based on limit states design procedures. The design shall comply with the national limit states steel design standard applicable in the country in which the materials handling machine will be operated.
4.5.2
Design Responsibility The design of the structures shall be performed by, or under the direction, control and supervision of a Competent person, who shall accept legal responsibility for the design. Such Competent person shall have appropriate knowledge of, and appropriate experience in, the analysis and design of materials handling machine structures, and shall comply with all the relevant requirements of professional conduct applicable in the country in which the materials handling machine will be operated.
4.5.3
Materials All structural steel shall be weldable graded steel, with a yield stress of at least 300 MPa, but not more than 700 MPa. The materials selected shall be stated in the tender documents, for approval by the Purchaser. Special provision for cold climates and cold seasons has to be made and recorded by the Contractor.
4.5.4
Design Standards, Specifications and Related Publications Design, manufacture, installation and testing shall conform to the requirements of the applicable national standards or other acceptable standards, modified as required by this Anglo American specification. In selecting appropriate standards, particular attention shall be paid to the fatigue requirements of the standards. The design standard selected by the Contractor shall be stated in the tender documents for approval by the Purchaser. Should any contradicting statement be found in any standard or specification, then the most conservative (most severe) statement has to be applied.
4.5.5
Strength Requirements
4.5.5.1 General strength The strength of all structural components shall be determined in accordance with the approved design standard. 4.5.5.2 Buckling strength The strength of all structural components subjected to buckling due to compression and bending loads shall be determined in accordance with the overall and local buckling requirements of the relevant national steel design standard. Special attention has to be given to sympathetic buckling of elements.
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The strength of all structural components subjected to buckling due to shear loads shall be determined as follows: a) Where any load reversal occurs or where the fluctuating portion of the operating loads exceeds 20 % of the total loads, the buckling strength shall not exceed the elastic buckling strength and In all other cases, the post-buckling strength may be utilised as defined by the relevant national steel design standard.
b)
4.5.5.3 Connection strength The Contractor shall identify the connections which are critical for the integrity of the structure, and submit the procedure by which their quality will be controlled. Wherever practical, connections shall be located away from highly stressed areas and eccentricities shall be minimised. Wherever practical, connections shall be detailed to represent the lowest possible fatigue class. Bolted connections Bolted connections shall use high strength bolts, installed fully tensioned. Threads shall be excluded from shear planes where possible. Where slippage cannot be tolerated (including connections subject to fatigue or frequent load reversal) connections shall be designed as slip critical connections. All bolted structural connections shall have at least two bolts. High tensile bolts shall use through-hardened washers. After completion of bolt tightening in all bolted connections employing high strength bolts, bolt tension shall be verified. All bolts and fasteners shall be protected against loss of tension under continuous dynamic conditions and the Contractor has to specify the method of protection. Welded connections Bolted site connections are preferred. Where welded site connections are used, they must be pre-approved by the Anglo American Engineer. All welds shall be full penetration but welds, unless specifically noted otherwise. All welds shall be continuous welds, unless specifically noted otherwise. Where backing plates are used they shall be continuous.
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4.5.6
Fatigue Design Life The required fatigue design life of the materials handling machine shall be as specified for the particular project. The design life shall in no case be taken as less than 25 years. The number of load cycles shall be determined from the actual operational requirements, taking due cognizance of all load fluctuations during each operating cycle of the machine. Fatigue life calculations shall be based on 97.5 % reliability, i.e. curve for mean minus 2 standard deviations. Damage fractions from all relevant load cycles shall be combined using Miners rule.
4.5.7
Vibration Limits There are two different requirements to limit vibration. These are:
4.5.7.1 Prevent Resonance In order to ensure that resonance does not occur, the natural frequencies of the entire machine, or of any structural component or module, shall be less than 0,6 times, or greater than 1,4 times the operating frequency of major equipment. 4.5.7.2 Limit Vibration Levels The ISO 2631 vibration limits given in Table 4.3 are applicable.
Location Operators cabin MC rooms Main mechanical and electrical equipment All other areas ISO 2631 vibration limit 8 hour fatigue reduced proficiency boundary 8 hour fatigue reduced proficiency boundary 2 hour fatigue reduced proficiency boundary 1 hour fatigue reduced proficiency boundary
Table 4.3: ISO 2631 Vibration Limits 4.5.8 Deflection Limits In general the deflections of structural members shall not exceed the limits specified in the relevant national standards. Table 4.4 provides additional guidance.
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Deflection Limit Deflection of main girders about any axis Deflection of clamping arms or end plates Deflection of ceramic lined chute panels Twist of boom under nominal load combination Twist of boom under special load combination, or failure of one rope or tie Deflection Limit Vertical deflection of boom, mast or tri-structure under nominal load combinations Lateral deflection of boom, mast or tri-structure under nominal load combinations Where the boom is hinged to shed the loads associated with boom collision with the stockpile or ship, the deformation at the hinge shall be limited to ensure that there shall not be any damage caused to any electrical, hydraulic, conveyors, or other equipment, nor any structural members in the vicinity of the hinge.
Stackers
Reclaimers
Draglines
Ship loaders Span/1000
Wagon tipplers Span/1000
--
--
--
-Width/750 Diam/1000 3
-Width/750 Diam/1000 3
--
Span/500 Width/750 Diam/1000 3
Span/500
--
--
--
--
Stackers Span/300
Reclaimers Span/300
Draglines Span/300
Ship loaders Span/300
Wagon tipplers
-Shall not negatively affect operation of machine Span/300 Span/300 Span/300 Span/300 -Shall not negatively affect operation of machine Applicable Applicable Not applicable Applicable Not applicable
Table 4.4: Recommended Deflection Limits
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4.5.9
Design Calculations The Contractor shall submit a design quality assurance and auditing plan to the Purchaser for approval. Formal calculations shall be prepared for all structures. Calculations shall be recorded on calculation sheets in a manner that shall be logical, easy to follow and in such a way that they can be easily audited. Calculations shall be retained by the Structural Engineer for a minimum period of 10 years from the date of commissioning. A copy of the calculations shall be provided to the Purchaser, who shall retain them for as long as the materials handling machine is in use. All structural calculations shall be thoroughly checked by the person conducting the Design. In addition, all structural calculations shall be reviewed for accuracy and approved by the Structural Engineer or the responsible registered person employed by the Structural Engineer. Approval is indicated by full signature on the front page of design calculations and initials on all following pages.
4.5.10
Design Drawings Design drawings shall comply with the requirements of relevant national standards, and shall contain all necessary design information and be approved by the Structural Engineer. Following completion of construction, a full set of as-built Design drawings shall be prepared and approved by the Structural Engineer and submitted to the Purchaser. These shall be retained by the Structural Engineer for at least ten years from the date of commissioning. One copy shall be provided to the Purchaser, who shall retain them for as long as the materials handling machine is in use. Design drawings shall be prepared for all modifications, by revising existing drawings or preparing new drawings.
4.5.11
Design Verification and Validation Design verification includes the Contractors own design verification, as well as provision of all design calculations and drawings to enable the Purchaser to review the design. The Contractor shall provide for design verification procedures in accordance with AA REQ 100. Design Verification is undertaken to ensure that the Design outputs have met the design input requirements. This results in a confirmation that the Design is adequate, meets the User Requirements and is fit for purpose. Validation of engineering and design is undertaken to ensure that the resulting product or system or facility (as fabricated or constructed or installed) is capable of meeting the requirements for the specified application or intended use. This results in a confirmation that the completed product meets the Users Requirements and is adequate and fit for purpose prior to taking into service.
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The Contractor shall not withhold information necessary for this purpose. Where confidentiality agreements are necessary to protect the contractors proprietary design information, this shall be stated in tender documentation. 4.5.12 Design Layout
4.5.12.1 General Cross bracing shall be connected at intersection points. All members shall have a slenderness ratio less than 100. Arrangements and details, which create closed areas which are difficult to reach for welding and painting, such as back-to-back angles, shall not be used. 4.5.12.2 Plate Thickness The tub bottom plate on draglines shall be at least 50mm thick with a 25mm thick liner plate. For the tub the ratio between plate width and thickness (B/T ratio) shall not exceed 50 for all vertical diaphragms unless intermediate stiffening is provided. 4.5.12.3 Access Access stairs, platforms and walkways shall be provided to all elevated points on the structures requiring cleaning, servicing, testing, maintenance or repair. Such points shall include: pivots; sheaves and fairleads; anemometer; conveyor belts and drives; fans and air conditioning equipment; cranes; air compressors; hoist and drag drums, gears and pinions; light fittings; rope tensioning stations and sockets; boom foot lugs; brake assemblies; motors and gears; windows etc. Walkways shall be provided along both sides of all conveyor belts. Walkways and platforms shall comply with AA SPEC 114005. Including shall be able to be safely accessed from a platform or walkway. Access shall be created at the suspension rope sockets and vicinity to facilitate the safe inspection of the suspension ropes. No cat ladders are allowed on the materials handling machine. Stairways must provide access to elevated platforms and walkways. Access to moving stairs must be perpendicular to the line of movement. Pinch points must be avoided. The walkways at conveyor belt splicing positions shall be a minimum of 1200mm wide. Attachable platform extensions at the splicing location are acceptable if permanent wide walkways interfere with operation. Safety gates shall be provided at walkways that are disconnected when any part of the materials handling machine is rotated to different operating positions. Emergency access shall be provided from the operators cabin in all operating positions.
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At least two access openings are required into any enclosed space where maintenance must be done. Provision must also be made for access holes into the revolving frame in various places around the machine deck. These holes will accommodate welding cables and air hoses during maintenance. The Contractors design shall locate access ways into the structural compartments in areas of low stress. Diaphragms, floor plates or deck plates with access, piping or cable holes installed shall be of sufficient thickness to compensate for increased stress incurred as a result of installing the access holes. Alternatively, locally thickened plate shall be used to achieve a high level of fatigue resistance. The free edge of such holes shall be machined or ground to be notch free. Doubler plate and T-style flange plate construction shall not be used. The locally thickened plate shall be provided with a minimum of 3:1 taper around its circumference to provide low stress concentration to the full penetration weld to the adjacent plate. In order to avoid vibration induced damages, the hand railing should have sufficiently high natural frequencies to avoid resonance. This can be achieved through the selection of appropriate hand railing dimensions as well as the provision of adequate torsional stiffness to the stringers to which the hand railing is attached. These designs must be approved by the Purchaser. Walkways on flexible components such as booms shall be constructed in segments, with flexible or no connections between them, so as to eliminate fatigue cracking of upright or support members. 4.5.12.4 Provision for maintenance lifting Where components and gearing cannot be dismantled and easily removed from the deck with materials handling machine house cranes, the Contractor shall design and install removable weatherproof roof or wall sections to allow removal with off board cranes. Where smaller items must be removed and installed crawl beams and dedicated lifting points must be provided. 4.5.12.5 Prevention of spillage Structural assemblies shall be designed to prevent dust build up reducing the risk of damage to belts, idlers, etc., and reduce the rate of corrosion. Flat areas and cavities shall be minimized. 4.5.12.6 Weather Resistance The Contractor shall ensure no harmful effects from runoff or drainage water impinging upon sensitive or critical components such as electrical enclosures, motors, gear reducers, bearings, shafts, pinions, hydraulic components, etc.
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Seal welds shall be used to provide an all-around seal on all welded connections except where such seal welds will adversely affect the fatigue performance of certain weld connections. Only where seal welding is not permitted by the welding code, the Contractor shall subsequently seal the unsealed portions of such connections using a suitable caulking or sealing material compatible with the paint system to be used. Normally, such sealing will be performed after application of primer paint and before application of topcoat paint. Provision shall be made for draining of rain water from all structural pockets, using drain holes which shall have a minimum diameter of 25mm to prevent clogging. Where practical, the member and connection details shall be designed to avoid accumulation and retention of dust or water during normal operation or washdown. Remaining areas which would otherwise be subject to accumulation of dust shall be provided with shedding plates so arranged as to not impede access to the structure or equipment for inspection or maintenance. Closed metal sections will be used where possible to assist in preventing build up. Closed sections shall be sealed to prevent ingress of moisture. Large closed sections shall be provided with a watertight means of access for inspection and maintenance. End cover plates of minimum 6mm thickness shall be installed by welding all-around on all open ends of all hollow structural section and structural pipe members, including handrails. All access holes and inspection ports into box structures and hollow sections shall be provided with bolted cover plates of minimum 10mm thickness. Access holes and inspection ports shall be sealed against the ingress of dust and moisture. These sections shall be corrosion protected on the inside. Entrance covers to any large hollow sections shall have an effective sealing arrangement to prevent the ingress of lubricant and water into any portion of the machine. At all low points in all box structures and all hollow sections whose greatest cross-sectional dimensions exceed 100mm, the Contractor shall provide tapped drain holes closed by threaded plugs to permit periodic inspection for dryness. Tapered pipe thread of minimum nominal diameter 12mm shall be used for drain holes and plugs. Plugs shall be provided with hexagonal head, square head, or hexagonal socket head to permit removal. For all box structures which contain internal baffles, diaphragms or stiffeners, the Contractor shall provide drainage, by means of drain holes of minimum 12 mm diameter and/or corner copes in internal structural elements to ensure that any moisture which enters any portion of the box structure will drain to low points equipped with drain holes and plugs. Stress concentrations arising from the use of internal baffles and diaphragms shall be considered in the design. 4.5.12.7 Clearance to conveyor belts Structural steel shall not intrude within a 150mm clearance limit around any conveyor belts.
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4.5.12.8 Rails The fixing of all rails shall make allowance for thermal expansion. Provision shall be made for electrical earthing of all rails by means of flexible cables to allow movement of the rails due to thermal expansion of at least 50mm in each direction. 4.5.13 Load Equalisation Each pair of boom support ropes shall be fitted with an equalising link permitting a difference in strand length of 25mm before one rope or the other attracts more than 55% of the total load. The extension of one rope in a pair by 70mm more than the other shall result in the full transfer of the load to the shorter rope. 4.5.14 Revision of Analyses Where any of the following applies, the Contractor shall revise the structural analysis and design: a) b) c) d) e) f) g) Change control procedure identifies a change requiring a revised structural analysis; Self weight or ballast mass changes by more than 5%; Bucket size, rake size, chute volume, or payload increases by more than 20%; Geometry of the machine, including boom length, height, slew angles, etc changes; Power delivered by the motors or gear box ratios changes by more than 10%; Boom construction support conditions or construction procedure changes and Control system philosophy, limits or functions change.
4.6
4.6.1
Construction
Shop Fabrication Before manufacture the Contractor shall submit for approval a list of structural items in order of classification i.e. critical, major or minor. The Contractor shall also submit for approval, before manufacture, any drawings and calculations that are required by the Purchaser. All structural components shall be categorised in accordance with AA REQ 100 following Table 4.5.
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AA SPEC 248002
Materials handling machine Stackers
Critical components
Major components
Minor components
Boom Mast Chassis Turntable
Tripper structure Conveyor support
All other structural components
Reclaimers
Boom Mast A frame Foot Chassis Turntable
Rakes Chutes Conveyor support
Draglines
Boom Mast Tri-structure A frame Foot Tub Chassis Revolving frame
House structure Crane gantry Crawl beams
Ship loaders
Boom Mast Chassis Revolving frame Quadrant beam
Conveyor support
Wagon tipplers
End discs Beams
Bin Conveyor support
Table 4.5: Component categorisation in Accordance with AA REQ 100 4.6.2 Rope Sockets The design and manufacture of rope sockets shall comply with the requirements of national standards. In the absence of national standards, the Contractor shall prepare a specification for by the client prior to manufacture. Alignment of the rope strand ends to the socket axis shall be within + 0,5. Alignment shall be measured after socketing with no load on the rope.
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AA SPEC 248002
Alignment shall be measured in two planes, one plane passing through the retaining pin axis, and one plane normal to this axis. 4.6.3 Materials All material used in construction shall be new and free from defects. Mill certificates or material test reports providing chemical composition and physical properties shall be obtained by the Contractor for all structural steel. Copies of mill certificates or test reports shall be furnished to the Purchaser in the installation manual. For all critical components, the steel shall have Charpy V-notch impact test energy absorption of 27 J at -10 oC. Additionally, all structural steel plate with a thickness of 50 mm or greater shall be produced using fine-grain practice and shall have Charpy V-notch impact test energy absorption of 27 J at 10oC. Plates and sections used for all critical components shall be certified plate to the Contractors nominated specification and shall be 100% ultrasonically tested against laminations and defects. All hollow sections shall be manufactured from seamless tube. 4.6.4 Shop Welding
4.6.4.1 General All structural welding shall be in accordance with the requirements of AWS D1.1. 4.6.4.2 Critical welds The contractor shall provide the Purchaser with a list of all critical welds in the structure. A critical weld is any weld where one or more of the following criteria apply: a) b) c) Failure of the weld is a significant hazard to the safety of persons working on the machine; Failure of the weld will cause catastrophic collapse of a major structural component of the machine and Failure of the weld will prevent further productive use of the machine until after the weld has been repaired.
The rail pad to circular diaphragm weld in the base of draglines, and all butt welded joints in these plates shall be classified as critical welds. 4.6.4.3 Welding Procedures The Contractor shall specify all weld procedures prior to commencement of any welding. A copy of all weld procedures shall be available for inspection by the Purchaser, and shall be included in the construction manual.
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All welding procedure data sheets, for other than pre-qualified welding procedures according to AWS D1.1 or other approved standard, shall be supported by a procedure qualification test record completed according to a welding standard acceptable to the Purchaser. Qualification of procedures for critical welds Tests shall be conducted to qualify the procedures and consumables to be used for all critical welds. Procedures qualified in these tests shall also be used for all welds involving low sulphur steel plates or sections that comply with the requirements of this specification. Destructive and non-destructive testing of the samples shall comply with the requirements of AWS D1.1, using samples reflecting the actual geometry and welded in the same orientation (downhand, vertical, etc), as the welded joint, A total of three tests shall be conducted. The Contractor shall supply the Quality Assurance Representative with completed weld procedure qualification records, prior to the commencement of the testing. Tests shall be conducted at an approved testing facility. The Contractor shall advise the Quality Assurance Representative prior to the commencement of welding of the procedure qualification tests, the date of the tests. This action shall be detailed on the Contractor's approved quality plan. Upon satisfactory completion of the tests, the Quality Assurance Representative shall record the test results from the procedures recorded during welding. Acceptance criteria The three sample welds shall be deemed acceptable if the following criteria are satisfied: a) b) c) d) e) f) Ultrasonic or radiographic test results shall comply with the requirements of AWS D1.1; A macro-etch test shows no evidence of cracks; The tensile strength shall exceed the ultimate tensile strength of the parent material; Charpy V-notch impact values taken from the weld metal shall be equal to or greater than 27 J at 0C for all samples; Charpy V-notch impact values taken from the parent metal in the heat affected zone shall be equal to or greater than 27 J at 0C for all samples; The maximum hardness on the surface shall not exceed 270 HB10 and the hardness in the depth of the joint shall not exceed 190 HV10 when determined in accordance with AWS D1.1; The side bend when tested in accordance with the method specified in Clause shall comply with the requirements of AS 1554 4.6.7.2 and Alternative testing may be proposed by the Contractor, but shall be approved by the Anglo American Engineer prior to use.
g) h)
The Contractor shall adopt manufacturing procedures identical to those procedures employed for the satisfactory qualification tests.
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Procedure alteration Any proposed change of welding process from that recorded on the approved weld procedure qualification sheets shall require procedure qualification establishment and testing. If this proposal should arise after commencement of manufacture, such tests shall be conducted at the Contractor's cost. In the event of such change of process, or extra procedure qualification tests being deemed necessary, the Contractor shall provide suitable access for the Quality Assurance Representative in order that he may witness all welding and testing proceedings. 4.6.4.4 Additional Welding Requirements For hot-dip galvanized hollow sections, the vent holes, required for the galvanizing process, shall be sealed by welding after completion of galvanizing. A zinc-rich paint suitable for repair of galvanized surfaces shall be applied to the vent-hole seal welds after completion of welding. Field welded splices in members will be not permitted. 4.6.4.5 Fabrication tolerances and fit-up All fabrication tolerances and fit-up shall comply with AWS D1.1. Edge preparations shall be visually and dimensionally inspected. Weld fit-ups shall be visually inspected after tacking but before welding. Alignment pins shall be provided in all major structural sub-assemblies to ensure accurate alignment prior to field welding. 4.6.4.6 Welder qualifications Welders shall be qualified and certificated to the requirements of AWS D1.1 Section 5 (or a standard that the Contractor can demonstrate is an equal or better standard) before commencing welding and shall have continuously welded to this standard without interruption for longer than three months since qualification. Welder certification shall be conducted by an approved authority. The Contractor shall provide proof to the Purchaser, upon request, that the welding Contractor employees are competent to produce the type and quality of welding required for the work. 4.6.4.7 Welding consumables Welding consumables shall conform to the requirements of AWS 1.1 Section 4. Electrodes shall be stored in unopened original containers. Flux-coated electrodes shall be kept dry-stored to prevent moisture absorption, and shall be handled in such a manner as to ensure no physical damage to the coating.
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AA SPEC 248002
All electrodes having low hydrogen coatings shall be dried before use for a minimum of 2 hours between 230C and 260C. Electrodes shall be stored immediately after drying in storage ovens maintained at a temperature of 120C minimum. Electrodes that have not been used within one hour after removal from an oven shall be redried before use. Reasonable precautions shall be taken to prevent electrodes from contacting moisture before use. 4.6.4.8 Weld quality Weld configuration, size and quality shall conform to AWS D1.1 Section 3.6 and to the Contractors weld procedures. For partial penetration welds, lack of root penetration shall not exceed 15% of throat thickness or 6 mm whichever is the lesser. 4.6.4.9 Extent of testing All welds shall be 100% visually inspected after final dressing, for undercutting, porosity and other surface defects as specified in AWS D1.1. All critical welds shall be 100% ultrasonically or radiographically inspected in accordance with the requirements of AWS D1.1. Ultrasonic testing shall be performed by personnel certified to a minimum of Level III Inspectors, other non destructive testing of welds shall be performed by personnel certified to a minimum of Level II Inspectors. A 10% random sample of non-critical welds shall be tested by ultrasonic or radiographic means as appropriate to the requirements of AWS D1.1. Should non destructive testing as described above show a tested length not complying, a total length of 300 mm adjacent to the failed length shall be tested. Non-compliance within these adjacent lengths shall be cause for inspection and correction of all the welds conducted by the welder involved within the weldment being tested. If the adjacent lengths are satisfactory the original failed length shall be re-welded. The adjacent lengths of 300 mm shall not be considered as part of the 5% testing length. In addition, the Purchaser shall have the right to conduct additional non-destructive testing of welds at his cost, provided that he gives the Contractor reasonable notice of his intention to do so. 4.6.4.10 Weld repair Welds which fail to comply with the requirements of AWS D1.1 shall be repaired using methods specified in AWS D1.1. Repaired welds shall be subjected to the same testing procedure as specified above. 4.6.5 Structural
4.6.5.1 Tolerances All structural elements shall be dimensionally inspected and verified to be within tolerances stated in the Codes and Standards or to tolerance limits provided by the manufacturer, whichever is the most rigorous.
AA SPEC 248002
4.6.5.2 Forming All structural plate formed by cold bending shall be visually inspected for tears, cracks or separation. Magnetic particle testing shall be used to check sharp or tight bends in heavy plates thicker than 6mm. 4.6.6 Corrosion Protection The corrosion protection system proposed shall be specified in tender documentation for approval by the Purchaser. All hollow section members in critical components shall be shall be gas filled to a pressure of 620 kPa to exclude oxygen and allow monitoring of leaks. Bolts of strengths up to and including Class 8.8 (ASTM A325) shall be galvanized. Bolts of higher strengths shall be electroplated. 4.6.7 Finishing Sharp corners and edges on items to be painted, lifting lugs and other areas where sharp edges may have detrimental effects, shall be rounded by grinding or machining to a minimum of 1 mm radius, unless otherwise noted. Edges of bolt holes shall be deburred, but need not be rounded. On items to be hot-dip galvanized, the Contractor shall deburr all sharp edges, corners and holes and shall break sharp outside corners using a grinder or file. On items to be painted or galvanized, laps or other irregularities in welds which would result in poor coating quality shall be blended into the surrounding surface by grinding. All weld spatter, welding slag and welding wire stubs shall be removed. 4.6.8 Trial Assembly and Marking All structural components shall be trial-assembled during fabrication to ensure correct fit. 4.6.8.1 Marking Following trial assembly, the Contractor shall identify all structural components by a unique mark to ensure site assembly is as trial assembly. The unique marks shall be clearly noted on construction drawings. 4.6.9 Site Erection Prior to commencement of construction the Contractor shall submit a detailed erection procedure for the Purchaser's review. 4.6.9.1 General The Contractor shall be responsible for all dimensional checks of the machine components prior to commencement of erection, allowing sufficient time for corrective measures. Corrections shall be made by the Purchaser as requested by the Contractor through the Anglo American Engineer.
AA SPEC 248002
The Contractor shall be responsible for checking clearances around all equipment prior to its installation. Should any interference be evident, it shall be reported to the Anglo American Engineer in writing immediately. Any portion of the work disclosed as defective through start-up testing due to improper installation shall be rectified and retested by the Contractor. All work shall be carried out in accordance with the codes and standards approved by the Purchaser. The Contractor shall be responsible for ensuring that the construction and installation techniques employed by the erection Contractor(s) are appropriate and do not reduce the effectiveness of the design. Should any non-conformances be detected by the Contractor, the Contractor shall issue a report to the Purchaser describing the non-conformance, and including a corrective action to rectify the non-conformance. 4.6.9.2 Equipment Installation Alignments All alignments on equipment either pre-assembled or field assembled shall be checked and adjusted where necessary by the Contractor. All alignments shall be to the Contractor's or manufacturer's specified tolerances, as specified in the construction manual. All alignment checks shall be witnessed by the Anglo American Engineer. The Contractor shall record the results of all alignment checks and shall submit a copy of these records to the Anglo American Engineer. Assembly The Contractor shall verify that off-site and on-site assemblies are identical and that match markings are aligned precisely. Dimensional Checks The Contractor shall check critical dimensions against the standards and the construction manual, record the results of all dimensional checks, and submit a copy of these records to the Purchaser. Structural Prior to erection, all structural steelwork shall be visually inspected for damage or deformation resulting from shipping and handling, and for any contamination on mating surfaces of slipcritical bolted connections. During erection and prior to making final connections, the Contractor shall check that: a) b) c) Members are straight, plumb and square to within specified tolerances; Match markings are correctly matched and aligned; Mating surfaces of bolted connections are parallel and fit flush, and that all bolt holes line up correctly and
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d)
After access doors to semi-permanently enclosed spaces have been closed for the last time, check the adequacy of cover gaskets and that each compartment is free from leaks which could lead to internal corrosion of box beam sections.
Corrosion Protection Before erection painted steelwork shall be visually inspected prior to erection to check for damage to or deterioration of shop applied coatings. Any corrections which require abrasive blast cleaning shall be performed prior to erection. After erection and completion of final inspections on all bolted and welded connections, the structure shall be inspected for damage to coatings. All damaged coating, unpainted steel at site welded connections, and portions of bolted connections which lack topcoat shall be painted in accordance with the provisions of these Technical Specifications. However, any corrections or painting which requires abrasive blast cleaning shall require the Engineer's prior approval. In the event abrasive blast cleaning on certain portions of the erected steelwork may create some risk to the performance of adjacent mechanical or electrical equipment, the Contractor may be required to use alternative surface preparation and/or painting procedures for those areas. Any additional costs shall be to the Contractor's account. The structure shall also be checked for narrow gaps or crevices which lead to hidden surfaces or which cannot be properly painted. Any such crevices shall be sealed using a suitable caulking compound. 4.6.10 Site Welding
4.6.10.1 Precautions for site welding The Contractor shall verify that temperature and weather conditions are satisfactory for welding, or else employ preheat and/or shelters as required, and that welding materials are stored and handled in accordance with specified standards. Temporary rust preventative material used to protect steel adjacent to the weld joints shall be removed prior to welding unless otherwise approved by the Anglo American Engineer. The Contractor shall provide proof that the welding Contractor employees are competent to produce the type and quality of welding required for the work. A photo record has to be submitted by the Contractor to the Purchaser of all site welds, stating date, position and welder certification on each photograph. 4.6.11 Supplied Materials Repair No work of inspecting and testing of supplied materials to be carried out without submission of repair procedures or relevant standards to the Anglo American Engineer. All repairs undertaken shall be inspected to determine compliance with relevant approved standards.
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The Anglo American Engineer reserves the right to witness this inspection. A written record detailing all necessary repairs and testing shall be supplied to the Anglo American Engineer after the repair. 4.6.12 Centre of Gravity and Ballast
4.6.12.1 Materials The Contractor shall be responsible for supply and installation of ballast. The ballast material shall be as specified on the relevant drawings. 4.6.12.2 Determination of Ballast Mass The Contractor shall specify in writing how the final ballast mass and layout will be determined. Where the ballast mass counterbalances the luffing boom mass, the procedure shall ensure that no tension exists in the hydraulic cylinder under any operating conditions. 4.6.12.3 Centre of Gravity Position The Contractor shall advise in the manuals supplied with the machine the acceptable range of positions of the centre of gravity horizontally and vertically for the materials handling machine as supplied. 4.6.13 Packing
4.6.13.1 Packing The method of packing where required shall protect all items against breakage damage, and the effects of climatic conditions during transportation and storage. Items shall be transported in as large a unit as practicable but within the limits specified by relevant shipping and land transportation regulations. Machined surfaces shall be adequately protected from corrosion and damage during transportation and storage. All fasteners and welding consumables shall be packed in sealed weatherproof containers, with clear identification of the contents marked on the outside. Identification of the contents shall include the materials handling machine, the area for which the fasteners are intended and the number of fasteners included.
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4.7
Commissioning Procedures
The Contractor shall submit written commissioning procedures, no later than ninety (90) days prior to the scheduled date for Performance Tests, for review by the Purchaser.
4.7.1
General The Contractor shall supply all necessary personnel, tools, test equipment and proof loads, and technical services to demonstrate guaranteed performance. The field personnel provided by the Contractor for dry and wet commissioning shall be capable, qualified and able to perform the duties required to the satisfaction of the Purchaser and shall be vested with authority to make decisions binding on the Contractor.
4.7.2
Dry Commissioning Tests Dry commissioning of the machine structure shall consist of motion testing and proof load testing as described in the following sections.
4.7.2.1 Motion Testing The Contractor shall demonstrate the ability of the machine to travel to the limits of its long travel, transverse travel and slew and luffing positions without fouling any fixed structures or adjacent equipment. 4.7.2.2 Proof Load Test Proof load testing shall be carried out as required by local legislation. 4.7.2.3 Testing of End Stops The Contractor shall demonstrate the ability of the end stops to bring the machine to a complete stop under full long travel speed, traversing speed, shuttle speed and slew speed. 4.7.3 Wet Commissioning
4.7.3.1 General Wet Commissioning shall commence after successful completion of machine erection, correction of all deficiencies and omissions to the Purchaser's satisfaction, and completion of Dry Commissioning tests. The wet commissioning tests shall be performed by the Contractor and they shall be witnessed by the Purchaser. The Contractor shall record all tests and the results obtained, and provide a copy of the record to the Purchaser. 4.7.3.2 Performance Test and Guarantee The Contractor warrants that the materials handling machine shall meet the structural design requirements as detailed in the technical specifications, and the performance tests specified below.
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AA SPEC 248002
Using the on board monitoring system, the Contractor shall demonstrate that under all performance tests the stresses, deflections and vibrations are within the design limits.
4.8
4.8.1
Monitoring
Provision for Monitoring Provision for monitoring shall include at least that shown in Table 4.6.
Materials handling machine Hydraulic or pneumatic cylinder forces, or oil pressure Continuous stress measurement Continuous acceleration measurement Wind speed and direction
Boom chords over luffing cylinder or at connection to slew frame Stackers Reclaimers Luffing cylinder Boom ties at connection to slew frame Top of wheel bogey assembly None
Boom chords over luffing cylinder or at connection to slew frame Ship loaders Luffing cylinder Slewing cylinder Boom ties at connection to slew frame Top of wheel bogey assembly None
Wind speed and direction shall be continuously measured at an unprotected location on the machine
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AA SPEC 248002
Materials handling machine
Hydraulic or pneumatic cylinder forces, or oil pressure
Continuous stress measurement
Continuous acceleration measurement
Boom chords, 1 m above connection to revolving frame Boom chords where analysis shows highest stress during normal operation Tri-structure or mast chords, 1 m above their connection to the revolving frame Tri-structure where analysis shows highest stress during normal operation A frame or back legs, 1 m above their connection to the revolving frame Main beams at connection to end frame Centre span of main beams Lateral acceleration at the top of the boom Vertical acceleration at the top of the boom In-line acceleration at the top of the tristructure or mast Lateral acceleration at the top of the tristructure or mast Lateral acceleration at the front and rear extremes of the revolving platform
Draglines
None
Wind speed and direction shall be continuously measured at an unprotected location on the machine
Wagon tipplers
Tipping cylinder
None
Table 4.6: Structural Monitoring Requirements 4.8.2 Monitoring Range All monitoring of parameters describing physical behaviour, including monitoring of load and torque, stress, acceleration, deformation, pressure, etc shall utilise devices and monitoring systems capable of measuring and recording the most extreme values of these parameters. The practice of only measuring and recording within the normal operating range is not acceptable.
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4.8.3
Limits when Monitoring The materials handling machine control system shall make provision for different levels of alarm and actions, based on stress and acceleration monitoring and wind speeds. The Purchaser shall decide on the type of action or intervention appropriate for the different levels. The action could be: triggering of an alarm; disabling and stopping of the materials handling machine; or disabling specific functions of the materials handling machine.
4.8.3.1 Level 1: Alarm and Action Condition An alarm shall be triggered in the operators cabin when any of the stress or the acceleration measurements exceeds 100 % of the theoretical unfactored values obtained from the structural analysis. 4.8.3.2 Level 2: Alarm and Action Condition The level 2 action shall be activated in the event that: a) b) Any of the stress or the acceleration measurements instantaneously exceeds 160 % of the theoretical unfactored values obtained from the structural analysis; Any of the stress measurements exceeds 130 % of the theoretical unfactored values obtained from the structural analysis for a sustained period exceeding 5 (five) seconds and Any of the acceleration measurements exceeds 130 % of the theoretical unfactored values obtained from the structural analysis repeatedly over a period exceeding 10 (ten) seconds.
c)
4.8.3.3 Extreme wind conditions The following actions shall be taken in extreme wind conditions: a) b) c) 4.8.4 Warning alarm at wind speed of 18m/s; Shut down of all operation at wind speed of 22m/s and Travel to park position at wind speed of 27m/s.
Monitoring Data All monitoring data shall be accessible to the Purchaser via agreed electronic communications ports for further analysis.
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4.9
Quality Assurance Provisions

The Contractors quality management system shall comply with the requirements of AA REQ 100. All provisions and requirements for quality assurance of structural components shall be incorporated in the Contractors quality assurance plan.
4.9.1
Tests Required Bolts A random sample of bolts shall be selected from the bolts supplied to be used for the erection of the materials handling machine and shall be tested to ensure that they comply with the relevant standards and the equivalent of 5% of all bolt and fasteners types and sizes must be tested to destruction to verify ultimate strength and minimum elongation. Welds All welds shall be 100% visually inspected after final dressing, for undercutting, porosity and other surface defects as specified in AWS D1.1. All critical welds shall be 100% ultrasonically or radiographically inspected in accordance with the requirements of AWS D1.1. Ultrasonic testing shall be performed by personnel certified to a minimum of Level III Inspectors, other non destructive testing of welds shall be performed by personnel certified to a minimum of Level II Inspectors. A 10% random sample of non-critical welds shall be tested by ultrasonic or radiographic means as appropriate to the requirements of AWS D1.1. Should non destructive testing as described above show a tested length not complying, a total length of 300 mm adjacent to the failed length shall be tested. Non-compliance within these adjacent lengths shall be cause for inspection and correction of all the welds conducted by the welder involved within the weldment being tested. If the adjacent lengths are satisfactory the original failed length shall be re-welded. The adjacent lengths of 300 mm shall not be considered as part of the 5% testing length. In addition, the Purchaser shall have the right to conduct additional non-destructive testing of welds at his cost, provided that he gives the Contractor reasonable notice of his intention to do so. Plate work and steel sections For all critical components, the steel shall have Charpy V-notch impact test energy absorption of 27 J at -10 oC. Additionally, all structural steel plate with a thickness of 50 mm or greater shall be produced using fine-grain practice and shall have Charpy V-notch impact test energy absorption of 27 J at 10oC. Plates and sections used for all critical components shall be certified plate to the Contractors nominated specification and shall be 100% ultrasonically tested against laminations and defects.
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For plates with a thickness of 16 mm or greater tensile tests, to test ultimate strength and minimum elongation, shall be done on three (3) specimen of every batch of plates. 4.9.2 Quality Assurance Plan The specific requirements of quality assurance for structural components include at least, but are not limited to, the following: 4.9.2.1 Testing of critical components The Contractor shall provide an appropriate quality testing plan for approval by the Client, and shall adhere to this plan. The quality assurance plan shall identify all critical components and appropriate tests or certificates required, as well as the timing and responsibility for these tests. Copies of mill certificates shall be provided to the Purchaser for all structural steel used in the work. For steel which is of 35 mm or greater in thickness and which is utilized in the fabrication of principal stress-carrying members, Charpy V-notch impact test certificates shall be provided to verify that material impact properties meet or exceed the requirements stated in this technical specification. 4.9.2.2 Notification of Witness and Hold Points Hold points shall include at least, but not be limited to, the following: a) Completion of trial assembly. The Contractor shall provide to the Purchaser a minimum of seventy-two hours (72) advance written notification of the occurrence of each witness or hold point. 4.9.3 Quality Dossier At the completion of the work, a quality dossier shall be submitted by the Contractor to the Purchaser. It shall incorporate all quality related documentation for structural components, including at least, but not limited to, the following: a) b) c) d) e) f) g) Design review checklist; Material certificates; Dimension sheets; Welding inspection reports; Heat treatment reports; Performance and overload test results and Baseline measurements of stress, vibration and thermal imaging.
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4.9.4
Personnel Qualifications All personnel engaged in design and production of the work shall be Competent persons. The Contractor shall provide to the Purchaser, upon request or as required by this technical specification, objective evidence confirming the competency of each person engaged in performance of the work. The Purchaser reserves the right to require testing of the skills of any of Contractor's personnel prior to their performance of portions of the Work, or upon any of Contractor's personnel engaged in the Work when there is reason to question the competency of such personnel.
4.9.5
Certification of Work All work shall satisfy the requirements of all Inspection Authorities having jurisdiction. The Contractor shall obtain all necessary permits and pay all fees in connection therewith, including fees for inspection of drawings and building approval. Upon completion of the work, the Contractor shall obtain certification of acceptance from the Inspection Authorities and submit this to the Purchaser.
4.10
4.10.1
Documentation Requirements
General The Contractor shall submit to the Purchaser documentation and drawings, including all revisions thereof, required for the design, furnishing of equipment, erection, installation, maintenance and operation of the Materials handling machine. The Contractor's furnished documentation and drawings shall include, but not be limited to, items indicated in the following subsections. The Contractors schedule should be based on a turnaround time of two (2) weeks, not including mail delivery time, for review of drawings and documents by the Purchaser. Any rework required because of documents not meeting the requirements of this Technical Specification shall not be grounds for an extension of time for completion of the Work. Appendix C lists specific requirements of Contractor submittals.
4.10.2
Drawings
4.10.2.1 General All drawings shall be produced in a format compatible with a 3D drawing package specified by the Purchaser. Drawing submittal schedules shall be established at the time of Notice to Proceed and shall be mutually agreed between the Purchaser and the Contractor. Drawings shall be issued for review on a distributed schedule and not bunched. Drawings required for cross-referencing during review shall be submitted at the same time as the drawings to which they relate are issued for review.
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The Contractor shall submit detailed certified drawings for all of the items supplied under the Agreement and certified drawings specifying the design requirements of the Contractor for related equipment provided by others, including but not limited, to: the causeway conveyor, Materials handling machine support structure and power supply and electrical control. All detail drawings are to be accompanied by a parts list/bill of materials that will include such information as to total mass of the assembly, and a list of the individual components complete with the material, and weight of component. These parts lists must include the revision of the drawing number to which they correspond. Drawing transmittals indicating the distribution are to accompany each issue. 4.10.2.2 Layout Drawings The Contractor shall submit certified drawings of all layouts, including but not limited to general arrangement drawings of the materials handling machine and drawings indicating the location of items of equipment. 4.10.2.3 Structural Drawings The Contractor shall submit general arrangement and detail drawings showing the materials handling machine structure and the loads for which it is designed. These drawings shall include but not be limited to: a) b) c) Overall general arrangements showing leading dimensions and the relationship of all the parts of the machine; Additional arrangement drawings as required to show the layout and dimensions of large structural assemblages forming components of the completed machine and Loading diagrams showing: 1. 2. 3. 4. External loads applied to the machine, including magnitude and points of application; External reactions corresponding to the applied loads; Internal reactive forces between machine components and Individual member design loads, including the load range and cycle life used for fatigue design.
4.10.2.4 Fabrication Drawings When stipulated in the Specification or upon request from the Purchaser, the Contractor shall submit fabrication drawings to the Purchaser for review. 4.10.2.5 Erection Drawings The Contractor shall provide erection drawings required for the Materials handling machine to be fully assembled and erected on site.
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AA SPEC 248002
Erection drawings shall include, but not be limited to, the following: a) Connection details for major assemblies showing welding and bolting requirements at all connections. (Except under the companion piece, where welding may be considered, no planned site welding shall be allowed); Weights and centres of gravity of major assemblies and Field run cable schedules, schematics, and wiring diagrams.
b) c)
4.10.2.6 Record Drawings The Contractor shall provide the Purchaser with complete set of certified full size, record drawings showing all as-built details of the Materials handling machine as actually built or constructed, plus electronic copies of all drawings as required in the Commercial and Special Conditions. Record drawings shall include all general arrangement drawings, all fabrication drawings, all mechanical component drawings, including fully dimensioned detail drawings and material specifications for all internal and external components, and all electrical drawings. On completion of any part of the work, the Contractor shall mark up and provide to the Purchaser two (2) sets of as-built drawings marked-up in red with all the field changes observed by the Contractor incorporated in the equipment. All record drawings shall be delivered to the Purchaser and accepted by the Purchaser prior to the issue of the Certificate of Total Performance. 4.10.3 Certificates Copies of the following certificates shall be provided to the Purchaser: a) b) 4.10.4 Material certificates, particularly for any special steels used and Certificates of all weld testing. These certificates must clearly indicate where repairs were carried out, so it is not only the successful test certificates that are required.
Retention of Documents Model and results files shall be reliably archived for a minimum of 10 years so that re-analysis may be performed by the Contractor if requested by the Purchaser at a later stage.
4.10.5
Manuals Manuals must be comprehensive, so as to form a reliable and easy source of access to all information necessary for the following functions. Language shall be in both English and the national language of the country in which the machine will be located. Procedures and instructions should be simple and valid.
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Structural information shall be included with other necessary information in the following manuals: a) b) c) d) Construction; Installation and commissioning; Operation and Maintenance.
The manuals must cover all aspects of the above functions without the need for reference to sources outside the manual. The manual will be used as an aid to the training of operation and maintenance personnel and should therefore make maximum use of exploded views, technical illustrations, charts, trees and tables. It should be remembered that manuals will be required by three distinctly different groups engaged in separate functions. a) b) c) The contractors who will install and commission the equipment; The equipment operators and The maintenance division of the operating company.
Each of these groups will be expected to operate to a large degree independent of each other. It is therefore essential that the manuals for each of these three functions are separate, or can be separated without loss of identity or completeness. Some drawings will have to be included in more than one of the installation, operation or maintenance manuals to maintain their integrity. 4.10.5.1 Construction Manual Section 1 - Introduction This section shall state: a) b) c) Equipment Number; Equipment Description and Location at Site.
Section 2 - Index This section shall include: a) b) Section Index and Detailed Index.
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The Section Index shall identify all sections of the manual against divider titles. The Detailed Index shall locate equipment data both by section and page numbers. Each item to which an equipment number has been allocated shall be included in this index. Section 3 - Equipment Function Include a brief statement of the function of the equipment within the overall facility. Section 4 Construction This section shall clearly detail all necessary information for the construction including at least the following: a) b) c) d) All structural design and general arrangement drawings, showing location of all equipment and design loads; Welding procedures; Copies of all material certificates and All specific alignment and tolerance requirements. This shall include, but not be limited to, slew ring and swing rail supports, boom connection lugs, sheave alignment, etc.
4.10.5.2 Installation and Commissioning Manual Sections 1 to 3 Requirements as for Sections 1 to 3 - Construction Manual. Section 4 Installation, Erection and Commissioning This section shall clearly detail all necessary information for the installation, erection and commissioning including at least the following: a) b) c) Special hoisting, slinging, placement and alignment data, including maximum masses of all major components; Erection procedures and Field bolt list.
4.10.5.3 Operational Manual Sections 1 to 3 Requirements as for Sections 1 to 3 - Construction Manual. Section 4 - Operation This section shall clearly detail in logical sequence, all the necessary information for the safe operation of the equipment and shall include at least the following:
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a) b) c) d) e)
Emergency stop facilities; Storm wind shut-down procedures; Upper and lower operating limits on all stresses, deflections and vibrations monitored; Failure or emergency procedures and Relevant reduced drawings all structural general arrangements.
4.10.5.4 Maintenance Manual Sections 1 to 3 Requirements as for Sections 1 to 3 - Construction Manual. Section 4 - Maintenance This section shall clearly detail all the necessary information for the safe and efficient maintenance of the equipment and shall include information on, at least, the following: a) b) Detailed maintenance instruction for all components and including repair, overhaul, change out and installation procedures; The requirements for periodic structural inspections. In particular, these should indicate areas of high stress where the potential for fatigue cracking necessitates crack detection tests and areas where thickness testing is required; Recommended inspections and frequencies and Relevant reduced drawings all structural general arrangements.
c) d)
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APPENDIX A: REFERENCED DOCUMENTS General Documents Unless otherwise specified the latest issues of the following documents are deemed to form part of this specification. AA REQ 100 ISO 2631 : : Quality Requirements for Suppliers of Critical and Major Equipment Guide for the Evaluation of Human Exposure to Whole Body Vibration
Structural Standards The design of the materials handling machine shall conform to standards prepared by the following authorities: AWS D1.1 : Structural welding code
APPENDIX B: RECORD OF AMENDMENTS Version 1 : Complete revision and re-write of entire document based on AAC SPEC 248002 rev 3 (Dr. G. Krige, K. Waelbers, March 2012)
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APPENDIX C: SUBMITAL REQUIREMENTS The Contractor shall submit the following documents to the Purchaser:
No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Submittal Legislation and regulations which are complied to. Risk analysis. Design loads, load factors, load combination factors and load combinations. Fatigue life assessment. Design standards and criteria selected. Design quality assurance and audit plan. Design information on drawings. Design verification procedures. Change control record of design changes. Welding procedures. Qualification of welding procedures. Alterations to welding procedures. Welder qualifications and certification. Corrosion protective system. Photo record of site welding. Commissioning procedures. Certificate of proof load test. Certificate of end stop tests. Performance test results and guarantee. Monitoring data. All test certificates as listed under the heading Quality Assurance Provisions. Quality testing plan for critical components. All the documentation (including manuals) as requested under the heading Documentation Requirements. Time With tender documentation. Before commencement of structural design. Before commencement of structural design. Before commencement of manufacturing. With tender documentation. Before commencement of structural design. Before commencement of structural design. With tender documentation. Before commencement of manufacturing. With tender documentation. With tender documentation. Before the amended welding procedure is implemented. With tender documentation. With tender documentation. Within one (1) week of welding. No later than 90 days before the performance test. Within one (1) week of testing. Within one (1) week of testing. Within one (1) week of testing. Immediate Material test results before commencement of construction and welding test results within one week of testing. With tender documentation. Paper copies 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Electronic copies 1
21
22
23
As per this specification.
Should any contradicting statement be found between this document and the contract, then the most conservative (most severe) statement shall be applied.
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Aa - Spec - 248002 Materials Handling Machines Structural Components Specification

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AA SPEC 248002

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

VERSION 1 27 MARCH 2012 COPYRIGHT

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Appendix A: Referenced documents Appendix B: Record of Amendments Appendix C: Submital Requirements

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

Duty and Service Requirements for Machine

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Physical Characteristics of Product

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Critical Level 1 Alarm Level 2 Alarm

Major Minor Purchaser

Quality Assurance Representative Site

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Design Risk Assessment

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Normal Travelling Accidental Travelling

Table 4.1: Minimum Load Combinations for Structural Design

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Fatigue Life Analysis

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Number of Negative maximum to buckets for positive maximum design production

Assess by Negative maximum to distance positive maximum travelled

Rope tensions Nominal and dynamic rope loads shall be applied.

Number of applications for design production

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

VERSION 1 27 MARCH 2012 COPYRIGHT

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

VERSION 1 27 MARCH 2012 COPYRIGHT

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

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Ship loaders Span/1000

Wagon tipplers Span/1000

Span/500 Width/750 Diam/1000 3

Ship loaders Span/300

Table 4.4: Recommended Deflection Limits

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION

VERSION 1 27 MARCH 2012 COPYRIGHT

MATERIALS HANDLING MACHINES STRUCTURAL COMPONENTS SPECIFICATION