Mine Operation Expansion Project and Benefit Plant: A D For Quotation MNS MNS MNS MNS 02.09.2014

MINE OPERATION EXPANSION
PROJECT AND BENEFIT PLANT
SHOUGANG PER S.A.A.

TITLE
Technical Specification Cable Reeler

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
This Manual is our property for which we reserve all rights. It must not be reproduced or used otherwise or made available to any third party without our prior permission in writing.
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C1847-TS-30-540-00-0
REVISIONS
IT: ISSUE
TYPE
Rev.
IT
A Preliminary
B - For Approval
C - For Information
D - For Quotation
Description
FOR QUOTATION
E - For Construction
F - As Purchased
G - As Built
H - Cancelled
By
Ver.
Apr.
Aut.
Date
MNS
MNS
MNS
MNS 02.09.2014
SHOUGANG PER S.A.A.

TITLE
N SHOUGANG

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
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Content
1
OBJECTIVE OF SPECIFICATION ............................................................................................. 3
TERMS AND DEFINITION ......................................................................................................... 3
REFERENCE TO CONTRACTUAL DOCUMENTS .................................................................... 3
SITE DATA ................................................................................................................................ 4
SCOPE OF WORK ..................................................................................................................... 5
TECHNICAL SPECIFICATION................................................................................................... 5
ENCLOSURES........................................................................................................................... 8
SCOPE OF SUPPLY .................................................................................................................. 8
PAINTING .................................................................................................................................. 8
10
CODES & STANDARDS ............................................................................................................ 9
11
DESIGN & CONSTRUCTION ................................................................................................... 11
12
TESTING & INSPECTION ........................................................................................................ 12
13
PACKAGING, TRANSPORTATION & STORAGE ................................................................... 12
14
DOCUMENTATION .................................................................................................................. 13

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TITLE
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Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
PAGE
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1 OBJECTIVE OF SPECIFICATION
This specification establishes the minimum requirements for design, manufacture, testing at
manufacturers work, transportation & delivery (transportation and delivery details will be
given in separate agreement) of POWER & CONTROL Cable Reel Drums.
2 TERMS AND DEFINITION

PS
PR
ITP
Stacker
Reclaimer
Inspection & Test Plan = Quality Control Plan (QCP)
3 REFERENCE TO CONTRACTUAL DOCUMENTS

The following documents are important for the requirements of this specification and part of
the attached specification package:
Title
Document Code / File Name
Specification Drawings
C1847-PS1-30-510-1-0.dwg
C1847-PR1-30-510-1-0.dwg
Client Electric Design Criteria
997601-5000-G-E-CD-001
992881-5700-G-E-CD-0001 Rev. C
Client Electric Specification
997601-5000-G-E-ET-001
Steel structure ITP
1847-QA-01_0 - ITP Steel structure

and / or
997601-5000-G-ST-ET-001 Rev.1
Paint ITP
1847-QA-04_0 - ITP Paint

and / or
997601-5000-G-ST-ET-002 Rev.1

SHOUGANG PER S.A.A.

TITLE

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
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N SHOUGANG
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4 SITE DATA
4.1
Location
The equipment described in this specification shall be installed in a iron ore mine located in
Distrito San Juan de Marcona / Peru in South America.
The following site conditions are to be considered for selecting the equipment offered.
4.2
Site Conditions EXCERPT

Criteria
Value
Altitude
850m
Max. Air Temperature (for design)
35C
Min. Air Temperature (for design)
5C
Relative Humidity min. / max
50% / 90%
Wind Speed (operational)
90km/h
Sea Breeze, highly corrosive and high
contamination level of an industrial type
Zone 3
(According to the Peruvian Technical
Standard Structure 030)
Atmosphere
Rated Seismic:
Design should be considering tropical climate weather conditions with rapid condensations,
heavy rain, windblown to near horizontal. The air is heavily saline and corrosive dust laden.
The equipment will be in open area, exposed to the all-adverse weather condition.
Refer to Specification 992881-5000-G-E-CD-0001
4.3
4.4
ELECTRICAL DATA
Medium Voltage Supply:
4,16kV (+/- 10%)
Motor Supply Voltage:
480VAC, 3 phase, 60 Hz
Small Consumers:
480/230 VAC, 3/1 phase / 60Hz
MCC Control Voltage:
220VAC
Control Signal Voltage:
24VDC for PLC input/output signals
Protection Class:
IPW55 for motors (weather proofed)

IP65 for junction boxes, control boxes, control panels,
and field devices
APLICATION
The mine operation Expansion Project and Benefit plant shall be equipped with a new bulk
handling system (BHS) for iron ore.
The stockyard of the BHS shall be mainly composed of the following:

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Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
4.5
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C1847-TS-30-540-00-0
Equipment
-
1 Stacker
1 Reclaimer
5 SCOPE OF WORK
5.1
General
The scope of work includes design, manufacture, inspection at manufacturers works,
transportation, delivery of complete cable reels and accessories required for specified duty
requirements of the above mentioned machines. Transportation requirements will be covered
in separate agreement.
5.2
Scope
Equipment
Qty
1.1
Stacker 01
C1703-PS1-30-540-0-0.dwg
Cable reels
1.2
Reclaimer 01
C1703-PR1-30-540-0-0.dwg
C1703-PR2-30-540-0-0.dwg
Cable reels
Sum
According Drawing
Equipment Type
6 TECHNICAL SPECIFICATION
Technical Data: (Power Cable Drum = 1 pcs.)
Drive description:
Used as Power Cable Drum on a moveable Stockpile Equipment (on rails) Land based
connection box at the end of the travel way
Drive data/requirements:
Standard drum type reeler AC squirrel cage drive, torque controlled via magnetic clutch
HV slip rings in fully welded stainless steel
Enclosure
IP65
Anti condensation Heater (230V) including Thermostat

Lockable doors / covers
warning labels
undrilled gland plates
Power supply
3 Phase + Earth
Rated Voltage
4.160V / 50Hz
Current
213,67A

SHOUGANG PER S.A.A.

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Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
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N SHOUGANG
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N SANDVIK
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Control slip rings in fully welded stainless steel

Enclosure
IP65
Anti condensation Heater (230V) including Thermostat

Lockable doors / covers
warning labels
undrilled gland plates
Control cores included in Power supply cable
Number of copper control cores:
min. 12
required cable length on reeler
290m + 40m Spare
cable type
round
recommended dimension
Reclaimer::
3x70mm+2x35mm/2+10x2.5+18LWL
Stacker:
3x35mm+2x25mm/2+10x2.5+18LWL
Safety equipment:
Gear limit switch
2 Windings left warning

1 Winding left alarm (stop long travel)
Reeler Full - Indication
Tension control switch
Cable tension too high

Cable tension too low
complete travel way distance
600m
total cable length
Reclaimer:
Stacker:\
mounting level centre cable reeler to ground
appr. 6,25m
Travel speed max.
0 - 20 m/min
min. time of acceleration
0 to 100% speed in 2,5sec
800m
750m
Motor data/requirements:
AC-squirrel cage motor (WEG Type), suitable for VVVF control Housing cast iron totally
enclosed fan cooled (TEFC)
Rated Power
acc. requirement
Rated Voltage:
480V
Rated Frequency:
50Hz
Phases
Poles
Winding insulation
class F

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TITLE
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Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
Temperature rise
class B
Frame
acc. requirement
Duty
S1
Duty cycle (relativ)
100%
daily operation hours
24
Protection
IP55
Winding Temp. Protection
PTC
Space Heater
230V / 50Hz
Shaft
one side only
max. plus Inclination
N.A
max. minus Inclination
N.A
Relevant Standards
IEC / CE / NEMA
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Scope of Supply
Cable Drum complete with Gearbox, Motor and magnetic clutch, Gear Limit Switch, HV- and
LV- Junction Box and/or Slip Ring with heaters, Reeler pendulum cable guide including overtension and under-tension detection switches.
Reeling Cable including Cable End Termination for Power and Control - & LWL cores on all
ends.
Provide following Data:
Reclaimer:
Cable Dimension
3 x 50mm
Cable Weight
7960kg/km
Max. tension force
......Nm
Stacker:
Cable Dimension
3 x 35mm
Cable Weight
7960kg/km
Max. tension force
......Nm
For more details and/or information please refer to enclosed clients specification
In case of any discrepancies between the Client specification and the SANDVIK specification
the conditions and details as per the SANDVIK specification shall be govern
Feeding point
(*)
Centre of travel length
Centre of travel length
Final data will be furnished after receipt of technical details of cable from cable
manufacturer.
SHOUGANG PER S.A.A.

TITLE
N SHOUGANG

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0004
N SANDVIK
PAGE
8/14
REV.
C1847-TS-30-540-00-0
The Power cable reeling drums shall be complete with squirrel cage torque controlled or
equivalent motor/system, suitable rated slip rings and brush / collector assembly, cable
guides for proper paying in / paying out of cables, cable laying arrangement, protection
against over tension and under tension of cable, gear cam limit switch, pendulum limit switch,
the directional limit switches etc. including cable guide & tension relieving drum to be located
at a suitable place close to feeding point, as necessary for the application.
Power cable reel shall be suitable for winding & unwinding of two parallel run of cables as
described. However both cables shall be terminated in a common slip ring enclosure.
Motor shall be suitable for operating at power supply with variation as indicated. The speed
of winding of cable shall be properly matched with machine travel speed.
7 ENCLOSURES
Annexure
Title
Docu-Code
Annexure 1
Vendor Manuals / Technical

Documentation
C1847-TS-Documentation
8 SCOPE OF SUPPLY
Quantity
Power CRD with all attachment, but without cable
Control CRD with all attachment, but without cable
Tension Relieving Drum, Cable funnel etc
:
:
:
1 no.
1 no.
1 set
9 PAINTING
Painting shall be done with powder coated epoxy based paint considering highly polluted
atmosphere laden with bauxite ore particles and strictly as per environmental requirements.
Paint shade shall be Grey shade RAL 7032.
The supplier shall indicate detailed painting procedure to be adopted and paint shade in the
respective dimensional drawing for approval.

SHOUGANG PER S.A.A.

TITLE
N SHOUGANG

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
PAGE
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10 CODES & STANDARDS

The manufacturer shall be qualified for producing cable reels, supplied for mobile machines
in coal mines and terminals, in similar applications in term of capacity, length, width, diameter
etc. Supplier shall provide the relevant reference list for each proposed item.
All equipment covered under this specification shall comply with all currently applicable
statutes, regulations & safety codes of European Standard as nominated within this
documents or any relevant national or government standard of any member of the European
Communities or any relevant International Standard recognised by such a member state, can
be used for compliance provided that the standard offers guarantees of safety, suitability and
fitness for purpose.
Especially, the whole supply and any of its parts shall be designed, manufactured and
erected in accordance with Africans laws and the local directives in force and with any
prescription from public authorities.
10.1 General
ANSI
- American National Standards Institute
DIN
- Deutsches Institut fr Normung
ISO
- International Organization for Standardization
10.2 Mechanical Standards

ISO 2262:
Steel Shackles
ISO 2372:
Analysis of Vibration
ISO 5049/1:
Mobile Continuous Bulk Handling Equipment
BS 302:
Stranded Steel Wire Ropes
BS 3643:
ISO Metric Screw Threads
BS 4235:
Metric Keys and Keyways
BS 4500:
ISO Limits and Fits
BS 5304:
Safety of Machinery (Guarding)
BS 970:
Shafting
10.3 Structural Standards

DIN 267:
Metric Threads - Laminated Metric Thread Screws
DIN 1026:
Metric channels
BS-EN 287 Part 1;
Approval testing of welders/fusion welding
BS-EN 288 Part 3:
Specification and approval of welding procedures for metallic materials
BS 5135:
Metal arc welding of carbon and carbon manganese steels
BS 4360:
Weldable structural steel
BS 2573 Part 1:
Classification, stress calculations and design of structures
BS 3923:
Methods for ultrasonic examination of welds

SHOUGANG PER S.A.A.

TITLE
N SHOUGANG

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
BS 2600:
Radiographic examination of fusion welded butt joints in steel
BS 4 Part 1:
I and H sections
BS 4848 Part 2:
Hot finished hollow sections
BS 6363:
Cold formed sections
BS 29:
Forgings
BS 3100:
Steel castings
BS 1452:
Cast iron
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ISO - R657/EN10056: Angles

SABS 094:
The use of high strength friction grip bolts and nuts
SABS 135:
ISO metric bolts, screws and nuts (hexagon and square) (coarse thread
free fit series)
SABS 1431:
Weldable structural steel
SABS 136:
Isometric precision hexagon-head bolts and screws, and hexagon nuts

(coarse thread medium fit series)
SHOUGANG PER S.A.A.

TITLE
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Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
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11 DESIGN & CONSTRUCTION

The equipment to be supplied shall be designed based on the information given in this
specification and additional requirements as per referenced documents. The bidder shall
carefully examine the data furnished and shall satisfy himself regarding the performance of
the equipment under specified operating conditions.
11.1 GENERAL INFORMATIONS

The cable reeler shall be designed taking into account the following main requirements:
The cable reeler shall be supplied in accordance with the official instruction by codes and
standards, herein mentioned, to come into force at the date of order. In particular the
European Community standard 89/392/CEE, Machinery Directive shall be followed and every
ISPESL and CE certificates shall be provided. Its also clarified that all the codes and
standards expressly mentioned in this TS shall be applied within the limitation or reference
values specified. Use of FEM standards, Section II is allowed only if not in conflict with the
regulation, codes and standards expressly indicated in the PTS.
The cable reeler shall be designed for service defined as heavy duty and continuous
operation and shall be installed outside.
The cable reeler shall be suitable for the specified operating conditions and it shall be
designed and manufactured for a minimum service life of (30) thirty years, same as for the
whole handling machine.
All the auxiliary components and related accessories shall be designed in order to have a
mean time between maintenance (MTBM) not less than the scheduled maintenance step
activities for the main equipment.
All the main equipment, auxiliary components and related accessories shall be pre-fabricated
as much as possible.
The cable reeler shall be designed considering all space requirements and all access for field
erection, pre-commissioning, commissioning and start-up, operation and maintenance
activities. If during any inspection activities, this requirement is not met, its suppliers
responsibility to perform all the necessary modification at its own care and cost.
Site welding activities shall be avoided or minimized.
Site painting activities shall be avoided or minimized.
Final equipment colours and shades will be communicated and are specified in the paint ITP.
All welds shall be continuous, seal type, in order to prevent the corrosion on all structural
parts where a visual checking and maintenance activities cannot be performed. Tack welds
are not permitted.
SHOUGANG PER S.A.A.

TITLE
N SHOUGANG

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
PAGE
12/14
REV.
12 PROTECTION TREATMENT
The design of protection against corrosion shall be done according to the

environment (severe marine and industrial atmosphere) and the functional
requirements (presence of coal dust). The result shall be proved by means of the
evidence on practical applications for a significant period and/or by laboratory tests.
All surfaces which are directly exposed to the external atmosphere shall be
galvanized and painted in accordance to paint specification.
The treatments against corrosion for all the other secondary structures shall be
designed and chosen by the designer(s) according to the above-mentioned
environmental conditions.
Until not revised by additional specification (paint ITP) 70m galvanized plus top
coat paint should be considered.
13 TESTING & INSPECTION

13.1 General
Tests shall be done both at manufactures shop. If applicable prior to manufacturing the
manufacturer shall provide a Quality Control Plan (QCP) or an Inspection & Test Plan (ITP)
for approval by Sandvik and if required by the client.
The ITP shall include hold and witness points for all parties involved.
Shop testing and inspection report shall be provided.
13.2 Test Scope

All Cable Reelers shall be inspected and tested in accordance with the applicable standards
and/or codes with the following clarifications:
Dimensional check before shipment
Visual control
14 PACKAGING, TRANSPORTATION & STORAGE

The Cable Reelers shall be securely stored and transported with protective seaworthy
packing.

SHOUGANG PER S.A.A.

TITLE
N SHOUGANG

Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24
992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
PAGE
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REV.
15 DOCUMENTATION
Details of the requirements for documentation are defined in a separate specification and
shall comprise:
15.1 Bidder documentation

The bidder shall present documents showing the equipment offered and prepare drawings
showing the positioning and functionality of the equipment in its working position.
1.
General arrangement and dimensional drawing of control desk including weight,

fixing details, etc.
2.
Equipment list complete with designation, rating, type and make of components
3.
Wiring diagram of control desk with termination details
4.
Equipment layout of Control Desk
5.
Catalogues of components used, including details of joysticks
6.
Painting and constructional details
15.2 Vendor Manuals

It shall consist of
Detailed description of the equipment supplied; technical data sheet etc.

Spare list
Assembly-, Commissioning-, Operation-, Maintenance and Repair instructions;
Transport and storage instructions
The supplier shall submit a typical vendor manual from similar project to SANDVIK for
review and approval by SANDVIK.
15.3 Quality
The manufacturers Data report (MDR) shall consist of:
Quality inspection and test reports, certificate as per ITP-requirements

CE-Declaration according to the EC Machine Directive
CE-Declaration in accordance with the ATEX Directives if any
Supplier shall provide a Certificate of the companys integrated Quality System
The supplier shall submit a typical MDR from similar projects to SANDVIK for review and
approval by SANDVIK.
15.4 REQUIRED Documents

GA Drawing:
14 days after signing the contract.
Final design drawing (CAD), documentation, bore holes position scheme and design
calculation with all relevant data shall be submitted no later than 14 days after signing the
contract.
Inspection and Testing Plan (refer to QA)
Spare Parts Catalogue
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Reclaimer (5921-RC-210) PR100-1200 / 45
Stacker (5921-ST-110) PS200-1000 / 24

992663-5921-D-E-ET-0004
N SANDVIK
C1847-TS-30-540-00-0
PAGE
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Project specific operating, maintenance, lubrication manuals (no generic documentation)

including transportation, storage and assembly instructions shall be supplied electronically
(only native files) and in paper
14 days before shipment..
Languages
German:
English:
1 electronically / 2 printed
Spanish:
1 electronically / 2 printed
If any doubt or in case any inconsistencies within this specification including its attachments
arise, please contact Sandvik Mining and Construction Materials Handling GmbH & Co KG

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MINE OPERATION EXPANSION

PROJECT AND BENEFIT PLANT

SHOUGANG PER S.A.A.

Technical Specification Cable Reeler

SHOUGANG PER S.A.A.

Technical Specification Cable Reeler