UNDERGROUND CONVEYOR DESIGN GUIDE

THERMAL COAL IMPLEMENTATION [2014-03-03]

UNDERGROUND CONVEYOR DESIGN GUIDE DOC NO AATC000860

UNDERGROUND CONVEYOR DESIGN GUIDE

AUTHORISATIONS

NAME

POSITION

Ferreira, Ian

Mechanical Engineer

REVIEWED BY

Schmidt, Thinus

Principal Mechanical Engineer

REVIEWED BY

Mathews, Darren

AATC Head Opencast Opencast Engineering

Maapola, Phanki

AATC Head of Engineering, Underground Operations

Ford, Julian

AATC Head of Engineering, Technical Services and Projects

AUTHOR

REVIEWED BY

APPROVED BY

SIGNATURE

DATE

Refer to the AATC Document Management System for the latest version of the document. Copyright resides with the company.

Page 1 of 44

IMPLEMENTATION [Date]


CONTENTS Page

1

AIM

4

2

SCOPE

4

3

DEFINITIONS

4

4

UNDERGROUND MINING SYSTEM

5

5

CONVEYORS

5

5.1

Section Conveyors

6

5.2

Trunk Conveyors

7

5.3

Shaft Conveyors

8

6

BUNKER FEEDERS/ UNDERGROUND SILOS

8

7

BELT FEEDERS

9

8

MATERIAL DESIGN PARAMETER

9

9

SUPPORTING STRUCTURES

10

9.1

General Layout

10

9.2

Section Conveyor Drive

10

9.3

Trunk Conveyor Drive

12

9.4

Section Belt Tail Section

13

9.5

Trunk Belt Anchor Point

14

9.6

Shaft Bottom Layout

15

9.7

Section Conveyor Stool and Stringers

16

9.8

Trunk Conveyor Stool and Stringers

17

9.9

Belt Crossings

18

9.10

Belt Sky’s (Tractor Road Bridge)

18

9.11

Walk under Protection

19

9.12

Section Conveyor Take-Up Structures

19

9.13

Trunk Conveyor Take-Up Structures

20

9.14

Lifting Beams

21

9.15

Civil Design Considerations

22


Page 2 of 44



10

11

TRANSFER POINTS

23

10.1

Chutes Design Considerations

23

10.2

Chutes Performance

23

10.3

Chutes

24

10.4

Impact Idlers

27

10.5

Skirts

27

10.6

Belt Scrapers and Nip Angles

28

POWER PACK INSTALLATIONS

30

11.1

Drive Specifications

30

11.2

Drive Type Selection

32

12

OVER BELT MAGNETS

32

13

SAFETY AND ENVIRONMENTAL

33

13.1

Illumination

33

13.2

Water

33

13.3

Conveyor Isolation and Protection

34

13.4

Designated Areas

34

13.5

Fire Protection

34

13.6

Dust Control

34

13.7

Guarding

35

13.8

Brakes and flywheels on Conveyors

35

13.9

Fabrication, Construction and Installation

35

13.10

Commissioning

35

14

REFERENCES

37

15

REVISION HISTORY

37

16

APPENDICES

37

APPENDIX A – STANDARDS STANDARDS AND SPECIFICATIONS

38

APPENDIX B – TRANSITION DISTANCE FOR FOR CONVEYOR BELTS

41

APPENDIX C – STANDARD DRAWINGS DRAWINGS

42


Page 3 of 44



1

AIM The AATC underground conveyor design guide is intended to serve as a best practice reference to all designers of underground conveyor systems with no specific reference to either mechanical, structural or civil components but rather to provide an overview to all aspects that need to be considered in the design of a successful underground conveyor system. This document shall be read in conjunction with the relevant Anglo American Specifications as quoted, which shall be issued as part of the equipment and/or contract enquiry documents. In project specific cases where the need arise to deviate from any item in this document a concession must be submitted to and approved by the Engineer in writing. Where an item is specified with a note stating “or equivalent”, the Engineer shall be requested in writing to grant permission to use such an “alternative”.

2

SCOPE This document is to serve as a design guide for all underground conveyor systems. Although design parameters are given for shaft conveyors, this design guide is focused more on section and trunk conveyor systems. With regards to shaft conveyors reference can be made to AATC000859.

3

DEFINITIONS Term

Definition

AATC

Anglo American Thermal Coal Coal

CEMA

Conveyor Equipment Manufacturers Association

CM

Continuous Miner

CMA

Conveyor Manufacturers Manufactur ers Association Associati on

Engineer

AATC Discipline Engineer assigned to the project

FCT

Flexible Conveyor Train

MCC

Motor Control Centre

PFD

Process Flow Diagram

SANS

South African National Standard

RoM

Run of mine

VSD

Variable Speed Drive


Page 4 of 44



4

UNDERGROUND MINING SYSTEM

Figure 1 – Typical underground underground mine layout (Refer drawing drawing 0000-0000-MED-0097) 0000-0000-MED-0097)

5

CONVEYORS a) b) c)

Normative reference specifications specifications are listed in Appendix A. All underground conveyors and structures structu res shall be designed and approved by an ECSA registered professional with the relevant experience. For conveyor designs, ISO 5048 will take preference over CEMA requirements. requirement s.


Page 5 of 44



5.1

Section Conveyors Low Production

Medium Production

High Production and FCT

800 tph

1000 tph

1200 tph

1200 mm

1200 mm

1350 mm

2 - 4 m/s

2 - 4 m/s

< 4 m/s

Design capacity per section *Recommended belt width *Recommended belt speed

Solid woven (Fire Solid woven (Fire Solid woven (Fire retardant) retardant) retardant) The recommended belt line height is 1000mm

Belt type Belt line *Recommended minimum belt class

Class 1250

Belt cover

Class 1250

Class 1250

0.8 mm PVC, 3 mm top and 2 mm bottom nitrile cover when required

Splicing

Mechanical Mechanical clips The following is a list of preferred mechanical clips for the use on section conveyors: Flexco Mato Industries Titan

  

Splice identification

Not required for section conveyors

Throughing idlers

35°, 127 mm, Series 35°, 127 mm, Series 35°, 127 mm, Series 25 25 25 (including FCT) 45° Idlers where additional capacity can be justified. Consideration should also be given where section belt could potentially be used as future trunk belt.

Return idlers

Two roll V-return *Recommended pulleys sizes for head, drive and tripper pulleys: 630 mm 630 mm 800 mm, 900 mm *Recommended *Recommended pulley sizes for f or tail and take-up pulleys: 500 mm 500 mm 500 mm *Recommended pulley sizes for low tension snub and bend pulleys:

400 mm 400 mm 400 mm Bearing centres Narrow Narrow Narrow Rubber is the preferred preferred material for lagging lagging pulleys. Alternative is Lagging/ Crowning ceramic lined pulleys. Tail pulleys shall preferably be crowned. Modular take-up structure shall be used with a rear mounted electric winch Take-up and winch (See Take-up section for more details). *Recommendations are given to the designer and section engineer as a nominal starting point. The final selection shall be based on the outcome of the detail design. The use of motorized pulleys shall be advised. 








Page 6 of 44



5.2

Trunk Conveyors Trunk Conveyor Design Criteria

Design capacity Belt width *Recommended belt speed Belt type Belt line *Recommended belt class Belt cover Splice type Splice identification Throughing idlers

Conveyor design capacity to be validated by a simulation study. Belt width selection to be based on the maximum load profile anticipated. Recommended belt widths are 1200 mm, 1350 mm, 1500 mm and 1800 mm. <4 m/s Solid woven + nitrile cover (Fire retardant) The recommended belt line height is 1000mm. Class 1250 0.8 mm PVC , 3 mm top and 2 mm bottom Nitrile cover when required Finger splice (hot splice) and mechanical splices under emergency conditions 0.5 mm Deep, 150 mm from the edge of the belt, within 2.0 m from the splice, contractors name, unique splice number, month and year completed 35°, 127 mm, Series 25 (152 mm where required) 45° Idlers where additional capacity can be justified

*Head, drive and tripper pulleys (recommended) *Tail and take-up pulleys (recommended) *Low tension and snub pulleys (recommended) Bearing centres

630 mm, 800 mm, 900 mm, 1000 mm 500 mm 400 mm Narrow

Rubber is the preferred material for lagging lagging pulleys. Alternative Crowning/ Lagging is ceramic lined pulleys. Tail pulleys shall preferably be crowned. Fixed take-up structure shall be used with a rear mounted electric Take-up and winch winch (Preferred). Side mounted will also be accepted. * Recommendations Recommendati ons are given to the designer and section engineer as a nominal starting point. The final selection shall be based on the outcome of the detail design. The use of motorized pulleys shall be advised. 








Page 7 of 44



5.3

Shaft Conveyors Shaft Conveyor Design Criteria

Design capacity Belt width *Recommended belt speed Belt type Belt line Belt class Belt cover Splice type Splice identification Throughing idlers

*Head, drive and tripper pulleys (recommended) *Tail and take-up pulleys (recommended) *Low tension and snub pulleys (recommended) Bearing centres

Conveyor design capacity to be validated by a simulation study. Belt width selection to be based on the maximum load profile anticipated is not to exceed 75% - 85% of its loading capacity. < 4 m/s Solid woven + Nitrile cover (recommended)/ Steel cord (Fire retardant) The recommended belt line height is 1000 mm. Class 1250 (Minimum) Solid woven: Minimum cover = 3 mm Top and 2 mm bottom. Steel cord: Minimum cover = 4 mm Top and 2 mm bottom (Final selection of belt cover to be project specific). Solid woven: Finger splice (Hot splice) Steel cord: Hot vulcanised splice 0.5 mm Deep, 150 mm from the edge of the belt, within 2.0 m from the splice, contractors name, unique splice number, month and year completed 35°, 127 mm, Series 25 (152 mm where required) 45° Idlers where additional capacity can be justified Anti-runback idlers idlers on incline incline section > 6° (According (According to OEM specifications) Belt clamps may be used as an alternative. 630 mm, 800 mm, 900 mm, 1000 mm 630 mm 400 mm

Wide centres Rubber is the preferred material for lagging lagging pulleys. Alternative Crowning/ Lagging is ceramic lined pulleys. Tail pulleys to be crowned. Take-up structure and winch shall be situated on surface. The takeTake-up and winch up configuration shall have a horizontal travel with a vertical take-up structure. No tail end take-ups will be considered. * Recommendations Recommendati ons are given to the designer and section engineer as a nominal starting point. The final selection shall be based on the outcome of the detail design. The use of motorized pulleys shall be advised. 







6

BUNKER FEEDERS/ UNDERGROUND SILOS a) b)

Underground bunkers or silos may be required in order to supply a constant feed of RoM material onto the shaft belt. The surge capacity of underground bunkers shall be determined through a bulk flow simulation.


Page 8 of 44



7

BELT BEL T FEEDERS a) b) c) d)

e) f)

8

Belt feeders will be used to withdraw withdraw coal from the underground bunker or silo onto the shaft belt. Belt drives shall be fitted with a mechanical mechanical drive with either either an automated automated or manual control system. The design shall take into account all permanent loads and other loads according to SANS 10160. The Contractor shall calculate all horizontal and vertical, static and dynamic loads arising from start-up, operation, and stopping of the t he belt feeder. These loads shall be calculated for full burden depth, or any other operational condition that might lead to greater loads. Allowance shall be made to take into account high impact from falling material. The design must consider allowance for removal and installation installat ion of belting (designated (designate d pulling, lifting and rigging anchoring points) and standard maintenance routines.

MATERIAL MA TERIAL DESIGN PARAMET ARAMETER ER The values tabulated below shall be used as a guide only. Actual values to be confirmed for the specific reserve. The plant and equipment shall be designed Duty to operate 24 hours a day, 7 days a week with one 8 hour maintenance shift week. ROM coal generated from continuous miner (CM) through feeder f eeder breaker. Consideration shall be given to t o contamination. Material handled Long wall mining and FCT continuous mining operations must consider additional volumes of material conveyed. The run of mine coal will contain approximately approximately 10% free stone st one and tramp metal from the mining operations. Contamination Long wall mining and FCT continuous mining operations will contain approximately 12% free stone and tramp metal. The particle size distribution will be typical of material sized to have a maximum top size Particle size distribution (PSD) of 300mm. A small amount of material (<0.5%) of up to 900mm x 700mm x 250mm may however occur. *Bulk density (Volumetric) 850 kg/m³ *Bulk density (Mass)

900 kg/m³ Average – 12%

*Moisture content

Dry season – 8%

*Material surcharge surcharg e angle

Wet season – 20% 15° - 20°

Maximum angle of belt inclination inclination u.o.s.

13°

* To be confirmed in the design phase Refer to the AATC Document Management System for the latest version of the document. Copyright resides with the company.

Page 9 of 44



9

SUPPORTING STRUCTURES

9.1

General Layout a) b) c) d) e)

9.2

Refer Refer Refer Refer Refer

to to to to to

drawing drawing drawing drawing drawing

0000-0000-MED-0097 0000-0000-MED-009 7 for 0000-0000-MED-0098 0000-0000-MED-009 8 for 0000-0000-MED-0099 0000-0000-MED-0 099 for 0000-0000-MED-0100 0000-0000-MED-01 00 for 0000-0000-MED-0101 0000-0000-MED-01 01 for

a typical layout of an underground mine. underground civil layout. underground lighting layout. underground sub-station sub-statio n layout. underground substation and sump area layout.

Section Conveyor Drive a) b) c) d) e) f) g)

h) i) j)

Where space allows, pulleys shall be designed to be fixed on stools to fac facilitate ilitate removal. A 100mm 100mm concrete slab is to be c cast ast a around round transfer area to facilitate cleaning cleaning around around drive unit. Refer to section on civil design considerations. The head section drive is to be securely anchored to the floor. Refer to AA Spec ‘Ground anchor bolts for underground underground coal conveyors’. conveyors’. Section conveyor drive to be skid mounted to allow easy relocation with a modular take-up structure to compensate compensate belt extensions. All head sections shall be provided with a means of providing safe access to conveyor idlers and pulleys. Head sections shall be designed in such a way that all mechanical equipment equipment can be inspected and safely maintained with minimal effort. All conveyor drives shall include a wash down point with with the provision that all polluted water will report to a sump fitted with a pump that reports to the central water reticulation system (Also refer to civil section for more details). A belt belt bridge or any any other other form of access access shall be provided provided for at both sides sides of of the head section to allow access to the opposite side of the receiving conveyor belt. Consideration Considerat ion must be given to equipment size to allow for ease of underground transportation. Approximately 150 mm belt clearance clearance is required required around structures structures to prevent prevent the belt from being damaged in the case of belt misalignment.

Figure 2 - STD ACCWS section conveyor belt drive (ACCWS-05—1005/4). (ACCWS-05—1005/4). Refer to the AATC Document Management System for the latest version of the document. Copyright resides with the Page 10 of 44 company.



Figure 3 - Photo of ACCWS belt drive.

Figure 4 - Photo of ACCWS take-up winch on belt drive.

Refer to the AATC Document Management System for the latest version of the document. Copyright resides with the Page 11 of 44 company.



9.3

Trunk Conveyor Drive a) b) c)

d) e) f)

g) h) i)

Where possible, pulleys shall be designed to be fixed on stools to facilitate removal. A 100mm 100mm concrete slab is to be cast around the head section to facilitate cleaning cleaning arou around nd drive unit. Refer to section on civil design considerations. All major conveyor support structures struct ures shall be fixed to a reinforced reinforce d concrete foundation foundatio n that will safely resist all the loads exerted by the t he conveyor belt during start-up and normal operating conditions. conditions. All areas fitted with mechanical mechanical equipment higher than1.5m that will require regular inspection or maintenance shall be fitted with access platforms. Access platforms shall be provided all around the head chute to faci facilitate litate inspection and maintenance of all mechanical equipment and plate work. All trunk conveyor drive sections shall include a wash down point with the provision that all polluted water will report to a sump fitted with a pump that reports to the central water reticulation system (Also refer to civil section for more details). A belt belt bridge or any any other other form of access access shall be provided provided for at both sides sides of of the head section to allow access to the opposite side of the receiving conveyor belt. The power pack of the trunk conveyor should preferably be positioned at a split to allow ease of access to power packs and pulleys. Where possible, allowance shall be made for the installation installat ion of a lifting beam in order to facilitate the removal of power packs and pulleys. The mono rail shall be load tested when installed.

Figure 5 – Typical layout of a drive station indicating the required guarding as per the designated area.




Figure 6 - Cross section through a typical drive station indicating walkways

9.4

Section Belt Tail Section a) b) c)

d)

Where possible, pulleys shall be designed to be fixed on stools. This is to assist with the removal of pulleys. Refer to AA Spec ‘Ground anchor bolts for un underground derground coal conveyors’ with regard to the fixing of conveyor tail ends. Tail sections shall be designed in such a way that all mechanical equipment equipment can be inspected and maintained with minimal effort e.g. tail end bearings to be fitted with an extended grease point to access from outside of guarding. Tail-end structure must be stand-alone stand-alone and fitted with adjustable legs.

Figure 7 - High seam : ACCW-05-894C




Figure 8 - Photo of high seam tail end

9.5

Trunk Belt Anchor Point a) b) c)

d) e)

f)

Where possible, pulleys shall be designed to be fixed on stools. This is to assist with the removal of pulleys. A 100mm 100mm Concrete slab is to be cast around around tail section section to facilitate cleaning cleaning around around drive unit. Refer to section on civil design considerations. Anchor point to be securely fixed to the ground as as per AA Spec ‘Ground anchor anchor bolts for underground coal conveyors’ (Note: comply to minimum number of anchor bolt requirements). The anchor point shall be designed in such a way that all mechanical equipment can be inspected and maintained with minimal effort. The anchor point should preferably be positioned positioned in a split section to allow allow easy access for maintenance e.g. anchor point bearings to be fitted with an extended grease point to access from outside of guarding. Guarding shall be constructed from Flatex welded in a rigid angle iron frame.




g)

As far as reasonably reasonably practical, the w weight eight of each each individual individual guard shall not exceed 25 kg.

Figure 9 - Anchor point: ACCW-05-911I ACCW-05-911I

Figure 10 – Typical layout of a fixed anchor point also showing the guarding as per designated area.

9.6

Shaft Bottom Layout a)

b)

A sump shall be installed in accordance with with water balance in order to provide adequate drainage that reports to the central water reticulation system. Refer to Appendix C for details on the standard layout of a sump area. Refer to drawing 000-000-0116 000-000-0116 for a typical shaft bottom layout.




c) d) e)

f)

g)

h)

i) j) k) l) m)

9.7

All areas around the tail end of the inclined/decline inclined/decl ine shaft must be free draining. Storm water water and or washing down water that are accumulated accumulate d at the tail end of the shaft, must be treated as polluted water. The polluted water from the tai taill end end must be transported to either either the underground underground water storage area by means of gravity feed or pumping, or to the surface pollution control dam by means of pumping. Gravity feed systems: Polluted water can be managed by feeding into the underground water storage area trough gravity. V-shaped lined or unlined canals must be designed and constructed to transport the water to t o the storage area. Pumping systems: Polluted water can drain into a constructed construct ed sump near the tail end of the shaft. The polluted water can then be pumped either to the underground storage area or to the surface pollution control control dam. Ensure access for cleaning cleaning the sump by means of mobile equipment. Install a wash down point at tail ends and transfer points with the provision that all polluted water will report to a sump fitted with a pump that reports to the central water reticulation system (Also refer to civil section for more details). All equipment installations installations shall comply with fire suppression suppression installation standard (Refer to AATC fire f ire standard for underground conveyors). conveyors). Where the shaft accommodates accommodates vehicle vehicle access, an arrester arrester sand bed and and emergency crash barrier will be allowed for in the design. Tail sections and transfer points in the shaft bottom shall preferably be installed in a split in order to accommodate access and maintenance. Install reinforced concrete foundations as required for tail ends and transfer stations. Refer to civil section for more details. Install adequate illumination. illumination. R Refer efer to se section ction on illumination illumination for more details.

Section Conveyor Stool and Stringers a) b)

c) d) e) f) g) h) i) j) k) l) m) n)

Conveyor stools shall be designed to allow for one belt size up on the return idler design. All run of conveyor will be floor mounted. Exception will be given to roof slung stringers where it can be proven that floor mounted structures are not practical due to the floor conditions and where the roof declared competent by the rock engineer (mine specific). No guarding is required on run of conveyor. All stool and stringer structures structur es are to be painted as per AAC 164051. Stringers will be fixed to the stool mounting with M16 bolts and nuts. Idler spacing: Carry side = 1500mm, return side = 3000mm. V-return idler frame shall be adjustable to assist with belt training. Maximum length of stringer shall not exceed 3.0m. The deflection limit shall be L/300. Each stool structure shall make allowance allowance to fit a pigtail to support the pull key wire. Height adjustment adjustment will be done done using a two-bolt two-bolt system to allow allow for infinite adjustment. adjustment. Garland type idler frames will not be considered in the design of underground conveyors. Idler frames shall be constructed of tubular cross-sections. cross-sections. Section conveyor stringers shall be constructed from standard tubular cross-sections. cross-sections. Section conveyor stringers shall be fitted with with two 10mm round bar carry handles.




Figure 11 - Standard stool and stringer arrangement arrangement (See Appendix C for standard drawings).

9.8

Trunk Conveyor Stool and Stringers a) b)

c) d) e) f) g) h) i) j) k) l) m) n) o) p) q)

Conveyor stools shall be designed to allow for one belt size up on the return idler design. All run of conveyor will be floor mounted. Exception will be given to roof slung stringers where it can be proven that floor mounted structures are not practical due to the floor conditions and where the roof declared competent by the rock engineer (mine specific). All trunk conveyor stringers shall be constructed from channel cross-sections. cross-sections. No guarding is required in non-designated non-designat ed areas. All stool and stringer structures to be hot dipped galvanized. Paining will be allowed on all mine employee constructed trunk belts. Stringers will be fixed to the stool mounting with M16 bolts and nuts. Height adjustment will be done using a two-bolt system to allow for infinite infinite adjustment. Idler spacing: Carry side = 1500mm, return side = 3000mm. V-return idler frame shall be adjustable to assist with belt training. Maximum length of of stringer shall not not exceed 4.5m. The deflection limit limit shall be L/300. The return belt shall not be lless ess than 500mm 500mm from the ground where roof height allows for it. Concrete boxed stool specifications: specifications: 12 Stools from the tail-end/ anchor point. 12 Stool from the drive/ head pulley. 12 Stool either side of the transfer points or other structures located between these fixed points. All stools mounted on a gradient shall be boxed and anchored to the floor. Every 5th stool is to t o be boxed and anchored to the floor.




Figure 12 - Trunk run-of-conveyor.

9.9

Belt Crossings a) b) c)

Belt crossings to be supplied as per the mine risk assessment considering belt length and roof height. All belt crossings and belt bridges shall be securely anchored to the floor. Belt crossings shall be adequatel adequately y illuminated for personnel to safely cross-over.

Figure 13 - Belt bridge (ACCWS-05-1045-2.3m (ACCWS-05-1045-2.3m and ACCWS-05-948-2.6m). ACCWS-05-948-2.6m).

9.10

Belt Sky’s (Tractor Road Bridge) a) b)

All belt skies shall be securely anchored to the floor. Belt sky shall be fitte fitted d with access walkways on both sides to allow safe access to conveyor idlers where ever possible.

c)

The adjacent run-of-conveyor run-of-conveyor structures should form a gradual angle of approach over the




d) e) f)

belt sky in order to minimize the load on the idler rolls. The design design of the belt radius should be such such that that it will not reduce reduce the life life of of the rollers. Use 20 deg troughing idlers across belt sky. Belts skies shall be guarded in order to prevent personnel from passing underneath the belt at the t he graded sections.

Figure 14 - Belt sky /Tractor bridge - used for vehicle crossing (Refer to ACCWS-998).

9.11

Walk under Protection a)

The walk under protection shall be securely anchored on to the floor.

Figure 15 - Walk under protection (ACCW-05-968).

9.12

Section Conveyor Take-Up Structures a) b) c) d) e) f) g)

Section belts shall be fitted with a modular take-up structure design. A guarded electric winch winch mounted at the rear of the take-up structure shall be used to apply the required tension. The take-up structure shall be fixed to the floor according to AA Spec – Ground anchor bolts for underground underground coal conveyors. The take-up trolley shall be spragged with four heavy duty chains. Two chains on either side of the take-up trolley to prevent movement in the long travel direction. An alternative spragging mechanism is to use a locking bar that passes through the takeup structure and trolley. Take-up structure guarding shall be constructed from light weight mesh. As far as reasonably practical, practica l, the weight of each individual guard shall not exceed 25Kg.




250 2.0

500 2.5

750 2.75

Conveyor length (m) 1000 1250 4 5

1500 6.5

1750 8.5

2000 10

Table 1- Minimum take-up lengths for section conveyors based on splicing allowance (1.2W) + elastic stretch

Figure 16 - ISO view of ACCWS modular take-up structure: ACCWS-05-972/2

Figure 17 - ACCWS take-up: side view

9.13

Trunk Conveyor Take-Up Structures a) b) c) d)

Long belts shall be fitte fitted d with a loop take up system. In the case of FCT and long wall continuous mining operations, additional belt storage may be achieved with a 4 or 6 lap belt storage system. As far as reasonably practical, practical , allow for 5 belt splices. The take-up trolley shall be spragged with four he heavy avy duty chains. Two chains on either side of the take-up trolley to prevent movement in the long travel direction. The design and selection of the spragging chains will be in accordance with acceptable engineering




g) h)

practices and shall be approved by the mechanical discipline engineer. An alternative alternati ve spragging mechanism is to use a locking pin that passes through the take-up structure and trolley. The design of the spragging pin will be in accordance with acceptable engineering practices and shall be approved by the mechanical discipline engineer. An electric winch winch shall be used and preferably preferabl y positioned in a split section to allow for easy access and maintenance. maintenance. Take-up structure guarding shall be constructed from a light weight mesh. As far as reasonably practical, the weight of each individual guard shall not exceed 25Kg.

i) j)

Guarding shall be placed around the take-up rope. The in-line winch winch type is preferred. preferred.

e)

f)

Figure 18 - Side mounted take-up winch.

Figure 19 - In line winch.

9.14

Lifting Beams a) b) c) d)

See figure below for details on mounting crawl beams from the roof. Use 20mm roof bolts with a 190kN load rating. Fastloc resin to be used (15 Sec curing time). All design involving roof anchoring shall be approved by a rock engineer.




Figure 20 - Typical arrangement for mounting crawl beams.

9.15

Civil Design Considerations

9.15.1

Structural concrete

a) b) c) d) e) f) g) 9.15.2

All other concrete

a) b) 9.15.3

All structural structu ral concrete is to be designed by a professional civil engineer; All structural concrete is to have have a minimum compressive compressive strength strength of of 30 30 MPa at 28 days; All steel reinforcement reinforc ement cover is to be a minimum of 50mm; All horizontal surface finishes are to be wood float finishes; All concrete concrete slabs are to drain drain off off the slab at at a minimum fall of of 1% in the direction direction of the collection dam; All underground slabs (tail ends, transfer tower or head end etc.) is to be cast at least 200mm above the surrounding ground level, ensuring drainage to the collection dam/sump. Refer to the relevant standards in Appendix A and and Appendix C for standard standard drawings.

All other (non-structural) (non-structural) concrete concrete is to have have a minimum compressive strength of at at least least 20 MPa at 28 days. Refer to the relevant standards in Appendix A.

Surface Run-off

a) b) c)

d)

Concrete ramp on the incline is have a fluted finish at 45 degrees, ensuring self – cleaning in the event of rain or washing The concrete concrete ramp at the the portal portal is to have have a cut-off trench trench with with pump pump sump sump to catch and pump water caught, running down the ramp All underground transfer points – tail-ends etc. - shaping of surrounding ground is be done to minimum fall of 1% to maintain gravity fed drains to a silt trap sump before entering the dam. Refer to the relevant standards in Appendix A.




9.15.4

Dams

a)

10

All underground dams and/or plugs (refer drawing/s). This standard is currently under review.

TRANSFER POINTS All transfer points must be treated as critical and must be engineered engineered accordingly in order to contain the flow of material and ensure continuity from the discharge point to the downstream equipment.

10.1

Chutes Design Considerations The following must be considered in the design of chutes and transfer points: a) b) c) d) e) f) g) h)

i) j) k) l) m) n)

10.2

Discharge models Trajectories Impact models Free fall models The specific material properties (moisture content, adhesive stresses, friction angles, etc.) must be classified. The flow of material must be represented graphically. graphically. All chutes shall be fitted with lifting lugs. Liners shall be designed for high impact and high abrasion resistance resistanc e in underground conveyor transfers. Liners shall be VRN 400 with a minimum thickness of 12 mm (16 mm on high impact). Tiles will not be considered for underground operations. The mass of any individual liner shall not exceed 25 kg. All steel plates used used for structural support support shall be 8 mm thick. All steel plates used for the control of spillage shall have a minimum thickness of 6 mm fitted with a steel liner. All steel plates used for covers or dust suppression suppression shall have a minimum thickness of 3 mm. All transfer transfer points points will will be fitted with with an access platform to allow allow for inspection inspection and maintenance. Allowance must be made for overrun into chute from feed conveyor onto receiving belt.

Chutes Performance The performance of any transfer point must be determined based on the following factors: a) Zero spillage b) Minimize material degradation c) Efficient dust suppression suppression mechanism that is in accordance with the specific mine standards. d) Engineered to prevent blockages e) Minimal impact and abrasion wear f) Low noise level




g) h) i)

Low maintenance Accessible to maintain and inspect Must be easy to clean

Figure 21 - Liner attachment detail

10.3

Chutes

10.3.1

Spiral chutes - Section conveyors

a) b) c)

This is is the preferred transfer chute for section section conveyors up to and and including 2200 tph Adequate dust suppression suppression is required to minimize fugitive material from being released into the surrounding air. The chute assembly must be fitted fitt ed with a working platform for access around pulley and bearings.

Figure 22 - Spiral chute installation i nstallation with walkways. Refer to the AATC Document Management System for the latest version of the document. Copyright resides with the Page 24 of 44 company.



10.3.2

Spiral chutes - Trunk conveyors

a)

b) c)

This is is the preferred transfer chute for trunk conveyors conveyors up to and including 2200 tph. When material transfer exceeds 2200tph, a special transfer chute arrangement shall be considered (see drawing below). Adequate dust suppression suppression is required to minimize fugitive material from being released into the surrounding air. The chute assembly shall be fitted fitt ed with a working platform for access around pulley and bearings.

Figure 23 - Spiral chute installation i nstallation with walkways.

Figure 24 - Alternative Alternative chute for material transfer in excess of 2200 tph.




10.3.3

Open Hood and spoon type

a)

10.3.4

No hood and spoon transfer chutes will be used on underground conveyors where slabs are anticipated. Special concession must be obtained from the discipline engineer to install a hood and spoon chute.

Trough chutes (Ski-jump transfer)

a) b) c) d)

A troughing chute may be used for angled installations installatio ns and piggy back arrangements. Adequate dust suppression suppression is required to minimize fugitive material from being released into the surrounding surrounding air. Liner shall be 16mm VRN 400. Chute must be fitted with a working platform for access around pulley and bearings.

Figure 25 - In line transfer chute with access walkway and also showing impact idlers.

Figure 26 - In line transfer chute with the drive and t ake-up spaced apart to allow ease of access and maintenance.




10.4

Impact Idlers a)

The quick release type impact idlers as seen below are preferred.

b) c) d) e)

Impact beds will not be considered. Impact rollers shall be installed at all transfer points. Impact rollers shall be Series 30, 159mm diameter. Impact idlers shall be spaced at 500mm – 750mm centers. The final spacing shall be verified in the final f inal design phase. 45° Troughing idlers to be used for all impact idlers.

f)

Figure 27 - Quick release type troughing idler.

10.5

Skirts a) b)

c) d) e) f) g) h)

All skirt boards boards shall be designed in order to pre prevent vent any material from falling of the belt within the settling zone. Deep troughed idler frames (45°, 60°, 80°) may be used at transfers with skirt boards, however, material properties shall be taken into consideration to ensure continuous material flow. All skirt boards shall be fitted with a 12mm VRN 400 liner. Skirt boards shall be designed to allow for easy replacement. The skirt board length and height shall be adequate to allow for complete settling of the material. Minimum skirt board length shall be in accordance with the table below. Specific skirt design shall be based on actual material size and flow requirements. The edge of of the skirt shall be placed 6mm from the belt at at the loading point to 12mm at the discharge point. The thickness of the skirt board must be sufficient to withstand pressures from blocked chute conditions (6mm for light construction and 10mm for f or heavy construction).




i) j) k) l)

Skirt boards must be stiff enough to prevent side movement that could damage the belt. Skirt boards shall shall be supported on on structural steel frames. Caution must be given to belt lift under the skirt board. No covers will be placed over the skirt boards.

Figure 28 - Typical skirt board layout.

Belt width 1050 1200 1350 1500 1800

1. 1 .5 2.4m 2.4m 2.4m 2.7m 3.0m

Belt speed, m/s. 2.0 2.5 3.0m 3.6m 3.0m 3.6m 3.0m 3.6m 3.3m 3.9m 3.6m 4.2m

3.0 4.2m 4.2m 4.2m 4.5m 4.8m

Table 2 - Minimum skirt length for underground belt conveyors.

10.6

Belt Scrapers and Nip Angles

10.6.1

Primary scraper

Primary scrapers are not usually fitted to underground conveyor pulleys. 10.6.2

Secondary scrapers

a) b) c)

All head pulleys will be fitted with with a double bladed secondary belt cleaner. The belt scraper must me positioned according according to supplier specific requirements. requirements. Ensure that the selected belt scraper is capable of sweeping over the splice that has been installed on that belt.




10.6.3

Tail protection a)

Bias plough 



 

 

b)

The plough must be positioned to allow for clear inspection and quick replacement of worn scraper blade. Plough must be of a flexible pressure type. Plough must be fitted to the main main structure structure with with a safety chain chain in case case of of mounting mounting failure. The plough must provide full belt coverage. The plough must be positioned that the ejected material can safely be cleaned and placed back on the belt. Material shall not be scraped of the belt near walkways and belt crossings or into the tail frame guarding.

V-Plough belt cleaner 

Mounted ahead of the tail pulley and nip angle.



Must be spring loaded to apply constant pressure.



 

10.6.4

A bias bias plough plough must be fitted when when itit is required to scrape scrape material to one side of the belt only.

Plough must be fitted to the main main structure structure with with a safety chain chain in case case of of mounting mounting failure. The plough must provide full belt coverage. The plough must be positioned that the ejected material can safely be cleaned and placed back on the belt. Material shall not be scraped of the belt near walkways and belt crossings or into the tail frame guarding.

Nip angles

a) b)

Refer to: AA 375001 – Conveyor best practice guide line. The design of nip angles shall consider access for maintenance maintenanc e and must be adjustable from the outside.




11

POWER PACK INST INSTALLA ALLATIONS TIONS

11.1

Drive Specifications a) b) c) d) e) f) g) h) i) j) k) l) m) n) o)

Power packs shall always be positioned as close to the ground as possible. All power packs will be shaft mounted. The installation installat ion of the power pack will be such that the torque arm will be in compression. A 3 ton (minimum) safety chain will be placed over the reducer unit in order to prevent rotation of the power pack in the opposite direction. The selection of power packs will be done in consideration consideratio n of the specific mine standard. Operations must be consulted to align new designs with existing standards. Conveyor reducers shall be fitte fitted d with a sight glass as a means of level inspection. Conveyor reducers shall be fitted with an inspection inspection cover to inspect gears. Conveyor reducers shall be fitted with a sampling port (clearly marked). Conveyor reducers reducers shall be fitted with a breather breather Conveyor reducers shall be fitte fitted d with a 3 micron breather in a raised position. Guarding should preferably be designed to allow visual inspection of fluid coupling without removing the guard. Plumber blocks shall preferably be accessible without removing guards. Alternatively, Alternatively, allowance shall be made for a grease pipe in order to grease bearings. During the design the design of the conveyor drive bases, provision must be made for the forklift tines. Labelling and numbering of drives must be clear and aligned with MCC labelling. All labelling must be clearly visible.

Figure 29 - Sampling valve on reducer.




Figure 30 - Different sampling ports on reducers: Split type (preferred), (preferred), Bend type (preferred) and the straight type (not preferred). preferred).

Figure 31 - Approved sampling port installation.




Figure 32 - Approved Approved installation of a raised breather and sampling port.

11.2

Drive Type Selection The selection guideline table for drive preference on various conveyor applications is shown below. Type of conveyor

VSD

Fluid Coupling

U/G - Section

Not permitted

1 choice

U/G - Trunk > 1500 m long

1 choice

Shaft - 50 m+ Lift

1 choice

12

st

Soft Start

Remark

Not permitted

Dusty, Low tech

st

2

nd

choice

Not permitted

Variable Speed (variable loading)

st

2

nd

choice

Not permitted

Start –up and inspection

OVER BEL BELT T MAGNETS a) b) c) d) e) f) g) h) i) j)

No oil cooled magnets may be used in underground coal mine operations. Magnets shall be of the self-air-cooled, self-air- cooled, self-cleaning self-cleani ng in-line type. Magnet coil to be disc wound with anodized aluminum strip conductor material. Over belt magnets shall preferably be placed on permanent installed trunk conveyors. Ensure that over belt magnet is installed and wired according to supplier recommendations. Shall be placed in a split to allow easy removal of tramp metal Isolation Isolatio n numbering must be clearly visible and match upstream MCC feeder panels. Structure Structu re must be secured on a concrete foundation. Magnets shall be height adjustable. Support structure shall shall be designed designed to allow the magnet to be move moved d away from the conveyor for ease of maintenance.




Figure 33 – Over-belt magnet support structure.

13

SAFETY AND ENVIRONME ENVIRONMENT NTAL AL

13.1

Illumination a) b) c)

13.2

Refer to STD.AATC.CON.03 - Haulage Lighting Installation Standard AATC.ELE.01 - Perform Illumination of Work Area Operations Illumination Illuminat ion specification specificati on must comply with MHSA unless otherwise stipulated stipulat ed and AC.OH.STD.001 – Anglo Anglo Coal Illumination Illumination Standard. Standard.

Water a) b)

c) d) e) f) g) h) i)

Allowance shall be made for wash wash down water and provision shall be made for all dirty water to report to the central ‘dirty water’ reticulation system. Allowance shall be made for dust suppression water. The quality of the water shall be such that any pollutants in the water shall not cause to dust suppression spray nozzles to block up. Allowance shall be made for fire protection water as per AATC fire standard for underground conveyors and equipment. Section water supply pipes will be placed on the floor right next to the s structure tructure to prevent any obstacle in the walkway next to the belt. Trunk belts and shaft belts water supply pipes shall be fixed to the run-of-conveyor run-of-con veyor structures. Refer to drawing 0000-0000-MED-0114 0000-0000-MED-0114 for services on section conveyors. conveyors. Refer to drawing 0000-0000-MED-0115 0000-0000-MED-0115 for services on trunk and shaft conveyors. conveyors. Refer to AA_SPEC_415003 AA_SPEC_415003 for high pressure mine water reticulation system design. Refer to AATC_00859 AATC_00859 for general mechanical requirements requirements on pipe installations. installations.




j) k) l)

13.3

Refer to IM STD 7 – Installation Installation and maintenance maintenance of of sprinkler and other other water based systems. Refer to IM STD 10 – Installation and maintenance of water storage tanks. Refer to IM STD 11 – Installation and maintenance of water spray fixed systems.

Conveyor Isolation and Protection AAC_SPEC_673018: AAC_SPEC_673018: Conveyor Conveyor belt protection systems systems

13.4

Designated Areas The designated area means the drive section, take-up tension section, snub-pulley section, transfer point section and tail pulley sections. The drawing below is a good indication of a typical transfer station showing all relevant guarding requirements.

Figure 34 - Representation of a typical transfer area showing required guarding.

13.5

Fire Protection Refer to: AATC000169 - Anglo Fire protection Standard for Conveyors and Coal Transfers.

13.6

Dust Control a)

b) c)

d) e) f) g)

Dust control is required for health reasons and to reduce the risk of creating an explosive environment. environment. Refer to AATC mandatory code of practice for an occupational health program on personal exposure to airborne pollutants (AATC document number to be advised). Reduce the air speed in chutes to less than 1.3 m/s. A passive dust control system is required at all conveyor loading and unloading points. Low velocity water sprays will be used to increase the cohesive force between particles (10 – 50 liter per ton). Ensure that drop drop height of material flow is kept to a minimum in order to reduce reduce the induced airflow at the transfer point. Where possible, design chutes so that the exit of the material flow is in the same direction as the receiving belt. Avoid abrupt changes in material flow. Ensure that adequate skirting is provided to minimize air from escaping escaping around the belt




and chute interface.

13.7

Guarding Ref to: AA_BPG_ 375001 – Conveyor guarding best practice guide. Guard panel type

Fixed Swivel Light weight removable

Frame construction

Guard mesh

Flatex type 348 / Eq. Flatex type 348 / 50x50x6L Eq. 100x20x3 None Specimesh M389 / Eq.* *Aperture size subject to specific application. 50x50x6L

Total mass

50 kg 50 kg <25 kg

Table 3 - Recommended guarding and mesh detail for underground conveyors. conveyors.

13.8

Brakes and flywheels on Conveyors a) b) c) d)

13.9

Brakes must only be installed where absolutely necessary to satisfy design and legal requirements. In the event of decline applications, brakes might be considered under a risk assessment process. At all times braking systems on u/g conveyor installations installatio ns should be regarded as high risk items and all controls thereof shall be approved by the mine. Flywheels will only be considered under specific conditions as determined by the design engineer and approved by the AA discipline engineer.

Fabrication, Construction and Installation AA_SPEC_114002 AA_SPEC_114002 - Construction Construction of structural steelwork steelwork

13.10

Commissioning a) b)

The designer of the conveyor conveyor system system shall develop a full commissioning commissioning procedure for each conveyor belt. Additionally, Additionally, refer to conveyor conveyor belt extension procedure AADC000474. AADC000474.







14

REFERENCES

15

REVISION HISTORY

Version No.

00

16

Reason for Change

New Document

Date

17/02/2014

APPENDICES

Appendix A

Standards and Specification Specifications s

Appendix B

Transition distance distance for belt conveyors conveyors

Appendix C

Standard drawings drawings




APPENDIX A – STANDARDS STANDARDS AND SPECIFICATIONS SPECIFICATIONS Document No.

Description / Title

AA_SPEC_114001

Design of Steel Structures

AA_SPEC_114002

AA_SPEC_114010

Construction of structural steelwork Design Fabrication, Installation and Maintenance of Open Grid Grating for Floors, Stairways and Hand railing Design of Concrete Structures

AA_SPEC_114011

Construction of concrete work

AA_SPEC_164000

Users guide for corrosion prevention: System selection

AA_SPEC_164050

Corrosion Protection of Steelwork with Coatings

AA_SPEC_164051

Plant colour coding

AA_SPEC_166005

Lubricants – specific requirements for industrial gear oils

AA_SPEC_166014

AA_SPEC_255004

Lubricants – specific requirements for greases Materials handling Machines Structural Components Specification. Stacking and Reclaiming Equipment – Mechanical and Structural Apron Feeders

AA_SPEC_371001

Conveyor pulleys and shafts

AA_SPEC_373001

Belt conveyor idlers and rolls

AA_SPEC_373005

Installation tolerances for belt conveyors and structures

AA_BPG_375001

Conveyor guarding best practise guideline

AA_SPEC_377002

Steel cord reinforced conveyor belting

AA_SPEC_377003

Splicing of steel cord reinforced conveyor belting

AA_SPEC_377005

Splicing of textile reinforced conveyor belting

AA_SPEC_377006

AA_SPEC_377010

Solid woven conveyor belting Splicing of PVC and nitrile covered Solid Woven Conveyor Belting Cold Splicing of Plied (Textile) Conveyor Belting

AA_SPEC_415003

High Pressure Mine Water Reticulation Systems

AA_SPEC_421017

General Purpose Valves

AA_SPEC_673018

Conveyor Belt Protection Systems

AA_SPEC_999022

Mechanical Standards

AATC000168

Fire protection for buildings and structures

AATC000169

Fire protection for conveyors and coal transfer

ACSA_114012

AA_SPEC_248002 AA_SPEC_254001

AA_SPEC_377008

Ground anchor bolts for underground coal conveyors Underground STD 5: Underground conveyors Electrical Design Criteria Electrical Substation Specification SANS 14 SANS 62-1 SANS 121 SANS 719

Malleable cast iron fittings threaded to IS0 7-1 Steel Pipes Part 1: Pipes suitable for threading and of nominal size not exceeding 150 mm Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods Electric welded low carbon steel pipes for aqueous fluids (large bore)




Document No.

Description / Title

SANS 1123

Fire retardant textile reinforced conveyor belting (Solid Woven PVC) Pipe Flanges

SANS 1173

General purpose textile reinforced conveyor belting

SANS 1313

Conveyor idlers

SANS 1669

Conveyor belt pulleys

SANS 1366

Steel cord reinforced conveyor belting

SANS 1431

Weldable structural steels

SANS 4427

Polyethylene (PE) pipes for water supply The measurement and assessment of occupational noise for hearing conservation purposes The installation, inspection and maintenance of equipment used in explosive atmospheres Part 2; Electrical equipment installed underground in mines The measurement and rating of environmental noise with respect to land use, health, annoyance and speech communication The application of the National Building Regulations Hot dip galvanized coatings on fabricated iron and steel articles -- Specifications and test methods Continuous Mechanical handling Equipment – Belt conveyors with carrying idlers – calculation of operating power and tensile forces American Welding Society - Structural W elding Code Cranes General design - Part 3-2: Limit states and proof of competence of wire ropes in reeving systems Guidance on safe use of machinery Pipe threads for tubes and fittings where pressure-tight joints are made on the threads (metric dimensions) Spur and helical gears. Definitions and allowable values of deviations relevant to radial composite deviations and runout information Specification for power driven overhead travelling cranes, semi-goliath and goliath cranes for general use Specification for bevel gears (machine cut)

SANS 971

SANS 10083 SANS 10086-2

SANS 10103 SANS 10400 ISO 1461 ISO 5048 AWS D1.1 DD CEN/TS 13001-3-2 PD 5403 BS 21

BS 436-5 BS466 BS 545 BS 1640

BS EN 10241

Steel butt-welding pipe fittings Specification for spiral wound gaskets for steel flanges to BS 1560 Specification for pipe supports. Large bore, high temperature, marine and other applications. (Withdrawn but still used in absence of alternative) Specification for steel pipe fittings, screwed and socket welding for the petroleum industry Code of practice for the selection and application of bellows expansion joints for use in pressure systems. Metallic bellows expansion joints Pipe threads where pressure tight joint are made on the threads Steel threaded pipe fittings

BS EN 10253-2

Butt-welding pipe fittings

BS 3381 BS 3974 BS 3799 BS 6129: Part 1 BS EN 10226-1




Document No.

Description / Title

BS EN 12513

Founding. Abrasion resistant cast irons

BS2853

The design and testing of Steel Overhead Runway Beams




APPENDIX B – TRANSITION DISTANCE DISTANCE FOR CONVEYOR CONVEYOR BELTS BELTS

Figure 35 - Solid w oven belt transition distance

Figure 36 - Steel cord belt transition distance




APPENDIX C – STANDARD STANDARD DRAWINGS DRAWINGS Drawing Number

0000-0000-MED-0080 0000-0000-MED-0081 0000-0000-MED-0082 0000-0000-MED-0083 0000-0000-MED-0084 0000-0000-MED-0085 0000-0000-MED-0086 0000-0000-MED-0087 0000-0000-MED-0088 0000-0000-MED-0089 0000-0000-MED-0090 0000-0000-MED-0091 0000-0000-MED-0092 0000-0000-MED-0093 0000-0000-MED-0094 0000-0000-MED-0095 0000-0000-MED-0096 0000-0000-MED-0097 0000-0000-MED-0098 0000-0000-MED-0099 0000-0000-MED-0100 0000-0000-MED-0101 0000-0000-MED-0102 0000-0000-MED-0103 0000-0000-MED-0104 0000-0000-MED-0106 0000-0000-MED-0107 0000-0000-MED-0108 0000-0000-MED-0109 0000-0000-MED-0110 0000-0000-MED-0112 0000-0000-MED-0113 0000-0000-MED-0114 0000-0000-MED-0115 P3249-01 P3249-02 P3249-03 P3249-04 P3249-05 ACCWS-998 Note: Refer to tables below for

Drawing Title

High seam conveyor layout Low seam conveyor layout High seam transfer section High seam drive section High seam turnout module section High seam take-up trolley section High seam winch bay section High seam graded section High seam tractor bridge section High seam magnet section High seam tail section Low seam transfer section Low seam drive section Low seam turnout module section Low seam take-up trolley section Low seam winch bay section Low seam tail end section Underground block plan Underground civil layout Underground lighting layout Underground sub-station layout Substation and sump area civil layout Lighting and cable rack layout High seam 90° hood & spoon layout High seam 90° dead box transfer High seam inline ski-jump transfer High seam angled dead box transfer High seam reverse angled dead box transfer Low seam 90° dead box transfer Low seam 90° spiral transfer Crawl beam anchor detail Standard trolley arrangement Services on section conveyor Services on trunk and shaft conveyor 1050 BW adjustable structure c/w 1200BW v-return 1200 BW adjustable structure c/w 1350BW v-return 1350 BW adjustable structure c/w 1500BW v-return 1500 BW adjustable structure c/w 1650BW v-return 1650 BW adjustable structure c/w 1800BW v-return Standard 8m belt sky specific dimension related to standard drawings

S25 S25 S25 S30 S30




Legend A B C D E F G H I J K LW LN M N O P Q R RS S

Explanation

Roof Height - If E<2.1m then A should increase. A(New)=(C+D+F) Haulage Width - If M<2m then B should increase. B(New)=(N+P+2*Q+L+R+2m) OR B(New)=(H+2*J+2*K+L+2m). Whichever is greater. Dimension based on a flooded belt with a 400mm slab on top Workable height from walkway or floor level to carry strand for maintenance and inspection Average distance between carry and return idler Minimum workable height >2.1m Distance to centre on drive pulley (dependent on power pack size) Minimum walkway clearance between equipment and sidewall Minimum clearance underneath structure for cleaning purposes Size is dependent on installed power pack size (refer to table 3 - dimension “Y”) Workable size from centre of Plummer block to end of Bikon coupling Wide bearing centres as per “AA_SPEC_371001 Conv Pulleys and Shafts” Narrow bearing centres as per “AA_SPEC_371001 Conv Pulleys and Shafts” Travelling side >2m. M=B-(H+2*J+2*K+L). Minimum walkway clearance between equipment and sidewall O=G-0.5*Drive Pulley Ø + 0.5*LTU Pulley Ø. O is also the entry to the winch drum Minimum walkway width on non-travelling side Workable distance from main steelwork to walkway Minimum walkway width on travelling side Rail centres of LTU carriage (can be the same as LN) Travelling side >2m. S=B-(N+P+2*Q+R+L).




Legend T U V W X Y Z TA AS BS DA AA AB AC AD AE AF AG AH MA MB MC *

Explanation

Dribble Chute Angle Receiving belt’s haulage width Workable distance from floor to receiving belt (1.2m) Floor to return strand for tractor road access Gearbox height (based on averages) Gearbox to Bikon (based on averages) Output shaft to base of gearbox (based on averages) Tripper Drive pulley centres (dependant on power pack size and wrap angles) Access side or travelling way of a conveyor Blind side or non-travelling way of a conveyor Distance dependant on drive configuration and drive pulley wrap angles Jib base length (dependant on jib height and system tensions) Underpass bridge length (>3m) Underpass / tractor bridge height (>2.1m for walkways & >2.8m for tractor clearance) these height are underside of guards Distance from jib to drive (generally less than one split length away to ensure that drive is situated in centre of split ) Drive length (dependant on drive configuration and structural design Turnout module length generally height and system tension dependant Rail bay length can vary between 3m & 4.5m Minimum height to be guarded at belt inclination (>500mm) Magnet Structure height – dependant on tripper height, magnet type, magnet weight Roof clearance above magnet structure – generally 500mm for assembly purposes Distance between pulley and magnet belt (specified by magnet suppliers) Dimensions must be determined by designer.


UNDERGROUND CONVEYOR DESIGN GUIDE

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