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WCRC Appendix 1 Slurry Pipeline Design Criteria - Design Criteria
WCRC Appendix 1 Slurry Pipeline Design Criteria - Design Criteria
Design Criteria
These Documents are intended to remain confidential to, and copyright in them belongs to, the Principal/Employer. They shall not be passed to any third party, other than a prospective Subcontractor, without the written permission of the Principal/Employer.
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INTRODUCTION
SCOPE
This document describes the key design criteria to be used as the basis for the feasibility study for the Escarpment Mine Coal Slurry Pipeline. The scope of these design criteria covers the following areas of the plant: General Site Conditions, Location & Plant Data Design Life Operating Hours Throughput Redundancy Process Coal Slurry water (flow, contaminants, turbidity, temperature, pH etc) Treated water (flow, quality, etc) Chemicals (type, form, quantity) Waste streams (type, form, quantity) Civil & Structural Geotechnical Drainage Roads Structural Design Mechanical Equipment and Component Design Electrical, Instrumentation & Controls Power supply & reliability, distribution Site electrical standards (motors, voltages, cables etc) Transformers, MCCs, VSDs & switchgear Motors Process control requirements E, I & C equipment supplied with mechanical packages
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Units
C C mm mm/h %
Value
TBA TBA ~6,000 6 TBA SW 37 45 1.8 0.30 (Westport)
Source
TBA TBA L&M Coal L&M Coal TBA L&M Coal AS/NZS 1170 AS/NZS 1170 AS/NZS 1170 AS/NZS 1170
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PROJECT DESCRIPTION
The following are the key project scope items forming a basis for the study: A Coal Preparation Plant (CPP) will be located approximately 1km to the north east of the Escarpment Mine Plan Area (MPA) The coal slurry pipeline will commence at the CPP location, and generally follow an alignment alongside a new pipeline to be constructed by Kawatiri Energy for a hydro power scheme. This pipeline alignment runs towards the north-west. A raw water supply pipeline, with an intake located around 6.5km north-east of the CPP on the upper Waimangaroa river. The coal loadout facility will be at Fairdown, alongside the rail line and adjacent to SH67. This is approximately 11km from the CPP location (in pipeline length terms). Dewatering of coal will be by screening, coal is to be deposited from the screen into a concrete bunker from where it will be stockpiled by mobile equipment for subsequent dispatch by rail. Water used to transport the coal will be treated and discharged to a local stream through a water treatment plant.
UNITS
The SI System of Units shall be used throughout the project. The following units will be used as required: Length Area Velocity Weights Capacity Elevation Forces Stresses Moment and Torsion Uniform Live Loads Site Co-Ordinates Flow Liquid Flow Gases Pressure (Gauge) Pressure (Absolute) Temperature mm (millimetres) m2 (square metres) m/s (meters per second) t (tonnes) or kg (kilograms) t/h (tonnes per hour) m (metres) kN (kilo-Newtons) MPa (mega-pascals) kN-m (kilo-Newton metres) kN/m2 (kilo-Newtons per square meter) m (metres) relative to plant site datum m3/h for main process flows, l/h for chemical dosing. Am3/min or Nm3/min (Actual or Normal cubic meters per minute) kPa, kPag or Bar, Barg kPaa or Bara C (degrees Celsius)
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Page 5
Units
t/m % mm % % of ROM % of ROM
3
Value
1.20 1.50 0.8 0.9 ~1 -50 18 55 25
Source
L&M Coal L&M Coal L&M Coal Marston Marston Marston Marston
Table 3a - Particle Size Distribution ex CPP Retained (mm) 31.5 16 12 8 4 2 1 0.5 0.25 0.125 0 Passing (mm) 50 31.5 16 12 8 4 2 1 0.5 0.25 0.125 Coking Coal Fractional Mass % 14.8 13.1 4.8 9.6 21.9 13.9 17.9 4.0 0.0 0.0 0.0 Thermal Coal Fractional Mass % 8.6 7.6 2.8 5.5 8.7 5.7 7.5 19.2 21.2 7.4 6.0 Source
Marston Marston Marston Marston Marston Marston Marston Marston Marston Marston Marston
Units
wk/y d/wk
Value
52 7 24 365 80 19.2 7,000 1,280,000 1,000,000 60 24 183
Source
Marston Marston Marston Marston Calculated Calculated Marston Marston Marston Assumption Assumption Calculated
Three-shift operation
h/d d/y
Availability Daily productive hours Annual productive hours Throughput (design) Throughput (average) Inter-campaign time Campaign duration (average) Transport rate (peak)
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Operating Schedule
Transport rate (average)
Units
t/h
Value
143
Source
Calculated
Units
Cw (%) Cw (%) m /hr m /hr m/s
3 3
Value
40 43 275 243 1.6
Source
Weir Weir Weir Weir Weir
Redundancy Design capacities for individual units shall be selected to be mid-range of current industry practice. Redundancy will not be provided on major process areas and in general the process will need to be shutdown to effect planned and unplanned maintenance. In the event of a major problem with the dewatering system and/or water treatment plant the contents of the slurry pipeline will need to be dumped to the emergency receiving pond. Buffer tanks between the raw water line and slurry pumps and between the dewatering screen and water treatment plant shall have approximately 30 minutes capacity. The philosophy for each of the major process equipment items is: Raw water pump - one duty pump installed, one complete spare not installed Slurry pumps - three duty, one standby Dewatering screen - one duty only with spare parts Coal solids removal (cyclone and dewatering screen) - spare parts only Clarification - spare parts only (complete spare sludge pumps) Filtration - spare parts only (complete spare backwash pumps) Sludge Mechanical Dewatering - spare parts only Chemical Dosing Systems - spare parts only (complete spare dosing pumps) Treated Water Pump - one duty only with spare parts NB: a more detailed analysis of individual unit vs. final plant availability will be carried out at subsequent design stages. Chemical Storage Chemical storage is to be designed to provide 30 days storage at average dose and maximum flow. A minimum of 14 days storage is to remain at the time of delivery. Chemical storage and distribution is to be located as close as practicable to the point of dosing.
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Units
m3/hr NTU Unit g/m g/m cm
3 3
Value
275 2.90 8.3 7.4 2.9 0.126
Source
Calculated Lab testing results Lab testing results Lab testing results Lab testing results Lab testing results
-1
m3/hr % Days/yr
g/m
3
g/m
3
75 Screen TBA
Sand filters 3 10
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Item
TREATED WATER TANK Residence Time TREATED WATER PUMPS Pumps Pump Flowrate
Units
Value
Source
minutes
15
Beca
No: m /s
3
1 0.08
Beca Calculated
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TRAIN LOADING By front end loader to hopper cars. Hopper cars 42t capacity each Train parcel size 925t 22 cars per train 4 trains per day, 6 days per week Design loading time (arrival to departure) 1.5 hours Cycle time (Fairdown-Westport return, including loading) 3.5 hours Average loading rate required over complete train 690t/h
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The slurry pipeline from the Denniston Plateau down to the Westport Flats may be subject to large and small scale instability. On the Westport Flats the pipeline and plant are likely to be founded on loose saturated soils with potentially some peat layers. Settlement (total and differential) may be of concern and liquefaction is likely to be an issue. Any structure below ground level may need to consider the potential for flotation and vibrations from machinery could result in localised liquefaction, over and above that from earthquakes.
DRAINAGE
Any new drainage that is proposed shall comply with the appropriate sections of the Regional Councils drainage requirements.
ROADS
TBA
STRUCTURAL DESIGN
All design will be in accordance with the relevant New Zealand standards where possible. All design codes listed are to be used in conjunction with the latest approved amendments dated at the time of issue of this design criteria report. The following Australian and New Zealand loadings codes will be used: AS/NZS 1170.0 - Structural Design Actions General Principles. AS/NZS 1170.1 - Structural Design Actions Permanent, imposed and other actions. AS/NZS 1170.2 - Structural Design Actions Wind actions.
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AS/NZS 1170.3 - Structural Design Actions Snow & Ice actions. NZS 1170.5 - Structural Design Actions Earthquake actions New Zealand. NZS 3404 Steel Structures Standards. AS/NZS 1170.0 Table C1 Suggested Serviceability Limit State Criteria. NZS 3101 Code of Practice for the Design of Concrete Structures. AS/NZS 4671 Steel Reinforcing Materials. Structural Design Actions Buildings will be designed to withstand a combination of loads due to gravity and lateral loads. Gravity loads are made up of permanent dead loads, superimposed dead loads and non-permanent live loads, including snow loads. Dead loads and superimposed dead loads result from the weight of the building elements and finishes (e.g. cladding materials, floor finishes, building services, self weight of structural elements, etc), and live loads from the type of occupancy (i.e. number of people, shelving, computers, etc). Wind and earthquake loads are often collectively referred to as lateral loads as they tend to act horizontally. Dead Loads Dead load includes the self-weight of the structural floor system and underlying structural support framing. Structural toppings over precast floor systems are also included. Non-structural screeds and permanent partitions, etc are categorised as superimposed dead loads and defined below. Dead loads are calculated for the structure based upon the proposed construction materials. Superimposed Dead Load Superimposed dead load (SDL) includes all permanent but non-structural elements of the building fabric. This includes screeds required to form falls and set downs, fixed partitions, suspended ceilings and services, and floor finishes such as tiles or carpet. On roofs and exterior balconies drainage falls and waterproofing systems are also included. Live Load Live load includes all gravity loads not described as dead or superimposed dead load and that are generally considered to be transient or non-permanent (i.e. stored materials, movable partitions, equipment, furniture and people). The New Zealand loading standard AS/NZS 1170:2002 defines minimum live load allowances for particular occupancies. Lateral Design Actions The structural frame will be designed to resist actions due to wind or earthquake loading. The magnitude of the calculated lateral loads are a function of the sites location (topography, exposure, ground conditions, seismicity and proximity to fault lines), the specified design life of the building, the importance level selected, the overall weight of the building, and the anticipated behaviour and performance of the structure when subjected to lateral loading. Factors pertaining to the site are as specified in the New Zealand Loading Standard AS/NZS 1170. The minimum design life is mandated by the NZ Building Code and is 50 years for normal buildings. Other factors influencing the overall lateral loads include the weight of internal partitions and cladding elements, location of heavy equipment, plant and tankage, weight and stiffness of the structural frame, structural frame spacing and building height. The distribution of these factors through the building also plays a significant role, as heavy equipment, building elements or heavy storage rooms located near the top of a building result in very high lateral forces being applied to the top of the structure. Thus, relocating heavy elements or occupancies to the lower levels can reduce the required structural element sizes. Earthquake The earthquake loads are calculated in accordance with AS/NZS 1170 using the following assumed parameters. These will need to be confirmed by subsequent geotechnical investigation:
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Site subsoil category: Importance Level: Risk Factor, Ru: Hazard factor, Z: Near-fault factor N(T,D): Ductility, Wind
Wind loads are calculated in accordance with AS/NZS 1170 assuming the following parameters: Basic wind speed: Terrain category: Wind directional multiplier: Wind shielding multiplier: Wind topographical multiplier: 45m/s U.L.S. 1.0 1.0 1.0 1.0
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GENERAL
Mechanical equipment and items shall be designed for continuous heavy duty operation in a coastal environment. Due consideration shall be given to potential for overload, impact, stress cycles, material properties and the minimisation of stress concentrations. Where possible, all mechanical items requiring periodic maintenance shall be standardized to minimize spare parts. Equipment drives shall be designed to minimize the need for field alignments where possible. Rotating equipment or items that produce vibration shall be designed to eliminate or minimise the transmission of movement and noise to the structural supports. Operating noise level measured under load one meter from any drives or equipment shall not exceed 85 dBa. Any subsection contained in these mechanical design requirements shall not be read without consideration for all other applicable subsections.
PUMPS
All pumps shall generally be centrifugal type, single stage, horizontal end suction, top vertical discharge. Pump casings and impellers shall be matched to existing pumps used on site, or fit for handling the materials specified. Suction and discharge connections shall have ANSI Standard Flanges. Chemical dosing pumps will be positive displacement type, with adjustable stroke and frequency.
FIRE PROTECTION
Fire protection in accordance with current NZ regulations shall be provided.
NAMEPLATES
All new equipment shall have nameplates.
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SHAFTS
Shafting shall be designed for a life in excess of the economic life of the equipment. Stress concentrations at turned down shaft ends shall be considered in the design of shafts. All keyways shall be in-line and square. Keys shall be supplied with shafts, shop fitted and taped in place for shipping. Keyed shaft ends and keyways shall be in accordance with ISO standards. Shafting over 100 mm in diameter and shafts in critical areas shall have their metallurgical composition and heat treatment procedures specified. All commercial sized shafting shall be cold rolled steel (CRS). Shafts 150 mm in diameter and larger shall be forged and ultrasonically tested before machining. All drive shaft ends shall be chamfered and provided with threaded centre holes. Turndown radii shall have a finish of 1.6 m or better and shall be at least 25% of the minor shaft diameter. Undercut at radius shall not be permitted. Repairs that involve welding shall not be carried out on shafts.
BOLTS
Bolts and nuts shall be metric thread sizes.
ADJUSTING SCREWS
Adjusting screws shall be stainless steel and metric thread sizes.
DRIVE BASES
Base frames shall be sufficiently stiff to withstand any undue deflection due to both static and dynamic loading conditions. Steel pads fabricated from a minimum of 25mm thick plate shall be welded to the base frame and machined where the motor and gearbox mounts come in contact with the base. Drive bases shall be stress relieved after welding but before machining.
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Each drive base shall be provided with adjusting screws and locknuts to assist radial and axial alignment of the motor. Four jacking screws and a minimum of 6mm shimming allowance shall be provided for the motor vertical alignment. Minimum 25mm of non shrink grout shall be provided under bases.
FLEXIBLE COUPLINGS
Flexible power transmission high-speed couplings shall be designed and constructed with a service factor of not less than 1.5 based on the nameplate motor power.
RIGID COUPLINGS
Rigid couplings shall be designed using a service factor of 1.5 on all applied loads including bending moment. A spigot shall be provided in order to locate the coupling halves and centre them on their respective shafts. The coupling shall be laid out so that removal of bolts is possible without removing the coupling or any of the adjacent drive components.
CHAIN DRIVES
Chain drives shall be avoided where it is practical. If approved, they shall be totally enclosed oil bath type, with oil pump and filter in larger sizes except for the shuttle chute drive that can be dry. Holes and covers shall be provided for insertion of a hand held tachometer.
LUBRICATION SYSTEMS
Manual lubrication will be applied for grease points that need to be serviced every 3 months or longer. All manually serviced grease lines shall be grouped together to central distribution blocks that are accessible from walkways and platforms. Grease nipples shall be provided where appropriate and shall be 1/4 standard Alemite fittings. Lubrication lines shall be fabricated in stainless steel S.S. 316 and located to permit servicing and dismantling of adjacent components. Brass or copper tubes shall not be used. Flexible lines, where required shall be minimum 6mm I.D. wire braid, grease resistant, rubber covered non-skive type hose. Initial lubrication, including that required for adjustment and testing shall be by Contractor. All lubrication points shall be accessible from, or piped out for ready access from walkways, platforms or stairs with extension tubing.
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GUARDS
All revolving parts such as belt drives, couplings, pulleys and exposed shafts shall be adequately guarded. Non-lubricated drives shall have guards of flattened expanded mesh for visual inspection. All guards shall be fabricated and mounted with provision for easy removal by one person. Lubrication capability, without requiring removing of guard, shall be provided. Guards shall be failsafe in that should the securing system fail or come loose, the guard will not fall off.
PAINTING
Vendor supplied & site fabricated mechanical equipment shall be painted in accordance with TBC Vendor supplied & site fabricated structural equipment shall be painted in accordance with TBC
SPEED REDUCERS
All speed reducers shall be of the manufacturers standard design. Expected service life for gears (G1: 1% expected failure rate) and bearings (L10) shall not be less than 60,000 hours. Reducers shall be rated in accordance with AGMA Standard 6010-F97, latest edition, for gear capacity, bearing capacity and strength of other components such as shafts, keys and bolting except where a higher requirement is specified elsewhere in these Design Criteria.
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LINERS
All interior surfaces of chutes and skirt boards which may become in contact with handled coal, shall be lined with 20mm thick, abrasion resistant liner plates. Liner sizes shall be coordinated with the chute design such that high wear areas of the chute can be replaced as a complete panel and relined in the shop. Protruding bolt heads or nuts are not acceptable on inside surfaces of liners. Liner Plate sizes shall be standardized and the weight of each plate shall not exceed 40kg where liner plates must be replaced individually inside the chute. Each chute section shall have uniform minimum gaps not to exceed 5mm between liners and these gaps shall be staggered between adjacent rows. No transition of liner plates shall be allowed from one section to another, i.e., surface continuity shall be maintained.
FIRE PROTECTION
A fire suppression system including hose cabinets with hose reels containing 40mm diameter, 30m long hoses shall be provided at nominated buildings and structures.
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SUPPLY VOLTAGES
Switchboard Power 11kV, 3 phase, resistance earthed, 50Hz. 400V, 3 phase, 4 wire, solidly earthed, neutral, 50Hz. Controls 220V, 1 phase, 50 Hz. 24V DC
EQUIPMENT
Transformers Distribution transformers (11kV/400VAC) shall be outdoor ONAN type unless otherwise specified. Transformers shall be standardised regarding size, rating and type as much as practicable to provide interchange ability. Primary and secondary terminations shall be made in cable boxes. Oil type transformers shall be located in a bund with oil water separator facility for drainage. 11kV Switchboards and MCCs Switchboards shall be constructed to AS1025 standards and type tested. Switchboards shall be fitted with surge protection. Switchboards and MCCs shall be located in dedicated electrical rooms with adequate ventilation. Switchboards and MCCs shall be designed with 20% spare capacity for future development. 400V Switchboards and MCCs Switchboards shall be constructed to AS/NZS3439 standards and type tested. Switchboards shall be fitted with surge protection. Power factor correction equipment shall be fitted to main Switchboards to maintain a plant power factor of 0.95. Switchboards and MCCs shall be located in dedicated electrical rooms with adequate ventilation. Switchboards and MCCs shall be designed with 20% spare capacity for future development. Motor Starters shall be provided with a facility for means of lockable isolation and manual selection controls. Status indication shall include available, fault and running.
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Connectivity to Distributed Control System (DCS) or Programmable Logic Controller (PLC) system is required, typically via serial communication link. Variable Speed Drives (VSDs) and Soft Starters All VSDs shall be designed with a DV/DT filter or better, to limit harmonics. Steps to minimise Radio Frequency Interference (RFI) shall be undertaken, such as fitting EMC filters. VSDs are to be of a suitable construction for the environment where they are to be located. Motors The voltage rating of AC motors shall be 400VAC, 3 phase 50 Hz. Motors larger than (TBC) kW shall have thermister protection. These motors are also shall have an integral anti-condensation heater, which is to be energised whilst the motor is stationary and de-energised whilst the motor is running. Motors shall be designed for high efficiency and energy saving, service factor 1.15, insulation class F. Motors larger than 95KW and are fed via a VSD, shall be of insulation class H. They are to have an insulated bearing at the non-drive sided and a conductive brush at the drive side to reduce EDM. Other EDM protection is to form the basis of the design for these motors. Emergency stop facility shall be provided local to the motor. Control Equipment The general and sequential control shall be through agreed type Distributed Control System (DCS) or Programmable Logic Controller (PLC) installed in stand-alone cabinets and located in dedicated airconditioned rooms. The SCADA or HMI equipment will be located in a clean air-conditioned room or be suitably rated for the environment in which it is located. Power for all instruments, PLCs, HMIs and alarm systems shall be provided from separate power sources. The PLC shall be provided with power from an uninterruptible power supply (UPS). In general, the instrumentation shall be electronic with 4 to 20mA DC signal range. Any control valves shall be provided with electric or pneumatic actuators. Electrical supply for instrumentation shall be 230V, 50 Hertz, or 24VDC. Field instrumentation shall comply with latest industry standards and practices. This shall be suitable for the environment in which it is to be located. Cabling All electrical cables shall have copper or aluminium conductors. Cables carrying low voltage and above, shall be armoured. All cables which are situated between a VSD an the respective motor, shall be of the variolex type, or equivalent. This cable only applies where the length of the cable is inside the VSD manufacturers tolerance. If the length is beyond the VSD manufacturers recommendation, then an alternative shall be specified within the design.
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Transmission Lines Electrical transmission lines shall have copper or aluminium conductors. Emergency Power and Lighting Where required, standby diesel power generation shall be provided, capable of meeting the full plant capacity load requirements. Al instrumentation and control systems are to be powered by an uninterruptable power supply (UPS), with a minimum 60 minute capacity. Emergency lighting shall be provided where required and shall consist of self-charging units complete with lamps, storage battery, charger and automatic transfer relay. Lightning Protection All lightning protection systems shall comply with AS/NZS 1768:2007