Aa Spec 331001 PDF

AA SPECIFICATION FEEDER BREAKER
331001 ISSUE 0 COPYRIGHT
CONTENTS 1 2 3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5 6 6.1 6.2 6.3 6.4 SCOPE TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER DEFINITIONS REQUIREMENTS GENERAL SAFETY INFORMATION TO BE SUPPLIED BY CONTRACTOR FEEDER BREAKER COMPONENTS LIFTING LUGS SURFACE PREPARATION AND PAINTING MANUFACTURING QUALITY ASSURANCE PROVISIONS PACKING AND MARKING REQUIREMENTS LIFTING LUGS NAMEPLATES PROTECTIVE COATINGS PACKING
PAGE 2 2 2 3 3 4 4 5 11 11 12 12 12 12 12 12 12 13 13
APPENDIX A: RELATED DOCUMENTS APPENDIX B: RECORD OF AMENDMENTS
AA_SPEC_33100100.DOC
APPROVED
03 September 2009
Page 1 of 13
Anglo Technical accepts no liability for any damage whatsoever that may result from the use of this material or the information contained therein, irrespective of the cause and quantum thereof.
SCOPE
This specification covers the requirements for the design and manufacture of feeder breakers for use in coal mines. Waiver of flame proofing shall be obtained in writing from Anglo Technical for application in non-fiery mines. The specification is an adaptation of New South Wales Department of Primary Industries MDG 31.
TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

The following requirements shall be specified on every order, contract, or invitation to tender. Reference number, title, date and issue of this specification. Process and project specific requirements. Site specific requirements (feed rate, lump size) If required, the name of the independent Quality Assurance Representative (See AA STD 100).
DEFINITIONS
For the purpose of this specification the following definitions shall apply
AGMA AWS CONTROLS PRIMARY: CONTROLS SECONDARY DATA BOOK
: : :
American Gear Manufacturers Association American Welding Society. Controls that are frequently or continuously used by the operator, e.g. traction, steering, brakes, working tools. Controls that are infrequently used by the operator, e.g. start, lights, test buttons. A hard cover, loose-leaf book containing a record of identification markings, heat treatments, mechanical, chemical and NDE certification and any other certification requirements of this specification. A control which is physically maintained by the operator and permits movement of a machine (i.e. tramming of the feeder breaker). In the event of the Deadman Control release, the feeder breaker will come to rest. Any failure of the machinery (i.e. Feeder Breaker), its associated safeguards, control circuits to its power supply that leaves the machinery (Feeder Breaker) in a safe condition. Finite element analysis.
DEADMAN CONTROL
FAIL TO SAFE (fail safe):
FEA
APPROVED
03 September 2009
Page 2 of 13
IN-FEED CONVEYOR
For the purposes of this guideline the in-feed conveyor may be any device which conveys material into the breaker section and includes armoured scraper conveyors, vibro feeders, screens, hoppers or gravity chutes. International Standards Organization Mining Design Guideline Magnetic Particle Inspection. National Electrical Manufacturers Association For the purposes of this guideline the out-feed conveyor may be any device which conveys the sized product from the breaker section to the conveyor belt system and includes armoured scraper conveyors. Quality Assurance Representative. Quality Assurance Procedure. Ultrasonic testing. Unaided vision, except normally used personal sight aids.
ISO MDG MPI NEMA OUT-FEED CONVEYOR
: : : : :
QAR STD UT VISUAL
: : : :
The following terms are defined in the General Conditions of Contract: Anglo American, Approved, Company, Contractor, Engineer
4 4.1
REQUIREMENTS GENERAL
The feeder breaker shall be Contractor's standard design for the specified service. Replacement parts for standard components shall be readily available. The unit shall meet the performance requirements as defined under section 2 above. The Feeder Breaker shall so far as practicable, be constructed of non-flammable material. No external surface shall exceed a temperature of 150 C under any condition of usage of the equipment. The materials of construction shall meet all requirements for the services stated at the rate and conditions specified. The materials shall be in accordance with Manufacturers standard practice for the intended service, unless the requirements listed below preclude their use. All material of construction for this equipment, its components and accessories shall be new and suitable for the service and meet the requirements as specified under Section 2 of this document.
AA_SPEC_33100100.DOC APPROVED 03 September 2009 Page 3 of 13
4.2
SAFETY
All rotating equipment shall be provided with safety guards and devices as required to comply with Anglo Fatal Risk Standard AA AFRS 5. The feeder breaker shall comply with all flame-proofing regulations as detailed in section 2 above. Nip guards shall be fitted to the tail pulley. In accordance with AA SPEC 375001Gaurding of Belt Conveyers. All nip points shall be painted red. The feeder breaker shall be fitted with a Booyco anti-collision system or equivalent. Isolation shall comply with AFRS 6. The following potential hazards should at least be considered via Risk Assessment undertaken for Feeder Breaker design and/or operation: the possibility of persons being inadvertently carried into the breaker by in-feed conveyor unplanned machine movement due to brake failure or malfunction, or brake release for towing purposes unplanned machine movement whilst in tramming mode which could place persons in the vicinity of the machine at risk of injury inadvertent starting of conveyor and/or breaker under any condition, including automatic or manually remote start/stop controls, without giving a warning alarm 10 seconds prior to start entrapment of personnel at the in-feed or discharge ends of the conveyor outbreak of fire from any source, including failures of breaker or conveyor drive shaft bearings, drive coupling, gearbox, conveyer belt continuously running against steel structure due to mistracking crush potential from items raised and lowered by hydraulic power trailing cable damage during tramming operations.
Note: The above listing is not intended to be representative of the only hazards which need to be considered.
4.3
INFORMATION TO BE SUPPLIED BY CONTRACTOR

General arrangement drawings Electrical motor interface (if excluded from scope of supply) Information defining lubricants and maintenance requirements to ensure trouble free operation shall be furnished as part of the technical information supplied with the equipment An issue based risk assessment for safe operating and maintenance of the feeder breaker Total Cost of Ownership (T.C.O.) model to be submitted with tender Mass of all sub assemblies
APPROVED 03 September 2009 Page 4 of 13
Operating and maintenance manuals Parts book
4.4
FEEDER BREAKER COMPONENTS

Components shall be of the contractor's standard heavy duty construction as recommended for the conditions described herein.
4.4.1
Body assembly The body shall have a design life of 40,000 operating hours. The deck shall have wear protection where applicable. All welding shall conform to AWS 1.1.
4.4.2
Anchoring Sufficient anchoring or feeder breaker mass shall be provided that would be necessary to withstand twice the belt tension at the tail pulley, when taking into account that the tail tension will increase as the conveyor length increases when sections develop.
4.4.3
Brakes Wheeled Feeder Breaker units shall be provided with a means of locking the wheels when the unit is not attached to a prime mover. This may be achieved by jacking systems which remove the weight of the Feeder Breaker from the wheels or by wheel sprags. These provisions shall be effective before the Feeder Breaker is detached from the prime mover.
Note: Consideration shall be given to the intended prime mover un-braked trailer mass and brakes fitted as appropriate.
Self propelled Feeder Breakers shall be provided with brakes which can manually be applied and automatically applied on loss of power to the traction drive system.
Note: Specific approval is required for electric brake motors and brake motor control and protection systems.
Traction brakes shall: a) be fully enclosed spring applied brakes fitted directly to the traction drive assembly (oil immersed multi-disc type is preferred). For any operational condition, the surface temperature of the brake assembly shall not exceed 150 C; fail to safe; have provision to ensure that traction power cannot be applied unless the brakes are released; have provision to be manually released.
b) c) d)
Fully loaded self propelled Feeder Breakers shall be capable of coming to a controlled stop whilst tramming down the maximum operating gradient. The contractor shall nominate the maximum gradients for safe operation of the Feeder Breaker when fully loaded and empty. A dead-man control if fitted shall apply the brake(s) as part of its function. Alternatively the brakes shall apply automatically when power is removed from the traction drive system.
The foregoing requirements for traction drive braking systems are specifically confined to mechanical systems and are additional to any alternative methods of braking. Hydrostatic traction braking is permissible if the findings of a detailed risk assessment determine that the system as reviewed is safe. 4.4.4 Wheels or tracks The Feeder Breaker may be mounted on wheels or tracks to allow movement during belt advancement and or retraction or be part of a fixed installation. Where tracks are provided, these shall be powered. 4.4.5 Tail pulley Preference will be given to feeder breakers with integrated tail-end i.e. conveyor pulley / tail-end must tram with the machine forward. The tail pulley must be fitted with hydraulic cylinders for conveyor belt alignment. This alignment must be achieved by means of remote control. Pulleys shall be installed and selected in accordance with AA SPEC 371001 Pulley lagging shall be 10mm thick and will have diamond grooves. Pulley lagging shall be fire retardant. The drop height of material from the Feeder breaker onto the belt shall not exceed 500 mm. 4.4.6 Dimension The width of the feeder breaker gate shall not exceed 2/3 of installed belt width or the receiving belt width will exceed this gate width by a factor 1.5. 4.4.7 Towing Towing attachments, suitable for use with rigid draw bars, shall be designed to a minimum factor of safety of 2.5 times the maximum rated gross weight of the Feeder Breaker when travelling on the maximum allowable grade. Provision shall be made for the connection of safety chains between the prime mover and the Feeder Breaker where the combined rating of safety chain attachments equals the maximum rated gross weight of the Feeder Breaker when travelling on the maximum allowable grade. Provision shall be made for the release of the traction brakes by external means for the purpose of towing a disabled Feeder Breaker. With any provisions made to satisfy this requirement it should not be possible to leave the Feeder Breaker parked without the brakes applied when not attached to the prime mover (See also section 4.4.3). 4.4.8 Breaker The breaker shall be designed to take standard continuous miner picks.
APPROVED
03 September 2009
Page 6 of 13
4.4.9
Marking and illumination Consideration should be given to provision of workplace lighting, for the purpose of illuminating the extremities of the Feeder Breaker. The lighting may be portable fittings which can be carried on the Feeder Breaker and hung from the roof at the operating location. All instrumentation should be colour coded to indicate normal and hazardous ranges as per SAE J209 or clearly labelled to indicate hazardous ranges if the instrument does not continually indicate. Self propelled feeder breakers should have a green revolving light on the drivers side and a red revolving light on the blind side. These shall be clearly visible to people approaching the breaker.
4.4.10
Dust suppression Suitably located water sprays shall be provided at the in-feed conveyor side of the breaker for dust suppression. The following should be considered in the design of any dust suppression system; a) b) Water flow should be monitored to ensure that excess dust does not occur. Spray nozzles should be manufactured from corrosion resistant material and be installed and located with proper considerations to the safety of person(s) required to carry out inspections and maintenance of the system. Adequate water filtration should be provided to prevent sprays becoming blocked. Consideration should be given to limiting the speed of rotation of the breaker/crusher mechanism in order to reduce dust.
c) d) 4.4.11
Gearboxes Gearboxes shall be of standard supply from reputable gearbox manufacturers. Gearboxes shall be rated for continuous operation at maximum motor power for the greatest gear ratio arrangement considered. Service factor shall be based on motor rating. Peak torques up to transmission capacity shall not damage the gear set. Gearing shall be designed and manufactured to AGMA quality level Q 6 or better. Feeder breaker gear chamber, lubrication and hydraulic systems shall be of dust-tight and moisture-tight construction.
4.4.12
Lubrication and hydraulic systems general requirements Monitoring shall be provided for hydraulic systems oil level and temperature. Where potential for overheating exists as a result of component malfunction then control shall be installed to cut power to the hydraulic pump motor when set points of the monitoring system are exceeded. Flexible hoses shall be compatible with the hydraulic fluid used, the maximum system pressure and operating temperature.
APPROVED
03 September 2009
Page 7 of 13
The hose factor of safety shall be a minimum of 4 to 1 based on hose burst pressure to maximum working pressure. Hydraulic hoses shall be of flame resistant type and comply with type 1 or 3 hose specifications as listed in ISO 6805. Where a hydraulic system incorporates an accumulator the attachment to the accumulator should be by means of a minimal length adaptor and flexible hose. Fittings should be located or otherwise guarded to provide mechanical protection. A manual bleed valve should be fitted to allow pressure relief for maintenance or lockout isolation valve fitted. Accumulators shall be securely installed. Conveyor booms, levelling jacks and other items raised and lowered by hydraulic power shall be fitted with a device which holds them stationary should loss of hydraulic pressure occur anywhere between the hydraulic power source and the cylinder e.g. Hydraulic Load Locking Valve. The system shall be designed for easy maintenance and replacement of parts, without draining of oil from reservoir and or lines. The feeder breaker shall have an automated central greasing system. 4.4.13 Electrical components All electrical components shall be flame proof where practicable. Where this is not possible precaution shall be taken or be clearly labeled on the machine to reduce chances of ignition of methane. Electrical equipment shall be approved by the Engineer in writing. Instruments shall comply with AA STD 673025 Option 2. The motor rating and characteristics shall be suitable to start and run the driven equipment in an ambient temperature and at the elevation given in section 2. Motors shall be approved by the Engineer in writing. 4.4.14 Controls Sequence interlocking must be such that the any receiving conveyor(section belt) will move before the discharging out-feed conveyor is started and that any discharging conveyor is stopped before the receiving conveyor is stopped in order to prevent excessive material over-run, unless chutes have been designed to store this material and this excludes any emergency stops that must be done. Feeder conveyor and breaker drive mechanism should not be energised when the Feeder Breaker is being trammed. Sequencing of the breaker drive and in-feed conveyor drive shall be such to prevent overloading of the breaker assembly during start-up. For radio control or other forms of remote control the following shall be specified by the manufacturers;
a) b) c)
The maximum distance between the controller and Feeder Breaker. A safe system of operation including use of a spare transmitting unit, charging of the batteries, changeover procedure and location of the spare unit. Operator safe standing zones.
Systems for control of the operation of Feeder Breaker which are duplicated i.e., have local manual controls and radio remote control should be provided with the following features: a) The selection of either mode of control shall be designed with an effective interlock to prevent the inadvertent operation of any controls associated with the unselected mode with the exception of emergency stop devices. Visual indication shall be provided at each point of control to indicate which mode has been selected. A single means of selecting each mode of control shall be provided (including OFF).
b) c)
The electrical supply cable should be prevented from over tension, crushing or other damage during tramming operations without requiring a person being located in a potentially hazardous position. Provision should be made to suitably restrain the trailing cable to the Feeder Breaker. The mine should develop a trailing cable handling procedure which provides for safe standing zones for personnel. A means of isolating and locking out the incoming mains power supply to the Feeder Breaker shall be provided for maintenance purposes. Such means of Isolation shall be lockable and capable of withstanding the prospective maximum short circuit current at the point of installation. This isolation should include any interlocking with associated equipment such as in-feed mechanisms and out-feed receiving conveyor systems. Gear boxes which are operational while the Feeder Breaker is unmanned shall be fitted with devices so that the oil level and temperature can be visually monitored and should be provided with controls to cut power to the drive system in the event of excessive high temperature. Temperature monitoring of bearing assemblies fitted to conveyor idler, conveyor drive and crusher shafts should be considered: A five (5) second pre-start warning device shall be fitted to automatically alarm prior to the starting of the conveyor or crusher. This warning device must be audible and/or visual.
Note: Pre-start warning devices shall be operational regardless of which form of control has been selected.
The feeder breaker shall be fitted with audible tramming and start-up alarms.
APPROVED
03 September 2009
Page 9 of 13
All operating controls for hydraulically powered systems shall be designed to automatically return to the OFF position on loss of power to the machine and/or loss of hydraulic system pressure unless a control does not introduce a hazard on restart e.g. conveyor speed select in which instance risk assessment process shall be used to assure the safety of that function. The receiving conveyor shall not be operated at speeds below that necessary to keep the cross-sectional area of material on the belt below is allowed 100% loading profile. Such minimum speeds shall be approved by the conveyor design engineer. This shall be calculated at the maximum capacity delivered by the feeder breaker. Emergency stop switches shall be provided to cut the power from all functions of the equipment and be accessible; a) b) c) from at least either end of the Feeder Breaker, but preferably along the full length of the equipment; from any remote control device; by any person discharging material into the hopper e.g. shuttle car driver. (Tarzan bar)
Note 1: Any emergency control device should be capable of being operated at all times regardless of which form of control has been selected. Note 2: If radio remote control is utilised and the portable control unit is taken out of transmitting range, power to be automatically removed from the Feeder Breaker. Power shall only be capable of being restored to the Feeder Breaker by selection of local manual controls at the Feeder Breaker.
Controls Layout a) Controls shall be laid out and designed to allow easy and safe operation and to prevent confusion over allocation of controls to function or direction of operation. Controls should be organised into primary and secondary groups as detailed in SAE J898. All primary controls including their displacement should be located with their neutral position and, if possible, all other positions in the zone of comfort as per SAE J898. All secondary controls should be located within the zones of reach. Controls, control linkages, hoses, tubes and connections shall be located in such a manner that they are not likely to be damaged by foreseeable external forces and are easily accessible for inspection. The distance between control levers, adjacent foot pedals, knobs, handles, operators body and other machine parts shall be sufficient to allow unhindered operation without unintentional actuation of adjacent controls. Controls shall be protected to prevent accidental operation by either the operator or from falling roof/rib material
APPROVED 03 September 2009 Page 10 of 13
b) c)
d) e)
f)
g)
Control Functions Operating controls shall be clearly marked to show their functions and preferred direction of movement controls as specified below:FUNCTION DIRECTION EMERGENCY STOP ON OFF RIGHT LEFT FORWARD REVERSE RAISE LOWER EXTENDED INCREASE DECREASE OPEN VALVE CLOSE VALVE DIRECTION Stay Put Red Push button or pull trip wire Up, right, forward, clockwise, pull (push/pull type switch) Down, left, backward, anti-clockwise, push. Clockwise, right Anti-clockwise, left Forward, down Backward, up Up, back Down, forward Down, forward, pull Forward, away, right, clockwise Backward, toward, left, anti-clockwise Anti-clockwise Clockwise
4.5
LIFTING LUGS
All heavy accessory equipment shall be furnished with lifting lugs for crane handling. Lifting lugs shall be positioned to give maximum balance with an even weight distribution and minimize handling hazards. On loads where only a single lugs is require it shall be designed to have a safe working load of at least six times the suspended load. Where multiple lugs are used (2 or more) the safe working load for any two lugs shall be at least three times the suspended load. Lugs shall be bolted to each component in the shop prior to shipment and remain attached until erection work is completed. Lifting lugs shall be: Designed for handling and installation Designed for use with standard shackles, Grade S Shown on drawings together with lifting illustrations Permanently fixed to all items requiring removal for inspection and maintenance For fabricated lifting lugs and attachments all welds shall be examined 100% using UT and wet MT. Acceptance criteria shall be in accordance with the Engineers certified design requirements
4.6
SURFACE PREPARATION AND PAINTING

All equipment shall have a clean and finished appearance when delivered.
APPROVED
03 September 2009
Page 11 of 13
Prior to painting, all surfaces shall be free of dirt, rust, grease, weld splatter, loose scale or other deleterious substances. Surface preparation, prime and finish paint and application procedures shall be as prescribed by the Engineer for the specific application (AA SPEC 164000 can be used as guideline). The Contractor may submit his standard surface protection system for acceptance by the Engineer. Paint colour will be specified by the Engineer. Machined surfaces shall not be painted. Touch up paints shall be supplied in sufficient quantity for field touch up painting.
4.7
MANUFACTURING
Construction of the feeder breaker shall comply with Section 5 below of this specification Quality Assurance, Inspection and Testing.
QUALITY ASSURANCE PROVISIONS

Quality assurance shall comply with provisions of AA STD 100.
6 6.1
PACKING AND MARKING REQUIREMENTS LIFTING LUGS

The gross weight of the lift shall be stenciled or painted in a conspicuous location and identified as the gross lifting weight.
6.2
NAMEPLATES
Feeder breaker components shall be identified by permanent serial number. Other equipment shall have permanent stainless steel nameplates attached that contain all pertinent identification and size information. The mass for sub-assemblies shall be clearly marked on the assembly.
6.3
PROTECTIVE COATINGS
Machined surfaces shall be protected by a coating of rust preventative grease or similar material during shipping and storage. The grease coating shall be easily removable in the field with solvents and without the need for wire brushing or other mechanical removal methods.
6.4
PACKING
Each item or sub-assembly shall be packed such that it is protected from damage and the elements during transport.
APPROVED
03 September 2009
Page 12 of 13
APPENDIX A: RELATED DOCUMENTS

AA SPEC 331001 Feeder Breaker
Unless otherwise stated the latest issue of the following documents shall be deemed to form part of this specification. AA AFRS 5 AA AFRS 6 AA SPEC 164000 AA SPEC 371001 AA SPEC 375001 AA STD 100 AA STD 673025 ANSI B93 ISO 6805 MDG 31 SAE J209 SAE J898 : : : : : : : : : : : : Equipment safeguarding Isolation Standard User guideline for Corrosion Prevention: System Selection Conveyor pulleys and shafts Gaurding of Belt Conveyers Quality Requirements for Suppliers of Critical Equipment Packaged equipment and plants Hydraulic Standards for Industrial Equipment Rubber Hoses and Hose Assemblies for Underground mining - Wire Reinforced Hydraulic Types for Coal Mining - Specification Design guidelines for the construction of feeder breakers Instrument Face Design and location for Construction and Industrial Equipment Control Locations for Off- Road Vehicles
APPENDIX B: RECORD OF AMENDMENTS Issue 0 : New document (C Chakawodza) September 2009
APPROVED
03 September 2009
Page 13 of 13

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AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

APPENDIX A: RELATED DOCUMENTS APPENDIX B: RECORD OF AMENDMENTS

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

AGMA AWS CONTROLS PRIMARY: CONTROLS SECONDARY DATA BOOK

FAIL TO SAFE (fail safe):

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

ISO MDG MPI NEMA OUT-FEED CONVEYOR

QAR STD UT VISUAL

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

INFORMATION TO BE SUPPLIED BY CONTRACTOR

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

Operating and maintenance manuals Parts book

FEEDER BREAKER COMPONENTS

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

SURFACE PREPARATION AND PAINTING

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

QUALITY ASSURANCE PROVISIONS

PACKING AND MARKING REQUIREMENTS LIFTING LUGS

AA SPECIFICATION FEEDER BREAKER

331001 ISSUE 0 COPYRIGHT

APPENDIX A: RELATED DOCUMENTS

APPENDIX B: RECORD OF AMENDMENTS Issue 0 : New document (C Chakawodza) September 2009

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