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DS SPEC 255004

Debswana Specification Apron Feeders

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APPROVED 25 March 2008

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DS SPEC 255004

1 2 3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 5 6 6.1 6.2 7 7.1 7.2

SCOPE TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER DEFINITIONS REQUIREMENTS DESIGN LOADS SUPPORT STRUCTURE FRAME STRUCTURE MATERIAL HEAD / TAIL SHAFTS CHAINS, ROLLERS AND SPROCKETS FLIGHTS HYDRAULIC DRIVE FLIGHT LINK BOLTS RUNNING SPEED DRAWINGS WELDING CORROSION AND WEAR PROTECTION QUALITY ASSURANCE PROVISIONS INSPECTION AND TESTING INSPECTION TESTING MARKING AND PACKING MARKING PACKING

3 3 3 4 4 4 5 5 6 6 6 6 6 7 7 7 8 8 8 8 8 9 9 9 10 10

APPENDIX A: RELATED DOCUMENTS APPENDIX B: RECORD OF AMENDMENTS

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APPROVED 25 March 2008

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DS SPEC 255004

SCOPE
This specification details the requirements for the design of apron feeders, both horizontal and inclined.

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER


The following requirements shall be specified on every invitation to tender, contract or order: Title, reference number, date and issue of this specification. Handling requirements of the apron feeder. Number of chains used to propel the flights. Minimum ore level in the bin to protect the apron feeder flights. Size and type of ore. Operating speed. Special environmental conditions in which the apron feeder may be operating, for example, high temperature, sea water, etc. Any limitations in terms of a confined operating environment.

DEFINITIONS
ANSI APPROVED APRON FEEDER : : : American National Standards Institute Approved by the Engineer in writing The complete apron feeder including the frame structure, chains, rollers, sprockets, head and tail shafts, flights, gearbox and hydraulic drive. American Welding Society British Standard Corrosion Protection System Magnetic Particle Inspection Non Destructive Testing Quality Assurance Procedure

AWS BS CPS MPI NDT QAP

: : : : : :

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APPROVED 25 March 2008

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DS SPEC 255004

QUALITY PLAN

A document compiled by the Contractor detailing all major events in the manufacture of the product including but not necessarily limited to inspection and test requirements and acceptance/rejection criteria, and equipment to be used during manufacture and testing. South African National Standard

SANS

The following terms are defined in the General Conditions of Contract: Contractor, Engineer.

4 4.1

REQUIREMENTS DESIGN LOADS


The design shall take into account all permanent loads and other relevant loads as specified in SANS 10160. The Contractor shall calculate all horizontal and vertical, static and dynamic loads arising from start-up, operation, and stopping of the apron feeder. These loads shall be calculated for full burden depth, or any other operational condition that might lead to greater loads. The design shall also take into account the impact of any rocks falling onto the apron feeder flights for the case where there is no burden depth on the flights. This impact height shall be determined by the dimensions of the rock box. The size and type of rock as specified in section 2 shall also be taken into account. Design calculations of the feeder and the structure shall also take into account the working elevation angle of the apron feeder.

4.2

SUPPORT STRUCTURE
The Contractor shall make available for review the calculations showing the expected horizontal and vertical, static and dynamic loads applied by the apron feeder onto the support structure. These loads shall be calculated at the maximum operating speed and maximum material load. Any specific requirements of the support structure for the apron feeder shall be clearly specified by the Contractor. In the case where the apron feeder is to be installed on an existing support structure, the Contractor shall inspect the existing support structure and satisfy himself that the structure is compatible with the proposed apron feeder design. Compatibility shall include, but not be limited to, the actual current condition of the support structure, space and geometric requirements, magnitude of loads applied by the existing apron feeder and the proposed new apron feeder, and dynamic behaviour of the support structure. The Contractor shall notify the Engineer in writing of this inspection. Should any modifications to the structure be required, these shall be stated clearly in the above-mentioned notice. In the case of incompatibilities at installation, resulting from inadequate or lack of inspection by the Contractor, the cost of modifications to the existing support structure or apron feeder shall be borne by the Contractor.
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DS SPEC 255004

4.3
4.3.1

FRAME STRUCTURE
Static design: The frame structure shall be designed in accordance with SANS 10160 and SANS 10162. The static load and the load cases specified in paragraph 4.1 shall be considered in the static design. The specified impact load as per paragraph 4.1 shall be treated as an additional static load for purposes of static design of the frame structure.

4.3.2

Fatigue design: The apron feeder shall be designed in accordance with BS 7608 to resist impact loads, and other dynamic or transient loads, as per paragraph 4.1. The apron feeder shall be designed for a minimum endurance life or a specified number of operating hours at the maximum rotational speed, using the mean minus two standard deviation S-N curves. The operating environment shall be taken into account when the expected life of the apron feeder is calculated. If the Engineer specifies a duty cycle, a fatigue analysis shall be performed in compliance with BS 7608 to prove that the apron feeder will achieve the specified number of operating hours. Failing this, the required fatigue life shall be based on 107 cycles, using stress ranges as specified in Table 1. The fatigue detail classes to be used for the design of the frame structure are defined in Table 1. Table 1: Fatigue Detail Classes Detail Material sections Bolted connections Butt welds (longitudinal) Butt welds (transverse) Fillet welds (not within 10 mm of any edge) Fillet welds (within 10 mm of any edge) Class C C D E F2 G Stress Range at 107 cycles 78 MPa 78 MPa 53 MPa 47 MPa 35 MPa 29 MPa

4.3.3

Information to be provided: The Contractor shall make available for review the calculations for the stress distributions in the frame structure, the head shaft and the tail shaft, for both the static and the fatigue designs.

4.4

MATERIAL
The following materials shall be used: Frame structure BS 4360 grade 43A SANS 1431 grade 350 WA Flights Austenitic Manganese steel alloy, according to SANS 407:2000 Type 1
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DS SPEC 255004

Head / tail shafts Chain links Sprockets

BS 970: 709M40 as per supplier as per supplier

4.5

HEAD / TAIL SHAFTS


The head and tail shafts shall be designed for a minimum operating life of 30 000 hours at the maximum operating speed with a minimum fatigue reserve factor of 1,3. The design shall take into account all stress concentration details, such as the changes in section on the shaft, the stress concentrations at the keyways, etc.

4.6

CHAINS, ROLLERS AND SPROCKETS


No more than two chains shall be used to propel the flights, unless the apron feeder is exceptionally wide, and prior approval has been obtained from the Engineer. The chains shall be standard chains as used by earthmoving equipment manufactures for crawler mounted equipment. It must however be proven that the selected chain design is adequate for the particular application by providing all the necessary information and calculations. A finite element analysis of the chain link subjected to the design loads followed by a fatigue assessment according to BS7608 must be part of this assessment. Contact must be modelled in between the pins and the link for accurate FEA stress prediction in the surrounding areas. The Contractor shall indicate which manufacturers chain shall be used, the chain model number, and the design tension rating of the chain. The chain tension shall be correctly set, to avoid premature failure of the chain links. If standard rollers and sprockets are to be used, the same information, as for the chains, shall be submitted by the Contractor. If non-standard rollers and sprockets are to be used, the Contractor shall make available for review all the design calculations for the rollers and sprockets. The sprockets shall be correctly aligned to ensure equal load sharing in the chains.

4.7

FLIGHTS
The flights shall be propelled by no more than two chains, to prevent unequal load sharing. They shall be designed to withstand any impact loads, as per paragraph 4.1. The flights shall be designed so that no rubbing between the flights and the rock box occurs, as this increases the operating load and decreases the life of the chains and flights.

4.8

HYDRAULIC DRIVE
The hydraulic drive shall be able to operate the apron feeder at the maximum design speed. It shall have a ramp start to provide easy start-up under load, and to reduce any shock loading to the system during start-up. The pressure release valve shall be set to avoid any damage to the drive unit under difficult starting applications. The Contractor shall supply the name of the manufacturer and provide full specifications of the drive unit and power pack.

4.9

FLIGHT LINK BOLTS


The flight link bolts shall have a design shear stress not exceeding 50 % of the proof stress, and shall be torqued to ensure a tension equal to 80% of the proof load.
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DS SPEC 255004

Bolts of the following property class and diameter shall be used in all bolted connections in accordance with SANS 1700: Hexagonal head bolt with washer face M20 x 90 - Class 10.9 according to SANS1700-7:2003 (ISO 4014:1999) with square nut M20 Class 10 to SANS 1700-5-2:1996 (ISO 898-2:1992)

4.10

RUNNING SPEED
The apron feeder running speed shall be optimised to minimise the number of start-ups, but to maintain the maximum average crusher throughput (which shall include the truck waiting and tipping times). The number of cycles in normal operation is independent of speed, but dependent on total throughput, ie. if the apron feeder runs too fast, it will stop for long periods, and will include many start-ups and shutdowns. If the feeder is run at a slower speed, fewer starts and stops will be needed.

4.11

DRAWINGS
The following information shall be clearly shown on the detail drawings of the apron feeder components: Weld details - weld preparation, size and finish Details of all fastening arrangements Material specification Machining requirements Corrosion protection Component masses Magnitude, location and direction of loads applied to the support structure

4.12
4.12.1

WELDING
General The following points concerning the welding of the apron feeder frame structure shall be noted: The welds shall be in accordance with ANSI/AWS D14.3, Specification for Welding Earthmoving and Construction Equipment.
The welder and the weld procedure shall be approved to ANSI/AWS D1.1,

Structural Welding Code, prior to the commencement of fabrication. General workmanship shall be in accordance with chapter 7 of ANSI/AWS D14.3. Welding shall be continuous. No stitch welding shall be allowed. All the components shall be stress relieved.
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DS SPEC 255004

4.12.2

Weld defects The maximum allowable defects shall be as described in chapter 6 of ANSI/AWS D1.1.

4.13

CORROSION AND WEAR PROTECTION


The corrosion protection shall be in accordance with Debswana Spec 164050 and Debswana CPS 132. For applications in a more corrosive environment, for example a marine environment, Debswana CPS 433 is recommended.

QUALITY ASSURANCE PROVISIONS


Debswana QAP 100 shall apply.

6 6.1
6.1.1

INSPECTION AND TESTING INSPECTION


Non-destructive testing: shall take place with the material in the unpainted condition. No shot blasting prior to inspection shall be permitted. Any scale shall be removed by hand wire brush or chemical cleaning. Welds: shall be subjected to MPI in accordance with the requirements of ANSI/AWS D1.1. The inspection shall take place at least 72 hours after completion of all welding and post weld heat treatment. Dye penetrant inspection shall not be accepted as an alternative to MPI. The Engineer reserves the right to request additional NDT inspections, for example, ultrasonic, to verify the structural integrity of the welded components. Should any weld repairs be necessary: they shall be conducted in accordance with an Approved repair procedure and such welds shall be subjected to another MPI test at least 72 hours after repairs.

6.1.2

6.1.3

6.2
6.2.1

TESTING
The Engineer reserves the right to perform the following tests:

strain gauge measurements any additional tests deemed necessary to verify the integrity of the apron feeder design and operation

6.2.2

The Contractors standard commissioning tests: shall be performed on site after installation, and copies of the test results shall be supplied to the Engineer. The tests shall be witnessed by the Engineer.

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APPROVED 25 March 2008

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DS SPEC 255004

7 7.1

MARKING AND PACKING MARKING


The following information shall be clearly stamped on an identification tag and permanently attached to the apron feeder where it is clearly visible after installation: name of the Contractor apron feeder serial number manufacturing date commissioning date

7.2

PACKING
The apron feeder shall be protected against damage and adverse climatic conditions during transportation and storage.

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DS SPEC 255004

APPENDIX A: RELATED DOCUMENTS The latest issue of the following documents are deemed to form part of this specification: Debswana 164050 Debswana CPS 132 Debswana CPS 433 Debswana QAP 100 ANSI/AWS D1.1 ANSI/AWS D14.3 BS 970: Part 1 BS 4360 BS 7608 SANS 407:2000 SANS 1700-7-1:2003 (ISO 4014:1999) SANS 1700-5-2:1996 (ISO 898-2:1992) SANS 1431 SANS 10160 : : : : : : : : : : : Corrosion protection of steel with coatings Mio epoxy and polyurethane Coastal resistant epoxy and high build polyurethane system Quality requirements for critical and major products Structural Welding Code Specification for welding construction and earthmoving equipment Wrought steels for mechanical and allied engineering purposes Weldable structural steels Fatigue design and assessment of steel structures Austenitic manganese steel castings Fasteners Part 7: External drive hexagon bolts and screws Section 1: Hexagon head bolts - Product grades A and B Part 5: General requirements and mechanical properties Section 2: Nuts with specified proof load values Coarse thread Weldable structural steels The General Procedures and Loads to be adopted in the Design of Buildings The Structural Use of Steel Part 1: Limit-States Design of HotRolled Steelwork

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SANS 10162-1

APPENDIX B: RECORD OF AMENDMENTS Issue 0 Issue 1 : : New document Clauses 4.1; 4.2; 4.3.1; 4.3.2; 4.3.3 updated SANS references added to 4.9 and Appendix A (March 2008)

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APPROVED 25 March 2008

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