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Смазочная система для горнодобывающего предприятия

Kaz Minerals
Проект № xxxxx

Контактной лицо на объекте: Титов Антон

Контактное лицо (лица) Fireball Equipment: Алан Фиц, Тара Литл

Хронология
редакции
Ред. Описание Дата Подготовил Проверил
0 Версия для рассмотрения 11.11.2020 ТЛЛ АФ
1 Повторная версия 20.11.2020 ТЛЛ АФ
 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

Contents
1.0 GENERAL ....................................................................................................................................... 3
1.1 Terminology....................................................................................................................................... 3
1.2 Applicable Codes & Standards ............................................................................................................ 3
1.2.1 Fluid Classification................................................................................................................................. 3
1.3 Supporting Documentation ................................................................................................................ 3
2.0 SCOPE OF SUPPLY .......................................................................................................................... 4
2.1 Offloading/Loading ............................................................................................................................ 4
2.1.1 Offloading Equipment ........................................................................................................................... 4
2.1.2 Piping Specification ............................................................................................................................... 4
2.2 Hydraulic Power Unit ......................................................................................................................... 5
2.3 Storage .............................................................................................................................................. 5
2.3.1 Containment ......................................................................................................................................... 5
2.3.2 Tank Level Monitoring........................................................................................................................... 6
2.3.3 Lubricants ............................................................................................................................................. 6
2.3.4 Grease .................................................................................................................................................. 6
2.3.5 Used Products ....................................................................................................................................... 7
2.4 Dispensing ......................................................................................................................................... 7
2.4.1 Equipment ............................................................................................................................................ 7
2.4.2 Piping Specification ............................................................................................................................... 8
2.4.3 Truck Shop ............................................................................................................................................ 8
2.4.4 Medium/Light Vehicle Shop .................................................................................................................. 8
2.4.5 Trax/Aux Vehicle Shop .......................................................................................................................... 9
2.4.6 Truck loading rack – optional, not included in current scope .................................................................10
2.4.7 Used product Collection – optional, not included in current scope ........................................................10
2.5 Fluid Management System – not currently included in scope............................................................ 10
3.0 PROJECT EXECUTION ................................................................................................................... 11
3.1 Schedule – General .......................................................................................................................... 11
3.2 Budget Pricing.................................................................................................................................. 12
3.3 Cost Savings Opportunities............................................................................................................... 12

Page 2 of 13 Fireball Equipment Ltd.

 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

1.0 General
This document supports the scope of supply for the Mine Operations Complex Lube Systems,
as described by the specification, A9PKS300‐1580‐255‐SPC‐001.

1.1 Terminology
‐ ITP ‐ Inspection Test Plan
‐ IFC – Issue for Construction
‐ SDI ‐ Supplier Document Index
‐ O&M – Operations and Maintenance
‐ FMS – Fluid Management System
‐ TLM – Tank Level Monitor
‐ AODD – Air Operated Dual Diaphragm Pump
‐ APEGA – Association of Professional Engineers and Geoscientists of Alberta

1.2 Applicable Codes & Standards

The National Fire Protection Association Code NFPA 30 will be used for this project as well
as Canadian Electrical Code.
The supplied specification, A9PKS300‐1580‐255‐SPC‐001 and related customer specifications
include the list of all the relevant local codes to be followed. TRCU compliance to be provide for
all major equipment.
Issue for construction (IFC) drawings are APEGA stamped. Further discussion is required regarding
Russian certification of drawings and translation.

1.2.1 Fluid Classification

As per the NFPA 30, fluids are classified as follows.
‐ Coolant and used coolant are Class IIIB combustible
‐ Used oil and fresh oil are Class IIIB combustible
During the project, the National Fire Petroleum Code 30 and local petrochemical handling
standards will be reviewed to ensure compliance.

1.3 Supporting Documentation

The following documents are attached for reference
‐ Supplier Document Index, Peschanka Mine
‐ RFI log, Peschanka Mine, Fireball Equip, 2020 11 20
‐ FluidBag information
‐ Process Flow Diagram, Peschanka Mine
‐ Engineering rates, FBEQ46016‐A

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 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

2.0 Scope of Supply

Fireball Equipment ltd. will design and supply the requested systems as listed in A9PKS300‐1580‐255‐
SPC‐001. This includes the truck offloading/loading station, piping specifications, tank specifications,
dispensing assemblies as well as the reel racks for the various shop locations.
The design includes all of the deliverables listed in the attached Supplier Document Index as per
standard A9PKS300‐0000‐255‐SPC‐003.
In addition, Fireball will provide commercial and design information regarding a truck fill rack for the site
lube trucks to be filled.

With respect to A9PKS300‐1580‐255‐SPC‐001, the sections below include more details regarding the
recommended design criteria for the Mine Complex Lube System. This document defines the technical
scope of work for our engineering team to complete the lube system design. Any deviations from the
documents provided from Kaz Minerals will be noted below and added to the RFI list.

2.1 Offloading/Loading
The offloading/loading area includes the offloading equipment, hydraulic power unit and piping
into the tanks. Fresh oil and coolant are loaded into the tanks from ISO containers. Grease is
transferred from barrels into the grease tanks. Used oil and coolant are evacuated to clean burn
heaters or tanker trucks, respectively.

2.1.1 Offloading Equipment

Each tank has a dedicated offloading pump and filter bank to prevent contamination into
the tanks. A 3” camlock with ball valve and lockable cap is attached to a 15ft hose. The
pump suction includes a strainer and ball valve. The pump is a positive displacement gear
pump with hydraulic motor. On the discharge of the pump is a filter bank assembly with
isolation valves and pressure differential indicator. Test ports are included on the filter
housing(s). The target flow rate for the pumps is 350 LPM.
For used product evacuation, the pumps are located next to the used product storage
tanks. Used oil is directed to the offloading bay or to the fired heater system. The target
flow rate for this system is 500 LPM.
Used coolant is directed to the offloading area only. The drawing, “Attachment 1: Lube
System Diagram” in document A9PKS300‐1580‐255‐SPC‐001 indicates that used coolant is
to be fed to clean burn heaters. Client to clarify (RFI 12).

2.1.2 Piping Specification

The piping to the hose reel racks is to be 3” carbon steel from the offloading pumps to
the tanks. Final pressure rating for the piping is to be confirmed based on the pump stall
pressures. Each line is to include a flanged isolation valve at all termination points. Hoses
can be used to connect to the filter assembly.

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 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

2.2 Hydraulic Power Unit

The offloading and dispensing pumps are powered by a Hydraulic Power Unit (HPU). This system
includes a reservoir, cooler, heating loop, redundant electric pumps, pressure and return
filtration as well as all instrumentation to control the offloading pumps. Alarms for this system
include, high return pressure alarm, high temperature alarm, high/low reservoir liquid level and
emergency shut‐down. A valve bank with section for each offloading pump
The HPU is PLC controlled with HMI interface for operators. This system is designed to offload
two fresh product ISO tanks at once as well as dispense two shop fluids at maximum flow rate.

2.3 Storage
Storage includes the containment, the storage tanks, tank level monitoring and overfill
protection. The procurement and pricing of the storage tanks is not included in the scope of work.
The specifications/data sheets and layout of the tank area is included.

2.3.1 Containment
The storage tanks are located in the lube storage building as per drawing A9PKS300‐1580‐
220‐GAD‐001. The tanks are surrounded by a concrete containment wall. The
containment design is not included in the scope of this project. Typical National Fire Code
requirements for the volume of containment is 100% of the largest tank + 10% of the
remaining aggregate. As the layout indicates generous spacing of the tanks as well as
room for other tanks, it is recommended that the containment be sized for any expected
expansion.
The spacing of the tanks can be decreased based on NFPA 30, Table 22.4.2.1, the
spacing can be 1/6 of the diameter of the sum of each adjacent tank. This is similar to
Canadian National Fire Code (1m spacing for classified fluids). As per section 22.4.2.1.2,
the guidelines for Class IIIA liquids is to be used for Class IIIB liquids.

Page 5 of 13 Fireball Equipment Ltd.

 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

This means that the lube room tank layout can be optimized and the additional space
can be used for future expansion or for grease tanks (see section 2.2.4 below).
A 2D site layout drawing has been included in the Engineering proposal to confirm spacing
of the tanks and dispensing equipment as well as routing of hydraulic lines.

2.3.2 Tank Level Monitoring

A tank level monitoring and overfill protection system is included for the tank farm. Each
tank includes a tank level monitor, a flexible probe for the oils, coolant, used products,
and ultra‐sonic monitors the grease tanks (see section 2.2.4).
An air operated shut‐off valve is included as overfill prevention for each tank to
prevent an override of the HPU system. The tank level monitors can be tied into the
site fluid management system.

2.3.3 Lubricants
General recommendations for the lubricant tanks include single walled, epoxy lined, with
a ladder/cage. Data sheets will be completed for each tank for local procurement as
requested in A9PKS300‐1580‐255‐SPC‐001, section 1.1(8). The storage tank quantity and
capacity is to be as per drawing A9PKS300‐1580‐220‐GAD‐001, however, as per section
2.2.1, the 2D layout is included in the Engineering proposal to optimize the system.
As per NFPA 30, fresh lubricants are classified as IIIB which would indicate that these tanks are
to be vented outside. However, the Canadian National Fire Code indicates that these tanks can
be vented inside. Client to advise if this deviation will be accepted (RFI 21).

2.3.4 Grease
The providing information has conflicting specifications for the grease system.
Document A9PKS300‐1580‐255‐SPC‐001, attachment 1 indicates 4m3 tanks for
low pressure and high pressure grease.
Document A9PKS300‐1580‐220‐GAD‐001 shows barrels for grease then lists the fluids
on the side with different sizes tanks. Please clarify that these are the greases to be
stored/dispensed and confirm the type of grease (open gear lube, specialty grease or
multipurpose grease (RFI 14).

50m3 Shovel Swing

28m3 Shovel Travel
28m3 Truck STR – multipurpose grease

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 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

It has been assumed that grease will be unloaded into these three tanks from barrels. Our
recommended system for barrel unloading is a 2” air operated dual diaphragm pump with
3” hose to the tank inlet (RFI 20). Three of these pumps are included.

If grease totes are to be used, then a mother tote system can be incorporated into
the design – this is not currently included in the design.
If FluidBags can be utilized from the fluid supplier (see attachment), a FluidBag system can
be recommended – this is not currently included in the design.

It is recommended that the grease tanks have sloped bottoms with a fabricated “foot” to
mount the pumps directly into the fluid.

2.3.5 Used Products

As per the Canadian National Fire Code, used oil is a combustible classified fluid, this tank
is to be built to fuel handling standards and vented outside. General recommendations
for these tanks include single walled, epoxy lined, with a ladder/cage. Data sheets will be
completed for each tank for local procurement as requested in A9PKS300‐1580‐255‐SPC‐
001, section 1.1(8).
Used oil is to be routed to a clean burner system. The current estimate includes a manual
valve for this transfer. Client to confirm the requirements for this system (RFI 19).

2.4 Dispensing

2.4.1 Equipment
The dispensing equipment includes dispense pumps, accumulators, thermal relief valves,
filters and associated valves and instruments. For oils, fluid flows from the tank into the
pump. The pump is hydraulically operated with an independent hydraulic control section
on the HPU valve bank. On the pump outlet is a pressure relief valve, pressure gauge,
accumulator and isolation valve. A pressure switch controls the HPU valve bank section.
The operation of the hose reel stations are intermittent. There is the potential for two
hose reels will operate simultaneously. It is recommended to design for a single hose reel
operating at a time (45 LPM for the heavy vehicle and aux. shop, 15‐20 LPM for the light
vehicle shop). The pumps for each oil is duplexed to allow for approximately 45 LPM at
two dispense points. The gear oil flow rate will be lower to the high viscosity (20‐30 LPM).
The accumulators and filters (bank of four per fluid) are mounted downstream of the
pump. Each filter bank has a pressure differential indicator, drain and sample ports.
Downstream of the filter bank is an isolation valve before the header to the hose reel
stations.
For coolant and grease, the assembly is the same, except there are no filters for these
products. Multipurpose grease has both bulk and high pressure pumps.

Page 7 of 13 Fireball Equipment Ltd.

 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

2.4.2 Piping Specification

The piping to the hose reel racks is to be 3” carbon steel for the headers and 1” carbon
steel for the branch lines to each hose reel rack. Final pressure rating for the piping is to
be confirmed based on the pump stall pressures. Each line is to include a welded isolation
valve at all termination points with threaded connection for each hose reel rack.

2.4.3 Truck Shop

There are eight (8) hose reel racks in the truck shop. The truck shop reel racks are
designed to minimize the space required on the shop floor. Each rack has four anchors to
be installed on the shop concrete floor. A drip pan with cleanout catches any minor
drips/spills. Each rack holds 10 reels. The truck shop rack includes:
1. Engine oil
2. Hydraulic oil
3. Gear oil
4. Coolant
5. Bulk Grease
6. HP Grease
7. Used oil and pump
8. Used coolant and pump
9. Electrical Cord Reel (see RFI 16)
10. Spare oil reel
See the attached Process Flow Diagram for assumed
fluid path.

The oil, coolant and bulk grease reels are spring

rewind with 20mm (3/4”) diameter, 30m (100’)
long hoses.
The high pressure grease reel is spring rewind
with a 9.5mm (3/8”) diameter, 30m (100’) long
hose. The used oil and coolant hose reels are air
rewind with 38mm (1.5”) diameter, 11m (35’) long
hoses. The electric cord reel has a single industrial
receptacle (size SD 10 12 AWG 18 Amp), spring
rewind, 29m long.
There are no air reels on this hose reel rack. Client to advise if additional air reels
are to be mounted to this rack for structural evaluation (RFI 9).

2.4.4 Medium/Light Vehicle Shop

There are six (6) hose reel racks in the Medium/Light Vehicle Shop. As the fluid reservoirs
for this equipment are smaller, lower flow rates can be used in the light vehicle shop,
therefore, it is recommended that 13mm (1/2”) diameter hoses are used for the oils and
coolant.

Page 8 of 13 Fireball Equipment Ltd.

 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

These racks have the same frame as the truck shop rack. The reels for these racks include:
1. Engine oil
2. Hydraulic oil
3. Transmission oil
4. Gear oil
5. Coolant
6. Bulk Grease
7. HP Grease
8. Used oil and pump
9. Used coolant and pump
10. Electrical Cord Reel (see RFI 16)
See the attached Process Flow Diagram for assumed fluid path.

The oil and coolant reels are spring rewind with 13mm (1/2”) diameter, 30m
(100’) long hoses.
The bulk grease reel is spring rewind with a 20mm (3/4”) diameter, 30m (100’)
long hose.
The high pressure grease reel is spring rewind with a 9.5mm (3.8”) diameter, 30m
(100’) long hose.
The used oil and coolant hose reels are air rewind with 38mm (1.5”) diameter,
11m (35’) long hoses.
The electric cord reel has a single industrial receptacle (size SD 10 12 AWG 18
Amp), spring rewind, 29m (95’) long.
There are no air reels on this hose reel rack. Client to advise if additional air reels
are to be mounted to this rack for structural evaluation (RFI 9).

2.4.5 Trax/Aux Vehicle Shop

There are six (6) hose reel racks in the Trax/Aux. Shop. These hose reel racks are the same
as the Truck Shop racks (section 2.3.3). If lower flow rates are acceptable for these racks,
the hoses for the oils and coolant can be reduced to 1/2" diameter.

2.4.5.1 Track Servicing Mobile Grease Carts – optional, not currently in

scope
As tracks are going to be serviced in these bays, three high pressure (7,500 psig)
mobile carts have been included for track expansion. Tracks require
approximately 5,000 psig at the nozzle. The high pressure grease at the reel rack
is at approximately 2,000‐3,000 psig. It is much more efficient and safer to have
a mobile cart for this service, rather than raising the operating pressure of the
entire high pressure grease system to 10,000 psig or more. (RFI 17). These carts
are priced separately as optional below.

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 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

2.4.6 Truck loading rack – optional, not included in current scope

A truck fill rack is recommended to fill site lube trucks (RFI 7). The fluids included on this
rack are identified on the attached Process Flow Diagram. Fluids such as shovel grease
will only be distributed to the lube trucks. Each hose reel is spring rewind with 25mm (1”)
diameter, 15m (50’) long hoses. The rack includes built‐in cabinet doors with bulk heads
and rollers to prevent heat loss while dispensing. This rack can be installed within the
concrete containment dyke.

2.4.7 Used product Collection – optional, not included in current scope

In addition to the hose reel racks, 10 oil collection trays and 10 coolant collection trays
are recommended along with 10 used oil drain trays. These have been subtotalled
separately in the pricing table below.
The used oil and coolant collection trays have a capacity of 95L and include a funnel,
sight tube, 10” wheels filter drain pockets and tool pockets.
The used oil drain trays have a capacity of 98L (42” LG x 30” W x 9” H) and are on
caster wheels.

2.5 Fluid Management System – not currently included in scope

Each of the tanks have a tank level monitor and each hose reel rack has a meter. The entire shop
is fluid management ready. Fireball Equipment recommends VeriDapt for the site fluid
management system.

2.5.1 VeriDAPT
The VeriDapt solution provides complete visibility and transparency across the whole
supply chain from a single platform. This solution is designed to ensure that all fluid
movements and consumption is reconciled down to the fluid consuming asset. The
system can ensure that all fluids delivered to site can be accounted for in real time to
within 1%. The ability to accurately account for all fluids procured allows savings to be
realized across an operation where fluid usage inefficient or unknown.

By authorizing each equipment item, the mine site can control dispensing and utilize the
following features:
‐ Limit dispense volumes per equipment item over settable periods:
shift/day/week/month.
‐ Limit dispense locations by the use of 'Authorization Areas'.
‐ Set automatic 'expiry date' on individual equipment items.
‐ Receive overfill (Safe Fill Level) alarms.
‐ Enable batch filling and ramp control for high flow fuel transfers.
‐ Monitor refuel times and flow rates to allow for preventative maintenance on filters
and pumps.
‐ If the heavy equipment is authorized by AdaptSMU RFID tag, then the AdaptMAC
captures engine hours as well, allowing for burn rates data reporting.

Page 10 of 13 Fireball Equipment Ltd.

 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

Photo of AdaptFMS Control system on Mining Lube Body (see AdaptMAC panel
AdaptMAC panel on left side)

3.0 Project Execution

The projects team at Fireball Equipment includes project management, engineering, drafting,
electrical/controls design and programming. A dedicated project manager is assigned to each project to
ensure smooth execution.
It is proposed that this project proceeds in two phases, Engineering and Execution.
The Engineering phase will be quoted as per the attached SDI. This is a budgetary quotation where the
Project Manager will report hours on a weekly basis (invoicing on a monthly basis). The Engineering
phase includes an Issue for Review Package (as per the attached SDI) and Issue for Tender Package. At
this point, the Execution phase will be quoted to finalize the fabrication/installation drawings, procure
equipment and complete shop construction.
A budgetary quotation is provided below based on the equipment recommended above.

3.1 Schedule – General

The following is a general schedule based on common lead times of equipment, fabrication
and engineering time required.

Activity Weeks ARO

Project Onboarding Complete (contract accepted) 1‐3
Concept Design Complete (Issue For Approval drawings) 4‐6
Detailed Design Complete (Issue for Tender drawings) 10‐12
Quotation submitted for construction 10‐12
Issue for Construction Design Complete (Fabrication drawings) 16‐18
Shop Construction and FAT 18‐20
Ready to ship 19‐22
Documentation Turnover 2 (after shop FAT)
Notes:
1. ARO: After receipt of order
2. Schedule to be confirmed upon commitment.
3. The tanks will be the longest lead time. Data sheets for the tanks can be completed for tender sooner
than the rest of the system to expedite construction schedule upon request.

Page 11 of 13 Fireball Equipment Ltd.

 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

3.2 Budget Pricing

The following table represents budgetary pricing (+/‐10%) based on the recommendations above
and the Supplier Document Index, attached.
Description Budget Price
Receiving system, including HPU, 11 fresh fluid pump/filter assemblies, $ 799,181
coolant pump assembly, 3 grease transfer assemblies, tank level
monitoring and overfill protection

Dispensing system, including dispensing pumps and accessories $ 360,235

Hose Reel Racks (20 total), heavy vehicle shop, aux. shop and light $ 1,717,214
vehicle shop

Engineering (Design), IFR and IFA documentation as per the SDI $ 89,200
attached

Engineering (Execution), IFC documentation as per the SDI attached $ 53,050

Total $ 3,018,880

Optional Items
Truck fill rack $ 168,560

Track mobile grease carts $ 8,745

Used oil and coolant receivers/drain trays $ 32,692

Optional Items Total $ 209,997

Notes:
1. Engineering to be completed as per the rate sheet attached. This is a budget estimate as per the
attached Supplier Document Index.
2. All pricing in CND.
3. Shipping is not included. All equipment to be Ex Works Fireball Equipment. All documentation to be
submitted electronically.
4. Installation and commissioning support not included. This can be quoted upon request.
5. Pricing for the VERIDAPT fluid management system available upon request.

3.3 Cost Savings Opportunities

The following cost saving opportunities have been identified for the project.

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 Doc No.:
Date: 2020‐11‐20
Author: TLL
Document Name: Scope of Supply, Kaz Minerals – Peschanka Mine Revision: 1

1. The largest cost savings opportunity for this project is to reduce the number of the fluids
required across the site. Currently there are 15 fresh fluids. In our experience, fluid suppliers
and clients work with equipment OEMs to select common fluids that meet or exceed the OEM
specifications. This can reduce the total fluids required.
The following equipment is not required for each fluid removed from the system
‐ The receiving equipment/piping
‐ The tank level monitoring equipment
‐ Dispensing equipment
‐ Dispensing piping/hose reels on truck rack

In addition, larger, more cost effective tanks with increased capacity can be purchased.
Operationally, less fluids means less risk of contamination, less specialty couplers and less
equipment to service.

2. Consider removing the tanks for the some of the specialty fluids that are only for the truck
rack. The truck rack is to fill site lube trucks to top up equipment or lube islands in the mine.
These can be loaded into the site truck directly from a barrel/tote or FluidBag.
This saves capital cost as the tank, controls, pumps and piping are removed.

3. Consider using FluidBags for grease handling. FluidBags can be shipped to site in sea
containers and have virtually no waste, unlike grease totes. Also, storage of the bags after
they are empty is simple as the pallets are broken down and the bags are much smaller than
a steel tote. See attached FluidBag information.

Page 13 of 13 Fireball Equipment Ltd.