Ecfn Aus en 0100 Spe 01002 (C1 PDF)

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ECFN-AUS-EN-0100-SPE-01002
Rev: C1
Table of Contents
1 Scope 1
2 Codes and Standards 1
3 GENERAL 2
3.1 Equipment 2
3.2 Conformity and Quality Marking 2
3.3 Standardization 2
3.4 Materials 2
3.5 Modular Equipment Packages 3
3.6 Accessibility and Safety 4
4 EQUIPMENT, MATERIALS AND FABRICATION 4
4.1 General 4
4.2 Speed Reducers 4
4.3 Bases for Speed Reducers and Motor Drives 5
4.4 Keys 5
4.5 Chain Drives 5
4.6 Belt Drives 6
4.7 Guards 6
4.8 Backstops (Anti Rollback Devices) 7
4.9 Shafts 7
4.10 Couplings 8
4.11 Pillow Blocks and Bearings 8
4.12 Bolts and Bolting 9
4.12.1 General 9
4.12.2 Bolt Holes 10
4.12.3 Tapped Holes 10
4.12.4 Washers 10
4.13 Gaskets 10
4.14 Lubrication 10
4.15 Noise Levels 11
4.16 Piping and Tubing 11
4.16.1 General 11
4.16.2 Flanged Connections 12
4.16.3 Threaded Connections 12
4.16.4 Grooved Connections 12
4.16.5 Solvent Welded Connections 12
4.17 Electrical / Instrumentation 12
4.18 Hydraulic Equipment 12
4.18.1 General 12
4.18.2 Hydraulic Cylinders 13
4.18.3 Hydraulic Pumps 14
4.18.4 Hydraulic Pump Drives 14
4.18.5 Hydraulic Power Pack Mountings 14
4.18.6 Hydraulic Fluid Tank 15
4.18.7 Hydraulic System Motors 15
4.18.8 Hydraulic Fluid 15
4.18.9 Hydraulic System Valves 15
4.18.10 Hydraulic System Pressure Gauges 16
4.18.11 Hydraulic System Protection 16
Rev: C1
4.18.12 Hydraulic System Filters 16
4.18.13 Hydraulic System Heaters 16
4.18.14 Hydraulic System Coolers 17
4.18.15 Hydraulic System Temperature Controls 17
4.18.16 Hydraulic Pipework and Fittings 17
4.18.17 Hydraulic Pipe System Assembly Methods 17
4.18.18 Hydraulic Pipe System Supports 18
4.18.19 Hydraulic Flexible Hose Assemblies 18
4.18.20 Hydraulic Accumulators 18
4.18.21 Hydraulic System Testing and Commissioning at Supplier’s Facility 19
4.19 Pneumatic Components 19
4.19.1 Operating Conditions 19
4.19.2 Connections and Distribution 19
5 TESTING 20
5.1 Mechanical Equipment 20
5.2 Electrical / Instrumentation 20
Appendix 1 – Preferred Suppliers for Mechanical Components
Rev: C1
1 Scope
This document defines the general mechanical requirements which are not specifically described in
individual equipment specifications for the Fruta del Norte Gold Project in Ecuador. Mechanical equipment
supplied according to any purchase order shall comply with the specification which applies to that
specific equipment.
When specific design criteria are given in the mechanical equipment specification issued by the
Purchaser, those criteria shall take precedence over this standard specification.
Any substitution to mechanical components described below shall be clearly indicated in the equipment or
system quotations, and shall be approved by the Purchaser before starting fabrication.
2 Codes and Standards

Design and construction of the mechanical systems and equipment shall be executed, as applicable, in
accordance with the relevant parts of codes, standards and regulations, latest editions of the following
authorities and technical organizations.
The following authorities and technical organizations shall govern:
AFBMA Anti-Friction Bearing Manufacturers Association

AGMA American Gear Manufacturers Association
ANSI American National Standards Institute
API American Petroleum Institute
ASHRAE American Society of Heating, Refrigeration and Air Conditioning Engineers
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
AWS American Welding Society
CEMA Conveyor Equipment Manufacturers Association
CMAA Crane Manufacturers Association of America
IEC International Electro-Technical Commission
ISO International Standards Organization
OSHA Occupational Safety and Health Administration
ECFN-AUS-EN-0100-SPE-01002 Page 1
Rev: C1
3 GENERAL
3.1 Equipment
All mechanical equipment shall be designed:

 For a service life of 15 years
 For unprotected outdoor operation (unless noted), high pressure hose cleaning, sun exposed,
tropical and corrosive conditions, if applicable
 Conservatively rated and sized in order to accommodate anticipated capacity changes due to
process alterations, surge conditions or upsets as indicated by equipment data sheets
 To comply with process performance parameters specified on equipment data sheets.
For site climatic conditions, refer to the technical specification for Site Conditions (ECFN-FDN-EN-0100-
REP-00001).
No spare parts for mechanical packaged equipment shall be provided, unless specified in the scope of
work.
All deviations from the requirements of this specification shall be clearly stated by the Vendor. In the
absence of such a statement, it shall be understood that the requirements of this specification are fulfilled
without exception. If there are no exceptions, the vendor shall state so.
3.2 Conformity and Quality Marking
The complete assembled equipment package and all components, including instruments, mechanical
components, electrical components and motors shall be supplied with the appropriate CE mark and/or
with a recognized North American or international approval (ASME, ANSI, API, UL, FM, etc).
3.3 Standardization
All components shall be standard items from reputable manufacturers who have stock-carrying
distributors.
Equipment component sizing shall be standardized (e.g., shaft sizes, bearings, V-belts, pulley sizes, belt
widths, screw conveyor diameter, etc.) to reduce the quantity of inventory spares.
The manufacturer, type, size and ratio of speed reducers shall be standardized to minimize inventory
spares.
Vendors shall be able to demonstrate that spares are easily and readily available. Availability of spare
parts and their cost will be considered in equipment selection.
3.4 Materials
In general, the equipment specification and data sheet shall state the material required and the
mechanical properties which must be achieved. Any special surface finish or treatment shall also be fully
specified.
Rev: C1
Any material selected for a special purpose or critical service shall comply in all respects with the
chemical and physical properties stated in the specifications and equipment data sheets. The
temperature at which impact testing is required, together with the minimum acceptable impact value, shall
be stated.
The acceptable tolerances for inclusions, defects, and dimensional accuracy will be included in the
relevant specifications, where applicable. If the vendor requires a deviation from the latter, it shall be
clearly stated on the item specification and/or drawings.
Any request by the vendor for substitution of an alternative material shall be in writing, and he shall not
proceed until he has received written approval of the Owner’s representative.
If a substitute material with an improved specification is accepted, the allowable stresses shall be at least
those of the originally specified material.
Undesirable materials, including PCBs, CFCs, asbestos, formaldehyde insulation and halon, will not be
accepted as part of the plant or equipment supplied.
3.5 Modular Equipment Packages
Modular equipment packages, including ancillaries for primary equipment, shall be as follows:
 Arranged functionally, with all operating controls and indicating devices grouped and positioned for
convenient operation and maintenance, including routine inspection, cleaning and lubrication, and
with good accessibility and clearances for component removal and replacement
 Each equipment package shall be pre-piped, with piping brought to conveniently located and
clearly identified connection points to connect to external piping by others
 All components shall be located within the modular “envelope” to minimize exposure to component
damage during shipping and handling.
 Where a package must be divided into two or more sub-packages for shipping or installation
purposes, wiring, conduit and piping shall be provided cut, fabricated and pre-formed as required
for interconnection of the sub-packages which make up the equipment package.
 Wiring and piping external to the equipment package shall be supplied and installed by others.
 Equipment packages shall be pre-assembled and mounted onto common stress-relieved bedplates
or skid mounts. All instruments should be pre-wired to a local junction box. Individual
instrumentation items may be removed for shipping to prevent damage. Such items shall be
securely boxed, identified and shipped with the appropriate equipment package.
 Skid mounts, structural supports and framework shall be sufficiently braced and structurally
adequate to withstand loads incurred during handling and shipping without damage. Lifting lugs or
eyes shall be provided to facilitate safe and convenient handling.
 Piping systems shall be thoroughly flushed after assembly. Systems shall be drained prior to
shipment and open ports capped or plugged.
 For a list of mechanical component preferred suppliers, see Appendix 1. Components not
mentioned in the list and supplied by the vendor must be submitted to purchaser for review.
Rev: C1
3.6 Accessibility and Safety
The design of mechanical equipment components shall allow for space and access required for routine
inspection and maintenance of the equipment and for replacement of components.
All lubrication and maintenance points shall be easily accessible and comply with safety standards.
Equipment drive mechanisms shall be fitted with protective guards compliant with ISO 14120 and
designed for easy dismantling.
Any equipment or component over 25 kg, requiring lifting shall be provided with means for safe handling
by crane such as lifting lugs or eye bolts. Lifting devices shall be designed and located to permit lifting
without damage to the equipment.
4 EQUIPMENT, MATERIALS AND FABRICATION

4.1 General
Purchaser shall provide relevant equipment specification and data sheet specifying the mechanical
properties that must be achieved, material of construction required and any special surface finish or
treatment, where applicable.
4.2 Speed Reducers
Gear reducers shall conform to AGMA standards and shall be horizontal with parallel shafts or concentric
shaft type with housings of ductile iron or heavy welded steel (preferred) fabrication. Gear reducers shall
be base mounted, unless otherwise specified for components such as screw conveyors or small belt
conveyors with motor sizes up to 75 kW.
Reduction ratios shall be based on standard induction motors having synchronous speed of 1,500 rpm,
unless otherwise specified.
Reducers shall be selected so that no external cooling is required (fan or heat exchanger), except for
reducers over 150 kW or on special applications.
Housings shall preferably be of stress-relieved welded steel construction in order to minimize any
breakage during shipment and subsequent handling, and be horizontally split to facilitate repair and
maintenance. On small drives, cast ductile iron may be acceptable.
The sealing systems at shaft extensions shall effectively retain the lubricant in the housings and shall be
designed especially to resist the entrance of abrasive dust and water, typically multi-labyrinth seals or
double-lip seals.
Mechanical output power rating shall have a minimum service factor of 1.5, or applicable AGMA class 11
service-factor, based upon maximum connected motor kilowatt requirements.
Thermal kilowatt rating shall not be less than the connected motor kilowatt rating.
Rev: C1
If the speed reducer operates in the sun at ambient temperature of 50°C or more, it shall be protected
with a protection canopy or reflective paint.
All gears and shafts shall be manufactured from heat-treated, precision-machined alloy steel.
Gear reduction units shall be fitted with an oil level indicator, positive lock type oil filler cap, oil drain,
magnetic plug and filtered air breather vent.
Shaft-mounted speed reducers shall be provided with adjustable motor mounts and adjustable tie-down
arms. Tie-down arms should be loaded in tension.
4.3 Bases for Speed Reducers and Motor Drives
Supply rigid and rugged cast iron or heavy welded steel base, for each reducer and electric motor drive.
The common base shall be rigid, braced, equipped with machined mounting pads and shimming
allowance, slotted anchor bolt holes to accommodate motor, coupling and speed reducer. Include
mounting of motor to coupling and to reducer on the base plate, aligning, bolting and dowelling in place.
Welded structures shall be stress relieved before machining.
The drive base of foot-mounted reducers shall be drilled for anchor or hold-down bolts to the supporting
floor in accessible locations.
Base plates for machines handling corrosive fluids shall be adequately protected.
Where side thrusts are applied to the motor or reducer, adjustable stops shall be provided.
Electric motor supporting bases shall be provided with adjustment for belt tensioning of belt drives, where
applicable.
4.4 Keys
Square keys shall be provided for all connections subject to torsion, unless otherwise specified. Key sizes
shall conform to ANSI standards or equivalent.
4.5 Chain Drives
Transmissions using chains and sprockets shall be considered only if V-belt or direct coupling
transmissions cannot be used. Chain drives shall be designed and supplied in accordance with ANSI
standard for “Transmission roller chain and sprocket teeth, B29.1" or equivalent.
All chain drives shall be permanently lubricated, and enclosed in chain cases.
Chain cases shall be split horizontally, dust proof and oil tight. Install seals around shafts, bearings and
hubs, and fit a gasket between facings when sections are bolted together.
The speed ratio of driver to driven sprocket shall not exceed 3 to 1.
Provision shall be made for chain tension adjustment; automatic tensioning devices shall be avoided.
All sprockets and chains shall be selected with a service factor of 1.6 based on motor kilowatt.
Rev: C1
All sprockets shall be cut steel, totally machined, heat treated and fitted with hubs.
Steel-fabricated sprockets shall have hubs welded concentrically on the sprocket plate with the hub
turned to a counter step on the welded side to fit the plate hole and ensure true alignment. The bore to be
properly machined to accommodate a split taper lock bushing, fitted with keyways for square section
keys.
All chains to be of standard riveted construction fitted with cotter pin connecting link, with bushing and
rollers, standard ANSI or equivalent, sizes 40 and up.
4.6 Belt Drives
V-belts shall only be used where necessary (e.g. no high moisture, elevated temperature or explosive
environment) and should not be used for motor sizes above 30 kW.
Belts shall conform to MPTA standards and non-stock sizes shall be avoided.
V-belts shall be of classic A, B, C, D or V series. A minimum of two (2) matched belts shall be used.
All belts shall have a minimum service factor of 1.5, based on motor kilowatt. The belt drives shall be
designed so that the drive shall be able to operate with one belt missing. The speed ratio between driver
and driven sheave shall not exceed 3 to 1. The sheave pitch diameter shall not be less than 125 mm for A
and B, 230 mm for C and 330 mm for D. Centre-to-centre spacing shall be selected to ensure maximum
belt wrap, which shall not be less than 120°. Drive design shall allow for start-up under maximum load
conditions at the lowest ambient temperature stipulated in the equipment specification.
All V-belts shall be of standard 3 V, 5 V, 8 V sections. Other belt sections may be used only with written
approval.
All sheaves shall be machine-finished, fitted with tapered hubs with split compression type bushings
keyed to shaft. Provide stock sheaves with Falk or Dodge taper-lock bushings. Single-belt drives shall not
be used. Provide V-belts in matched sets.
Motor sheaves shall be machine finished, bored and key seated in accordance with certified motor
drawing dimensions and provided by the motor supplier.
Drive and driven sheaves shall be installed on the shaft with a minimum overhang.
Maximum belt speed shall be 25.3 m/s.
4.7 Guards
All exposed rotating or moving parts shall be provided with totally enclosed safety guards made to comply
with ISO 14120 or approved equivalent.
V-belts shall be protected by a guard made from 2 mm minimum thick plate and 12 mm maximum
opening expanded metal. The guard shall be constructed such that a bolted face can be removed for
V-belt replacement, with the body remaining in place.
Mount all guards on rigid frames. Fasten all frames to machinery or structural base. All guard contours to
be made of mild steel plate (unless otherwise specified) covered with expanded metal mesh of minimum
3 mm thickness.
Rev: C1
All guards shall be painted “safety yellow”. Design safety guards for:
 Removal without disturbing or removing other parts
 Lubrication of enclosed moving parts where appropriate and tachometer readings on shafts,
without dismantling safety guards
 Easy removal of entire safety guards using normal maintenance tools by installing lifting lugs
 Heavy duty service
Guards not made with expanded metal should be able to support a person’s weight.
Guards shall also be provided around hot surfaces in locations that are frequented by personnel (e.g.,
refractory-lined ducts).
Guards for driver and driven sheaves shall be of sufficient size to accommodate an increase of at least
three standard sheave sizes based on the driven (largest) sheave supplied with each unit.
4.8 Backstops (Anti Rollback Devices)
All backstops shall be of the eccentric cam blocking principle, mounted directly on the head pulley shaft at
the opposite side of the drive.
The capacity of the backstops that shall be mounted on either inclined belt conveyors or bucket elevators,
shall be sized on the basis of the maximum load, including surges that can be carried on the respective
belt conveyor or bucket elevator.
4.9 Shafts
Shaft design shall be based on the latest ANSI Standard B106.1M or equivalent – Design of
Transmission Shafting.
Shafting shall be free of any sharp corners and all shaft ends shall be chamfered. Large diameter shafts
may be turned down at bearing and attachment locations. Turndowns shall be limited to the following
ratios:
 Major/minor diameter: ≤ 1.5
 Fillet radius/minor diameter: ≥ 0.25
Key seats shall not extend into the fillet radius.
Conveyor pulley shafts shall be deflection limited so that the maximum angular deflection of the shaft at
the shaft/pulley hub connection shall not be greater than 5 minutes (0.0015).
Shaft ends shall not protrude from the bearing, unless required for power transmission, to permit the use
of bearing end caps.
All shafts shall be made from SAE C1045 steel for up to 150 mm and SAE 4140 for larger diameters.
They shall be turned and polished, and keyed as required.
All exposed areas of the shaft shall be coated with a thick coating of non-water soluble rust inhibitor.
Rev: C1
Shafts with lip seals running against them shall have removable wear rings incorporated into the design.
4.10 Couplings
Flexible couplings are preferred for driving process machinery such as pumps, compressors, etc. Use
spacer coupling on pumps (Woods or equal) and agitators (Koppers or equal).
Spacer-type couplings shall be provided on back-pull-out machines.
Lubricated end float couplings shall be used with motors having sleeve bearings when thrust from the
drive machine can be expected.
Type and materials of flexible members shall withstand corrosive or low and high temperature
environments.
For standard applications such as reducer output shaft or electric motor coupled to a driven element,
"Falk" steel flex coupling Type T10 or T20 tapered grid type or approved equal shall be used.
For high torque and high speed applications where it becomes impractical to use standard grid-type
coupling, use crowned tooth single or double engagement gear couplings manufactured by Falk (Type G-
51 or G-10) or approved equal.
For applications where there is a possibility of excessive start-up resistance, torque limiting couplings
shall be used between motor and reducer input shaft. Couplings shall be Falk types T41 or T41-2
controlled torque couplings, or approved equal.
Fluid couplings shall be of the extended delay type when specified on the equipment specification sheets.
Fluid couplings shall be capable of 5 equally spaced start-ups per hour at maximum design load.
Controlled torque couplings to prevent damage to the motor in case of equipment stall shall be
considered where applicable.
4.11 Pillow Blocks and Bearings
Pillow block bearings shall be of the self-aligning, double row, spherical roller, adaptor-mount type, in
split, ductile iron or cast steel housings. Bearing selection shall be in accordance with the AFBMA L-10
life rating specified in the table below, in conjunction with the maximum running radial loads. Pillow blocks
shall be type FSAAFD 22500 Series or SAFD 22500 Series, FAG, SKF or approved equal.
Rev: C1
Mechanical Equipment Minimum L-10 Life (hours)
Cranes, trolleys and hoists (maintenance) 3 000
Gear drives – combination drives 60 000
Blowers and pumps 60 000
Agitators 80 000
Conveyor pulley pillow blocks 80 000
Conveyor idlers 60 000 (B.U. = 90 000)
Screens 80 000
Compressors, process fans and turbines 100 000
Pillow blocks shall be fitted with electroplated Alemite grease nipples. The lubrication points shall be
readily accessible to grease the bearings with the equipment running. Pillow blocks shall permit both
grease or oil lubrication.
Pillow blocks shall be used to support shafts. The use of flange-mounted bearings shall be restricted to
light duty applications in machinery, where such bearings are normally used.
When bearing/pillow block assemblies are mounted in pairs, one bearing shall be laterally floating and
one shall be fixed.
Pillow blocks shall include triple labyrinth (taconite) seals to prevent the ingress of dust or water into the
bearings. The labyrinth seal shall be designed to avoid sliding contact and offer as little resistance to
rotation as possible. The sealing arrangement shall accommodate the shaft deflection encountered in
operation.
Four (4) hole-bases are preferred for all pillow blocks. The supporting steel work shall be provided with
adjusting screws for longitudinal adjustment of pillow blocks.
Where the shaft does not extend through the pillow block, a housing end closure or cap shall be provided.
Pillow blocks shall, generally, be fitted with lifting lugs.
4.12 Bolts and Bolting
4.12.1 General
Bolts and nuts shall conform to ASTM A307 and A320 or ASTM A193 and A194 for high temperature
applications.
Bolts used for attaching mechanical equipment to structures shall be placed so that the nut is on the
underside.
Where wing nuts are used for attaching guards, etc., the bolt shall be a minimum of 12 mm in diameter.
Rev: C1
Bolt lengths shall be chosen so that a minimum of 2 threads and a maximum of 5 threads shall project
beyond the nut.
Where bolts are subject to vibration, the nut shall be prevented from loosening by means of slotted or
castle nuts and a split pin, or by proprietary deformed nuts, or locking element (drilling and lockwire), or
locknuts. Nylon locking elements shall not be used since high temperatures may affect their performance.
Where there is more than one bolt to be tightened to hold a particular piece of equipment, the bolts shall
be tightened in stages so as not to exert uneven stress on the parts being bolted.
4.12.2 Bolt Holes
Bolt holes shall be drilled so that when the item being affixed is placed in position, the bolt shall pass
through it at a right angle.
Under no circumstances shall it be permitted to ream through to correct an out-of-line bolt hole.
4.12.3 Tapped Holes
Tapped holes shall be threaded to a depth of at least twice the thread diameter.
4.12.4 Washers
A hardened steel washer shall be placed on each bolt underneath the element being tightened.
Provide tapered washers, where required, to produce a flat surface.
All washers (flat or tapered) shall conform to ASTM F436 specification.
4.13 Gaskets
Where gaskets are installed between the joints of chutes and equipment, they shall, unless otherwise
stated, be 3 mm thick neoprene, full flange width, punched to match flange boltholes. Each gasket shall
be made up of single thickness material and be no more than one piece per leg of the peripheral length to
be joined.
Piping flange gaskets shall comply with the Piping Materials Engineering Specification (ECFN-AUS-PI-
0100-SPE-01002). For flat-faced flanges, gasketed area shall cover the full face of the flange.
Asbestos gaskets are NOT allowed.
4.14 Lubrication
Equipment shall be thoroughly lubricated and filled with lubricant, prior to shop testing. Prior to shipment,
drain lubricants from the equipment, unless otherwise specified.
To ensure proper functioning of the equipment, all moving mechanical parts shall be provided with
lubrication.
Permanently lubricated components shall be designed to be dismantled and rebuilt.
Rev: C1
The lubrication points shall be accessible. Hard to reach lubricating points shall be piped to convenient
locations. Each lubrication point shall have its individual remote servicing inlet. All grease lubrication
fittings shall be the same size, make and model. The grease fittings shall be self-sealing types. Grease
cups are not acceptable.
All enclosed equipment lubrication points shall be piped to an external access panel with proper
identification of each point.
Oil lubricating points shall have positively closing covers. Guards shall have adequate openings to give
access to lubrication. A dirt-free level indicating device shall form part of all sumps.
All grease fittings shall be standard Alemite straight hydraulic type or equal, with 3 mm or 6 mm nipples,
easily accessible for greasing without removing guards.
All equipment shall be supplied with complete information on lubrication requirements, including list of
approved product manufacturers.
Automatic grease lubrication systems, where specified, shall be provided with a tank adequate for seven
days consumption equipped with a low level alarm.
Oil lubrication systems shall be splash type with closed circulation, if required. Closed circulation systems
shall have air-cooling, wherever practical. Oil lubrication systems shall be equipped with level and
temperature sensing instrumentation for alarming and shutdown. Oil filters shall be dual type with
provision to detect and replace blocked filter while the system is in operation.
All equipment supplied with lubrication systems shall be provided with containment trays and drains to
avoid lubricant spillage, including during servicing. Containment tray volume shall be 150% of total tank
volume.
4.15 Noise Levels
Noise levels of all equipment under normal operation shall not exceed an eight-hour equivalent
continuous A-weighed sound pressure level of 85 dB (A) at 1 m in all directions. If exceeded, suitable
sound enclosures shall be provided.
4.16 Piping and Tubing
4.16.1 General
Piping class and materials shall conform to the piping specifications applicable to and as identified in
each technical package specification. Provide companion flanges or adapters, as required.
The use of pipe sizes 32 mm, 65 mm, 90 mm, 125 mm and 550 mm shall be avoided. Where special
interconnecting piping such as high pressure lube lines or flexible pipe or hose are not supplied, vendor
shall include complete ordering instructions, including the names of one or more suppliers for lines and
connections.
All piping systems shall comply with the latest edition of ASME B31.3, Process Piping. Flanges, fittings
and valves shall be identified with the ASTM/ASME material designation.
Bolt holes shall straddle natural centre lines. Ensure that flanges clear pipe supports by at least 300 mm.
Rev: C1
Pipe termination points on equipment skids may be any of the types described below; however, they shall
comply with the specified pipe.
Pipe supports shall be provided. Tubing shall be supported for the full length of the tube run.
4.16.2 Flanged Connections
Threaded flanges shall not be used without the approval of Purchaser. Install flange bolts with anti-seize
compound on the threads.
4.16.3 Threaded Connections
Cut threads straight and true, to correct form and fit, to ensure that connections are made pressure tight.
Threading shall conform to ANSI B2.1.
Coat the threads with an approved thread tape or compound.
4.16.4 Grooved Connections
Ensure that the exterior of the pipe is free of defects to ensure a leak-tight seat for the gasket.
Assemble couplings in compliance with the coupling manufacturer’s instructions.
4.16.5 Solvent Welded Connections
Make solvent welded connections in compliance with the pipe/solvent manufacturer’s instructions.
4.17 Electrical / Instrumentation
All electrical, instrumentation and control system hardware provided shall comply with standard
specification ECFN-AUS-EL-0100-SPE-01001 - E&I Equipment Supplied with Packages.
4.18 Hydraulic Equipment
4.18.1 General
All design calculations shall be submitted to the purchaser for approval.
Hydraulic power units shall be designed with all control wiring terminated at a junction box and power
wiring as specified in standard specification ECFN-AUS-EL-0100-SPE-01001 - E&I Equipment Supplied
with Packages. When not mentioned, the PLC shall be supplied by others.
Where loss of supply or control pressure may result in damage to equipment, loss of accuracy or injury to
personnel, means shall be provided to prevent operation under those conditions.
Working pressure for hydraulic systems shall not exceed 20 MPa and systems shall be designed with a
safety factor of 4.
The internal diameter of piping shall be at least 12 mm (½”) (except for pressure gauges) and of such a
size that the oil velocity does not exceed 4 m/s in pressure lines and 1.5 m/s in return lines and 1 m/s in
suction lines.
Rev: C1
ANSI flanges on pumps and cylinder ports are required. Threads may be parallel and in compliance with
ANSI standards where pumps and cylinder ports are threaded and spot faced.
The systems shall be equipped with a by-pass to return oil from the pump discharge back to the tank via
the heat exchanger when the system is operating under no load.
When failure of any component of the system may cause production loss a stand-by component may be
specified by the consultant in an individual specification. These shall be piped and valved in parallel such
that the stand-by item can be put into service and the damaged unit removed without loss of production.
The hydraulic unit shall be equipped with four permanent lifting points and fork channels to allow
placement by forklift truck.
4.18.2 Hydraulic Cylinders
Tie rod construction cylinders are not acceptable.
Stop tubes of adequate length shall be provided for cylinders working in compression.
Cylinders shall be provided with cushions and bleed valves at both ends. Lip seals shall be provided for
the pistons and cylinder wipers. Zero leak piston and rod seals shall be fitted to cylinders where the load
has to be held for a long period.
The static test pressure shall be at least 1.5 times the maximum working pressure as per ANSI standards.
The barrels shall be constructed from hot rolled or cold drawn seamless steel tubing or bored steel tubing.
The barrel bores shall be honed to give a 0.25- to 0.5-micron surface finish.
Cylinder heads, rear caps and front end caps shall be of one-piece construction, machined from suitable
rolled carbon steel plate, bar stock or forgings. Forgings are preferred.
Where a cylinder end cap is welded to the barrel, the materials must be compatible. The welds shall be
free from inclusions and porosity. No distortion shall be created during welding and the bore shall be
honed after welding.
The clamping force on the cylinder head or front end cap, exerted by the bolts, shall not be less than
twice the force resulting from the rated operating pressure. The minimum yield strength of the bolts shall
not be less than twice the total clamping force.
The piston shall be a one-piece design.
The piston rod material shall be hardened alloy steel, chrome plated, and be designed with a minimum
factor of safety of 4, in compression, based on the rated maximum pressure and the least cross-sectional
area. The surface finish of the piston rods shall be ground to 0.1 to 0.4 microns. The piston rods shall
have a spanner flat which shall be fully exposed when the rod is fully retracted. Sharp machined edges
shall be removed, to avoid seal damage.
Viton cylinder seals, compatible with the hydraulic fluid used in the system, and suitable for operating
temperatures up to 100°C, shall be used. Rod wipers shall be fitted to all cylinders and the material shall
be selected to suit the environment at site.
Rev: C1
Protection bellows for piston rods shall be fitted to all cylinders and the material shall be suitable for the
environment and conditions at site.
Cylinder mountings shall be designed and manufactured to ensure that the unit cannot vibrate or work
loose under any circumstances. Items such as clevis ends screwed on to piston rods shall have provision
for positive locking.
Mounting clevises shall be fitted with spherical self-aligning, sealed bearings, where there is no other
method of self-aligning.
Detailed drawings of the cylinders shall show the longitudinal cross-section, mounting, port details and
dimensions and shall include a parts list. Provide calculations for the length and the diameter of piston
rods, giving the permissible maximum tension and compression loads.
4.18.3 Hydraulic Pumps
The minimum rated pressure of the pumps shall be 25% greater than the specified requirements of the
system, and shall be tested at the supplier’s facility.
The pumps shall be rated for continuous operation at maximum system pressure and shall be selected for
unlimited starting frequency and shall be able to operate efficiently when the temperature of the hydraulic
fluid is 100°C.
Under full flow conditions, the vacuum at pump suction shall be within the allowable pressure limits, as
recommended by the pump supplier.
The pump shaft shall be parallel and keyed.
Pump discharges shall be fitted with air bleed valves and pressure tapping points.
4.18.4 Hydraulic Pump Drives
The hydraulic pumps shall be directly coupled to the electric motors by means of a flexible coupling.
V-belt drives are not acceptable. The hydraulic pumps with drive motors and couplings (pump units) and
the tank shall be mounted on a common base above a drip tray.
The pump units shall be mounted adjacent to the tank, and preferably below the minimum fluid level of
the tank, to ensure flooded suction. The pump suction lines shall be as direct as possible with all fittings
and valves free-flow type.
4.18.5 Hydraulic Power Pack Mountings
Each power pack shall have a control panel, on which all valves and gauges are mounted.
The base plate and framework forming part of the power pack shall be made of steel angle profiles and
plate. It shall be designed as a drip pan and shall be capable to contain all fluid that may leak from the
tank. A 20 mm (¾”) plugged drain shall be included.
The units shall be installed in areas where they are not exposed to any precipitation that may fill the drip
pan and cause its overflow.
Rev: C1
Support structures shall be self-supporting and shall not rely on attachment to other structures or
foundation for internal rigidity.
4.18.6 Hydraulic Fluid Tank
The tank shall be of sufficient capacity to contain the total volume of fluid in the system or the volume
equivalent to 3.5 minutes of pumping time (i.e. capacity in liters equal to 3.5 times the pump capacity in
litres/minute), whichever is the greatest. It shall be sufficiently sized to allow for changes due to cylinder
actions or temperature variations.
The tank shall be equipped with an easily removable, oil tight, inspection cover, oil level indicator, low
level switch, high fluid temperature transmitter, temperature gauge, and drain port. An oil filling point shall
be provided for filling, complete with non-return valve, magnetized filter basket and 5 micron filter. The
tank shall be leak tested.
The return line port(s) shall be at the furthest point from the pump suction and the return lines to enter the
reservoir at or near the top. The return lines shall drop vertically, with diffusers fitted, the ends of which
shall be approximately 50 mm from the bottom of the reservoir.
Baffles shall be fitted inside the tank and to extend upwards to approximately three-quarters of the normal
working fluid level.
The base of the tank shall be not less than 150 mm from floor level, to facilitate handling, draining and
heat dissipation.
4.18.7 Hydraulic System Motors
Power requirements shall be based on maximum pump volumetric displacement at 25% above maximum
operating pressure.
4.18.8 Hydraulic Fluid
Hydraulic fluid shall be selected so that only one grade may be used through the year, i.e., the fluid must
not be temperature sensitive. Refer to the Site Conditions Design Criteria (ECFN-FDN-0000-EN-REP-
0001). The fluid shall contain oxidation and corrosion inhibitors and anti-foam and anti-wear additives.
Fire-resistant fluid shall be used.
Provide complete information on hydraulic fluid requirements, including list of approved product
manufacturers.
4.18.9 Hydraulic System Valves
All control valves shall be manifold mounting types. The directional control valves shall be solenoid
operated with fully encapsulated coils. The valves shall be capable of operating continuously at 20%
excess flow and pressure.
All pressure and flow control valves shall be tamper proof. The by-pass pressure relief system shall be
capable of operating continuously at 50% excess pressure.
Rev: C1
4.18.10 Hydraulic System Pressure Gauges
Pressure gauges shall be provided and installed in strategic positions to identify faults. Pressure gauges
and switches shall be protected against pressure surges and shock loads.
Pressure gauge accuracy shall be 1%. Pressure gauges shall be glycerin-filled and shall be fitted with
isolation valves.
Pressure gauge test points shall be installed at the ports of all actuators and at other key testing points in
the hydraulic circuit.
4.18.11 Hydraulic System Protection
Protection shall be provided to ensure the system is fully protected against high or low pressures, high or
low temperatures, low oil levels, and blocked filters.
Pressure switches shall be field adjustable.
An isolating valve shall be fitted between the tank and the pump suction and the isolating valve shall be
equipped with a limit switch, which shall prevent the pump from starting if the isolating valve is closed.
Furthermore, it shall trip the drive motor, should the isolating valve be closed accidentally during
operation.
The unit shall be failsafe in the event of power loss.
4.18.12 Hydraulic System Filters
5 micron pressure filters with clogging indicator-transmitters shall be installed on the discharge side of all
pumps. Filters shall be rated to take twice the rated flow of the pumps.
Return line filters shall be rated for twice the maximum flow.
In the event of a filter becoming blocked, a signal shall be provided.
The class of filtration shall comply with Supplier’s requirements for the equipment installed.
Where practical, stand-by filters shall be provided and piped in parallel for quick change over.
All filters shall be complete with electrical interlock ‘telltales’ with visual indicators and shall be mounted
such that these will be easily cleaned or replaced without spillage.
4.18.13 Hydraulic System Heaters
The tanks shall be equipped with thermostatic controlled “low density” submerged electric heaters for
automatic start-stop operation.
See Standard Specification ECFN-AUS-EL-0100-SPE-01001 - E&I Equipment Supplied with Packages.
Rev: C1
4.18.14 Hydraulic System Coolers
When the application requires a cooler, it shall be installed at the side or top of each hydraulic fluid tank,
with all necessary controls for automatic start-stop operations and cut-off temperature switch when the
temperature reaches the critical temperature. This condition will be indicated in the control room by a high
temperature warning light, followed by a shut-down sequence.
The cooling medium used (air or water) shall be as stipulated in the technical specification of particular
equipment.
4.18.15 Hydraulic System Temperature Controls
The supplier shall use a temperature sensing element, installed in a thermowell, to sense the hydraulic
fluid temperature at 150 to 200 mm from the bottom of the tank and to turn heaters on at 0°C and turn
them off at 10°C.
4.18.16 Hydraulic Pipework and Fittings
Hydraulic lines up to and including 25 mm diameter (1”) shall be of stainless steel tubing or piping, rated
for the working pressure and securely fastened to framework.
Pipe fittings to also be of stainless steel and shall be vibration proof. Hydraulic lines above 25 mm
diameter (1”) shall be carbon steel.
Safety factor for fittings shall be 4, and tubing 1.5.
4.18.17 Hydraulic Pipe System Assembly Methods
Precautions shall be taken during storage and installation to keep the inside of all pipes, fittings and
valves free of dirt, rust, weld slag, pipe cuttings, thread compound, etc. The ends of the pipe shall be
closed with caps.
The ends of tubes and bends shall be smooth and at right angles to the centreline and the ends shall be
reamed.
Threads are not permitted on hydraulic tubing. Tube bends shall be cold formed.
Highpoints or similar positions where air may accumulate shall be fitted with air bleed valves.
Connections shall be designed, sized and located to ensure correct operation of actuators, remotely
piloted controls and similar fluid-operated devices. Mountings and clamping shall be rigid to eliminate
vibration.
Runs shall be as direct as possible, with a minimum number of bends.
Tubing shall be bent at direction changes. Minimum radius of the bend being 2½ to 3 times the outside
diameter of the tube.
Each run shall be integral and continuous from one piece of apparatus to another. Couplings shall only be
used where necessary.
Rev: C1
4.18.18 Hydraulic Pipe System Supports
Pipe or tube support clamps shall be of approved design and these shall be heat resistant up to 100°C,
corrosion and oil resistant, rigid and able to absorb vibrations.
Clamps shall be so arranged that a single tube can be removed without disturbing the others.
Supports shall not be welded to the piping, nor the piping to the structure.
Spacing of Hydraulic Pipe System Supports
Pipe Outside Diameter Length between supports
Up to 12mm (½”) 1000 mm (40”)
Over 12 mm (½”) and up to 25mm (1”) 1500 mm (60”)
Over 25mm (1”) and up to 50mm (2”) 2000 mm (80”)
The location of supports and method of mounting shall allow adequate expansion and contraction of the
hydraulic lines and shall ensure that all pipe work is securely restrained under the operating conditions.
Clamps shall be positioned within 150 mm of all connections, with the exception of hose connections
where pipes shall be clamped as close as practical to the hose connection.
4.18.19 Hydraulic Flexible Hose Assemblies
Flexible hoses shall be double wire-braided, and suitable for 25% in excess of maximum working
pressures. The f safety actor based on maximum working pressures shall be as in Section 4.0 Hydraulic
Equipment – General.
Flexible hoses shall be compatible with the hydraulic fluid used, and shall be suitable for temperatures up
to 100°C.
The fittings used for flexible hoses shall be crimped (swaged) type. Reusable fittings are not acceptable.
If failure of a flexible hose constitutes a hazard, the hose shall be restrained, shielded or protected. Burst
hose protection shall be fitted to cylinders used for lifting.
All hoses shall be assembled and mounted in accordance with the supplier’s recommendation, i.e., bend
radii shall always be greater than the supplier’s nominated minimum. There shall be no chafing, kinking or
twisting, and hoses shall only flex on one plane.
No adverse restrictions on flow or high pressure drop condition shall be accepted from hoses or hose
fittings.
4.18.20 Hydraulic Accumulators
Accumulators shall comply with ASME standards and codes of practice.
The accumulator design shall be such that it shall not be possible to remove any detachable component
from the accumulator.
An isolating valve shall be fitted between the accumulator and the main fluid line. Accumulators shall not
be mounted or supported on associated lines or equipment.
Rev: C1
A manual drain valve shall be incorporated to enable the accumulator to be drained to the reservoir.
The accumulator shall be protected by a relief valve.
An external pressure gauge shall be provided on bladder.
The accumulators shall be decompressed during transportation and shall be charged with pure nitrogen
once on site.
4.18.21 Hydraulic System Testing and Commissioning at Supplier’s Facility
Each hydraulic system shall be pressure tested to 1.5 times of the maximum operating pressure at the
Supplier’s facility to ensure the systems are leak free and in compliance with ASME B31.3.
Each hydraulic system shall be completely performance-tested at the Supplier’s facility to ensure
compliance with the duty. Upon completion of tests, the complete unit shall be flushed thoroughly by
installing a jumper line with a manual flow metering valve between the power unit pressure port and
return port. Fluid shall be circulated at design pressure for not less than two hours and until there is no
further deposition of material on the filter.
Upon completion of the tests, all openings shall be properly plugged, prior to packing and transportation
to site.
After pre-commissioning, a sample of oil shall be tested for water contamination.
4.19 Pneumatic Components
4.19.1 Operating Conditions
The vendor shall design and select pneumatic circuits, systems and components for external
environmental conditions as per the Technical Specifications for Site Conditions (ECFN-FDN-EN-0100-
REP-00001).
4.19.2 Connections and Distribution
Lines shall be connected to the distribution network through an isolation valve with manual control.
All lines shall be equipped with a pressure gauge. All directional control valves and other valves shall be
arranged on enclosed, embedded supports near the areas of operation.
Cabinets shall have 15% of their space allowed for future expansions.
Cabinets shall be divided according to functions to facilitate the arrangement of all operational parts, such
as the following:
 Directional control valves
 Pilot safety valves
 Reducers
 Regulating and sequence valves
 Pressure gauges and switches
Rev: C1
Tapped orifices in pneumatic system components shall be NPTF dry seal type conforming to the ANSI
B1.20.3 standard, or European equivalent standard.
5 TESTING
5.1 Mechanical Equipment
Mechanical equipment shall be shop tested as described in the technical equipment specifications,
equipment data sheets and/or scope of work.
All mechanical equipment shall be guaranteed for their performance for the basic parameters such as
tonnage, throughput, flow, power, head developed, and efficiency as listed on the relevant equipment
data sheets.
5.2 Electrical / Instrumentation
All process control systems, instrumentation, electrical equipment and software shall be comprehensively
tested at the vendor’s premises prior to dispatch to site. Refer to standard specification No. ECFN-AUS-
EL-0100-SPE-01003.
Rev: C1
Appendix 1 – Preferred Suppliers for Mechanical Components
Mechanical Component Preferred Suppliers

Actuators Refer to standard specification No. ECFN-AUS-EL-0100-SPE-01003
Agitators Lightning, OSNA, Philadelphia Mixers, Chemineer Mixer, Milton Roy Mixing, Missenard
Quint Industries, Ekato
Backstops Falk, Morse, Formsprag
Bearings SKF, FAG, Cooper
Belting Goodyear, Scandura Canada (Uniroyal), Phoenix AG, Contitech
FAM, Koch Voest Alpine, Thyssen Krupp, Robson, FFE Minerals, Man Takraf,
Belt conveyors
Continental Conveyors, TNT (Terra Nova Technologies Inc.), SENET LTD., THOR
Belt conveyors pulleys Precision, Rockwell/Dodge, Browning (Van Gorp), Lorbran/Bosworth, Steller, Ras
Industries
Belt covers (hoods) RPS Engineering, Scalfo, Dacon Conveyor Equipment
Belt scrapers Martin Engineering, Conveyor Components Co., Richwood Industries, Gosdon
Belt scales Instruments Refer to standard specification No. ECFN-AUS-EL-0100-SPE-01003

Brakes Hagglunds Hydraulic, Bubenzer, Johnson Industries, Svenborg
Central Lubrication Systems Lincoln, Alemite, Trabon, Pall
Couplings Falk, Hansen, Woods, Koppers
Couplings, fluid Falk, Voith, Flender
Dampers, fan inlet and discharge Bachmann, Lawson Taylor, Wahlco, Voith
Magnetic separators Eriez, Dings, O.S. Walker
Mechanical seal John, Crane, Chesterton, Sealol, Safe Matic, Garlock
Metal detectors Eriez, Ramsey
Misalignment switches Refer to standard specification No. ECFN-AUS-EL-0100-SPE-01003
Plugged chute detectors Refer to standard specification No. ECFN-AUS-EL-0100-SPE-01003
Pull cord switches Refer to standard specification No. ECFN-AUS-EL-0100-SPE-01003
Pumps Envirotech, Metso, Warman, TURO Pumps, AR Wilfley, ITT Goulds, GIW, Lewis,
Ensival-Moret, Bungartz, KSB
Screw take-ups Rockwell/Dodge, SKF, FAG
Speed reducers Falk, Flender, Hansen, SEW, David Brown, Sumitomo
Speed switches Refer to standard specification No. ECFN-AUS-EL-0100-SPE-01003
V-belt drives Rockwell/Dodge, TB Woods, Goodyear, Gates, Flender
Vibration detectors Refer to standard specification No. ECFN-AUS-EL-0100-SPE-01003
ECFN-AUS-EN-0100-SPE-01002 Appendices
Rev: C1

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Appendix 1 – Preferred Suppliers for Mechanical Components

2 Codes and Standards

The following authorities and technical organizations shall govern:

AFBMA Anti-Friction Bearing Manufacturers Association

All mechanical equipment shall be designed:

3.2 Conformity and Quality Marking

3.5 Modular Equipment Packages

4 EQUIPMENT, MATERIALS AND FABRICATION

4.2 Speed Reducers

4.3 Bases for Speed Reducers and Motor Drives

4.5 Chain Drives

The speed ratio of driver to driven sprocket shall not exceed 3 to 1.

4.6 Belt Drives

Maximum belt speed shall be 25.3 m/s.

4.8 Backstops (Anti Rollback Devices)

Key seats shall not extend into the fillet radius.

Spacer-type couplings shall be provided on back-pull-out machines.

4.11 Pillow Blocks and Bearings

Cranes, trolleys and hoists (maintenance) 3 000

Gear drives – combination drives 60 000

Blowers and pumps 60 000

Conveyor pulley pillow blocks 80 000

Conveyor idlers 60 000 (B.U. = 90 000)

Compressors, process fans and turbines 100 000

Pillow blocks shall, generally, be fitted with lifting lugs.

4.12 Bolts and Bolting

4.12.2 Bolt Holes

4.12.3 Tapped Holes

Provide tapered washers, where required, to produce a flat surface.

All washers (flat or tapered) shall conform to ASTM F436 specification.

Asbestos gaskets are NOT allowed.

Permanently lubricated components shall be designed to be dismantled and rebuilt.

4.15 Noise Levels

4.16 Piping and Tubing

4.16.2 Flanged Connections

4.16.3 Threaded Connections

Coat the threads with an approved thread tape or compound.

4.16.4 Grooved Connections

Assemble couplings in compliance with the coupling manufacturer’s instructions.

4.16.5 Solvent Welded Connections

4.17 Electrical / Instrumentation

4.18 Hydraulic Equipment

All design calculations shall be submitted to the purchaser for approval.

4.18.2 Hydraulic Cylinders

Tie rod construction cylinders are not acceptable.

The piston shall be a one-piece design.

4.18.3 Hydraulic Pumps

The pump shaft shall be parallel and keyed.

4.18.4 Hydraulic Pump Drives

4.18.5 Hydraulic Power Pack Mountings

4.18.6 Hydraulic Fluid Tank

4.18.7 Hydraulic System Motors

4.18.8 Hydraulic Fluid

Fire-resistant fluid shall be used.

4.18.9 Hydraulic System Valves

4.18.11 Hydraulic System Protection

Pressure switches shall be field adjustable.

The unit shall be failsafe in the event of power loss.

4.18.12 Hydraulic System Filters

In the event of a filter becoming blocked, a signal shall be provided.

4.18.13 Hydraulic System Heaters

See Standard Specification ECFN-AUS-EL-0100-SPE-01001 - E&I Equipment Supplied with Packages.