PT. MIFA Bersaudara PT.

Bangun Arta Hutama

TECHNICAL SPECIFICATION
FOR
BELT CONVEYOR

STANDARD DESIGN PROCEDURE FOR BELT CONVEYOR

Project : Barge Loading Conveyor System, Nangroe Aceh Darussalam-Meulaboh
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CONTENT

1.0 GENERAL

1.1 Scope of Specification

1.2 Specification
1.3 The Installation

2.0 SCOPE OF WORK

2.1 Contract Requirements

2.2 Spare Parts and special tools
2.3 Training of Operators and Maintenance Personnel
2.4 Preferred Brand

3.0 DESIGN CRITERIA/TECHNICAL SPECIFICATION

3.1 Coal Properties
3.2 Civil/Structural Technical Specification
3.2.1 Reference Document
3.2.2 Transfer Stations
3.2.3 Foundations
3.2.4 Bolt & Nut
3.2.5 Painting
3.3 Mechanical Technical Specification
3.3.1 Reference Document
3.3.2 Conveyors
3.3.3 Tramp Iron Magnet
3.3.4 Belt Scale
3.3.5 Dust Suppression System & Washdown
3.3.6 Maintenance Access
3.3.7 Transfer Stations and Chute
3.3.8 Skirt
3.4 Electrical Technical Specification

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3.4.1 Reference Document

3.4.2 General
3.4.3 Transformer
3.4.4 MCC & Control Room
3.4.5 Main Power Supply, Motor & Control Voltage
BELT CONVEYOR SPECIFICATION
May 2012 Page 3 of 38
3.4.6 Power Cables & Control Cables
3.4.7 Earthing
3.4.8 Earth Leakage Protection Scheme
3.4.9 Motor Control Centre
3.4.10 Control Desk
3.4.11 Variable Frequency Drives
3.4.12 Uninterruptible Power Supply
3.4.13 Marshalling Cubicle
3.4.14 Cable Tray & Cable Ladder
3.4.15 Plant Lighting & General Purpose Outlet
3.4.16 Lightning Protection
3.4.17 Plant Operating Philosophy
3.4.18 PLC
3.4.19 Field Devices

4.0 INSPECTION, TESTING AND COMMISSIONING

4.1 General
4.2 Proprietary Equipment
4.3 Tests Prior to Delivery
4.4 Tests and Commissioning on Site
4.5 Commissioning

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1.0. General
1.1. Scope of Specification
This Specification covers the design, manufactures, construction, inspection, and commissioning
of Belt Conveyor.
The work shall be carried out strictly accordance with:
i) The conditions, requirement, Schedules and drawings contained in the Contract
ii) Any variation and/or modification agreed to by the Principal and the BAMA.

1.2. Specification
The minimum technical requirement for quality and workmanship for design, Materials,
Supply, Manufacture, Assembly, Inspection, Testing, Preparation for Shipment, Erection,
Testing and Commissioning of the Belt Conveyor shall be as set out in the following Standard
Specifications. While the Specification is arranged in sections and clauses, with titles and
headings, the Specification shall be read as a whole and such arrangement, titles, and heading
shall not affect the intention and construction of the Specification. Although some cross-
references have been included to facilitate reading, such cross-references or lack there of shall
not be construed as limiting the application of the Specification as a whole.

1.3. The Installation

The plant and equipment supplied under this Contract shall be installed at PT. Bangun Arta
Hutama Meulaboh, Nangroe Aceh Darussalam – Indonesia.
General ambient conditions for the site are listed below :
Altitude : 3 - 6 m above sea level
Air Temperatures : 40° C – max
Relative Humidity : data not avaiable
Maximum Wind Velocity : data not available
Average Rainy Days/Month : data not available
Seismic load : refer to Indonesian Code

2.0. Scope Of Work

2.1. Contract Requirement

The Contract encompasses the complete detail design, supply, fabrication, surface treatment,
inspection, testing, Delivery to site, construction, erection, and commissioning of the conveyor
belt. Any item of equipment or work whether or not indicated on the Drawings or specified in the
Contract Specification, and where it is clearly the intention that should be supplied or where they

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are obviously required and necessary for the safe, efficient operation of the plant, then they shall
be deemed to be included as part of the Contract.
All material and or Equipment supplied under the contract, except for installation equipments,
shall be:
• New equipment /material, in good condition and manufactured/fabricated within one
year before the beginning of the contract award.
• Good quality, manufactured/fabricated based on recognized standard, suitable for coal
mining industry application, tropical whether and dust laden condition.
• Approval from the Principal is required prior to fabrication/manufacture of the
equipment/material.

2.2. Spare Part and Special Tools

The Contract shall include the supply of initial Performance spares and consumable spares
necessary for Testing, startup and commissioning.

2.3. Training of Operators and Maintenance Personnel

BAMA staff who are familiar with similar plant installation, operating and maintenance
requirements shall train the Principal’s operators and maintenance staff on site to a standard
which is satisfactory for the operation and maintenance of all plant supplied under the Contract.
The required classification of shall be specified at least two months prior to the estimated
commencement of commissioning. The BAMA Programme for training of the Principal’s staff
shall be submitted for approval by the Principal at such a time prior to the commencement of
commissioning that the approved training can completed during and after the completion of the
commissioning. The BAMA shall, at its own expense, keep on site sufficient staff for the
satisfactory operation of the plant until the Principal is satisfied that the
Principal’s operators are sufficiently trained, and not until then shall Certificate of Principal
Completion be issued.

2.4. Preferred Brand

The following is a list of preferred brand which should be considered in tender submission.
No. Description Preferred brand
1 Electro Mechanical actuator Tsubaki or approved equal
2 Idler Vortex, Rullmeca or approved equal
3 Pulleys Bama or approved equal. Bearing shall be SKF or FAG. Locking assembly
shall be Tsubaki or approved equal
4 Belt scale Ramsey or approve equal

STANDARD DESIGN PROCEDURE FOR BELT CONVEYOR

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5 Gear box/Coupling Flender, SEW or Nord

6 Brake Bubenzer or approved equal
7 Belting Bando, Bridgestone, Goodyear, or Phoenix
8 Electric Motor ABB or Siemens
9 Variable Speed Drive ABB or Siemens
10 Belt Scraper Flexco or Martin
11 Tramp Iron Magnet Mecal, Sturton Gill or Ding
12 Take Up Sampler Ramsey or SGS
13 Transformer Trafindo, Unindo or Bambang Djaja
14 Switchgear Schneider or Siemens
15 MCC Schneider or Siemens
16 PLC Siemens or approved equal
17 PLC Software Siemens or approved equal
18 Lighting & fixture Philip or approved equal
19 Control/Filed Device Schneider, Siemens, or approved equal.
20 Cables Supreme, GT Cable, Jembo, Tranka or Kabelindo
21 Cable tray/ladder NOBI, EGA, Lion or approved equal
22 Pump EBARA or approved equal
23 Pipe & fittings as approved by the principal
24 Valves & fitting As approved by the principal

3.0. DESIGN CRITERIA / TECHNICAL SPECIFICATION

3.1. Coal Properties
The following coal properties are supplied for the information of BAMAs and shall be used as a
basis for design and selection of equipment. Other data required is available on request from the
Principal:
• Total Moisture : 35 %
• Bulk Density (Volume Calculations) : 0.80 – 0.9 t/m3(average 0.85 t/m3)
• Bulk Density (Mass Calculations) : 1,1 t/m3
• Angle of Repose : 37 0
• Hard grove Grind ability Index (HGI) : 50 - 70
• Surcharge Angle : 200
• Maximum Size – Product : 50 mm

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3.2. Civil/Structural Technical Specification

3.2.1. Reference Document
All steelwork and concrete works shall be designed for all static, dynamic, wind and
earthquake loads as is appropriate for this site in according to the followinglatest
standard
Where there is no company’s standard applicable, the latest appropriate ISO, Australian,
British, American, Japan or Indonesian shall be used. In all instances, precedence shall
be given to Indonesian and Australian Standards first.
Indonesian Standard:
• SNI-1726 : Indonesian Code for Earthquake Design
• SNI-1729 : Indonesian Code for Steel Design
Australian Standard:
• AS1170.0 : Structural Design Actions – General Principles
• AS1170.1 : Part 1 – Permanent, imposed and other actions
• AS1170.2 : Part 2 – Wind Actions
• AS1554 : Structural Steel Welding
• AS4100 : Steel Structures

3.2.2. Transfer Stations

All conveyor and process transfer stations in the plant shall be provide with structural
steel supports, maintenance access and stairs to ground level. A concrete apron shall be
provided under each transfer and shall extend at least 1 m past the column lines to
enable collection and clean up of any spilt coal. All
flooring in transfer stations shall incorporate galvanized steel grating and handrails shall
be provided to all stairs and openings. A colorbond trimdeck roof shall be provided over
all transfer stations but wall cladding is not required.

3.2.3. Foundations
Generally all structures shall be supported on isolated, strip or spread footings. Strip
footings shall be used for conveyor trestles.
Isolated footings shall be used for conveyor modules. Isolated or spread footings should
be used for transfer towers, motor control center and control rooms. Piled footings shall
be used where appropriate.
All footing shall be designed to adequately resist all imposed static and dynamic loading
including earthquake loads and provide resistance against overturning. All foundation to
be designed and constructed by the Principals, except anchor bolts and grouting. The

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BAMA shall supply and delivered all anchor bolts to site within duration of 90 (ninety
days) from signing of contract

3.2.4. Bolt & Nut

Except where otherwise noted all bolts in platework & structural work items shall be
high strength structual bolts grade 8.8 and hot dip galvanized. Minimum size for grade
8.8 is M16. Bolt for liner plate connection shall countersunk bolt with self locking nut
and made from stainless steel. Minimum size for countershunk bolt is M12.

3.2.5. Painting
All structural steelwork, plant, equipment, pipework and platework including walkway
checker plate shall be painted otherwise protected against corrosion in accordance with
this Specification unless exempted herein to approved in writing by the Principal. All
fabricated structural steel. pipework and platework including checker plater shall be
abrasive blast cleaned to Class 2 ½ finish and primed within four hours and before any
surface tarnishing occurs. Any surfaces tarnished shall be reblasted before priming.
Cleaned surface shall be kept free of contamination and not be touched by bare hand.
Any oils, grease or other surface contamination of bare steel or previous coatings shall
be solvent cleaned before applying the next coat. All sheet steel used for electrical
cubicles and panels shall be acid de-scaled and phosphate passivated prior to fabrication.
After surface preparation the following appropriate coating system-1 shall be applied :
Primer coat : inorganic zinc silicate, DFT 50 micron.
Intermediate coat : high build epoxy, DFT 100 micron.
Finish coat : gloss 2 pack recoatable acylic top coat, DFT 50 micron.
Interior surfaces of chutes are to be primed only as for fabricated steelwork. External
surfaces shall be fully coated as for other fabricated steelwork. Refer to company’s
standard specication.

3.3. Mechanical Technical Spesification

3.3.1. Reference Document
The folowing list is the company’s standard specification that is related to Mechanical
Work or standard specification applicable, the latest ISO, CEMA, Australian, German,
Japan or Indonesian shall be used.

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3.3.2. Conveyors
Conveyor belt speed shall be calculated using the following criteria:
• Minimum material bulk density.
• Nominal capacity shall not exceed 90% of the CEMA cross sectional area.
• Surchage angle of 20o.
• If the loading angle is less than or equal to 5° the surcharge angle shall not be
reduced.
• If the loading angle is greater than 5° and less than or equal to 10° the
surcharge angle shall be reduced by 5°.
• Plant conveyors shall not exceed a belt speed of 5 m/s. Conveyor demand
powers shall be calculated using the following criteria:
• Design capacity shall be 110% of the nominal conveyor capacity.
• Power utilisation shall not exceed 97% of the installed motor power at the
design capacity.
Conveyor power and tension requirement shall be calculated based on the
following standard:
• ISO 5048 : Continuous mechanica handling equipment or
• CEMA : Belt Conveyor for BulkMaterial or
• DIN 22101
All conveyor components shall be selected to minimize spare parts requirements and
shall be rationalized for maximum interchangeability. The Principal will require
standardization of pulleys and idlers with components on other plants. All conveyors,
except the portion in the reclaim tunnel, shall be provided with wind hoops over the top
of the conveyor. Rain/wind covers are not required.

a. Belting
The belt width of all conveyors shall be 1800 mm . Type of belt shall be rationalized for
maximum interchangability. Only two type of belt allowed for all conveyor. Belt shall
have 6 x 3 mm grade M covers. Conveyor Belt troughing angles shall be a minimum of
35°. Maximum design tension in any conveyor belt shall be that tension to convey the
maximum design tonnage. Belt tensions at start up or stop shall not exceed 140% of
allowable working tension of the belt. If excessive belt lengthening occurs during the
warranty period, the BAMA shall shorten and replace the belt at its own expense.

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b. Idler
Troughing idlers shall be 3 roll type, 152 mm diameter, 6307 ZZ bearing with a
troughing angle of 35° and rigid frame. Graduated adjustable transition idlers shall be
used sufficient to avoid distortion stresses in belt edges and center but in general shall
not less than three idler spaces. Tail transitions shall have the belt line with the pulley.
Spacing of troughing idlers shall be maximum 1500 mm. Under loading skirts, spacing
shall not exceed 750 mm in areas where impact idlers are not installed. Rubber disc
impact idlers shall be used over the length of discharging chutes at loading point at a
maximum spacing of 300 mm. Impact idler frame shall be retractable type for easy
maintenance. Impact idler shall be 3 roll type, 152 mm diameter, 6307 ZZ bearing with
a troughing angle of 35o.
Return idlers shall be 2 roll type, 152 mm diameter, 6307 ZZ bearing with a troughing
angle of 10°. Spacing of return idlers shall be maximum 3000 mm. Idler roller bracket
and base frames shall be hot dip galvanized and shall be slotted to accommodate drop-in
dead shaft type rollers. All bracket slots shall be neat fitting to prevent rattling of
components during operation.

Bearing Type.
Unless specified otherwise, all bearings shall be deep grooved ball bearings with C3
clearances. Both bearings of each roller shall be positively locked to the shaft. Dead
shaft type idler bearings shall be lubricated and sealed for life. Unmodified L10 life of
80,000 hours under design load conditions and full speed.

Sealing Mechanisms
Bearings seals shall shed water and be rain and hose proof. Sealing mechanisms shall
be shielded grease filled bearing inside a dry labyrinth seal, with an external dust seal.

Shafts
Shafts shall be machined from carbon steel to AS 1442 or AS 1443. Shaftdeflection at
the bearings shall not exceed the bearing manufacturer's recommendations under
flooded belt and impact conditions.

Idler manufacture
Idler roller shells and tubes shall be from precision finished Electric Resistance Welded
type to AS 1450 Grade 200 or better. Surface roughness of outside of idler roller shall

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not exceed Ra = 12.5 μm. Welds between end discs and shells shall be continuous and
smooth with a minimum corner radius of 3 mm.
Plain steel rollers (excluding weigh idlers) shall be concentric with the shaft to within:
Idler diameter 152 mm TIR < 0.3. Impact idlers rubber covers TIR < 1.0 mm.
Rollers fitted with rubber or plastic discs shall be concentric with the shaft to within 1.0
mm Total Indicated Runout (TIR). Rollers and tubes shall be straight to within 1/1,000.
Idler Static Balance:
• Steel rollers 0.055 N.m or conform to ISO 1740 G 40
• Weigh rollers 0.015 N.m or conform to ISO 1740 G 6.3

c. Pulley
Each pulley assembly shall be heavy duty design supplied complete with shaft, hub
connection, lagging, plummer blocks and bearings located on their respective bearing
housing center and ready for field installation.
Pulleys shall be live shaft type designed for both belt life and pulley life consideration.
Pulley face shall be belt wide + 200 mm and pulley diameters shall be not less than the
published minimum diameter recommended by the belting. Pulley assemblies shall be
designed for unprotected outdoor operation under all weather conditions. Bearing shall
be designed for 60.000 hours life. Pulley bearings shall be double row spherical roller
self aligning type mounted on adaptor sleeve.
All plummer block housings shall be cast iron with split construction and shall be either
SSN 500 or SD series of the four bolt slotted hole type for all shaft diameters. All
bearing housings shall be fitted with a rubbing seal and grease purged labyrinth
(taconite) type seals. Grease nipples shall be fitted for regreasing of the labyrinth seals
only:
Shafts shall be connected to the shell/end discs using Ringfeeder or equivalent locking
assemblies. The oiled condition Ringfeeder assembly rated transmissible torque shall be
not less than 2.0 times the specified peak torque generated by the belt tensions during
starting or braking. Drive pulleys shall be lagged with 12 mm ceramic lagging. Non
drive pulleys shall be lagged with 10 mm diamond grooved rubber lagging. Rubber
lagging shall have a Shore Hardness between 50 and 60. All pulleys shall be live shaft.
Normal internal clearance bearings shall be used.
Bearings shall be fitted such that initial and final clearances are in accordance with the
bearing manufacturer's instructions. Records of bearing installation clearances shall be
maintained and submitted.

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Minimum L10 service life of 60,000 hours to AS 2729 under normal full load/full speed
running conditions. Bearings shall be provided with seals which effectively exclude all
dirt, foreign matter, water due to rain or high pressure water hoses and prevent loss of
bearing lubricant. Open ends of housings shall be fitted with synthetic rubber wiper
seals with the lip position such that it prevents entry of grease or injurious material to
the bearing chamber. This wiper seal shall be protected by a multi-labyrinth seal.
The labyrinth shall be positioned to give a grease cavity between the wiper seal and the
labyrinth, i.e. Taconite. Unless otherwise specified 6 mm NPT tapped holes shall be
provided for purging of the labyrinth seals. 8 mm NPT tapped holes shall be provided
for bearing re-greasing but shall be fitted with blank plugs. 'V' ring seals shall not be
used without external sealing to the atmosphere.
Replaceable wear sleeves or plates shall be provided where practical. All seals shall be
Viton type. Bearings less than 25 mm internal diameter may be sealed-for-life type

Pulley Shaft, Shell & End disc:

Pulley shafts shall be designed in accordance with AS 1403. Pulley shafts shall be
machined from grade K 1045 normalised carbon steel to AS 1442 or better. No welding
shall be carried out on any pulley shaft.
Shafts shall be concentric to within 0.05 mm TIR when measured at any point along the
shaft. The shaft diameter shall be slightly reduced between the end discs to ease
assembly. The diameter of the shaft at the bearing shall not be less than 60% of the shaft
diameter at the locking assembly. All surfaces of shaft shall be machined with generous
radii at all changes in diameter.
Shells shall be manufactured from carbon steel in accordance with AS 3678. Pulleys
with shell thicknesses less than 10 mm may be fabricated from line pipe provided this
has been approved by Purchaser. End discs shall be manufactured from carbon steel in
accordance with AS3678
or Grade C-3 (or better) cast steel in accordance with AS2074. Non drive pulleys - Total
Indicator Reading (T.I.R.) of 0.75mm at all positions along the face after machining.
Drive pulleys - T.I.R. of 0.50mm at all positions along the face after machining. The
difference in diameter of the shell at opposite ends shall not exceed 0.6mm.
For conveyors with primary and secondary drive pulleys, the variation in diameters
between the drive pulleys shall be less than 0.05% of the diameterover the bare shell.

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d. Scraper
All conveyors shall be Conservatively designed to provide an appropriateservice life and
shall incorporate dual scrapers at the discharge (primary and secondary scraper) and V-
ploughs along the return strand of the conveyor prior to tail pulley and vertical gravity
take up.
Primary scraper shall be Belle Banne Flexco H type primary scraper with tungsteen
carbide tip or Martin Heavy Duty (HD type) pre-cleaner with urethane blade. Secondary
scraper shall be Belle Banne Flexco U type secondary scraper with urethane blade or
Martin Secondary Cleaner (DT2S type) with tungsteen
carbide tip. V-plow shall be self adjusting V-plow type. Belle Banne V-Plow or Martin
VPlow with polyurethane blade.

e. Safety guard
Adequate safety guarding shall be provided at all potential danger points as follow:
a) Tail pulley
b) Gravity take ups
c) Rotating part such as fluid coupling and V-belt
In the design of all guards consideration shall be given to the method of attachment to
enable easy and quick removal and replacement for maintenance or other purposes.

f. Take up
Take up shall be automatic gravity type take up except for conveyor less than 40 m, a
screw take up can be used. Screw take-ups shall be of heavy duty, self cleaning type
complete with a rigid welded steel 4 holes base frame, spherical roller bearings housed
in plummer blocks and a protected manually adjustable
positioning concentric screw.

g. Protection Devices
As the minimum requirement, the conveyor shall be equipped with the following
protection devices:
• Underspeed switches
• Belt drift/Belt missalignment switches
• Block chut switches
• Pull wire/rip cord switches
• Take up limit swicthes (upper & lower)
• Belt rip detection switches

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• Starting sirens
• Emergency stop buttons near drives
• Brake limit switches
• Fluid coupling thermal detection switch

i. Drive unit
General
Conveyor drive units shall be designed for continuous operation, 24 hours per day. 330
days per year with at least 95 % availability with down time only for schedule
maintenance. All equipment will be required to operate in extremely dirty conditions.
All enclosures shall be capable of withstanding heavy and abrasive dust loads. And
humid, hot and wet ambient conditions.
Drives shall be suitable for a minimum of 6 equally spaced full load starts or stops per
hour. In addition drives shall be designed for 2 consecutive starts under full load
conditions,without damage to the equipment.

Electric motor
Electric motor for less than and including 200kW shall be squirrel cage induction type,
TEFC enclosure, IP 55 enclosure protection, Class F insulation, 1500 rpm and 380 V/50
Hz /3 Phase.
Electric motor for above 200kW shall be squirrel cage induction type, TEFC enclosure,
IP 55 enclosure protection, Class F insulation, 1500 rpm and 3300 V/50 Hz /3 Phase.
Method of starting shall be soft starter for motor above and include 30 kW.

Gear box
Worm reducers are not acceptable. Gearbox bearings shall be ball or roller antifriction
type having a minimum L 10 Life of 60,000 hours based on full load power demand.For
gearboxes fitted .with holdbacks, extended shafts shall be provided to suit the holdback
on both ends of the intermediate shaft. All gearboxes of a similar size to those having
holdbacks shall have extended shafts for interchangeability.

Fluid coupling
Fluid couplings shall be provided on all conveyor drives Incorporating motors of 37kW
and above. Fluid couplings on conveyors shall incorporate a delay chamber and
annularchamber to give a Smooth progressive build up of torque during starting and

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acceleration.The fluid couplings shall be selected to accelerate the conveyor by

transmitting the minimum starting torques nominated at the gearbox output shaft and
not exceeding 140% of the full load torques during any part of the phase. The full load
torque delivered during an empty start shall be somewhat less. Due account shall be
taken of the inherent drive assembly inertia and conveyor inertia. During acceleration of
the motor, the torque/speed curve of the couplings shall at no stage intersect the
torque/speed curve of the motor before peak motor torque has been developed.
Each fluid coupling shall be provided with a thermal element switch with auto reset and
a backup fusible plug to limit torque transmission by controlling the fluid temperature in
the event of Conveyor overloading or extended stall condition. The thermal switch shall
activate at 125°C and the back-up fusible plug at 140°C.
Couplings shall be selected to be capable of starting the conveyor twice in direct
succession and at the rate of 6 evenly spaced start per hour. For the above conditions it
shall be assumed that the coupling has attained its operating temperature.

Flexible coupling
Flexible couplings may be provided on the gearbox input shaft on all drives less than or
equal to 30kW in size.
Coupling sizes shall be selected such that the power rating required by theoupling is
determined on the same basis as that used for the gear unit with which it is to operate.
Where couplings are fitted with seal, these shall suitablefor a mildly abrasive dust laden
atmosphere. All coupling shall be fitted with guards. Non lubricated coupling are
preferred.

Brake
Brakes shall be provided on conveyors where excessive drifts are acountered or where
conveyors have different stopping times during emergency shutdown and there is the
possibility of material build up at the transfer station.
All brakes shall be fail safe type with sufficient energy dissipating and shall be installed
on the reducer high speed shaft or directly onto the pulley shaft. Brakes shall be electro-
hydraulic thruster release. Brake pads shall be asbestos free and brake disc shall be
stainless and dynamically balanced.

Holdback
Holdbacks shall be used to prevent roll back of conveyors. Holdbacks shall be installed
when the force required to lift the material on the conveyor (based on maximum design

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capacity as shown on the flowsheet) is greater than the friction force required to move
the belt and material horizontally. The friction force shall be calculated friction factor of
0.012.

3.3.3. Tramp Iron Magnet

Tramp iron magnets shall be provided over the discharge of conveyor CV02 to remove
ferrous tramp material as small as an M12 nut and as large as 25 kg of piece metal from
the underside of the coal stream. The tramp iron magnets shall be stationary electro-
magnets with a permanent residual magnetism feature to retain tramp in the event of
sudden power loss. The magnets shall be mounted on electric motorized trolleys so that
they can be remotely withdrawn from the transfer chute for cleaning.
The tramp iron magnets shall be normally cleaned in an automatic cycle which
withdraws the magnet, reverses the field, discharge the tramp into a collection chute,
replaces the magnet back in the chute and re-activates the field. Each tramp iron magnet
shall be an oil cooled type, housed in an oil tight, oil
filled container. The container shall be equipped with drain plug, oil level gauge, filler
plug and cover pressure relief valve that prevents air, dust andmoisture entry on cooling.
The container shall have steel plate on all faces with the exception at the bottom plate
which shall be a non-magnetic stainless steel.
A terminal box located on front or top of the magnet shall be provided for cabling to the
transformer/rectifier unit. The tramp iron magnet shall be equipped with a
transformer/rectifier unit, fully
enclosed in an IP55 rated enclosure and complete with main isolation switch, magnet
reversing contacts and surge suppression. The magnet shall be equippedwith a tough,
rubber sheathed flexible power supply cable.

3.3.4. Belt Scale

Conveyor belt scales shall be provided at the locations nominated. Weigh scale shall
have an operating accuracy of ±0.25% operating accuracy. Accuracies shall be achieved
from 30% to 120% of conveyor nominal capacity.
Belt scale shall be supplied including belt speed measurement devices,
integrator/totalizer local panel with local display, remote rate/totalizer and calibration
weight.
Each belt scale shall be located on a clear section of the conveyor, and machined idler
sets shall be provided at least for 2 idlers positions leading into and out of the scale

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carriage. The weigh zone (which includes both the scale and lead in/out machined
idlers) shall be located at least 15 m from the loading
point of the conveyor and at least 15 m from the tangent point of any vertical
curve in the conveyor or as recomended by the manufacturer.

3.3.5. Dust Suppression System & Wahdown

The BAMA shall provide a single water service for wash down and dust suppression
system for the plant. The BAMA shall supply and install 195,000 L Southern Cross
water tank and the necessary pumps (main and standby pumps) including pump control
system, surge tank, associated valves, strainers and water distribution pipework to
deliver a required flowrate at required operating pressure.
Hose reel for washdown shall be provided at appropriate locations around dump
station, transfer station/crushing station and along conveyor routes at 60 m center. Hose
reel shall be 25 mm nominal bore hoses complete with reels and spray nozzles and
standard 30 m length hose on each reel. Dust suppression sprays shall be provided in
dump hopper, all transfer chutes, stacking discharges, reclaim points and loading point.
These shall be solenoid operated remotely from control room or locally and shall only
apply water when coal is being transferred. The water service shall be complete with all
valves, piping (galvanized mild steel), branch lines etc. necessary for a completely
functional operating system.
All valves, strainers, pipes and fittings shall be design for nominal working pressure of
1000 kPa. All above ground pipes and fitting shall be paint as directed by the Principal

3.3.6. Maintenance Access

Access shall be provided for maintenance and inspection of all plant and equipment.
Walkways and stairs complete with handrail system shall be provided leading to and
from all access areas. Access walkways shall be provided along one sides of all elevated
section of conveyors. The walkways shall have a minimum width of 800 mm and
incorporate galvanized floor grating. All stair treads shall be checquered plate
construction with a bent nosing and shall incorporate an anti-slip strip screwed to the
nosing.

3.3.7. Transfer Stations and Chute

The transfer station shall be designed to modern design principless and practice to
ensure that minimum spillage and dust is created. Chutes shall be designed on the
principles of controlled velocity fluid flow that:

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• Central loads material on the following belt

• Avoids direct impact on the following belt
• Provides a forward velocity of material in the direction of the following belt at
the point of impact.
All chutework shall be fabricated from at least 6 mm mild steel plate and suitably
stiffened to ensure a true robust construction. Chutes shall be lined internally with 12
mm thick wear resitantance ceramic liner or other approved liner material in all areas
subject to continual material impact and wear during
normal operation and 6 mm thick wear resistance ceramic liner in all other area. Chutes
shall be completed with manhole.
Dimension of liner plate for the whole chutes shall be rationalised for maximum
interchangeability. Chutes shall be manufactured in manageable segments and bolted
together using flanges on installation. Flange plates shall have a minimum thickness of 8
mm and leakage of coal or water is possible flanged connections shall be sealed using
gaskets or approved sealant. Transfer chutes on conveyors shall incorporate a lined
adjustable impact plate to receive the coal trajectory from the incoming conveyor. The
lower section of the chute shall also be designed to provide gentle directional loading of
the coal onto the receiving belt.
The upper sections of chutework surrounding the electro-magnetsmanufactured from
stainless steel.
Where bifurcated chutes are required to split flows or to direct to alternative directions
an electro-mechanically operated flop gate shall be provided in the chute. Both sides of
the flop gate shall be lined with wear resistant ceramic liners having a minimum
thickness of 12 mm. Flop gates shall be supported by and rotate in flanged bearing
housings and shall be of a robust design. The electro-mechanical actuator shall be
conservatively selected to ensure sufficient operating strength in either direction. Shaft
actuator shall be enclosed in leatherboots to protect them from ingress of water and dust.

3.3.8. Skirt
Skirt plates shall be provided as an extension of the sides of the loading trough and
extend parallel to one another for at least 1.2 m for 1.0 m/s belt speed and minimum
three (3) meters past the discharge point. Sealing strips shall not be used with the
standard chute/trough arrangement.
In the situation .where loading troughs cannot be adopted, skirt plates shall incorporate a
sealing arrangement of the hand operated clamp type with skirt rubbers easily adjustable

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to compensate for wear without the use of tools. Skirt rubbers shall be adjustable and
renewable from the outside of the chute and
shall be FRAS neoprene without fabric or fiber reinforcement. Rubber seals shall be
12mm thick (minimum) and 250 mm wide with a shore durometer hardness between 45
and 55. The minimum skirt plate thickness shall be 6 mm. The skirt boards shall be
covered, and not more than two-thirds the belt width apart. The height shall be
determined by the burden cross section but shall be not less dm 450 mm. Skirt boards
shall be fully enclosed to contain dust.

3.4. Electrical & Control Specification

3.4.1. Reference Document
This following list is the Principal’s Standard Specification that is applicable for
electrical and control works:
• Electrical Installations
• Supply of Electrical and Instrumentation Equipment for Production Areas
• Supply of Low Voltage Switch and Controlgears Assemblies
• Supply of Lighting and Small Power Distribution Boards and Field
Controlgear Cabinets
• General Electrical Testing and Commissioning Procedures.
Where there is no Company’s Standard applicable, or not included in thisdocument, the
latest appropriate Australian, American, Bristish, International,Indonesian or other
approved standard shall be used.All standards shall be the most recently published
edition, including all amandements relating to the standards.
The latest edition of the codes and standard and their revisions or addenda, shall be the
reference for this document. They shall include but not be limited to the following:
• SNI 04-0225-2000 (PUIL 2000)
• IEC Standard
• IEE
• EEEC Standard
• Australian Standard
• Germany Standard (VDE)
• The standards as listed and called up in Appendix A of IEC and IEEE.
• Any Government Authority which has jurisdiction over the site.

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3.4.2. General
The BAMA shall be responsible for the complete design, supply,installation, and
commissioning of the electrical and control system for coal handling facility, including
design, supply, install and commission the power supply for the plant from the generator
set house. This Specification defines the specific requirements of that system. All
materials and equipment supplied under this Contract shall be new and of the highest
quality. All materials and equipment, the electrical design and the installation shall be in
accordance with the relevant codes and standards and the project specifications as listed
in this Specification.

3.4.3. Transformer
Hermetically sealed transformer tanks shall have flexible corrugated or folded walls and
a completely welded construction. The tank, cover and cooling system assembly shall
have the mechanical strength to withstand without any permanent distortion, the internal
pressures caused by the contraction or expansion of the oil/liquid and gas volumes under
the specified service conditions.
The tank material shall be made as far as possible of Hot Dip Galvanised steel - or, for
large size transformers, coated with a Zinc-ethyl-silicate primer - with a coating adapted
to the environment (salt laden marine environment, corrosive environment, etc.).
For special offshore application-Stainless steel 316 L can be used for tank material, but
it will require prior the Principal approval. The tank shall be mounted on a base frame.
The tank cover shall be designed to prevent the water accumulation. The tank, cover,
valves and all accessories shall be hermetically sealed against air, water and insulating
oil.

3.4.4. MCC & Control Room

The BAMA shall provide the MCC and Air conditioned Control Room complete with
lighting and power outlet that refer to AI-E05.
The BAMA shall provide Hand held fire extinguishers in MCC and control room. These
shall be minimum 5 kilograms dry powder fire extinguisher ABC class, with a minimum
of 2 in each MCC & control room. The MCC & control will be sized to house all
equipment which is to be installed. All equipment shall have adequate clearances with
doors open.

3.4.5. Main Power Supply, Motor & Control Voltage

3.3KV power supply shall be reticulated from the generator set house to the

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MCC 1. Stepdown transformer 3.3KV/380V shall provide for MCC 2 and

MCC 3. at coal handling facility.
All motors more than 200KW will be supplied from 3.3KV, 3 phase, 50Hz and motors
less than 200KW will be supplied from 380V, 3 phase, 50HZ. The main cabling
between the genset house and the motor control center incoming circuit breaker shall be
single core double insulated, installed and supported in trefoil formation in accordance
with IEC or IEEE unless note otherwise. All field, MCC and proprietary equipment
control voltages shall be 24 VDC which refer to AI-E02. BAMA shall provide stepdown
transformer as required. No other control voltage shall be used unless specifically
approved by the Principal in writing.

3.4.6. Power Cables & Control Cables

HV Cable:
Power cable with 3.3 kV rating Voltage shall be manufactured generally to AS1429 Part
1 with tinned copper conductors, ethylene propylene rubber insulation, single wire
armoured (for three core cable only) and PVC sheathed.
LV Cable:
Power cable shall be copper conductor, PVC insulated, PVC inner sheated with double
galvanized steel tape, anti termit and Sunlight Resistant PVC outer sheated (NYFGbY).
All power cable shall be minimum 2.5 mm2 copper conductor of grade 600/1000V.
Lighting cable shall be copper conductor, PVC insulated, PVC inner sheated with
double galvanized steel tape, anti termit and Sunlight Resistant PVC outer sheated
(NYFGbY) for outdoor and copper conductor, PVC insulated, PVC inner sheated, anti
termit and Sunlight Resistant PVC outer sheated (NYY) for indoor. All lighting cable
shall be minimum 2.5 mm2 copper conductor of grade 600/1000V. Control cable shall
be multicore high conductivity stranded 7/0.67mm copper conductors with 0.6/1KV
White V75 PVC insulation and Black 4V-75 PVC sheath. Core insulation shall be
embossed with black core numbers every 300mm. A green/yellow PVC insulated
7/0.67mm earthing conductor shall be laid up within each cable.
All underground cables shall have a mechanical protection, this may be either in the
form or armouring built into the cable or the unarmoured cable housed in a protective
duct

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3.4.7. Earthing
Earthing grid shall be supplied and installed by the BAMA. A combined earthing system
shall be used. The BAMA shall connect this earthing to the MCC earth. The earth grid
shall have a resistance not exceeding 2 ohm which refer to AI-E01.
Electrical design shall take this into account, particularly with respect to the limitation of
step and touch potentials. Adequate bonding earths shall be installed to meet these
requirements.

3.4.8. Earth Leakage Protection Scheme

An earth leakage protection scheme shall be incorporated in all lighting and small power
distribution systems. To satisfy this requirement all DBs shall be fed from a main
distribution board, by means of an earth leakage protected circuit breaker.
This earth leakage devices is selected with a minimum 300 mA sensitivity and time
delayed. This upstream earth leakage protection is to prevent a fire and to reduce
equipment damage. All down Stream earth leakage devices shall discriminate with the
upstream device.
Down stream devices shall provided on all general purposes outlets which refer to AI-
E01. The sensitivities of the respective circuits shall be as follows:
• GPOs - 30mA instantaneous
• Motors and welding machines - 150mA instantaneous or timed.

3.4.9. Motor Control Center (MCC)

Each motor control center shall be supplied and installed in accordance with the
following:
• Be constructed to Form 3 in accordance with IEC or IEEE; include the main
incoming circuit breaker fitted with shunt trip facilities.
• IA earth leakage protecting the complete MCC. The torroid shall enclose all
phase and neutral conductors or be installed on the neutral earth connection. A
test circuit shall be provided.
• The MCC busbars shall be continuously rated at a minimum of 150% of the
full load.
• Thermal conditions. Temperature rise.
• Ambient conditions. Corrosion, condensation, vermin protection.
• The MCC shall be designed to be extendable at both ends.
• Include kilowatt hour metering and cos phi metering for the MCC. The meter
shall have kilowatt hour and cos phi pulse output.

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• the MCC shall be fixed type, compartementalized design, dust and vermin
proof type with IP-54 enclosure protection. It shall be free standing floor
mounted type made of 14/16 SWG steel sheet with epoxy and polyester powder
polymerized painted at high temperature.
• Internal wiring shall be done with 1.5 mm2 PVC insulated wire up to terminal
block.
• Refer to AI-E04

3.4.10. Control Desk

The control desk shall be totally enclosed, dust and vermin proof in IP 56 enclosure
protection free standing, floor mounted suitable for indoor duty made of 14/16 SWG
steel sheet painted with epoxy base paint. It shall be completed with selector switches,
indicating lamps, push buttons, fault accept/reset push button and hooter. The control
system of plant also consist of Personal Computer and mimic type diagram panel,
indicating LED type lamps.
Internal wiring shall be done with 1.5 mm2 PVC insulated wire up to terminal block.
Earthing terminal shall be provided.

3.4.11. Variable Frequency Drives

Where possible, variable frequency drive controllers shall be mounted as part of the
MCC module. This shall only occur where the variable frequency drive controller will
fit into the depth and width of a standard MCC module. The MCC module shall contain
door isolator, circuit protection, contactors, motor
protection and appropriate indication.
Where the variable frequency drive controller is too large to fit into an MCC module it
shall be mounted in a separate cubicle. This cubicle shall be fed from a fused isolator in
the MCC. The cubicle shall contain door isolator, contactors, motor protection and
appropriate indication and be free standing.
In both situations, the variable frequency drive cubicle or module shall beadequately
ventilated, using an exhaust fan.

3.4.12. Uninterruptible Power Supply (UPS)

An on-line UPS incorporating line conditioning shall be supplied and installed by the
BAMA at substation.
The UPS should have the following characteristics:
Technologies :

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* On-Line Double Conversion

* Voltage Frequency Independent (VFI)
* Digital Signal Processor (DSP)
* IGBT Transistor and Digital Control
* Flexible up-grading and redundancy placing up to 4
* Cost saving with ECO MODE Function
* The Advanced universal battery charger
- INPUT
Voltage : 380 V ~ 400 V ~ 415 V
Voltage Tolerance : 400 V ± 20 %
Frequency : 50 ~ 60 Hz
Frequency Tolerance : 45 Hz ~ 65 Hz
Power Factor : > 0,98
- OUTPUT
Power Factor : 0,8
Nominal Voltage : 380 V ~ 400 V ~ 415 V
- Voltage Stability
- Static Condition : ± 1 %
- Dynamic Condition on load step from
0 to 100 % : -4 % + 2 %
- Harmonic Distortion
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Rate (THDV)
On linear load : < 1,5 %
On non linear load : < 5 %
Crest Factor : Up to 3
Nominal Frequency : 50 – 60 Hz
- Inverter Frequency : ± 0,1 %
- Overload
- 150 % : 1 minute
- 125 % : 10 minute
- Overall Efficiency
- Global : 93 %
- In ECO MODE : 98 %
- Sound Level : < 49 dBA at 1 meter
- Batteries Type : Valve Regulated Lead Acid Battery (VRLA)

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- Back Up Time : 30 minutes

As a minimum a 380V, 40A, fuse switched isolator module shall be provided in each
substation's MCC to supply these UPS'S. The output of the UPS shall be connected to an
Instrument Power Distribution
Board (IPDB), to be supplied and installed by the BAMA. It shall be a minimum of 40
pole and the same design as standard light and power distribution boards.
All devices requiring a regulated power supply or requiring transient voltage or noise
protection shall be connected to the IPDB.

3.4.13. Marshalling Cubicles

The marshalling cubicles shall provide the wiring interface between the field, MCC,
PLC and other device connections. The cubicles shall be arranged with vertical terminal
strips. A marshalling cubicle shall be provided for all control/instrumentation wiring.

3.4.14. Cable Tray & Cable Ladder

All cable trays, ladders and cable ladder supports shall be provided which refer to AI-
E01. The design of the cable trays and cable ladder shall ensure:
• All equipment is serviced by the cable trays and ladder. This shall include
space allocated for future equipment;
• Cable ladders shall have a maximum rung spacing of 300mm and be of heavy
duty construction constructed from galvanized steel.
• The maximum between supports shall be 1500mm cable ladder sections which
shall be bolted together and locked.
• Changes of direction and elevation shall be carried out using the manufactures
standard bends, risers, tees and joints. Joints in ladder sections shall not be
further than 600mm from any rack supporting structure.
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• Earth bonding straps of not less than 35mm² green/yellow PVC insulated
copper cable shall link between sections of discontinous cable ladder or tray.
• All ladders shall be bonded to the systems earth bar.
• All outdoor or cable ladders and trays that have the cables in direct sunlight
shall have covers provided that shad all cables.

3.4.15. Plant Lighting & General Purpose Outlets

The BAMA shall design, supply and install all plant lighting including floodlighting. All
conveyors, load out area, transfer stations, reclaim feeder, stockyard, generator house,

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fuel tank, etc. shall be provided with adequate lighting. The complete plant must be
adequately lit so safe operation is possible
around the clock.

3.4.16. Lightning Protection

A system of lightning protection shall be provided at a suitable location. The location of
the terminal(s) shall ensure complete protection of the plant. The terminal shall be
electrostatic type with minimum covering radius of 100 m. The terminal shall be EF,
HELITA or Airprotec.
These terminals shall be connected to an insulated conducting system. This conductor
shall be routed to the base of the building and connected to earth via a separate earthing
system or grid for lightning protection supplied and installed by the BAMA.

3.4.17. Plant Operating Philosophy

The plant operating philosophy shall be as per the Scope of Work or the Principal
Requirement, or as directed by the Principal.

3.4.18. PLC
3.4.18.1. PLC Networking Cables
The PLC network cables shall be classified as instrumentation cables. The
cables shall be installed separate to power and control cables, i.e. Separated by a
barrier and installed with other instrumentation cables.
The network cables shall be installed to the BAMA design requirements. Space
shall be allowed in all cable ladder and trenches for the installation of these
cables. Prior to installation of cable ladder covers
or backfilling of trenches, inspection by the Principal shall be requested. Cable
tests may be carried out by the BAMA, prior to backfilling of trenches or
installation of cable ladder covers. Where installed in cable ladder, these cables
shall be bundled together and cable tied at the upper edge of the cable ladder. A
barrier shall be
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installed to separate these and other instrumentation cables from power/control
cables. The Principal accepts that these cables may need to be installed
underground for some of the cable route. Where installed underground these
cables shall be installed collectively in a 100 mm PVC conduit. The conduit

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shall provide complete protection to the cables and shall be equipped with a
draw wire for future installation.

3.4.18.2. PLC Hardware

a. General
Each PLC in the coal handling plant shall be networked to allow central control
and monitoring
To ensure PLC network comparability, to limit site spares inventory and to
minimize the requirements for maintenance personnel training, only one type of
PLC shall be used on the site. These PLC's and the
associated software shall be purchased by the BAMA from a supplier approved
by the Principal.

b. PLC Networking Cables

The PLC network cables shall be classified as instrumentation cables. The
cables shall be installed separate to power and control cables, i.e. separated by a
barrier and installed with other instrumentation cables. The network cables shall
be installed to the BAMA design requirements. Space shall be allowed in all
cable and trenches for the installation of these cables. Prior to installation of
cable ladder covers or backfilling of trenches, inspection by the Principal shall
be requested. Cable tests may be carried out by the BAMA, prior to backfilling
of trenches or installation of cable ladder covers.
Where installed in cable ladder, these cables shall be bundled together and cable
tied at the upper edge of the cable ladder. A barrier shall be installed to separate
these and other instrumentation cables from
power/control cables.
The Principal accepts that these cables may need to be installed underground for
some of the cable route. Where installed underground these cables shall be
installed collectively in a 100 mm PVC conduit. The conduit shall provide
complete protection to the cables and shall be equipped with a draw wire for
future installation.

c. Hardware
The PLC hardware supplied by the BAMA shall be in accordance with the
following specification. The BAMA shall supply and install the PLC in an IP52
free standing cubicle. The PLC input/output

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shall be pre-wired to a terminal strip.

General
The PLC hardware shall embrace the latest available technology, be robustly
constructed, simple to assemble and wire, expendable and accessible for
maintenance and fault finding. The requirement for
component redundancy shall redundancy as specified in the scope of work

Central Processor
Each PLC shall have its own central processor. The shall communicate with the
network via an interface and with each PLC module. The Following minimum
functions are required:
- solving logical statement and ladder rungs.
- processing integer and floating point maths;
- timers, counters and shift registers;
- P.I.D. computations;
- Boolean logic.
- 1/0 can be forced.
- RS 232 interface;
- facility for connection of portable programming unit;
- on line programme changes;
- programming and monitoring access security system using keylock or
passwords;
- scan time not to exceed 50 milliseconds;
- non-volatile RAM memory for programme.
- processor self diagnostics and diagnostics for I/0 modules:
- the detection of internal faults or loss of C.P.U. power shall cause all
outputs to go to 'fail safe' normally (de-energized mode) and, will
alarm condition.
The latest revision of firm ware shall be provided up to the end of the contract
Period. Where remote Input/Out put are used, the facility to plug in a portable
programming terminal shall be provided at the
remote Input / Output location. This shall allow monitoring and programming
PLC of the processor from this location.

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Input/Output Modules
Input and output modules shall be of the plug in type, easily removable for
Replacement. They shall be optically isolated to a minimum of 3000 volts.
L.E.D. status indicators shall be provided for each input and output. If internal
fusing is provided in the modules then blown fuse indicators are also required.
The modules shall be keyed, to prevent modules of differing voltages or
functions being accidentally interchanged. The modules shall be replaceable
without de-energizing the equipment.
The maximum loop length of circuits capable of being connected to each type
of module shall be stated at the time of tender. Minimum cabling requirements
shall also be specified. Input modules shall have the following features and
ranges:
• 12 – 24V DC
• 5V D.C.
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• 4 - 20mA, 0 - 20mA
• 1 - 5V DC, 0 – 10V DC
• BCD inputs
• Thumb wheel inputs
• Pulse input modules.
Output modules shall have the following features and ranges:
• 12 - 24V DC
• 5V DC TTL
• 4 - 20mA , 0 - 20mA
• 1 – 5V DC, 0 - 10V DC
Digital outputs shall be rated at 2A for resistive loads and IA for inductive
loads, at full module loading.
Standard analogue input/output signals shall be 4-20mA. All new control
system shall incorporate 110V AC control voltage and 24V DC for low level
PLC input/output signals and instrumentation signals.
All outputs shall be direct connected, i.e. two wire. The use of interposing
relays shall only be acceptable where the substation or field load exceeds the
module output current rating.

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Data Line Protection.

Where network cables, remote input/output drop cables or other data
communication cables remain within a substation building or MCC there is no
requirement for surge protection of these cables. Where
cables leave buildings and enter the field. surge protectors or data line
protectors shall be installed

Input Output
Control circuits and the associated input/output connections shall be designed to
take into account the specifications of the PLC hardware and PLC software
capabilities.The completed design and a PLC hardware list (with signal voltages
and levels) shall be forwarded to the Principal, who will review and
approve the selection

Wiring
The BAMA shall provide the PLC and associated terminal strips complete,
installed in a cubicle. The cubicle shall be complete with entries for connection of inter
panel wiring to the marshalling panel. The BAMA will cable and connect
between the PLC input/output modules and the PLC terminal strips. These cores
will be ferruled in accordance with the BAMA connection schedule or
termination
drawings. It shall be the BAMA responsibility to connect the panel wiring
between the substation marshalling panels and the PLC terminal strips. These
cores shall be correctly ferruled.
Field or MCC analogue input/output shall be directly connected to the
respective PLC input/output module. These cables shall not go through the
marshalling panels.

3.4.18.3. PLC Software

a. General
The PLC software shall be supplied by the BAMA. It shall be the responsibility
of the BAMA to define the requirements of this software, based on the plant
design requirements, and to develop the
software.

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b. Software Functionality
Mechanical, electrical and process equipment software shall be designed to
ensure correct plant operation in accordance with this Specification. To ensure
correct plant operation, the PLC software controlling sequential, process, alarm,
and supervisory logic must be correct. The BAMA shall develop the
requirements and methodology of the plant operation. This "plant operational
description" shall be in a combination of written text and block diagram or logic
diagram format. It shall include an alarm list and a list of the input/outputs and
data, requiring transfer to the operator interface system. This description shall
be given to the Principal for review and comment.
The BAMA shall develop a functional specification which shall define:
• a functional description of the plant operations
• sequence diagrams - auto start up, auto shut-down and fault trip shut-
down
• a breakup of the proposed programme structure into blocks
• description of each programme block
• alarm list and input/output list.
This functional specification shall be reviewed and approved by the Principal
prior to the commencement of the software development. Areas of the
functional specification may be altered upon reviewing and any changes shall
be clearly documented. If the changes are excessive it may be necessary for the
BAMA to forward the revised functional specification for re-approval. The PLC
software
functionality and input/output list shall be deemed final at this stage, and the
BAMA shall begin development of the software.

c. Software Development
Development of the PLC software shall be completed by the BAMA.
3.4.18.4. Operator Interface System
a. General
The PLC network shall be monitored: and controlled via control panelsin the
control room. The control panels shall be supplied and installedby the BAMA.
The following minimum components in control panel are required:
• mimic panels
• pushbuttons and switches
• gauges

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• potentiometers
• enunciator lights
• acknowledge and reset pushbuttons
• enunciator buzzer.
The control panels shall be directly connected to the PLC only The control
panel shall be designed and manufactured to control and monitor all equipment
as specified in the Scope of Work or the Principal Requirement, or as directed
by the Principal. In addition to the emergency stops required in the field, one
emergency stop shall be provided in each control room. This shall be mounted
on the control panel. The emergency stop shall be hardwired to the appropriate
control circuit(s). The emergency stop shall be fitted with a clear hinged lid to
prevent accidental operation.
In control room the following displays/indication shall be provided for the
operator:
Operator Controls
• drive stop/start
• drive group stop/start
• selection switches
Drive Status
• running/stopped
• motor current
• drive or drive group ready
• magnet status
Alarms
• motor thermal overload trip
• motor thermistor trip
• pullwire switches
• belt alignment switches
• underspeed switches
• position limit switches
• blocked chute
• pressure/temperature/flow alarms
Analogue Variable
• motor current
• pressure/temperature/flow
b. Functionality

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The BAMA shall develop a functional specification, which shall be reviewed

and approved by the Principal prior to commencement of the control panel
development. Areas of the functional specification may be altered upon
reviewing and any change shall be clearly documented. If the changes are
excessive, it may be necessary for the BAMA to forward a revised functional
specification for re-approval. The control panel functionality and input/output
devices shall be deemed final at this stage, and the BAMA shall begin
development of the control panel.

3.4.18.5. PLC and Control Panel Works Testing

The system testing shall be at the PLC equipment supplier's works. The BAMA
shall be present and assist during the works testing of the software and
hardware and shall verify and accept that the
functional operation is as specified.

3.4.18.6. PLC and Control Panel Site Commissioning

The BAMA shall commission the PLC and control panels in accordance with
the following.

a. Site Inspection, Testing and Pre-Commissioning

The BAMA shall co-ordinate and direct this work and be responsible for
verifying that the PLC software controls the drive, sequence, process, alarm and
supervisory logic, as defined by the
approved functional specification. The control panel software functions shall
also be verified as per the approved functional specification. It shall be accepted
that the PLC software and control panel operates correctly, before energizing
any drive.During this work, it shall be assumed at all times that any incorrect or
faulty operation is a result of MCC or field wiring or equipment. The correct
voltage or signal level at the PLC terminals shall be confirmed, prior to
checking software.

b. Site No-Load Commissioning

Pre-commissioning shall be completed before energizing any drive or sequence
of drives. Any subsequent damage to equipment, materials or personnel shall be
the BAMAs total responsibility.
c. Load Commissioning

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Any damage to equipment, materials or personnel as a result of incorrect

operation of PLC software or control panels shall be the total responsibility of
the BAMA.

3.4.19. Field Devices

All conveyors shall be fitted with lanyard/rip cord, belt alignment and
underspeed switches, block chute switches, limit switches and other control
devices as required.

a. General
All devices shall be of a heavy duty type, of proven design, suitable for
theapplication. The device housing shall be metallic construction.

b. Belt Alignment Switchsse/Belt sway.

Belt alignment switches shall have a non-latching bypass pushbutton, totally
enclosed, dust and vermin proof. Belt alignment switches shall be cast
aluminium, IP65 encloseure protection. Switch shall have 1 NO + 1 NC contact
each rated for 10A at 240 V.

c. Underspeed switch
Proximity type underspeed switches shall be used. The remote evaluation unit
shall be installed in the associated drive M.C.C. cubicle or a general control
marshalling cubicle. Alternatively, the evaluation shall be performed in the
P.C.L.

d. Conveyor Lanyard Switches/Rip cord.

Lanyard switches shall be of heavy duty construction, totally enclosed dust and
vermin proof. It shall be cast aluminium with IP65 enclosure protection. Switch
shall have 1 NO + 1 NC contact each rated for 10A at 240 V. On conveyors
with more than four lanyard switches, each unit shall incorporate an indicating
light with a domed red lens at least 75mm and 50mm in diameter.

e. Warning Devices
All warning devices shall be weatherproof. Sirens shall be used as start up
warning devices for conveyors. All other warning devices shall be horns. A
warning device with switch adjustable modes and tones shall be supplied.

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f. Local Control Panels/Stations

Beside each drive shall be located a local control station containing a ‘start’
pushbutton, latching “stop” pushbutton and auto/off/manual selector switch. It
shall be sheet steel clad dust and vermin proof made from 16 SWG sheet metal
construction or stainless steel. It will be wire up to the terminal with 1.5 mm2
PVC insulated copper conductor. The enclosure protection shall be IP55 for
outdoor application.

g. Emergency Stop Pushbutton

These items shall be strategically located around the plant.

h. Local Isolators
Unless otherwise stated, all motors shall be fitted with a lockable local
isolator.The isolator shall be of the full-load current break type, fitted with early
breakand late make auxiliary contacts. This should form part of the local control
station.
i. Solenoid Valves
Unless otherwise specified, solenoid valves shall be brass body, soft seating
general purpose type with epoxy resin encapsulated 110V AC, 50 Hz, coil, in a
weatherproof enclosure.

4.0. INSPECTION, TESTING AND COMMISSIONING

4.1. General
General requirements for inspection, testing and commissioning shall be in accordance with
appropriate standard and approved by the Principal. Quality control shall be in accordance with
appropriate standard and approved by the Principal. All costs associated with these procedures
shall be the responsibility of the BAMA. The BAMA shall submit with their proposals details of
the inspection points, shop testing procedures and load and no-load commissioning tests for
major equipment items included in the supply, to enable prior evaluation and acceptance by the
Principal.

4.2. Propriety Equipment

The BAMA shall supply and install proprietary equipment in accordance with installation
instructions supplied by the manufacturer. Following installation of equipment the BAMA shall
arrange for inspection and acceptance of the equipment installation by the manufactures

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representative, who shall then present the proposed commissioning procedure for implementation
by the BAMA.
The BAMA shall integrate the testing and commissioning of the equipment items with the
overall plant commissioning program and shall be responsible for carrying out all the
recommended procedures as directed by the manufacturer of the equipment. The BAMA shall
arrange for a representative of the manufacturer to be on-site during commissioning to direct the
BAMA staff through the appropriate procedures and make any necessary
adjustments/modifications to ensure the equipment operates
satisfactorily.
Allowance shall be made for the appropriate staff to be made available to carry out such
adjustments/modifications as deemed necessary. Any carnage or materials necessary to adjust or
modify the equipment during commissioning will be supplied by the BAMA as part of this
Contract.

4.3. Test Prior To Delivery

One sub-assembly of each type and size of drive unit shall be tested under load conditions
(where possible) simulating actual operating conditions to determine the operating speeds,
torques and suitability of the equipment.One conveyor pulley of each type and size shall be
tested for balance and concentricity
with respect to its supporting shaft. Half of one per cent of the total of each type and size of idler
roller selected by the Principal shall be tested for balance and concentricity as specified in this
Specification.
For the purpose of identification, idler rollers shall be marked in batches of two hundred (200) of
each type and size.
Samples of each conveyor belt shall be tested dimensionally and physically in accordance with
AS 1334. If two or more individual lengths of belting are spliced to snake a belt length, one
sample for testing shall be taken from each individual length. The principal's test certificates will
be provided to the BAMA when requested.

4.4. Testing & Commissioning on Site

A detailed plant commissioning program shall be prepared by the BAMA and submitted to the
Principal for approval prior to any commissioning activities being undertaken. The program shall
incorporate specific reference to proprietary equipment items to enable co-ordination with the
manufacturer's commissioning representative. The BAMA shall arrange for the Commissioning
Engineer to be present at the appropriate times during total plant commissioning procedure and
the specific commissioning tests to be conducted on the equipment will have been previously

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prepared by the manufacturer and accepted by the Principal. Those procedures will be the basis
for commissioning and testing of the equipment and the BAMA shall support those procedures
on site.
The BAMA shall carry out tests as specified to show correct assembly and erection of the plant.
Adequate notice shall be given to the Principal that each piece of plant is ready for testing,
including the adjusting and setting of all limit switches, indicating lights, signals and other
protective devices.
Testing specifically required by the manufacturer in installation instructions shall be performed
after the inspection and approval of the installation by the manufacturer's engineering
representative. During conveyor belt tracking, if idlers are moved from right angles to the
conveyor center line, they shall be clearly marked and shall be returned to their right angle
alignment before testing of belt tracking is completed.
Each feeder and conveyor shall be tested under local control and all necessary adjustments made
to ensure it is in a safe operating condition. Conveyors shall be run empty for a period of not less
than four hours after alignment of components and training of the belt.
Feeders shall be run empty for a period of not less than four hours. Starting time, stopping time,
noise levels, bearing temperatures, and motor amp reading shall be recorded as applicable.
After all equipment has been run individually to the satisfaction of the Principal, it shall then be
operated continuously in groups as directed by the Principal under no load conditions, and
normal operating sequence control from the control centers appropriate to the operating sections
of the plant. 2 x 12 hours of continuous and uninterrupted operation of each complete section
shall be attained.
The operation is deemed uninterrupted operation if:
a. Number of interruption is less than 6 time over the 12 hours operation with single
interruption time less than 5 minutes and
b. Total interruption time over the 12 hours operation is less than 30 minutes.
During this period, all motions and all devices shall be tested in the presence of and to the
satisfaction of the Principal or its representative. If any equipment or device in any section
proves unsatisfactory in the opinion the Principal, the BAMA shall effect rectification of each
fault or faults, and a further uninterrupted trouble free period of 2 x 12 hours operation of such
section shall be attained before commissioning may
proceed.

4.5. Commissioning
The BAMA shall demonstrate the correct operation of all items of plant up to the design
maximum and shall make such adjustments as required to ensure operation of the plant,

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according to this Specification and the satisfaction of the Principal. During such commissioning,
the BAMA shall demonstrate that the required rates are as specified in this Specification. If such
requirements are not attained, then the BAMA shall make such adjustments as are necessary, and
the entire operation shall be repeated until the specified rates is attained in three complete and
uninterrupted twelve hour periods of operation. After completion of such throughput tests, all
equipment shall be washed down and otherwise cleaned of coal, and all faults shall be rectified.
The entire equipment shall then be operated under no load for an uninterrupted period of four
hours.
The BAMA shall keep proper records of the commissioning of each section of the Plant,
including the load currents of every motor. Where load or speed variations occur, recordings
shall cover the complete variations. A Practical Completion Certificate for the plant will only be
issued following successful completion of all commissioning procedures and acceptance by the
Principal.
The operation is deemed uninterrupted operation if:
a. Number of interruption is less than 6 time over the 12 hours operation with single
interruption time less than 5 minutes and
b. Total interruption time over the twenty-four hours operation is less than 30 minutes.
c. The plant has reach nominal capacity as specified.

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