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Appendix E

Design Criteria

Escarpment Mine Slurry Pipeline

Design Criteria

Doc Nº 0412-DC-GEN-001

Job Nº 2930412 at Denniston Plateau

By Beca Carter Hollings & Ferner Ltd

11/06/2010

These Documents are intended to remain confidential to, and copyright in them belongs to, the Principal/Employer. They shall not be passed to any third party, other than a prospective Subcontractor, without the written permission of the Principal/Employer.

to any third party, other than a prospective Subcontractor, wi thout the written permission of the

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

Page 1

INTRODUCTION

SCOPE

This document describes the key design criteria to be used as the basis for the feasibility study for the Escarpment Mine Coal Slurry Pipeline. The scope of these design criteria covers the following areas of the plant:

General – Site Conditions, Location & Plant Data

Design Life

Operating Hours

Throughput

Redundancy

Process

Coal Slurry water (flow, contaminants, turbidity, temperature, pH etc)

Treated water (flow, quality, etc)

Chemicals (type, form, quantity)

Waste streams (type, form, quantity)

Civil & Structural

Mechanical

Geotechnical

Drainage

Roads

Structural Design

Equipment and Component Design

Electrical, Instrumentation & Controls

Power supply & reliability, distribution

Site electrical standards (motors, voltages, cables etc)

Transformers, MCC’s, VSD’s & switchgear

Motors

Process control requirements

E, I & C equipment supplied with mechanical packages

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

Page 2

SITE CONDITIONS, LOCATION AND PLANT DATA

Site conditions and plant data are as summarised in Tables 1 and 2 below:

Table 1 - General Characteristics

Location

Denniston Plateau, Westland, New Zealand

Plant Elevation

Denniston Plateau – 674m, Fairdown – 12m

Climate

Temperate

Operating schedule

24 h/d, 7 d/wk

Table 2 - Site Characteristics

Site Conditions

Units

Value

Source

Ambient temperature max.

°C

TBA

TBA

Ambient temperature min.

°C

TBA

TBA

Annual precipitation rain

mm

~6,000

L&M Coal

Rainstorm event

mm/h

6

L&M Coal

Relative humidity

%

TBA

TBA

Prevailing wind direction

 

SW

L&M Coal

Maximum wind gust (*S.L.S.)

m/s

37

AS/NZS 1170

Maximum wind gust (*U.L.S.)

m/s

45

AS/NZS 1170

Snow Load

kPa

1.8

AS/NZS 1170

Seismic Hazard Factor (NZS 1170.5)

z

0.30 (Westport)

AS/NZS 1170

*S.L.S. – Serviceability Limit State *U.L.S. – Ultimate Limit State

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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PROJECT DESCRIPTION

The following are the key project scope items forming a basis for the study:

A Coal Preparation Plant (CPP) will be located approximately 1km to the north east of the Escarpment Mine Plan Area (MPA)

The coal slurry pipeline will commence at the CPP location, and generally follow an alignment alongside a new pipeline to be constructed by Kawatiri Energy for a hydro power scheme. This pipeline alignment runs towards the north-west.

A raw water supply pipeline, with an intake located around 6.5km north-east of the CPP on the upper Waimangaroa river.

The coal loadout facility will be at Fairdown, alongside the rail line and adjacent to SH67. This is approximately 11km from the CPP location (in pipeline length terms).

Dewatering of coal will be by screening, coal is to be deposited from the screen into a concrete bunker from where it will be stockpiled by mobile equipment for subsequent dispatch by rail.

Water used to transport the coal will be treated and discharged to a local stream through a water treatment plant.

STANDARDS AND CODES

The specification and design of all new equipment and structures shall be in accordance with the latest revision of the standards referred to in these Design Criteria. Where no specific requirement is stated, the design and construction shall meet or exceed the requirements of the latest edition codes and standards listed in the following subsections. In case of conflict between standards and these Design Criteria, the most appropriate requirements shall apply.

UNITS

The SI System of Units shall be used throughout the project.

The following units will be used as required:

Length Area Velocity Weights Capacity Elevation Forces Stresses Moment and Torsion Uniform Live Loads Site Co-Ordinates Flow – Liquid Flow – Gases Pressure (Gauge) Pressure (Absolute) Temperature

mm (millimetres) m 2 (square metres) m/s (meters per second) t (tonnes) or kg (kilograms) t/h (tonnes per hour) m (metres) kN (kilo-Newtons) MPa (mega-pascals) kN-m (kilo-Newton metres) kN/m 2 (kilo-Newtons per square meter) m (metres) relative to plant site datum m3/h for main process flows, l/h for chemical dosing. Am 3 /min or Nm /min (Actual or Normal cubic meters per minute) kPa, kPag or Bar, Barg kPaa or Bara °C (degrees Celsius)

3

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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GENERAL DESIGN CRITERIA

EQUIPMENT DUTY

Design Life

The intended economic life of the Escarpment Mine is 7 years, however the equipment and facilities will likely be required to operate with future new mine areas. Mechanical equipment will therefore be specified for a design life of 20 years and foundations, building steelwork and concrete will be designed for 30 years.

Operating Hours

All equipment to be selected and designed for continuous operation, 24 hours per day, 365 days per year, with allowance for short planned outages for inspection and maintenance. The site is to be designed for manned operation 24 hours per day, 7 days per week.

Standardization of Components

All new components shall be standardized and rationalized with existing where practical to minimize new types spare parts inventory.

WATER DISCHARGE QUALITY STANDARDS

The discharge from the water treatment plant is to be designed to Class AE Water (being water managed for aquatic ecosystem purposes).

The key requirements of this are:

(1) The natural temperature of the water shall not be changed by more than 3° Celcius.

(2) The following shall not be allowed if they have an adverse effect on aquatic life:

(a)

Any pH change:

(b)

Any increase in the deposition of matter on the bed of the water body or coastal water;

(c)

Any discharge of a contaminant into the water.

(3) The concentration of dissolved oxygen shall exceed 80% of saturation concentration

(4) There shall be no undesirable biological growths as a result of any discharge of a contaminant into the water

Activities that reduce pH of receiving waters must avoid, remedy or mitigate acidity effects and should achieve the natural pH level of the affected river wherever practicable; and

(6) Activities that increase dissolved iron concentrations or the concentration of any other metal or non- metal in the receiving water must avoid, remedy or mitigate adverse effects and the natural metal/non- metal concentration of the receiving water should be achieved wherever practicable.

(7) The following effects must be avoided:

the production of any conspicuous oil or grease films, scums or foams or floatable or suspended materials;

(5)

any conspicuous change in the colour or visual clarity;

any emission of objectionable odour;

the rendering of fresh water unsuitable for consumption by farm animals;

any significant adverse effects on aquatic life

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

Page 5

PLANT DESIGN CRITERIA

Table 3 - Coal Characteristics

Coal Data

Units

Value

Source

Specific gravity

-

1.20 – 1.50

L&M Coal

Bulk density

t/m 3

0.8 – 0.9

L&M Coal

ROM Moisture content

%

~1

L&M Coal

Top size ex Coal Preparation Plant (CPP)

mm

-50

Marston

CPP Product Moisture content

%

18

Marston

Proportion of coking coal (s.g. 1.20 - 1.35)

% of ROM

55

Marston

Proportion of thermal coal (s.g. 1.35 - 1.50)

% of ROM

25

Marston

Table 3a - Particle Size Distribution ex CPP

Retained

Passing

Coking Coal Fractional

Thermal Coal Fractional Mass %

Source

(mm)

(mm)

 

Mass %

 

31.5

50

 

14.8

8.6

Marston

 

16

31.5

 

13.1

7.6

Marston

 

12

16

 

4.8

2.8

Marston

 

8

12

 

9.6

5.5

Marston

 

4

8

 

21.9

8.7

Marston

 

2

4

 

13.9

5.7

Marston

 

1

2

 

17.9

7.5

Marston

 

0.5

1

 

4.0

19.2

Marston

 

0.25

0.5

 

0.0

21.2

Marston

0.125

0.25

 

0.0

7.4

Marston

 

0

0.125

 

0.0

6.0

Marston

 

Table 4 - Operating Schedule

 

Operating Schedule

 

Units

 

Value

Source

Slurry Pipeline Operation

 

wk/y

 

52

Marston

 

d/wk

 

7

Marston

Three-shift operation

 

h/d

 

24

Marston

 

d/y

 

365

Marston

Availability

 

%

 

80

Calculated

Daily productive hours

 

h/d

 

19.2

Calculated

Annual productive hours

 

h/y

 

7,000

Marston

Throughput (design)

 

t/y

 

1,280,000

Marston

Throughput (average)

 

t/y

 

1,000,000

Marston

Inter-campaign time

 

Min

 

60

Assumption

Campaign duration (average)

 

Hrs

 

24

Assumption

Transport rate (peak)

 

t/h

 

183

Calculated

rate (peak)   t/h   183 Calculated Beca Carter Hollings & Ferner Ltd 2930412 Job N

Beca Carter Hollings & Ferner Ltd

2930412

Job N o 2930412 // 11/06/2010 NZ1-3002328-10 Rev B

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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Operating Schedule

Units

Value

Source

Transport rate (average)

t/h

143

Calculated

Table 5 - Pipeline Characteristics

Data

Units

Value

Source

Coal Slurry density (coking)

Cw (%)

40

Weir

Coal Slurry density (thermal)

Cw (%)

43

Weir

Transport water (coking design rate)

m

3 /hr

275

Weir

Transport water (design rate)

m

3 /hr

243

Weir

Minimum pipeline velocity

m/s

1.6

Weir

Redundancy

Design capacities for individual units shall be selected to be ‘mid-range’ of current industry practice. Redundancy will not be provided on major process areas and in general the process will need to be shutdown to effect planned and unplanned maintenance. In the event of a major problem with the dewatering system and/or water treatment plant the contents of the slurry pipeline will need to be dumped to the emergency receiving pond.

Buffer tanks between the raw water line and slurry pumps and between the dewatering screen and water treatment plant shall have approximately 30 minutes capacity.

The philosophy for each of the major process equipment items is:

Raw water pump - one duty pump installed, one complete spare not installed

Slurry pumps - three duty, one standby

Dewatering screen - one duty only with spare parts

Coal solids removal (cyclone and dewatering screen) - spare parts only

Clarification - spare parts only (complete spare sludge pumps)

Filtration - spare parts only (complete spare backwash pumps)

Sludge Mechanical Dewatering - spare parts only

Chemical Dosing Systems - spare parts only (complete spare dosing pumps)

Treated Water Pump - one duty only with spare parts

NB: a more detailed analysis of individual unit vs. final plant availability will be carried out at subsequent design stages.

Chemical Storage

Chemical storage is to be designed to provide 30 days storage at average dose and maximum flow. A minimum of 14 days storage is to remain at the time of delivery.

Chemical storage and distribution is to be located as close as practicable to the point of dosing.

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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WATER TREATMENT PLANT PROCESS DESIGN CRITERIA

Item

Units

Value

Source

COAL SLURRY WATER PARAMETERS

   

Design Raw Water Flow

m

3 /hr

275

Calculated

Turbidity

NTU

2.90

Lab testing results

pH

Unit

8.3

Lab testing results

Suspended Solids

g/m 3

7.4

Lab testing results

DOC

g/m 3

2.9

Lab testing results

UV254

cm

-1

0.126

Lab testing results

TREATED WATER PARAMETERS

     

Treated Water Flow Design

m

3 /hr

275

Calculated

Treated Water Parameters

 

-

Refer above

REM

Availability

 

%

80

Marston

Allowable Plant Outages

Days/yr

73

Marston

FLOCCULATION

     

Flocculent Chemical

 

-

Polyacrylate

Beca

Bulk Storage

 

-

25kg bags

Beca

Dosing system

 

-

Skid mounted batch plant

Beca

Flocculent Dose Rate

g/m 3

0.5 (est.)

Beca

LIME ADDITION

     

Lime Source

 

-

Hydrated Lime

Beca

Bulk Storage

 

-

25kg bags

Beca

Dosing system

 

-

Skid mounted batch plant

Beca

Lime Dose

g/m 3

15 (est.)

Beca

SOLIDS SYSTEMS

     

FINE COAL HANDLING

     

Cyclone cutoff size

 

μm

75

Beca

Dewatering technology

Type:

Screen

Beca

Dewatering Capacity

m

3 /d

TBA

Beca

SLUDGE HANDLING

     

Sludge Thickener Capacity

m

3 /d

6,600

Calculated

Dewatering technology

Type:

Belt press filter

Beca

Dewatering Capacity

m

3 /d

640

Beca

FILTRATION

     

Filtration technology

 

-

Sand filters

Beca

Units

 

No:

3

Beca

Unit size

 

m

2

10

Beca

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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Item

Units

Value

Source

TREATED WATER TANK

     

Residence Time

minutes

15

Beca

TREATED WATER PUMPS

     

Pumps

No:

1

Beca

Pump Flowrate

m

3 /s

0.08

Calculated

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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MATERIALS HANDLING SYSTEM CRITERIA

DESIGN LIFE

All structures shall be designed for a 30 year service life. All mechanical components shall be designed for a 20 year service life.

COAL SLURRY PIPELINE FEED CONVEYOR

Single conveyor feeding slurry pipeline constant density tank. Loading hopper for front end loader reclaim from CPP product stockpiles.

Design capacity 200t/h (at 18% moisture content)

Operating hours 24h/d

STOCKYARD CONVEYOR AND STACKER

Single yard conveyor taking dewatering screen product for transfer to linear stacker.

Stockpile sizes: 2 x 15,000t (one thermal, one coking)

Conveyor and stacker design capacity 200t/h (at 15% moisture content)

Operating hours 24h/d

Stockpile formation aided by mobile equipment (dayshift only)

TRAIN LOADING

By front end loader to hopper cars.

Hopper cars 42t capacity each

Train parcel size 925t

22 cars per train

4 trains per day, 6 days per week

Design loading time (arrival to departure) 1.5 hours

Cycle time (Fairdown-Westport return, including loading) 3.5 hours

Average loading rate required over complete train 690t/h

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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CIVIL/STRUCTURAL DESIGN CRITERIA

STANDARDS AND CODES

Refer to General Design Criteria Section for the projected design life of the project.

As a minimum, the Works shall comply with the current editions of relevant internationally recognised Codes, Standards and Regulations, together with New Zealand Codes, Standards and Bylaws. Where conflict between International Standards and the equivalent New Zealand Standards exist, the more stringent requirements shall prevail.

GEOTECHNICAL AND FOUNDATION DESIGN CRITERIA

No site specific geotechnical investigations or testing has been carried out to date. Golder Associates Ltd (Golder) have been retained as the project geotechnical engineers, and the following information is indicative only and therefore subject to Golder verification and confirmation.

Based on a 2002 Geological Map of the area, it can be inferred that

The slopes from the Dennison Plateau to the coastal plain are largely landslide debris from the coal measures above

The coastal plain is a mixture of alluvial and fan deposits with dune sands near the coast. These soils are sand, gravel and swamp deposits (peat)

The slurry pipeline from the Denniston Plateau down to the Westport Flats may be subject to large and small scale instability. On the Westport Flats the pipeline and plant are likely to be founded on loose saturated soils with potentially some peat layers. Settlement (total and differential) may be of concern and liquefaction is likely to be an issue. Any structure below ground level may need to consider the potential for flotation and vibrations from machinery could result in localised liquefaction, over and above that from earthquakes.

DRAINAGE

Any new drainage that is proposed shall comply with the appropriate sections of the Regional Council’s drainage requirements.

ROADS

TBA

STRUCTURAL DESIGN

All design will be in accordance with the relevant New Zealand standards where possible. All design codes listed are to be used in conjunction with the latest approved amendments dated at the time of issue of this design criteria report.

The following Australian and New Zealand loadings codes will be used:

AS/NZS 1170.0 - Structural Design Actions – General Principles.

AS/NZS 1170.1 - Structural Design Actions – Permanent, imposed and other actions.

AS/NZS 1170.2 - Structural Design Actions – Wind actions.

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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AS/NZS 1170.3 - Structural Design Actions – Snow & Ice actions.

NZS 1170.5 - Structural Design Actions – Earthquake actions – New Zealand.

NZS 3404 – Steel Structures Standards.

AS/NZS 1170.0 – Table C1 – Suggested Serviceability Limit State Criteria.

NZS 3101 – Code of Practice for the Design of Concrete Structures.

AS/NZS 4671 – Steel Reinforcing Materials.

Structural Design Actions

Buildings will be designed to withstand a combination of loads due to gravity and lateral loads. Gravity loads are made up of permanent dead loads, superimposed dead loads and non-permanent live loads, including snow loads. Dead loads and superimposed dead loads result from the weight of the building elements and finishes (e.g. cladding materials, floor finishes, building services, self weight of structural elements, etc), and live loads from the type of occupancy (i.e. number of people, shelving, computers, etc). Wind and earthquake loads are often collectively referred to as lateral loads as they tend to act horizontally.

Dead Loads

Dead load includes the self-weight of the structural floor system and underlying structural support framing. Structural toppings over precast floor systems are also included. Non-structural screeds and permanent partitions, etc are categorised as superimposed dead loads and defined below. Dead loads are calculated for the structure based upon the proposed construction materials.

Superimposed Dead Load

Superimposed dead load (SDL) includes all permanent but non-structural elements of the building fabric. This includes screeds required to form falls and set downs, fixed partitions, suspended ceilings and services, and floor finishes such as tiles or carpet. On roofs and exterior balconies drainage falls and waterproofing systems are also included.

Live Load

Live load includes all gravity loads not described as dead or superimposed dead load and that are generally considered to be transient or non-permanent (i.e. stored materials, movable partitions, equipment, furniture and people).

The New Zealand loading standard AS/NZS 1170:2002 defines minimum live load allowances for particular occupancies.

Lateral Design Actions

The structural frame will be designed to resist actions due to wind or earthquake loading. The magnitude of the calculated lateral loads are a function of the site’s location (topography, exposure, ground conditions, seismicity and proximity to fault lines), the specified design life of the building, the importance level selected, the overall weight of the building, and the anticipated behaviour and performance of the structure when subjected to lateral loading.

Factors pertaining to the site are as specified in the New Zealand Loading Standard AS/NZS 1170. The minimum design life is mandated by the NZ Building Code and is 50 years for normal buildings.

Other factors influencing the overall lateral loads include the weight of internal partitions and cladding elements, location of heavy equipment, plant and tankage, weight and stiffness of the structural frame, structural frame spacing and building height. The distribution of these factors through the building also plays a significant role, as heavy equipment, building elements or heavy storage rooms located near the top of a building result in very high lateral forces being applied to the top of the structure. Thus, relocating heavy elements or occupancies to the lower levels can reduce the required structural element sizes.

Earthquake

The earthquake loads are calculated in accordance with AS/NZS 1170 using the following assumed parameters. These will need to be confirmed by subsequent geotechnical investigation:

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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Site subsoil category:

C

Importance Level:

2

Risk Factor, Ru:

1

Hazard factor, Z:

0.3

Near-fault factor N(T,D):

1.0

Ductility, µ

1.25

Wind

Wind loads are calculated in accordance with AS/NZS 1170 assuming the following parameters:

Basic wind speed:

45m/s U.L.S.

Terrain category:

1.0

Wind directional multiplier:

1.0

Wind shielding multiplier:

1.0

Wind topographical multiplier:

1.0

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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MECHANICAL DESIGN CRITERIA

STANDARDS AND CODES

Refer to General Design Criteria Section for the projected design life of the project.

As a minimum, the Works shall comply with the current editions of relevant internationally recognised Codes, Standards and Regulations, together with New Zealand Codes, Standards and Bylaws. Where conflict between International Standards and the equivalent New Zealand Standards exist, the more stringent requirements shall prevail.

GENERAL

Mechanical equipment and items shall be designed for continuous heavy duty operation in a coastal environment. Due consideration shall be given to potential for overload, impact, stress cycles, material properties and the minimisation of stress concentrations.

Where possible, all mechanical items requiring periodic maintenance shall be standardized to minimize spare parts.

Equipment drives shall be designed to minimize the need for field alignments where possible.

Rotating equipment or items that produce vibration shall be designed to eliminate or minimise the transmission of movement and noise to the structural supports.

Operating noise level measured under load one meter from any drives or equipment shall not exceed 85 dBa.

Any subsection contained in these mechanical design requirements shall not be read without consideration for all other applicable subsections.

PUMPS

All pumps shall generally be centrifugal type, single stage, horizontal end suction, top vertical discharge. Pump casings and impellers shall be matched to existing pumps used on site, or fit for handling the materials specified.

Suction and discharge connections shall have ANSI Standard Flanges.

Chemical dosing pumps will be positive displacement type, with adjustable stroke and frequency.

FIRE PROTECTION

Fire protection in accordance with current NZ regulations shall be provided.

NAMEPLATES

All new equipment shall have nameplates.

PIPING AND VALVES

All piping and valves shall be designed, supplied and installed in accordance with

TBC

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SHAFTS

Shafting shall be designed for a life in excess of the economic life of the equipment.

Stress concentrations at turned down shaft ends shall be considered in the design of shafts.

All keyways shall be in-line and square. Keys shall be supplied with shafts, shop fitted and taped in place for shipping. Keyed shaft ends and keyways shall be in accordance with ISO standards.

Shafting over 100 mm in diameter and shafts in critical areas shall have their metallurgical composition and heat treatment procedures specified.

All commercial sized shafting shall be cold rolled steel (CRS). Shafts 150 mm in diameter and larger shall be forged and ultrasonically tested before machining. All drive shaft ends shall be chamfered and provided with threaded centre holes.

Turndown radii shall have a finish of 1.6 μm or better and shall be at least 25% of the minor shaft diameter. Undercut at radius shall not be permitted. Repairs that involve welding shall not be carried out on shafts.

BOLTS

Bolts and nuts shall be metric thread sizes.

ADJUSTING SCREWS

Adjusting screws shall be stainless steel and metric thread sizes.

BEARINGS AND BEARING SEALS

Minimum L10 life of all bearings shall be 60,000 hours after taking into account all service factors.

Each shaft shall have one fixed and one floating type bearing, the fixed bearing being on the drive end of any driven shaft.

Seals shall be taconite, grease purged, radial design, replaceable triple labyrinth type or accepted equal. Where a shaft terminates at a bearing, the shaft shall terminate within the bearing housing and the housing shall be equipped with a dust-tight end disc. Seals shall be designed taking account of fabrication and running alignment tolerance.

All pillow blocks for 50mm shaft diameter and larger shall have cast ductile iron, cast steel, or fabricated steel split housing. All pillow blocks shall be arranged such that the line of force acting through the pillow block shall be perpendicular to the pillow block supports. Pillow blocks for shafts larger than 90mm shall be furnished with four bolt-bases.

Adjusting screws with locknuts and lugs shall be welded to supporting steel to facilitate alignment of components. Maximum angular misalignment between shaft and housing shall be 0.25°.

Grease fittings shall be installed on all bearing housings. shipping.

Housings shall be filled with grease before

DRIVE BASES

Base frames shall be sufficiently stiff to withstand any undue deflection due to both static and dynamic loading conditions.

Steel pads fabricated from a minimum of 25mm thick plate shall be welded to the base frame and machined where the motor and gearbox mounts come in contact with the base.

Drive bases shall be stress relieved after welding but before machining.

Escarpment Mine Coal Slurry Pipeline – DESIGN CRITERIA

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Each drive base shall be provided with adjusting screws and locknuts to assist radial and axial alignment of the motor. Four jacking screws and a minimum of 6mm shimming allowance shall be provided for the motor vertical alignment.

Minimum 25mm of non shrink grout shall be provided under bases.

FLEXIBLE COUPLINGS

Flexible power transmission high-speed couplings shall be designed and constructed with a service factor of not less than 1.5 based on the nameplate motor power.

RIGID COUPLINGS

Rigid couplings shall be designed using a service factor of 1.5 on all applied loads including bending moment.

A spigot shall be provided in order to locate the coupling halves and centre them on their respective shafts.

The coupling shall be laid out so that removal of bolts is possible without removing the coupling or any of the adjacent drive components.

CHAIN DRIVES

Chain drives shall be avoided where it is practical. If approved, they shall be totally enclosed oil bath type, with oil pump and filter in larger sizes except for the shuttle chute drive that can be dry. Holes and covers shall be provided for insertion of a hand held tachometer.

LUBRICATION SYSTEMS

Manual lubrication will be applied for grease points that need to be serviced every 3 months or longer.

All manually serviced grease lines shall be grouped together to central distribution blocks that are accessible from walkways and platforms.

Grease nipples shall be provided where appropriate and shall be 1/4” standard Alemite fittings.

Lubrication lines shall be fabricated in stainless steel S.S. 316 and located to permit servicing and dismantling of adjacent components. Brass or copper tubes shall not be used. Flexible lines, where required shall be minimum 6mm I.D. wire braid, grease resistant, rubber covered non-skive type hose.

Initial lubrication, including that required for adjustment and testing shall be by Contractor.

All lubrication points shall be accessible from, or piped out for ready access from walkways, platforms or stairs with extension tubing.

HOPPERS AND BINS

Hoppers shall be fabricated of a minimum 10 mm thick, grade 250 steel plate, adequately reinforced.

The minimum valley angle in hoppers shall be 50° from the horizontal and minimum hopper angle for wedge type hoppers shall be 55°.

All hopper and miscellaneous plate and steel work shall be designed and fitted for efficient dust sealing and shedding.

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GUARDS

All revolving parts such as belt drives, couplings, pulleys and exposed shafts shall be adequately guarded.

Non-lubricated drives shall have guards of flattened expanded mesh for visual inspection. All guards shall be fabricated and mounted with provision for easy removal by one person. Lubrication capability, without requiring removing of guard, shall be provided.

Guards shall be failsafe in that should the securing system fail or come loose, the guard will not fall off.

ZERO SPEED SWITCHES

The switches shall be of the non-contacting pulse counting type, consisting of sensing probe and remote mounted control unit. Switches shall be conveniently located and protected against spillage.

PAINTING

Vendor supplied & site fabricated mechanical equipment shall be painted in accordance with

TBC

Vendor supplied & site fabricated structural equipment shall be painted in accordance with

TBC

GENERAL CONVEYOR REQUIREMENTS

All conveyors and conveyor accessories shall be designed according to the requirements of the Conveyor Equipment Manufacturer’s Association (CEMA).

All conveyors shall be capable of starting under any and all operating conditions.

Design Capacity - is a peak capacity that all of the equipment can handle for extended periods of time, without any impact on the equipment performance.

The conveyor drive motor power shall be greater than 1.1 x the calculated absorbed power at the motor shaft, based on the conveyor design capacity.

Conveyor belt speed and the drive reduction ratio selection shall be based on the CEMA recommended material cross section, at the standard edge distance for a bulk density of 800 kg/m³. A suitable automatic take-up shall be provided for all conveyors. Vertical gravity take-up is the preferred take-up design.

Elevated conveyors shall have a 900 mm wide operator’s walkway on one side of the conveyor.

All inclined conveyors shall be fitted with a backstop.

An area of each conveyor structure shall be identified for the belt splicing station. Belt splicing table support shall be provided on the structure along with power outlets for belt vulcaniser and equipment.

SPEED REDUCERS

All speed reducers shall be of the manufacturer’s standard design.

Expected service life for gears (G1: 1% expected failure rate) and bearings (L10) shall not be less than 60,000 hours. Reducers shall be rated in accordance with AGMA Standard 6010-F97, latest edition, for gear capacity, bearing capacity and strength of other components such as shafts, keys and bolting except where a higher requirement is specified elsewhere in these Design Criteria.

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LINERS

All interior surfaces of chutes and skirt boards which may become in contact with handled coal, shall be lined with 20mm thick, abrasion resistant liner plates.

Liner sizes shall be coordinated with the chute design such that high wear areas of the chute can be replaced as a complete panel and relined in the shop.

Protruding bolt heads or nuts are not acceptable on inside surfaces of liners.

Liner Plate sizes shall be standardized and the weight of each plate shall not exceed 40kg where liner plates must be replaced individually inside the chute.

Each chute section shall have uniform minimum gaps not to exceed 5mm between liners and these gaps shall be staggered between adjacent rows. No transition of liner plates shall be allowed from one section to another, i.e., surface continuity shall be maintained.

CONVEYOR WEIGH SCALES

Load cell type system with steel weighbridge complete with 4 precision idlers shall be rated for a maintained accuracy of 0.5% over the full operating capacity range.

DUST CONTROL SYSTEM

A water spray dust suppression system shall be used in the coal stockyard for dust control at the stockpiles.

FIRE PROTECTION

A fire suppression system including hose cabinets with hose reels containing 40mm diameter, 30m long hoses shall be provided at nominated buildings and structures.

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ELECTRICAL AND INSTRUMENTATION DESIGN CRITERIA

GENERAL REQUIREMENTS

All equipment and systems supplied shall comply fully with the requirements of the local Regulations and all Local Authorities at the place of installation having jurisdiction over any part of the works.

All equipment and systems shall conform to the latest editions, including amendments, of the relevant New Zealand, Australian or IEC Standards, unless specified otherwise.

SUPPLY VOLTAGES

Switchboard Power

11kV, 3 phase, resistance earthed, 50Hz.

400V, 3 phase, 4 wire, solidly earthed, neutral, 50Hz.

Controls

220V, 1 phase, 50 Hz.

24V DC

EQUIPMENT

Transformers

Distribution transformers (11kV/400VAC) shall be outdoor ONAN type unless otherwise specified. Transformers shall be standardised regarding size, rating and type as much as practicable to provide interchange ability. Primary and secondary terminations shall be made in cable boxes. Oil type transformers shall be located in a bund with oil water separator facility for drainage.

11kV Switchboards and MCCs

Switchboards shall be constructed to AS1025 standards and type tested.

Switchboards shall be fitted with surge protection.

Switchboards and MCCs shall be located in dedicated electrical rooms with adequate ventilation.

Switchboards and MCCs shall be designed with 20% spare capacity for future development.

400V Switchboards and MCCs

Switchboards shall be constructed to AS/NZS3439 standards and type tested.

Switchboards shall be fitted with surge protection.

Power factor correction equipment shall be fitted to main Switchboards to maintain a plant power factor of

0.95.

Switchboards and MCCs shall be located in dedicated electrical rooms with adequate ventilation.

Switchboards and MCCs shall be designed with 20% spare capacity for future development.

Motor Starters shall be provided with a facility for means of lockable isolation and manual selection controls. Status indication shall include ‘available’, ‘fault’ and ‘running’.

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Connectivity to Distributed Control System (DCS) or Programmable Logic Controller (PLC) system is required, typically via serial communication link.

Variable Speed Drives (VSDs) and Soft Starters

All VSDs shall be designed with a DV/DT filter or better, to limit harmonics.

Steps to minimise Radio Frequency Interference (RFI) shall be undertaken, such as fitting EMC filters.

VSDs are to be of a suitable construction for the environment where they are to be located.

Motors

The voltage rating of AC motors shall be 400VAC, 3 phase 50 Hz.

Motors larger than (TBC) kW shall have thermister protection. These motors are also shall have an integral anti-condensation heater, which is to be energised whilst the motor is stationary and de-energised whilst the motor is running.

Motors shall be designed for high efficiency and energy saving, service factor 1.15, insulation class F.

Motors larger than 95KW and are fed via a VSD, shall be of insulation class H. They are to have an insulated bearing at the non-drive sided and a conductive brush at the drive side to reduce EDM. Other EDM protection is to form the basis of the design for these motors.

Emergency stop facility shall be provided local to the motor.

Control Equipment

The general and sequential control shall be through agreed type Distributed Control System (DCS) or Programmable Logic Controller (PLC) installed in stand-alone cabinets and located in dedicated air- conditioned rooms.

The SCADA or HMI equipment will be located in a clean air-conditioned room or be suitably rated for the environment in which it is located.

Power for all instruments, PLCs, HMIs and alarm systems shall be provided from separate power sources. The PLC shall be provided with power from an uninterruptible power supply (UPS).

In general, the instrumentation shall be electronic with 4 to 20mA DC signal range. Any control valves shall be provided with electric or pneumatic actuators.

Electrical supply for instrumentation shall be 230V, 50 Hertz, or 24VDC.

Field instrumentation shall comply with latest industry standards and practices. This shall be suitable for the environment in which it is to be located.

Cabling

All electrical cables shall have copper or aluminium conductors.

Cables carrying low voltage and above, shall be armoured.

All cables which are situated between a VSD an the respective motor, shall be of the variolex type, or equivalent. This cable only applies where the length of the cable is inside the VSD manufacturers tolerance. If the length is beyond the VSD manufacturer’s recommendation, then an alternative shall be specified within the design.

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Transmission Lines

Electrical transmission lines shall have copper or aluminium conductors.

Emergency Power and Lighting

Where required, standby diesel power generation shall be provided, capable of meeting the full plant capacity load requirements.

Al instrumentation and control systems are to be powered by an uninterruptable power supply (UPS), with a minimum 60 minute capacity.

Emergency lighting shall be provided where required and shall consist of self-charging units complete with lamps, storage battery, charger and automatic transfer relay.

Lightning Protection

All lightning protection systems shall comply with AS/NZS 1768:2007

E, I & C EQUIPMENT SUPPLIED WITH MECHANICAL PACKAGES

Electrical, instrumentation, and control equipment supplied as part of mechanical packages must comply with project standards, including:

All criteria defined within this document

Pre-installation, pre-wiring and pre-testing in the supplier’s factory, as far as possible

Provision for remote control and monitoring

General intent of the operating and control requirements for the package.