Technical Specification

TS5 - Mechanical Plant Supply &

Installation

CBH Engineering Pty Ltd

P | (08) 9236 5350
F | (08) 9236 5370
www.cbh.com.au
TS5 Mechanical Plant Supply & Installation

Document Control
Document owner: Senior Maintenance Engineer

Change Control Policy

Any amendment to this standard must be recorded in the table below.

If substantial changes are made a new version of the document shall be created to preserve an
audit trail.

Review Date Author Description of amendments

A 21/5/2009 T. Tyler
B 20/7/2009 T. Tyler
C 30/4/2009 T. Tyler
D 13/11/2014 T. Tyler
Reformatting, CBH changed to BWE, update reference
codes and standads.
Previously TS10
Re-brand
Re-brand and formatting

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Contents
1. Scope 4

2. Governing standards 4

3. General installation requirements 5

4. Materials 5

5. Lifting facilities 5

6. Instruction plates and labels 6

7. Gearing and gearboxes 6

8. Couplings 6

9. Bearings 6

10. Seals 7

11. Lubrication 7

12. Nominated lubricants 7

13. Vee belt drives 8

14. Shafts 8

15. Safety guards 8

16. Conveyor belts 8

17. Sprouting 9

18. Miscellaneous steel work 9

19. Platforms, ladders and handrails 9

20. Fasteners 9

21. Welding and flame cutting 10

22. Baseplates 10

23. Integral pipework, valves & fittings for compressed air lines 10

24. Inspection and testing 10

25. Operation and maintenance manuals 12

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1. Scope
This specification establishes the principles to be followed for the design, supply, installation,
testing of mechanical plant and equipment and the performance requirements of all operations
necessary to complete this work.

All plant and equipment shall be supplied, installed, lubricated and tested in accordance with
this specification and the drawings provided or approved by the Engineer.

This specification shall in no way supersede any specific instruction or requirement given by
manufacturers for the erection of their equipment or by the Contractor's responsibility for the
erection of that equipment to the satisfaction of the Engineer.

This specification is to be read in conjunction with the Scope of Work and General Provisions
as outlined in Exhibit C.

2. Governing standards
2.1 General

Except where otherwise stated, the works shall be in accordance with the current issue,
including amendments of the relevant Australian Standards. These should include, but not be
limited to those identified here-in:

2.2 Standards

The latest edition of the following Australian Standards and other publications shall apply to
this specification. These are the minimum requirements and precedence shall be given to
specific reference within the body of this document or in the drawings.

AS 1110.1 - 2000 ISO Metric Hexagon Bolts and Screws, Grade A & B
AS 1111.1 - 2000 ISO Metric Hexagon Bolts and Screws, Grade A & B
AS 1112.1 - 2000 ISO Metric Hexagon Nuts. Style 1 A & B.
AS 1112.2 2000 150 Metric Hexagon Nuts. Style 2 A & B.
AS 1112.3 2000 150 Metric Hexagon Nuts. Grade C1
AS 1112.4 2000 150 Metric Hexagon Nuts Chamfered Thin Nuts Grade A & B
AS 1210.SUPP1 - 1990 Unfired Pressure Vessels
AS 1214 - 1983 Hot Dipped Galvanised Coatings on Threaded Fasteners
AS 1237.1 - 2002 Plain Washers for General Engineering Purposes
AS 1275 - 1985 Metric Screw Threads for Fasteners
AS 1403 - 2004 Design of Rotating Steel Shafts
AS 1470 1986 Health and Safety at Work Principles and Practices
AS/NZS 1554.1 - 2004 Structural Steel Welding
AS 1657 - 1992 Fixed Platforms, Walkways, Stairways and Ladders - Design,
Construction and Installation
AS 1755 - 2000 Conveyors Design, Construction, Installation and Operation
Safety Requirements
AS 3679.1 - 1996 Structural Steel Part 1 Hot Rolled Bars and Sections
AS 3679.2 1996 Structural Steel Welded Section

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AS 3947.3 2001 Low Voltage Switchgear and Controlgear

AS 3439.1 - 2002 Low Voltage Switchgear and Controlgear Assembly
AS 4100 1998 Steel Structures Code
AS 4856 2000 Welding Consumables
AS 4857 2006 Welding Consumables
BS 3790 2006 Specification for Belt Drives

Reference in this specification of specific clauses of the various codes is intended to highlight
those points and shall not be taken to imply a lesser importance for all other applicable
clauses or codes.

3. General installation requirements

Before installation, all parts shall be thoroughly cleaned and all rust, dirt, grit and foreign
matter shall be removed. Grease or other protective coatings supplied for protection of the
equipment in shipment and/or storage, except prime coating, shall be removed by using
suitable solvents or cleaners which will not damage the finish of the equipment.

All foundation elevations and bolt locations shall be verified and accepted by the Contractor
prior to the start of installation of equipment. Bending of bolts to fit equipment baseplate holes
shall NOT be permitted.

Levelling and alignment of all equipment shall be within the tolerance specified on the
drawings or as specified in the manufacturer's instructions. Where equipment is received as a
shop assembled unit, alignment shall be checked and adjusted where necessary.

Care shall be taken to ensure that equipment is not damaged during installation.

Site modifications to plant and equipment shall NOT be carried out unless approved by the
Engineer. Dismantling of sub-assemblies shall not be done unless approved by the Engineer.

4. Materials
All materials shall be new and of best quality. No welding, filling or plugging of defective parts
will be permitted without prior approval by the Engineer.

All components shall be suitably marked to facilitate assembly. When two or more similar but
not identical components are used they shall also be marked to obviate incorrect assembly.

5. Lifting facilities
All items of equipment weighing more than 50kg shall be provided with a convenient
arrangement of slinging or handling during erection and maintenance. Any special devices and
special lifting tackle necessary for the maintenance of the Plant shall be provided by the
Contractor and shall be subject to the approval by the Engineer.

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6. Instruction plates and labels

Instruction plates, name plates and labels (in the English language) shall be fitted to all Plant
requiring identification and instructions for operation. Where possible they shall be fitted to
Plant before packing for transit. Where this is not practicable they shall be supplied loose for
fitting during erection, but great care shall be taken in identification and packing to minimise
the chance of misplacement or loss. The construction, location, size and engraving of all name
plates and labels shall be such that they are easily readable from Plant operation levels.

7. Gearing and gearboxes

All gearing shall be in accordance with American Gear Manufacturers Asociation (A.G.M.A)
Rating.

Gearboxes and oil baths shall be provided with filling and drain plugs, both of adequate size
and shall be provided with an approved means of oil level indication.

8. Couplings
Couplings shall be of the flexible type, unless approved by the Engineer.

The limits and fits of shafts and coupling bores, alignment of couplings and allowable gaps
shall be as recommended by the equipment supplier.

9. Bearings
Where possible, ball/roller bearings shall be supplied in housings, complete with specified
seals, locating rings sleeves etc. Particular attention is to be paid to radial clearance during
assembly.

Plummer blocks shall be mounted so that direct static tension loads on the holding down bolts
and cap bolts are avoided. However, the plummer block units shall be designed to withstand
any form of loading imposed upon them during normal operation of the plant.

Pairs of plummer blocks shall be fully self-aligning with one "fixed" and one "free" type for each
shaft.

When plummer blocks are mounted at shaft ends, covers shall be supplied.

All bearings, motor and driven equipment bearings shall be opened and inspected before
equipment is lubricated or placed in operation, unless such inspection is waived by the
Engineer.

All shafts and bearings shall be maintained in a clean condition during installation and covered
whenever work is not proceeding.

Unit type bearings which are utilised on the majority of non drive pulley shafts are of the single
row deep groove self aligning outer race type with camlock and grub screw location to shafts.

After assembly and prior to initial running of the plant all plugs shall be removed (if applicable)
and grease nipples be fitted. Bearings shall then be greased using pressure type equipment.
After initial run all grub screw locking arrangements shall be re-tightened.

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10. Seals
Seals for shafting shall be of the rubbing type (ie. felt washer, spring steel washers and lip
seals), or the "non-rubbing" type (labyrinths). These shall be selected for each application so
as to preclude the ingress of dust, moisture and other contaminants and to retain within the
housing the lubricants (grease or oil) used.

The clearances between the mating surfaces on all the seal components shall ensure that
friction power loss and shaft wear are kept to a minimum.

Shafts and housing shall be machined to the limits and surface finishes recommended by the
seal suppliers.

11. Lubrication
Provision shall be made for suitable lubrication wherever necessary to ensure smooth
operation and freedom from undue wear.

Gearboxes and oil baths shall be provided with filling and drain plugs, both of adequate size
and shall be provided with an approved means of oil level indication.

The seals must be adequate to retain the lubricant.

Attention is drawn to the need to ensure that the lubrication will be adequate during start-up
and run down of plant and machinery. This is particularly essential on standby equipment
which can be inoperative for a considerable period of time.

A separate nipple shall be provided to serve each lubrication point and all grease nipples or oil
cups and dip sticks shall be readily accessible. Where necessary for accessibility, nipples may
be remotely mounted at a point as near as is practicable to the lubricating point, and
connected thereto by means of suitable tubing. PVC pipe or tubing shall not be used, unless
approved in writing by the Engineer. Where a number of nipples supplying remote lubricating
points are specified, they shall be grouped together on a conveniently placed battery plate.

The Contractor shall supply a schedule showing all the lubricating points and the required
lubricant from the recommended supplier. The Contractor shall adopt the minimum range of
oils and greases to facilitate rationalisation of stocks.

All necessary oils and lubricants for site erection shall be provided by the Contractor.

12. Nominated lubricants

The type and grade of lubricant required for a particular item of equipment shall be as
recommended by the equipment supplier and shall be selected from the range nominated by
the Engineer.

All necessary oils and lubricants for site erection shall be provided by the Contractor.

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13. Vee belt drives

Vee belt drives shall be in accordance with BS 3790. Belts shall be provided in matched sets.

Belt sheaves shall be accurately balanced and fitted with taper lock bushes or equivalent.

After belt tensioning, the location of the drive motor on the slide rails shall be checked to
ensure sufficient space is available for future adjustment.

All vee belt drives shall be adequately guarded and protected from dust and moisture.

14. Shafts
Rotating and fixed shafts for cranes and hoists shall be designed in accordance with AS 1403.

Where changes in diameter occur, suitable fillet radii shall be provided.

Chamfers shall be provided at shaft ends.

Where keys are used, they shall be supplied with their appropriate shafts.

15. Safety guards

All exposed moving parts of machinery shall be fully guarded, in accordance with AS 1470 and
AS 1755.

The guards shall be of substantial construction and rigidly fixed. They shall be easily removed
and fitted with gates or doors where access is required for inspection and maintenance. Care
must be taken to ensure the stationary points requiring access, such as grease nipples, are
readily accessible without the removal of guards.

Adjustment of tail pulleys take ups and other relevant items shall be possible without removal
of guards.

Guards shall be capable of supporting a load of 1kN without permanent distortion.

16. Conveyor belts

All conveyor belts shall be provided by the Contractor, or if noted in the Scope of Work, by the.
The installation and vulcanising shall be undertaken by the Contractor. The vulcanising
sub-contractor shall be approved by the Engineer.

All vulcanised joints shall be carried out in accordance with the manufacturer's
recommendation.

The Contractor shall pay particular attention to the sealing of joints for exclusion of dust and
liquids, linear alignment of vulcanised joint and smoothness and flatness of joint.

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17. Sprouting
The correct installation of spouting is of major importance. It shall be carried out in accordance
with the detail drawings and all relevant specifications.

Trueness and smooth interior finish of plates, valves and connection flanges are essential for
correct and long wearing characteristics of the spouting.

All spout supports shall be correctly located prior to the installation of the spouting and all
co-ordinates and elevations checked. When spouts are trimmed for length they must be
carefully measured and connecting segments 'NOT' pulled out of correct position.

18. Miscellaneous steel work

All associated steelwork, chutes, bins, platework, access platforms and walkways etc, shall be
fabricated and erected in accordance with the detail arrangement drawings and Technical
Specification "Structural Steelwork Fabrication and Erection", TS 5 and 6.

Should any additional steelwork be required, it shall be similarly designed and fabricated.

19. Platforms, ladders and handrails

The equipment to be provided shall comply with AS 1657 for means of operation inspection
and overhaul. They shall be of sufficient strength to support personnel, tools and portions of
plant which may be placed on them. Particular attention shall be given to their rigidity.

The plant shall be detailed such that permanent platforms, walkways, stairways and ladders
may be erected early in the construction phase to provide safe access for construction
personnel.

20. Fasteners
Unless otherwise specified or approved all bolts, studs and nuts shall be of steel.

After tightening, the threads on all bolts and studs shall extend at least four threads beyond
the inside face of the nuts and project one thread beyond the outer face.

A plain parallel washer shall be fitted under each nut except when subject to vibration or
movement when spring washers or nylon insert lock nuts shall be used. Where nut adjustment
is required castellated nuts with split cotter pins are preferred.

Where additional bolting is required or equipment has been left undrilled unless required to be
reamed or for fitted bolts, the holes shall be drilled 1.5mm larger than the bolt size.

Threads exposed to water or weather and subject to future disassembly for maintenance or
replacement shall be lubricated with graphite and oil before tightening.

All site erection bolts are to be provided by the Contractor.

All bolts wherever used shall be metric series and galvanised.

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21. Welding and flame cutting

The Engineer's approval shall be obtained before welding or flame cutting of any mechanical
plant or equipment.

Surfaces to be welded shall be clean, free of scale, grease, oil or other contaminants
detrimental to sound fusion. All weld spatter shall be cleaned off after completion.

Electric arc welding shall NOT be carried out in the proximity of bearings.

Earthing conductors shall be connected as close as possible to the point of welding.

Plant and equipment shall be suitably protected while welding or flame cutting is being carried
out to avoid damage from weld spatter, molten metal spray etc.

22. Baseplates
Baseplates and machinery shall be erected on prepared foundations and aligned to the
prescribed centre lines and elevations as shown on the erection drawings.

Any variations to dimensions as shown on the drawings shall only be with the Engineer's
approval.

Baseplates and machinery shall be properly levelled, aligned, set and adjusted on packers and
shims.

Packers shall be of sufficient size to sustain an effective load bearing area. They shall be of
one piece thickness.

Shims shall be the same size as the packer. The maximum thickness of shim shall be used to
reduce the number of shims required at any one point to a minimum.

Grouting shall be carried out in accordance with Technical Specification "Structural Steelwork
Fabrication and Erection", TS 5 and 6.

23. Integral pipework, valves & fittings for compressed air

lines
All integral pipework, valves and fittings shall be erected in accordance with the drawings.

Should any additional pipework be required it shall be designed and fabricated in accordance
with the manufacturers specification and the Engineers approval.

24. Inspection and testing

24.1 Installation checks

After the plant and/or equipment has been installed, the following shall be performed and
recorded.

24.1.1 Check installation for conformance with the design and specifications using available
data (design drawings, vendor's drawings and manuals, process and instrument

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drawings, schematic diagrams, connection diagrams, etc).

24.1.2 Confirm suitability of mechanical equipment operation by:

i) Checking alignment of all couplings, belts, gears etc.
ii) Checking freedom of shaft rotation.
iii) Checking tightness of seals, inspecting packing of glands etc.

24.1.3 Check that lubrication of equipment is complete.

24.1.4 Check that all moving parts are properly protected with guards.

24.1.5 Check cleanliness of equipment and systems. The above shall include all checks and
tests which can be performed without energising the plant or equipment.

24.2 Testing

When construction completeness is confirmed, pre-operational tests which require energising

of all plant and equipment shall be carried out. These shall be the initial operational tests of the
equipment under minimum load conditions and subsequently at full load conditions.

The Contractor is to provide all materials, equipment, instruments, labour and services for the
testing. Where formal testing is required to demonstrate that performance requirements have
been achieved, the services of a NATA approved laboratory shall be used.

When an item of equipment is ready for test the Contractor shall give the Engineer at least two
(2) days notice of the intention to carry out testing and shall not commence such testing until
the approval of the Engineer has been obtained.

Submit at least four (4) weeks ahead of testing, a program and schedule outlining the testing.
Include particulars of test stages and procedures.

All run-in tests shall consist of continuous operation until all bearing temperatures and
equipment vibration reach a steady state condition, within the limits allowed by the
manufacturer. The following tests shall be made :

24.2.1 Check direction of rotation of all equipment, initially with the equipment uncoupled
and then ensure speeds are in compliance with design. Ensure that equipment
operates with minimum vibration and within limits established by the manufacturer.

24.2.2 Check operation of hydraulic and lubrication systems. Oil supply to gears and
bearings shall be confirmed to be of proper volume. Gear spray systems shall provide
full coverage of the face of the gears.

24.2.3 Checks shall be made between all moving parts to be sure there is no interference
and that clearances are to manufacturer's tolerances.

Belting for conveyors and feeders shall be properly tensioned to ensure no slipping
between belt and pulleys. The belt shall be properly trained and skirting adjusted.
Additionally it is necessary to:

24.2.4 Ensure that all instrument devices (zero speed switches, alignment switches,
emergency stop switches etc) are operating properly.

24.2.5 Simulate plant or equipment operation (without material) and make other adjustments
as required.

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Representatives of the plant and equipment manufacturers shall attend the site testing and
commissioning, and shall certify that the plant and equipment is operating correctly.

For each test and procedure, provide a report or certificate in a form suitable for inclusion in an
operation and maintenance manual. These shall include all details of tests, modifications,
adjustments and the like.

24.3 Load testing

When all pre-operational testing is completed to the satisfaction of the Engineer the Contractor
will advise CBH in writing and request a full load test to be arranged.

The full load test will require all sections of the plant to be operated at design throughput of
grain and to do so in compliance with the specification.

The full load test shall include the operation of all elevators, conveyors, spouts, trippers, valves
and swing chutes at the nominal design rate of 400 tph.

All plant items are required to be proven to the satisfaction of the Engineer. Any defects which
are revealed during such testing are to be corrected by the Contractor who will be required to
attend site during such testing and have available the appropriate technical capability to
undertake such work.

25. Operation and maintenance manuals

25.1 Manual

Three (3) copies of final Operation and Maintenance Manuals are to be provided by the
Contractor to the Engineer one (1) week prior to the date of Practical Completion. The
Operation and Maintenance Manuals are to contain all of the information necessary for the
CBH and their appointed maintenance contractor's to:

(a) Understand the purposes for which aspects of the facility were designed;
(b) Understand the correct method of operation of fittings, services and equipment;
(c) Understand the requirements for periodic maintenance and repairs;
(d) Have a knowledge of the sources for specialist maintenance and repair work;
(e) Have a knowledge of the sources of supply for replacement; and
(f) Have a documentary means to establish locations of services and equipment in the
event of minor changes to the facility being required.

25.2 Operating guidelines

The Operating Guidelines are to include a description of the purposes for which all aspects of
the facility were designed and full instructions on the operation of the facility and emergency
procedures.

25.3 Maintenance guidelines

The Maintenance Guidelines are to include maintenance instructions for the services and
equipment in the facility. The manual is to include a comprehensive index of materials and
equipment used in the facility, giving the name and address of the supplier and service agent

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for each item. Include a schedule listing frequency at which items of maintenance work should
be undertaken, weights of major items, fault finding procedures and a description of special
precautions. Items requiring periodic rectification to comply with statutory requirements are to
be listed separately showing item name, description, location, periodicity, last test date, next
test date and applicable code.

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