t11m408-i1-takraf-03910-vdcme02-p1me01-004

Construction Manual - Mechanical TAKRAF GmbH

2013-08-26 Revision: B

Product: Conveyor CV -11 Extension of conveyor CV-11

Document: T11M408-I1-TAKRAF-03910-VDCME02-P1ME01-004 Seller: TAKRAF GmbH

Torgauer Straße 336 04347 Leipzig Federal Republic of Germany

Client: CORPORACIÓN NACIONAL DEL COBRE DE CHILE (CODELCO) División El Teniente Santiago, Chile 11 Región, Chile

TAKRAF Project-No.: G0268

Year of Construction 2014

Prepared by: DB – André Kreter

Prepared on: Aug. 2013

Project: G 0268 EL Teniente - Nuevo Nivel Mina Document:

T11M408-I1-TAKRAF-03910-VDCME02-P1ME01-004

Subject: Construction Manual Conveyor CV-11

2013-08-26 Revision: B Construction Manual - Mechanic

2

Record of Revisions ISSUE DATE

EFFECT ON DESCRIPTION PAGE PARA

B 26.08.2013 All All ISSUED FOR APPROVAL





Construction Manual - Mechanic 3

The text, drawings/sketches and all attachments of this technical documentation are protected by the supplier’s copyright. The receiver is entrusted with this documentation for personal use only. Without the supplier’s written approval, it must not be copied or otherwise reproduced, passed on to third people, in particular competitors, or misused in any other way. Illegal use by the receiver or third persons will have consequences under civil law and criminal law. This order-related documentation is available in German language. The German version shall apply in case of any problems in formulation and understanding.

TAKRAF GmbH

Torgauer Straße 336

04347 Leipzig

Federal Republic of Germany






Table of Contents

1 General Mechanical Installation................................................................................... 5 1.1 Installation description .................................................................................................... 5 1.2 Installation procedure ..................................................................................................... 5 1.3 Field joints and connections ............................................................................................ 6 1.4 Temporary supports ........................................................................................................ 6 1.5 Securing of structure during construction period ............................................................. 6 1.6 Lifting appliances ............................................................................................................ 7 1.7 Storage & handling of supplies ....................................................................................... 9 1.8 General requirements ..................................................................................................... 9

2 Guideline for Construction description ..................................................................... 11

3 Construction Description ........................................................................................... 12 3.1 General conditions Construction Yard ........................................................................... 12 3.2 General Remarks for Installation and Commissioning ................................................... 12 3.3 General Arrangement Drawings .................................................................................... 13 3.4 List of Weights* ............................................................................................................. 14 3.5 Tail Station Installation .................................................................................................. 15 3.5.1 Main Frame Installation ................................................................................................. 15 3.5.2 Motor Unit Installation ................................................................................................... 16 3.5.3 Take-up Station Installation .......................................................................................... 19 3.5.4 Walkway Installation ..................................................................................................... 22 3.6 Loading Module CV-4A to CV-11 Installation ................................................................ 22 3.7 Loading Module CV-10 to CV11 Installation .................................................................. 23 3.8 Head Return Station Installation ................................................................................... 23 3.9 Conveyor Module Installation ........................................................................................ 24 3.10 Equipment Installation................................................................................................... 25 3.10.1 Hydraulic and Lubrication Systems ............................................................................... 25 3.10.2 Belt Scraper Installation ................................................................................................ 25 3.10.3 Mechanical Equipment / Monitoring Devices ................................................................. 25 3.10.4 Safety Guards Installation ............................................................................................. 26 3.11 Belt Installation ............................................................................................................. 27

4 Attachments ................................................................................................................ 28






1 General Mechanical Installation

1.1 Installation description

The present document gives only a general description of the installation procedure as of July 2013, which shall be understood in the context of the applicable local regulations and must be detailed on the basis of the lifting appliances and installation tools actually and workforce available with the erection company. The individual working operations shall be described in detail by the erection company. In order to ensure adequate performance of the installation work, all drawings mentioned in the list of applicable drawings shall be complied with. This also includes the adequate preparation of the erection yard and equipment used by the erection company.

ATTENTION!

The erection company has to check carefully this manual and all documents within prior erection starts. If something missing or not clear the erection company has to request the missing documents or information from TAKRAF immediately.

1.2 Installation procedure

The Installation procedure described below shall be strictly complied with – as it ensures the stability of the main structures and units to be pre-assembled throughout all phases of construction process. The weights of the assembly groups must not be exceeded so that lifting appliances in order to avoid overload affecting lifting tackles, temporary supports, piles of wooden sleepers/steel bars, etc. Major deviations from the installation sequence and technical specifications must be agreed with the TAKRAF design department or site management. The receiving and processing of transmitted modification report during installation duration should be documented by TAKRAF Supervisor. After end of installation all documents should be transmitted to the responsible employee of the TAKRAF Erection Department. Possibly, adaptations will have to be made on site, e.g. of the frames arranged the truss structures, TAKRAF supplies to be integrated in the units, etc. The erection contractor shall be responsible for the execution of all the above adjustments. The above provisions and subsequent agreements between TAKRAF and the customer shall be observed by the contractor and complied with.






1.3 Field joints and connections

All joints and connections of steel structures to be bolted or welded on site, e.g. bracings, truss structures and platforms, shall be aligned, reamed and bolted, respectively welded before lifting the respective structure to the mounting position. Bolted joints and structures to be connected only in their mounting position, shall be reamed and bolted when in place. The joints shall be locked in their position by setting plugs or tacking bolts. This provision similarly applies to the welded joints of each individual steel structure (held by splicing plates). Individual members shall be connected applying the full torque specified by the supplier/manufacturer, using fitted bolts, setting plugs or splicing plates, before suspending them from the lifting appliance. After completion of the bolted joints, the butt joints (on top and lateral) shall be sealed. Silicon paste or other elastic sealing materials may be used for this purpose (for additional information see QM 36-15-307). For execution of high-tension and friction-grip connections the QM 36-09-1202 shall be considered For all site welding the QM 36-09-2004 shall be considered.

1.4 Temporary supports

The contractor shall provide temporary supports. They shall be selected on the basis of the assumed maximum load, overload and adequate safety factor. They shall be tied town to prevent turnover. The hydraulic jacks to be arranged under the supports or on the piles of wooden sleepers or steel bars (with setting ring and crowned thrust piece) shall be arranged in central position, generally. Example: Load center

Piles of wooden sleepers, if serving as support, shall be suitably structured (crosswise arrangement of sleepers) to meet the maximum load. Sleepers or timber bars must be arranged perfectly horizontal resting safely on each other. The piles shall be loaded with the load imposed on the centre of each pile, generally. Wooden piles shall suitably protect to avoid fire, if welding work or flame cutting is to be performed on them (impregnation, sand or similar). Lifting platforms, scaffolds, ladders and similar shall be employed in accordance with the legal provisions applicable to this respect in the country where the construction takes place.

1.5 Securing of structure during construction period

Steel plate ± 0,0






Following safety measures should be done to prevent damages and accidents: • Secure travel mechanism against moving (inclination of runway and wind loads) • Secure superstructure to undercarriage against rotation (wind loads)

Blocking of gear rim Fixing of storm anchors Installation of chain hoists (crosswise) between superstructure and undercarriage Anchoring of boom structures (crosswise) with tie ropes

• Secure Temporary construction supports (Wind loads) Installation of knags between machine structure and supports head section) Bracings between single supports Anchoring of supports with tie ropes

All provisions should be coordinated with TAKRAF engineering department. Lifting platforms, scaffolds, ladders and similar shall be employed in accordance with the legal provisions applicable to this respect in the country where the construction takes place.

1.6 Lifting appliances

The lifting appliances planned to be employed in the construction process must be released by the competent technical control board or inspection board in the country where the construction takes place. It is a general requirement that the sling points, lifting eyes, lugs, etc. indicated in the specifications must be used. The lifting schemes shown in the drawings shall be adhered to. These schemes shall be revised and presented to the manufacturer if, due to the progress of construction work (level of completion of the units), other than the specified loads or centre of gravity are applicable. The lifting beams and spreaders shall be provided by the construction company. Wherever slinging work is applicable, the sling points shall be lined carefully with timber, whereas sharp edges must be covered to protect the lifting ropes/tackles (e.g. shaped plate, rubber, timber etc.). The sling points must be slip-proof so as to prevent deformation of the items to be lifted.






Example:

The erection contractor shall be responsible for all slinging and lifting work, including monitoring and supervision of heavy loads lifting operations, in general. Prior to each lifting, the lifting accessories such as ropes, belts, chains and shackles shall be checked as follows:

Visual inspection for damage Check of test date on inspection plate

If the lifting weight is > 10 t, then a trial suspension of at least 10 min shall be carried out prior to the heavy load lifting operation. The trial suspension shall be as follows:

Lift the component evenly until there is a distance of about 10 cm to the pile points.

Trial suspension of at least 10 min. Check the suspended loads (e. g. by means of the existing crane displays) In case of any deviations of the suspended load, they shall be corrected.

Prior to each heavy load lifting operation, the personnel involved shall be trained and instructed on record. The instruction record shall include the following:

Lifting appliances involved and their manning as well as reserve crane drivers Supervisor of heavy load lifting operation Communication by means of radiotelephony and commands Performing of lifting appliance movements Safety guards Behavior in case of irregularities

The work to be performed during the heavy load lifting operation shall be monitored by a supervisor from a central location. This person shall be in direct contact with the employed lifting appliance operators via radiotelephony. Before starting the heavy load lifting operation, information on the general weather situation shall be obtained.

Square timber

Edge protection






The erection company shall be responsible for all slinging and lifting work, including monitoring and supervision of heavy loads lifting operations, in general.

1.7 Storage & handling of supplies

All supplies shall be stored on pads (sleepers, concrete blocks and similar) to protect them from damage, corrosion, extreme dirt prior until the moment of installation Structural parts shall be inserted without constraint or deformation. Holes in the main structure must not be closed by welding! Damaged parts must not be installed. The manufacturer’s design department shall decide whether they can be installed or must be repaired. Damaged paint coats, if any, shall be touched up, and rust shall be removed. All items stored on site shall be protected from dirt (dust and weather protection). Surfaces that will be inaccessible after the mounting shall be coated prior to that applying the paint system specified for this purpose. Protective covers and sleeves, if any, shall be removed before installing each item. Mechanical parts, bolts, shafts, axles and sliding surfaces, if not otherwise specified must be grease prior to installing them. The instructions for treatment with molybdenum sulphide powder shall be strictly adhered to, where applicable to the mechanical parts. Inflammable items (cables, conveyor belts, timber frames) shall be suitably protected before performing welding work or flame cutting.

1.8 General requirements

• The erection company shall appoint a coordinator for the implementation of the project (site planning and organization, monitoring of time schedules, etc.), who will be at the disposal of the TAKRAF supervisor for settling all questions.

• The quality documents including measurement reports and test records requested by TAKRAF shall be submitted to the customer / TAKRAF at the dates fixed.

• Any work beyond the scope of supplies and services shall be subject to prior agreement with the customer / TAKRAF and their written approval.

• In the event of any damage, malfunction, non-conform execution or delay, the erection company shall subject itself to the judgment of the customer / TAKRAF – within its scope of supplies and after joint assessment. The customer / TAKRAF shall have the right to define actions for eliminating this situation. Any delays and costs arising from this shall be borne by the erection company. It shall be fully responsible for keeping the deadlines agreed in the contract.

• Immediately after becoming aware of circumstances interfering with the smooth execution of the project the erection company shall inform the customer / TAKRAF about such circumstances and arrange with the customer / TAKRAF about the measures to be initiated.

• Corrosion protection instructions shall be prepared and submitted to the erection company in due time. Erection Company shall be responsible to apply the finish coat and repair any damage of the coat caused during transport and / or erection. Damage due to transport, handling and storage to parts supplied by TAKRAF shall also be repaired by Erection Company. Sufficient paint will be supplied to the erection company.






• The field joints (welded or bolted) specified in the design drawings shall be made accessible by scaffolds complying with the regulations.

• The tacking bolts required for the erection shall be supplied by the erection company. • Attaching and removing of weld backups and end crater plates to and from field joints are

included in regular erection work and shall be allowed for by the erection company. • The erection company shall provide a material guard / warehouse man for monitoring the

incoming and outgoing goods. • Complying with the regulations, the erection company shall provide heatable quivers as well as

drying ovens for the electrodes. • For the machines the temporary supports shall be fabricated or adapted according to the

position / load as per drawings and provided with regard to deadlines. • Modification work up to 5 % of the overall scope shall not be deemed as additional work but

shall be part of the normal tasks of the erection company. This may also include the necessary indirect material such as plates, angles, beams etc.






2 Guideline for Construction description Purpose of this construction manual The purpose of this document is to give a general guideline on how to assemble and erect the delivered components to a functional unit to allow the safe operation under the specified conditions. For planning and execution of any work all information given in this manual, its attachments and related documents of the supplier’s documentation must be considered. These documents shall be checked carefully and be understood in full prior to the start of any work and if required clarifications shall be requested. This manual does not relieve the responsible construction company to plan in detail all aspects of the required works, in particular the site preparation, the sequences of pre-assembly and final assembly, also the selection, timely availability and use of required tools, devices and cranes. All instructions given by TAKRAF and sub-supplier must be followed. All work must be done in conformance with all applicable technical and safety standards.






3 Construction Description 3.1 General conditions Construction Yard Existing obstacles, if any and where these interfere with construction shall be relocated. All electrical supply and control cables for the lights and temporary substations shall be buried. The Construction pad shall be levelled and compacted according drawing (position and condition of pre-assembly and construction areas will be agreed before start of construction) and the conditions for the storage of mechanical and electrical supplies as specified by the manufacturer / supplier shall be met. Materials sensitive to temperature variations (e.g. coating materials, certain electrical items, conveyor belt splice kits) shall be stored in air-conditioned storage rooms which are to be provided in the construction yard or nearby. Temporary substations shall be provided in the construction yard for connecting of electrical tools.

3.2 General Remarks for Installation and Commissioning In generally erection company should take into consideration all additional assembly instructions at design drawings. In addition to these requirements the following works are part of the normal construction scope:

• Testing (UT, X-ray, red-white test) of all site welds (if necessary) according TAKRAF requirements (design and quality assurance drawings)

• Correct installation and fine adjustment of idler (height tolerance idler to idler max. 3mm), belt cleaner, wear plates, chute side walls and sealing

• Installation of brackets for final assembly of cable trays, piping etc. • Correct installation and alignment of belt pulleys – pay attention to tooth disc location in regard

to limit switch position or sensor connection • Position of take-up pulley (installed on take-up carriage) before and after final belt vulcanization

and/or applying of final belt tension • Adaptation of gratings, railings and kick-plates (where necessary) • Seal welding of all field joints at walkway railings (use connection pieces) • Installation (drilling and welding) of limits switches incl. brackets and ruler • Installation of protection guards and covers – drilling and welding could be necessary • Final alignment of conveyor modules (highness, side) • Installation of liner plates and lip liners at site • Adaptation and additional installation of wear plates during commissioning • Adaptation of staircase to ground level (if necessary) • Alignment of drive (motor, brakes, gear box) components • Function test of mechanical parts incl. adjustment and re-adjustment if necessary • Installation of lubrication and hydraulic systems incl. all piping works – cover these installation

areas to keep it clean • Cleaning and flushing (if necessary) of hydraulic and lubrication pipe system • Filling of hydraulic and lubrication system according TAKRAF instruction (oil and lube type,

cleanliness of oil • Touch-up painting of transport and construction damages






• Installation of hand fire extinguisher, warning and company signs and warning coat

NOTE!

All equipment installed during shut-down has to be pre-assembled to the highest possible degree. The final degree of preassembly as well as the sequence should be determined between client, erection company and the TAKRAF Supervisor and depending on the detailed shut-down schedule.

3.3 General Arrangement Drawings For general arrangement and overview for conveyor CV – 11 see:

• General Overview drawings: o GA – conveyor CV-11, Dwg. 49046335 o GA – Belt line CV-11, Dwg. 49046334 o GA - Drive/ Take-up station CV – 11, Dwg. 49046328 o GA – Transfer CV4A to CV – 11, Dwg. 49046329 o GA – Transfer CV – 10 to CV – 11, Dwg.49046345 o GA – Standard Ground Module, Dwg. 49046326 o GA – Head return station, Dwg. 49046336






3.4 List of Weights*

Ass.-Group Designation Total weight

(ton)

1000 Drive / Take-up station 205,05

1110 Steelwork Drive / Take-up station 29,96

1120 Walkways and Podests Drive / Take-up station 14,93

1410 Drive Units 89,24

1510 Drive Pulleys 68,63

1610 Belt Cleaner Drive / Take-up station 0,36

1910 Small Parts Drive / Take-up station 1,93 2000 Head Return Station 37,26

2110 Steelwork Head Return Station 8,85

2210 Walkways and Podests 0,12

2230 Discharge Chute 11,95

2510 Pulleys Head Return Station 16,34 3000 Conveyor Route 15,83

3210 Conveyor Modules 10,74

3910 Safety Guards 5,09 4000 Loading Module 54,51

Loading Module CV-4A to CV-11 41,95

4110 Steelwork Loading Module 12,92

4120 Walkways and platforms 13,74

4140 Loading Chute and Skirt Boards 12,66

4150 Safety Guards Loading Module 2,63

Loading Module CV-10 to CV 11 12,56

4210 Steelwork Loading Module 3,88

4240 Loading Chute and Skirt Boards 8,24

4250 Safety Guards Loading Module 0,40 5000 Take Up Device 21,27

Steel structure - Take Up Device 19,67

Mechanical parts - Take Up Device 1,52 8000 Equipment ----

As of Aug. 2013






3.5 Tail Station Installation 3.5.1 Main Frame Installation

NOTE! Before the construction starts, survey protocol for tail station foundations

shall be available and cross checked with steel work anchoring points!

• Mark the Conveying center line before start main frame installation

NOTE!

Accurately marking of conveyor center line is essential for alignment!

For tail end assembly see assembly drawing – drive / take-up station CV – 11, Dwg. 49046337!

• Installation of Main frame – drive / take-up station, Dwg. 48029224, Group 1110, ~ 23,63ton o Main frame will be delivered in three parts o Start installation with front ( ~ 11,7ton) and rear part (~ 8,1to) to the foundations on

ground, exact height according Dwg. 49046340 - Foundation loads tail drive station o Installation of Main frame middle part (~ 3,4ton) to front and rear part Bolted

connection as per drawing 48029224! o Installation of diagonals between main frame parts (bolted) o Levelling and aligning of main frame as accurately as possible to conveyor line o Grouting of the foundations of the main frame before proceed with the next step o Installation of wedge box for drive puley, Dwg. 49047381, Group 1510 for Pulley

adjustment o Installation of drive pulleys, Dwg. 42016580, Group 1510, ~27,3ton to main frame

Fasteners for pulley, Dwg. 49047383, Group 1510 Levelling and aligning drive pulleys as accurately as possible as per pulley

drawing NOTE!

Levelling and alignment of Main Frame and Pulleys on Main frame is essential for the exact positioning of the Motor base plates and the Motor unit too!

• Installation of primary drive unit, Dwg. 49046344 consisting of: o Disc Brake BSFK535DS, Dwg. 59046488, Group 1410 o SOBO Controller, Dwg. 59046489, Group 1410 o Hydraulic power unit, Dwg. 59046490, Group 1410 o Flexible coupling, Dwg. 59046492, Group 1410 o Shim plates, Dwg. 49047377, Group 1410






• Installation of brake unit future secondary drive, Dwg. 49047380, Group 1410, ~1,25ton consisting of:

o Disc Brake BSFK535DS, Dwg. 59046488, Group 1410 o Hydraulic power unit, Dwg. 59046494, Group 1410 o Shim plates, Dwg. 49047377, Group 1410

3.5.2 Motor Unit Installation

• Installation of Baseplates Dwg. 42016509, Group 1410 for Motor Unit Installation:

NOTE!

The drive motors come to site complete with the base frames attached. The total weight is 75 tons. The base plates for the motors are part of the foundation. They need to be set attached to the dummy frame. The dummy frame keeps the base plates in their correct position to each other and in the same plane. The final setting and grouting of the base plates should be done only after the drive pulley has been set. The accuracy for the foundation is high and difficult to accomplish without installing the pulley first. The fact that it is a combination of foundation (civil) and structural tolerances (main support structure) makes matters worse. Therefor it is advisable to set the main conveyor structure first and align the pulley before final setting/alignment and grouting the base plates for the motor. This sequence should allow achieving the tolerances as shown in the sketch below. As better the system is aligned as less wear the flexible coupling will see.

o Install all four baseplates to the dummy frame, Dwg. 42017085, Group 8390 o Installation of dummy frame to foundation o Levelling and aligning of baseplates to conveyor center line and to pulley center line (see

Fig. 1, Dwg. 42017487)






Fig. 1 Baseplates alignment

o Grouting of baseplates with concret

NOTE!

Before motor unit installation starts baseplates shall be grouted!

• The Motor unit, Dwg. 42016940, Group 1410, ~ 71,7ton consisting of:

o Motor with frame, Dwg. 42016530 o Spindle for height adjustment, Dwg. 42016510 o Adjusting cleat – left side, Dwg. 42016511 o Adjusting cleat – right side, Dwg. 42016512 o Threaded bolt, Dwg. 52016695






NOTE! For installation / lifting of motor unit see erection manual of ABB for electrical

equipment too!

• Installation of spindle for height adjustment pos. 4, Dwg. 42016940 to motor unit • Adjustment / Alignment of motor unit according Motor unit drawing 42016940, coupling

drawing 59046492 and sub-supplier documentation! o Check the levelness of the motor unit standing surface (baseplates) to each other o Mark the middle lines on the baseplates in X-Y layer (Fig. 2)

Fig. 2 Marked Baseplates

o Mark the X-Y layer on motor unit frame

Fig. 3 Marks at motor unit to mark






o Grease contact area between baseplate and height adjusting spindle o Installation motor unit to baseplates & align motor unit on baseplate as accurately as

possible while installation of motor unit by crane (Rough alignment) o Installation of adjusting cleats (Pos 2 & 3, Dwg. 42016511 & 42016512) to baseplate

welding according Dwg. 42016940, sheet 2 Check adjusting cleats after welding and regrease if necessary!

o Leveling and align motor unit with the cleats in X – Y Layer and the adjusting spindle for adjusting in Z - direction

o After height adjusting install shim plates Pos. 8 Dwg. 42016940 below contact area and retract spindle

NOTE!

The Crane shall be used to supporting adjustment / alignment works by taking over a part of the weight of the motor unit!

o After adjustment install threaded rods to fix motor unit to ground, Use Primerless

Threadlocker Loctite 243 or similar to secure rods!

NOTE! Erection Company has to prepare a test record about the alignment of the

coupling / motor unit! (See Inspection and Test Plan)

NOTE!

For further mounting instructions of the drive & motor units see sub-supplier documentation too!

3.5.3 Take-up Station Installation

• Take-up station will be delivered fully assembled, ready for installation, with the following parts: o Take-up carriage, Dwg. 48029298, Group 5200, ~5,4ton o Carriageway support, Dwg. 48029300, Group 5200, ~ 9,3ton o Locking pins, Dwg. 49047390, Group 5300 o wedge box for take-up puley, Dwg. 49047382, Group 1510 o Take-up pulley to take-up carriage, Dwg. 42016717, Group 1510, ~ 13ton o Fasteners for pulley, Dwg. 49047383, Group 1510 o Take-up trestle to carriageway support, Dwg. 48029299, Group 5200 (secureed with

locking pins) o Take-up spindle, Dwg. 49047387, Group 5300 to take-up trestle, Dwg. 48029299, Group

5300 See notes on spindel drawing for details! o Hydraulic cylinder, Dwg. 49047389, Group 5300

• Installation of take-up station to main frame drv. / take-up station o Figures 3, 4, shows details about Take-Up station lifting






o After installation take-up carriage and trestle shall be in the upper position for belt installation and first startup (installed hydraulic system can be used for this operation)

Fig. 4 Lifting Scheme for Transportation






Fig. 5 Lifting Scheme for Installation

Fig. 6 End Position of Take-up Carriage for Belt Installation






NOTE!

• Carriageway is temporary protected with tectyl. Before move the take-

up carriage to the upper position clean carriageway completely with cleaning solvent.

• After belt installation removing the locking pins in take-up carriage! • Check the alignment of the Take-up pulley after Installation (For

details see Pulley Drawing.

3.5.4 Walkway Installation

• Installation of stair and walkway sec. drive pulley, Dwg. 48029229, Group 1120, ~3,7ton • Installation of walkway at carriageway support, Dwg. 48029227, Group 1120, ~5,3ton • Installation of support for flexible cable routing, Dwg. 49047391, Group 5900 • Installation of walkway at motor frame primary drive, Dwg. 48029230, Group, 1410, ~4,5ton • Installation of idler support beam, Dwg. 48029225, Group 1110, ~6,4ton

o Installation of idler stations to beam according GA – Beltline CV-11, Dwg. 49046334 • Installation of walkway at idler station support beam, Dwg. 48029226, Group 1120, ~ 6,0ton

3.6 Loading Module CV-4A to CV-11 Installation

• See following drawings for further details: o GA – Drawing 49046329 o Assembly – Transfer CV4A to CV-11 Drawing 49046338

• Installation of loading chute support structures: o Support structure CV-1, Dwg. 48029265, Group 4110, ~4,3ton o Support structure CV-2, Dwg. 48029266, Group 4110, ~4,3ton o Installation of idler station to support structures according GA – Belt line CV-11, Dwg.

49046334 • Installation of loading chute support structure, Dwg. 48029236, Group 4110, ~4,3ton to

foundations • Installation of idler stations to support structure according Dwg. 49046334 - GA – Belt line CV-

11 • Installation of liner plates Dwg. 48029235, Group 4140 to feeding box, Dwg. 48029233, Group

4140 • Installation of feeding box to support structure (~ 5,4ton) • Installation of liner plates Dwg. 48029234 Group 4140 to loading hopper Dwg. 48029232, Group

4140, ~5,7ton • Installation of loading hopper to support structure • Installation of platform for intermediate chute, Dwg. 48029239, Group 4120, ~13,1ton • Installation of walkways and stairs, Dwg. 48029241, Group 4120, ~ 0,6ton






3.7 Loading Module CV-10 to CV11 Installation

NOTE!

Description of the dis-assembly of existing structure is not part of this manual! Adaption works between existing structures and new parts delivered by TAKRAF GmbH may become necessary and are in the responsibility of the client!

• See following drawings for further details:

o GA – Drawing 49046329 o Assembly – Transfer CV4A to CV-11 Drawing 49046338

• Drilling of holes as per drawing 48029296, sheet1 into existing supports • Installation of liner plates, Dwg. 48030196 to loading chute, Dwg. 48029296 • Installation of liner plates, Dwg. 48030197 to skirt boards, Dwg. 48029297 • Installation of skirt boards to loading chute • Installation of fully assembled loading chute to existing structure (~7,3ton) • Installation of support for rope winch to existing structure, Dwg. 48029319, Group 4280

o Welding of supports as per drawing sheet 2 • Installation of rope winches, Dwg. 49047408, Group 4280 to supports and connect the rope to

the skirt boards and lift skirt boards by using of the winches • Drilling of holes as per drawing 48029294, sheet1 into existing supports • Installation of main beam for idler stations, Dwg. 48029294, Group 4210, ~3,7ton to existing

structure • Installation of support for idler station, Dwg 48029295, Group 4210, ~0,2ton • Installation of idler stations according drawing 49046334 - GA – Belt line CV-11 to main beam

3.8 Head Return Station Installation

• See following drawings for further details: o GA – Head return station, Dwg. 49046336 o Assembly – Head return station CV-11, Dwg. 49046339

NOTE!

Description of the dis-assembly of existing structure is not part of this manual! Adaption works between existing structures and new parts delivered by TAKRAF GmbH may become necessary and are in the responsibility of the client!

• Installation of steel structure support for belt scale, Dwg. 48030190, Group 3210 • Installation of supports for snub pulley and rollers, Dwg. 48029293, Group 2110 to head return

station – main frame, Dwg. 48029246, Group 2110 before install the main frame to transfer tower

• Installation of head return station – main frame, Dwg. 48029246, Group 2110 to transfer tower • Installation of return pulley, Dwg. 42016717, Group 2510 to main frame

NOTE!






See Pulley Drawings for Mounting Instructions!

• Installation of snub pulley, Dwg. 42016874, Group 2510

Use fasteners, Dwg. 49047384 and wedge boxes, Dwg. 49047382 for installation!

• Pre-assembly of discharge chute, Dwg. 48029247, Group 2230 o Discharge Chute consisting of three parts: bottom part, upper front part and upper rear

part o Installation of wear liners, Dwg. 48029248, Group 2230 to bottom and upper rear part

• Installation of discharge chute, Dwg. 48029247, Group 2230 to head station o Installation shall be carried out in three steps:

Bottom part Upper rear part Upper front part (after belt installation)

• Installation of idler station support, Dwg. 48029249, Group 2110 • Installation of idler station according GA – Belt line CV-11, Dwg. 49046334 to idler support

station • Installation of support frame for calibration equipment, Dwg. 48030198, Group 2110 • Installation of calibration equipment to support frame ( see Sub-Supplier Documentation)

3.9 Conveyor Module Installation

• For See following drawings for further details: o Assembly – Conveyor CV-11, Dwg. 49047450 o GA – Belt line CV-11, Dwg. 49046334

• Pre-assembly conveyor modules according to drawings: o Standard module, Dwg. 48029245, Group 3210 o Reinforced module, Dwg. 48029267, Group 3210 o Special module, Dwg. 48029268, Group 3210 o Pull cord hook, Dwg. 48029261, Group 3210

NOTE!

Using of an assembly rig for conveyor module assembly is recommended!

• Installation of pre-assembled conveyor modules according Assembly Drawing – Conveyor CV-

11, Dwg. 49047450 • Check alignment of idler stations according Sketch 01, Attachment 5.1






3.10 Equipment Installation 3.10.1 Hydraulic and Lubrication Systems

See Piping Specification for general information! • Installation of Hydraulic Routing for disc brakes according sub-supplier documentation • Installation of lubrication systems for pulleys and motor unit according sub-supplier

documentation

3.10.2 Belt Scraper Installation

• Installation of cleaners (after belt installation): o V-Plow 1, Dwg. 49046350, Group 1610 to take-up station o V-Plow 2, Dwg. 49046351, Group 1610 to take-up station o Primary belt scraper, Dwg. 49047385, Group 2610 to head station (Fasteners, Dwg.

49047401) o Secondary belt scraper, Dwg. 49047386, Group 2610 to head station (Fasteners, Dwg.

49047401)

3.10.3 Mechanical Equipment / Monitoring Devices

• Installation of rip detection system, Dwg. 490473940, Group 8205 • Installation of cord monitoring system, Dwg. 49047416, Group 8205 • Installation of splice elongation system, Dwg. 49047417, Group 8205 • Installation of Mobile thickness system, Dwg. 490470418, Group 8205 • Installation of Mounting for pull-rope switches old modules, Dwg. 48029302, Group 8210 • Installation of Mounting for pull-rope switches new standard modules, Dwg. 48029303, Group

8210 • Installation of Mounting for pull-rope switches new reinforced modules, Dwg. 48029304, Group

8210 • Installation of Mounting for pull-rope switch and start-up warning old modules, Dwg. 48029305,

Group 8210 • Installation of Mounting for pull-rope switch and start-up warning new standard modules, Dwg.

48029306, Group 8210 • Installation of Mounting for pull-rope switch start-up warning new reinforced modules, Dwg.

48029307, Group 8210 • Installation of Mounting for belt misalignment switch head end, Dwg. 48029308, Group 8210 • Installation of Mounting for belt misalignment switch tail end 1, Dwg. 48029309, Group 8210 • Installation of Mounting for belt misalignment switch tail end 2, Dwg. 48029310, Group 8210 • Installation of Mounting for material build-up probe, Dwg. 48029311, Group 8210 • Installation of Mounting for ultrasonic belt rip detection, Dwg. 48029312, Group 8210 • Installation of Mounting for electronic cord monitoring, Dwg, 48029313, Group 8210 • Installation of Mounting for electronic splice elongation monitoring, Dwg. 48029314, Group 8210 • Installation of Mounting for speed monitoring HOG16, Dwg. 48029315, Group 8210 • Installation of Mounting for speed monitoring at drive pulley, Dwg. 48029316, Group 8210 • Installation of Fixing plates for bypass switches, emergency push buttons, local push buton

stations and junction boxes, Dwg. 48029317, Group 8210 • Installation of Mounting microwave sensor for material build-up probe, Dwg. 48030191, Group

8210






3.10.4 Safety Guards Installation

• Installation of Safety guards (before commissioning / start-up): Drive / Take-up Station:

o Safety Guards around prim. drive pulley, Dwg. 48029290, Group 1910 o Safety Guards at Walkway sec. drive pulley, Dwg. 48029291, Group 1910 o Safety Guards brake disc, Dwg. 48029288, Group 1910 o Safety Guards for standard module – carry strand type1, Dwg. 48029260, Group 1910 o Safety Guards for transition area, Dwg. 48029287, Group 1910 o Shaft end cover primary drive unit, Dwg. 48030186, Group 1910 o Shaft end safety cover secondary drive unit, Dwg. 48030187, Group 1910 o Safety Guards at disc brake – type 1, Dwg. 48030188, Group 1910 o Safety Guards at disc brake – type 2, Dwg. 48030189, Group 1910

Head Return Station: o Safety Guards for transition area, Dwg. 48029252, Group 2210

Conveyor Route: o Safety Guards for standard module – carry strand type 1, Dwg. 48029260, Group 3910 o Safety Guards for standard module – return strand, Dwg. 48029262, Group 3910 o Safety Guards for standard / special module – return strand type 1, Dwg. 48029263,

Group 3910 o Safety Guards for reinforced module – return strand, Dwg. 48029264, Group 3910 o Safety Guards for special module on concrete type 1 – return strand, Dwg. 48029269,

Group 3910 o Safety Guards for standard / special module – return strand type 2, Dwg. 48029270,

Group 3910 o Safety Guards for standard / special module – carry strand, Dwg. 48029271, Group 3910 o Safety Guards for standard module – carry strand special type 2, Dwg. 48026617, Group

3910 o Safety Guards for standard module – return strand type 3, Dwg. 48026618, Group 3910 o Safety guard special size type 1 – carry strand, Dwg. 48030170, Group 3910 o Safety guard special size type 2 – carry strand, Dwg. 48030171, Group 3910 o Safety guard special size type 3 – carry strand, Dwg. 48030172, Group 3910 o Safety guard special size type 1 – return strand, Dwg. 48030173, Group 3910 o Safety guard special size type 2 – return strand, Dwg. 48030174, Group 3910 o Safety guard special size type 3 – return strand, Dwg. 48030175, Group 3910

Loading Module CV-4A to CV-11: o Safety guards, Dwg. 48029238, Group 4150 o Safety guards, Dwg. 48029320, Group 4250 o Safety guards – future conveyor 1, Dwg. 48030142, Group 4150 o Safety guards – future conveyor 2, Dwg. 48030143, Group 4150






3.11 Belt Installation

NOTE! The belt pulling is not part of TAKRAF`s scope. However for safety reasons

we would recommend that TAKRAF should review the final procedure to ensure that it is compatible with the overall conveyor design.






4 Attachments 01: Procedure of Site Handling 02: Instruction for greasing of sliding bearings 03: Fastening Connections 04: Guideline for design, workshop & erection 05: Drawings and Sketches

06: Work and Test Instructions 07: Inspection & Test Plan 08: Corrosion Protection Specification 09: Belt Installation 10: Piping Specification 11: Tools List 12: Labour Qualification






Attachment 01: Procedure of Site Handling






Attachment 02: Instruction for greasing of sliding bearings






Attachment 03: Fastening Connections






Attachment 04: Guideline for design, workshop & erection






Attachment 05: Drawings and Sketches






Attachment 06: Work and Test Instructions






Attachment 07: Inspection & Test Plan






Attachment 07.1 Completion Certificate






Attachment 08: Corrosion Protection Specification






Attachment 09: Belt Installation






Attachment 10: Piping Specification






Attachment 11: Tools List






Attachment 12: Labour Qualification






--END OF DOCUMENT--

t11m408-i1-takraf-03910-vdcme02-p1me01-004

Documents

construction description

construction period

chile takraf project

g0268 year of construction

takraf gmbh torgauer

extension of conveyor

installation description

b product