Académique Documents
Professionnel Documents
Culture Documents
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
1 of 22
Prepared by,
Checked by,
Approved by,
AVU
Trevor Salter
Ediie Arsyad
1)
2)
Engineering Manager
Project Manager
Revision history
Revision No.
Date
Remarks
01
27.02.2014
Revised on comment
00
24.02.2014
First Published
3)
Number
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
2 of 22
TABLE OF CONTENTS
1. GENERAL
2. INTRODUCTION
3. PURPOSE
1. GENERAL
To carry out all duties in a professional, conscientious, responsible, healthy and safe manner.
All operatives shall be experienced and trained in their respective trades and will be fully
familiar with the correct method of installation of the Coal mining facility so that both short
term as well as long-term installation work and product warranties are in qualified
approach.
This document describe the detailed commissioning plan of the conveyor system and the
methods involved in the commissioning of overland conveyor system, in the Project North
Sumatra, MDB coal project, material handling facility.
Communication between Project team PT.BAMA and Project team of PT. MDB should be
defined after Kick of meeting. All communications between other members of the Project
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
3 of 22
2. CONVEYOR INTRODUCTION
Belting
Skirt Board
Actuators
3. PURPOSE
This document describes how PT. BAMA intends to carry out erection, co-ordinate
commissioning and complete the Works and to fulfill all its contractual obligations and the
achievement of Milestones.
Magnetic Separator
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
4 of 22
standard testing and commissioning procedure. General Inspection report to be verified for
all components involved in system.
TESTING AND
COMMISSIONING
Number
After positioning
FI
N/A
Measuring instrument
FI
N/A
Before start up
After start up
Performance Appraise
FI
N/A
Before start up
FI
N/A
After start up
Performance Appraise
FI
N/A
Upon Readiness
FI
N/A
DOCUMENTATION
As built drawings
As soon as system
Completed
of the contract
of the contract
Installed
W : Witness Point
SW : Spot Witness Point
H : Hold Point
R : Document Review
FI : Full Inspection
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
5 of 22
S.no
4 Ensure all safety switches are in on Mode and not in touch with conveyor
5 Greasing of all components and oil level to required level
6 Ensure Skirt Board fixing, not to touch with belt
7 Check to remove any items lying in conveyor
8 Ensure alignment drive components
Remarks
Number
COMMISSIONING PLAN
Date
: 03.06.2014
Revision :
Page
: BAMA-OLCS-CP-002
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6 of 22
Site Manager-Selva
Commissioning
Specialist-Avu
Engineer Mechanical
Engineer Electrical
Waris/ujang
Roy
Automation - Myrsa
Supervisor Mechanical
Supervisor-Electrical
Onshore - Bambang
Onshore- Agung
Electrician
Team Onshore -1
conveyors 8 NOS
Helper
Team Onshore -2
conveyor- 8 NOS
Supervisor Electrical
Offshore
Electrician
Helper
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
7 of 22
Pre-commissioning
Dry-commissioning
Wet-commissioning
COMMISSIONING
PRE-COMMISSIONING
CONSTRUCTION VERIFICATION
DRY-COMMISSIONING
Contracts, drawing
& documentation.
Standards
and
codes
CHECK CABLE
CHECK COMPONENTS
CONVEYOR
1.
Alignment
2.
Lubrication
3.
4.
TERMINATION
Lightings
Manufacture
requirements
WET-COMMISSIOINING
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
8 of 22
Prior to being placed into service the conveyor system shall be subject to the following
commissioning activities,
5. Lightings commissioning
Tests and calibration shall be carried out to prove that all systems are operational,
including protective and measuring devices.
1. General Mechanical
5. Pulleys
6. Drives
Mechanical testing shall only commence after motor rotational tests and electrical control
and all safety checks have been carried out,
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
9 of 22
The plant shall be run for a sufficient length of time to establish that it is in a reliable and
serviceable condition. Following Test reports shall be used to test equipment under noload condition,
1. General Mechanical
Idlers
Pulleys
7. Scrapers
8. Actuators
9. Motor
10. Couplings
operating under loaded condition i.e. running material through the process equipment. All
the above mentioned stages of commissioning will be carried out under the supervision of
the commissioning specialist and his specified trained team.
With reference to the test reports from the dry commissioning, all the parts of the conveyor
system have to be inspected again to envisage the behavior of the system. From the above
observation, all the faults have to be rectified to make the system get ready for 100%
TEST running and commissioning.
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
10 of 22
BLOWS 2 TIMES
NO
CHECK FEEDBACK
SET 1 MIN
INTERVAL
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
11 of 22
All conveyor operates from PLC, can monitor using the SCADA Programming software to
ensure the installed system is running properly according to the sequence made in the PLC.
Any error in sending the signal to the system will be highlighted in the monitor, with which
we can take corrective measures to resolve it.
Number
COMMISSIONING PLAN
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
12 of 22
11. OLCS CONVEYOR STARTING & STOPPING SEQUENCE PROCESS FLOW CHART
CONVEYOR STARTING SEQUENCE
CV 06
CV 06
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
PROCESS FLOW DIAGRAM OF COMPLETE PLANT:
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
13 of 22
Number
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
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Item
required
2
3
4
5
6
Coal stock
Fuel
consumption
Coal Delivery to
Radial stacker
Equipments
required to dump
coal inside RF
Operators
Commissioning
Team
From RF-03
Yard
Genset
13,500 MT
hours
Dry Run
12
Total
Wet run hours
10
load
Client Scope
Client Scope
Client Scope
Client Scope
1500 MT
Client Scope
12000 MT
13,500 MT
22 hrs
Client scope
Total
13, 500 MT
Client Scope
FROM BAMA
Commissioning team with specialist as mentioned in the Man Power Histogram should be
Tachometer
Temperature Gun
Hammer
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
15 of 22
SAFETY
Proper PPE
HSE Officer
Walkie Talkie
Belt Tracking
When belt conveyors are installed within accepted conventional alignment limits with
idlers and pulleys parallel, belt spliced square and true and material loaded centrally
the belt will track correctly without the need of special training or tracking devices.
In practice, these ideal conditions are seldom achieved and corrective devices and
accessories are required to maintain satisfactory training.
Few common causes of poor belt tracking are set out below. Corrective action necessary
for each of these is readily ascertained when the particular cause (or causes) is
identified.
2. Driving and idler pulleys are not normal to the conveyor centre line and not parallel
to each other.
3. Carrying and return idlers are not set normal to the conveyor belt centre line (This
point is of particular concern for reversible belt conveyors).
4. Out-of-round or stiff idler rollers giving belt contact forces asymmetrical to the belt
centre line.
5. Poor belt splicing giving a transverse bend to the belt centre line at the splice.
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
16 of 22
7. Pulley diameters are not symmetrical about the centre line of belt.
8. Build up of material on pulleys, idlers and /or belt.
10. Excessive tensioning of belt which is precluding all idlers from assisting in belt
steering.
11. Under-tensioning of belt which precludes pulleys from controlling drift.
12. Belt take-ups not taking up slack effectively during running and acceleration.
13. Belt take-up not travelling in line with belt center line.
14. Belt take-ups giving different forces on opposite sides of the belt this can occur
during take-up motion and is prevalent with hydraulic take-ups.
15. Jammed idlers or extraneous jammed articles along the conveyor.
A newly installed belt must be lined up to run on centre of the pulleys and idlers. The tail
end, take up pulleys and all the idlers should be squared up so that they are at 90 deg. with
the centre line of the conveyor. Belt can be aligned properly, only by adjusting the carrying
and return idlers. Self-aligning rollers are supplied with an actuating swivel base, which
will be bolted to the bottom side of the idler frame and will tilt the idler in proper direction
to centralize the belt
Important Tips
a) When starting a new belt for the first time, run it slowly and intermittently and
check the entire length to ensure that it is not running off at any point to an extent
that it will damage the belt.
c) The return run should be checked first for belt alignment. When a belt runs off a
return roller, the edges may get damaged. To train the return belt, start at the head
end. In general the adjustments are made 3 to 4 meters behind the point where the
belt runs off.
d) All troughing idlers are provided with slotted holes for the hold down bolts to
permit shifting of the ends for belt alignment. To adjust the idlers loosen the hanger
bracket bolts slightly and move the idler slightly forward or backward. The belt will
shift to the side where it touches the roller first.
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
17 of 22
e) For training the belt on carrying side start with the tail pulley and follow the
procedure as explained above.
f) Do not try to collect belt alignment by extreme shifting of one idler but rather by
slightly changing a number of idlers. Proper alignment of idlers at the head end will
train a belt to run on the centre of the head pulley.
g) If the belt does not run centrally after adjustment of idlers and take up screws, check
to ensure that the belt lacing is square.
h) Conveyor take up should be adjusted to provide enough tension for the belt to
operate under load without slipping. Correct belt alignment must be maintained
while tension adjustments are made. When correctly aligned and adjusted, the belt
will be centered on the tail pulley while the conveyor is operated. The amount of
tension is correct when the belt sags slightly between return rolls.
i) Do not apply excessive tension because it results in damaging the belt and bearing.
After the belt has been run in, tension should be checked at frequent intervals and
take up adjusted when necessary.
To operate the conveyor system we recommend one operator. This will take approximately
hour to start the system and Operation will be as follows:Estimated time required to start up the conveyor system:
Number
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
18 of 22
minutes
SCHEME OF OPERATION:
There are two distinct mode of operation.
c) All safety switches PCS, BSS, ZSS and CBS should be in healthy condition in local
push button station, stop push button should be in Normally closed position.
e) If the above mentioned conditions are not satisfied PATH READY prompt will
appear in control desk at annunciate window.
f) Now press the system start push button to energize the whole system
g) Plant start hooters which are provided along the conveyor will sound.
MAINTENANCE MODE
a) In this mode of operation equipments will not have sequencing timing and
interlocks
b) Each and every equipment shall be started from the respective local push button
stations independently by switching NORMAL / MAINTENANCE selector switch in
MAINTENANCE mode.
Belt Controls
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
: BAMA-OLCS-CP-002
Date
: 03.06.2014
Revision :
Page
02
19 of 22
Interlock: The sequence control between the master and slave conveyors.
To ensure maximum life, the following Cdns for loading of the conveyor should be met.
The material should be fed in the same direction in which the belt travels. Also material
should be loaded at an angle, moving approximately at the same speed as of the belt,
whereby the cover wear is minimized. Conversely, if the material were loaded at an
angle of 90 deg. transversely to the direction of the belt travel, the wear of rubber
covers would be maximum. Also if the material has no velocity in the direction of the
belt travel or has negative velocity cover wear would be maximum.
Free fall of the material on the belt should not be more than 500 mm. A properly
designed loading chute and closely spaced impact idlers, also reduced free fall,
minimize cover belt.
Loading area of the belt should be horizontal or should have a slope of not more
than 8 deg. If the slop were more than 8 deg. cover wear would be high.
For very abrasive materials, grizzly screen should be used so that fines are placed
on the belt first and provide a bed for larger lumps.
Cover wear for general purpose belt is minimum i.e. where the material conveyed
does not react chemically with the belt and has a maximum temperature of 70C.
For reactive material or hot material, special covers are provided but their wear
resistance is relatively lower.
By means of skirt board, spillage on the return side of the belt may be prevented.
Cause
Complaint
Cause
In order of
In order of
probable
probable
occurrences
occurrences
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
Number
Date
pulley
7 15 14 17 21
26, 17, 15, 21, 4,
16
: 03.06.2014
Revision :
: BAMA-OLCS-CP-002
Page
Excessive wear,
02
20 of 22
26, 4, 17, 8, 1, 21
broken edges
8, 23, 22, 18
Belt slip
Covers become
8, 18
19, 7, 22, 10
Longitudinal grooving
14, 21, 22
pulley
Excessive belt
stretch
Belt breaks at or
behind fasteners;
checked or brittle
or cracking of top
cover
Longitudinal grooving
or cracking of bottom
cover
spots in belt(gouges)
Ply separation
14, 21, 22
12, 20, 5, 10, 8, 24
13, 23, 11, 8, 3
1. Belt bowed: Avoid telescoping belt rolls or storing them in damp locations.
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
21 of 22
4. Belt strained on one side: Allow time for new belt to break in. If belt does not
break in properly or is not new, remove strained section and splice in a new
piece.
5. Breaker strip missing or inadequate: When service is lost, install proper breaker
strip ( Breakers are woven fabric of nylon &/or polyester placed above the
carcass to dissipate impact energy and to prevent belt puncture)
slightly.
10. Drive under belted: Recalculate maximum belt tensions and select correct belt.
Determine if extension is feasible or another belt to be installed. Check the
carcass is rigid enough for load, replace if service is lost.
11. Edge worn or broken: Repair edge. If the edge is out of square or badly damage
replace the worn portion of the belt.
12. Excessive impact of material on belt or fasteners: Use correctly designed chutes
and baffles. Make vulcanized splices. Install impact idlers. Where possible load
fines first. Where material is trapped under skirts, adjust skirt boards to
13. Excessive tension: Recalculate and adjust tension. Use vulcanised splice within
recommended limits.
14. Frozen Idlers: Free idlers. Lubricate. Improve maintenance. Dont over lubricate.
15. Idlers or pulleys out of square with centre line of the conveyor: Realign. Install
limit switches for greater safety.
16. Idlers improperly placed: Relocate idlers or insert insert additional idlers
spaced to support belts.
17. Improper loading, spillage: Feed should be in direction of belt travel and at belt
speed, centered on the belt. Control flow with feeders, chutes and skirt board.
COMMISSIONING PLAN
PT BANGUN ARTA HUTAMA
COMMISSIONING PLAN FOR OVER
LAND CONVEYOR SYSTEM
Number
Date
: BAMA-OLCS-CP-002
: 03.06.2014
Revision :
Page
02
22 of 22
19. Insufficient traction between belt and pulley: Increase wrap angle with snub
pulley. Lag drive pulley. In wet condition use grooved lagging. Install correct
cleaning devices for safety.
20. Material between belt and pulley: Use skirt board properly. Remove
accumulation. Maintain properly.
21. Material build-up: Remove accumulation. Install cleaning devices, scrapers and
inverted V decking. Improve housekeeping.
22. Pulley lagging worn: Replace worn pulley lagging. Use grooved lagging for wet
conditions. Tighten loose and protruding bolts.
24. Radius of convex vertical curve too small: Increase radius by vertical
realignment of idlers to reduce excessive edge tension.
25. Relative loading velocity too high or too low: Adjust chute or correct belt
velocities. Use impact idlers.
26. Side loading: Load in the direction of belt run and at the centre of the belt.
27. Skirts improperly placed: Use adjustable skirt boards and check that it does not
rub the belt.