Belt Conveyors

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Title:

BELT CONVEYORS

Number:

ES-14-403-03

Version Number:

8.0

Date Revised:

30 January 2015

Owner:

Harish Chopra

Authoriser:

Manoj Thakur

Reasons for Creating

or Amending
Document

Full Review of Document

Actual Change Details:

Full Review of Document. No changes to content. Control block

updated to new template.

TABLE OF CONTENTS
1.

SCOPE....................................................................................................................................................... 4

2.

PURPOSE ................................................................................................................................................. 4

3.

RESPONSIBILITY .................................................................................................................................. 4

4.

DEFINITION OF TERMS ...................................................................................................................... 4

5.

STANDARDS............................................................................................................................................ 5

6.

BASIS OF DESIGN .................................................................................................................................. 9

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9

7.

BELT CONVEYOR DESIGN PROCESS ......................................................................................... 9

BELT SPEED ..................................................................................................................................... 9
BELT WIDTH .................................................................................................................................... 9
DRIVE CAPACITY ......................................................................................................................... 10
GENERAL ....................................................................................................................................... 10
DESIGN COMPUTATIONS ........................................................................................................... 10
FOUNDATIONS AND SUPPORTS ............................................................................................... 10
TECHNICAL DATA ....................................................................................................................... 10
DESIGN REVIEWS ......................................................................................................................... 10

DRAWINGS............................................................................................................................................ 11
7.1

GENERAL REQUIREMENTS ........................................................................................................ 11

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Belt Conveyors
7.2

SPECIFIC REQUIREMENTS ......................................................................................................... 11

8.

CONVEYOR BELTING........................................................................................................................ 13

9.

PULLEYS................................................................................................................................................ 13
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8

10.

CONSTRUCTION ........................................................................................................................... 13
DIAMETERS ................................................................................................................................... 13
OVERALL WIDTH AND BEARING CENTRES .......................................................................... 13
TOLERANCES ................................................................................................................................ 14
PULLEY LAGGING ........................................................................................................................ 14
BALANCING................................................................................................................................... 15
PULLEY SHAFTS ........................................................................................................................... 15
PULLEY SHAFT BEARINGS ........................................................................................................ 16
CONVEYOR IDLERS ........................................................................................................................ 16

10.1
10.2
10.3
10.4
10.5
10.6
10.7

GENERAL ....................................................................................................................................... 16
TROUGH IDLERS .......................................................................................................................... 17
TROUGH IMPACT IDLERS (IF REQUIRED) .............................................................................. 17
TROUGH TRAINING IDLERS ...................................................................................................... 17
RETURN IDLERS ........................................................................................................................... 18
RETURN TRAINING IDLERS ....................................................................................................... 18
AMMONIUM NITRATE CONVEYORS ....................................................................................... 18

11.

GEARBOXES ...................................................................................................................................... 19

12.

BELT TAKE-UP ................................................................................................................................. 19

12.1
12.2

GRAVITY TAKE-UP ...................................................................................................................... 19

SCREW TAKE-UP .......................................................................................................................... 19

13.

BELT SCRAPERS .............................................................................................................................. 20

14.

RUBBER SKIRTING ......................................................................................................................... 20

15.

CHUTES AND HOODS ..................................................................................................................... 20

15.1
15.2
15.3

DESIGN ........................................................................................................................................... 20
DUST SUPPRESSION..................................................................................................................... 21
CONSTRUCTION ........................................................................................................................... 22

16.

CLEARANCES ................................................................................................................................... 22

17.

ACCESS AND MAINTENANCE FACILITIES .............................................................................. 22

18.

SAFETY EQUIPMENT ..................................................................................................................... 23

18.1
18.2
18.3
18.4
18.5
19.

IDENTIFICATION............................................................................................................................. 24

19.1
19.2
19.3
20.

CONVEYOR GUARDS................................................................................................................... 23
ANTI-ROLL BACK ......................................................................................................................... 23
EMERGENCY LANYARD SWITCHES ........................................................................................ 24
MONITORING DEVICES............................................................................................................... 24
NOISE .............................................................................................................................................. 24

EQUIPMENT NUMBERS ............................................................................................................... 24

MOTOR IDENTIFICATION TAG .................................................................................................. 25
EQUIPMENT LABELS ................................................................................................................... 25

MATERIALS ...................................................................................................................................... 25

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Belt Conveyors
21.

HANDLING OF STEELWORK AND EQUIPMENT .................................................................... 25

22.

FABRICATION .................................................................................................................................. 25

23.

WELDING ........................................................................................................................................... 25

24.

BOLTING ............................................................................................................................................ 26

25.

PROTECTIVE COATINGS .............................................................................................................. 26

25.1
25.2
25.3
25.4
26.

INSTALLATION ................................................................................................................................ 26

26.1
26.2
27.

STAGE 1 - PRE-COMMISSIONING .............................................................................................. 28

STAGE 2 DRY COMMISSIONING ......................................................................................... 29
STAGE 3 WET COMMISSIONING ......................................................................................... 30

OPERATIONAL PHASE ................................................................................................................... 30

29.1
29.2
30.

INSPECTION AND TEST PLAN ................................................................................................... 27

WELD INSPECTION AND TESTING ........................................................................................... 27
FABRICATED STEELWORK INSPECTION ................................................................................ 28
INSPECTION DURING INSTALLATION .................................................................................... 28

COMMISSIONING ............................................................................................................................ 28

28.1
28.2
28.3
29.

MECHANICAL/STRUCTURAL .................................................................................................... 26
ELECTRICAL .................................................................................................................................. 27

INSPECTION AND TESTING.......................................................................................................... 27

27.1
27.2
27.3
27.4
28.

STEELWORK .................................................................................................................................. 26
MECHANICAL AND ELECTRICAL COMPONENTS ................................................................. 26
BOLTS ............................................................................................................................................. 26
FLOOR GRATING AND STAIR TREADS.................................................................................... 26

MAINTENANCE STRATEGY ....................................................................................................... 30

INSPECTION DURING OPERATIONAL PHASE ........................................................................ 31

RECORDS MANAGEMENT ............................................................................................................ 32

30.1
30.2
30.3

AS - BUILT DRAWINGS ............................................................................................................... 32

ENGINEERING PROJECT FILES .................................................................................................. 32
MAINTENANCE WORK ORDERS ............................................................................................... 32

TABLES
Table 1

Pulley Width ................................................................................................................. 14

FIGURES
Figure 1

Belt Conveyor Maintenance Process Flow Diagram ..................................................... 33

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Belt Conveyors

1.

SCOPE

This Standard establishes the minimum technical requirements for the design, fabrication,
installation, testing, commissioning, preventative maintenance and inspection of belt conveyors.

2.

PURPOSE

To ensure that all belt conveyors in CSBP facilities are in compliance with WorkSafe WA
regulations and other relevant codes and practices and that the companys requirements for
operability, safety and reliability are assured at all times.

3.

RESPONSIBILITY

During the development phase it is the responsibility of the Superintendent to ensure that the
requirements of this Standard are adhered to.
Following completion of project handover, it is the responsibility of each business unit to ensure
that their belt conveyors remain compliant with this Standard and are safe to use.

4.

DEFINITION OF TERMS

Contractor/Vendor
The company that provides the equipment and services needed.
Sub-Contractor
A third party to be employed by the Contractor/Vendor, who has been approved by the
Superintendent.
Superintendent
CSBP Limited or authorised representative. For internal works, the Superintendent shall be the
Responsible Officer.
CSBP
CSBP Limited.
Works
The scope of works that a Contractor is or may be required to execute under an agreement
including variations and remedial work.

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Belt Conveyors
Idler
An assembly for supporting a conveyor belt. An idler is comprised of one or more rolls and the
mounting frame or brackets for the rolls.
Roll
An individual rotating element of an idler (i.e. roller).
Pulley
An assembly comprising an enclosed cylinder fitted with a shaft, used to change the direction of a
conveyor belt. Pulleys are located at drive, head and tail ends and gravity take-ups. Also referred to
as a drum.

5.

STANDARDS

The Contractor shall perform the Works in accordance with this Standard, the latest issue of
reference standards and Contractor regulations for on-site work. Should there be a conflict between
the Works, Statutory Requirements and the Standards the Contractor shall notify the
Superintendent in writing for resolution. In general, the most stringent requirements will prevail.
CSBP Engineering Standards
ES-14-101-02
ES-14-101-03
ES-14-101-04
ES-14-101-06
ES-14-102-09
ES-14-102-12
ES-14-202-14
ES-14-301-05
ES-14-302-01
ES-14-302-02
ES-14-401-01
ES-14-402-01
ES-14-402-02
ES-14-403-20
ES-14-701-01
ES-14-902-01
ES-14-902-02
ES-14-903-12

Version No. 8.0

Drawing Management
Drawing Preparation
Drawing Numbering
Equipment Numbering System
Labels and Signs: Plant and Equipment
Protective Coatings
Grouting
Fixed Platforms, Walkways, Stairways and Ladders
Fabrication of Structural Steel
Erection of Structural Steel
Mechanical Preferred Equipment
Mechanical Equipment Design, Supply and Installation
Testing and Commissioning of Mechanical Installations
Monorails
Electrical/Instrument Preferred Equipment
Materials and Workmanship for Electrical Installations
Testing and Commissioning of Electrical Installations
Electric Motors

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Belt Conveyors
CSBP Guide Manuals
GM-05-043-01
GM-05-050-01
GM-10-020-04
GM-11-035-02
GM-11-038-02

Technical Data Requirements for Plant and Equipment

Engineering Modifications
Contractors Site Instructions
Basic Safety Rules
Slings, Rigging and Lifting Equipment Safety

CSBP Procedures
DP-05-011-03
DP-05-013-01
DP-05-013-04
DP-05-013-05
DP-05-014-01
EP-08-030-05
EP-08-030-19

Maintenance Daily Schedule

Work Order Entry and Approval
Closing Maintenance Work Orders
Developing Maintenance Strategies
Maintenance Breakdown Repairs
Engineering Project Files
Engineering Project Design Review

EP-08-030-38

Engineering Project Handover

CSBP Standard Forms

ES-14-101-12

Technical Data Sheets Mechanical, Electrical and Instrument

Stage 1 Commissioning Inspection Reports

SF1811
SF1812
SF1813
SF1814
SF1815
SF1816
SF1823
SF1824
SF1825
SF1850

M101
M102
M103
M104
M105
M106
M113
M114
M115
M140

General Mechanical
Fabric Carcass Conveyor
Miscellaneous Conveyor Equipment
Conveyor Idlers
Conveyor Pulley
Belt Conveyor
V-Belt Drive
Base Mounted Gear Reducer
Shaft Mounted Gear Reducer
Chute

Stage 2 Commissioning Test Reports

SF1911
SF1912
SF1916
SF1923
SF1924
SF1925

M201
M202
M206
M213
M214
M215

Version No. 8.0

General Mechanical
Fabric Carcass Conveyor Belt
Belt Conveyor
V-Belt Drive
Base Mounted Gear Reducer
Shaft Mounted Gear Reducer

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Belt Conveyors
CSBP Standard Drawings
9900-3-0001/001
9900-3-0001/002
9900-3-0001/003
9900-3-0001/004
9900-3-0001/006
9900-3-0005/001
9900-3-0005/002
9900-3-0005/003
9900-3-0005/004
9900-3-0006/000
9900-4-0053/001
9900-4-0200/004
9900-4-0210/000
9900-4-0240/000
9900-4-0250/000
9900-4-0250/001
9900-4-0251/000
9900-4-0260/000
9900-4-0260/001
9900-4-0260/002
9900-4-0260/003
9900-4-0500/000
9900-4-0550/001
9900-4-2400/001
9900-9-7011/000
9900-9-7012/000
9900-9-7013/000
9900-9-7015/000

Version No. 8.0

Standard 75 Ladder and Safety Cage Details

Standard Vertical Ladder and Safety Cage Details
Standard Stairway Details
Standard Platform, Handrail and Floor Grating Details
Landing for Stairs and Ladders
Standard Beam and Bracing Connection Details
Standard Beam Connection Details and Member Schedule
Structural Base Plates
Standard Column and Beam Bolted Splice Connection Details
Low Level Clearance Dummy Gantry
Standard Access Door
Conveyor General Stringer Arrangement
Typical Conveyor General Arrangement
Typical Head End Arrangement
Screw Take-up Arrangement
Screw Take-up Details
Gravity Take-up Arrangement
Typical Skirt Details (Dry Materials)
Conveyor Skirting Details (Dry Granular Materials)
Typical Skirt Details (Wet Materials)
Typical Skirt Details (Dry Uncoated AN Prill)
Conveyor Transfer Design For Dry Granular Fertilisers
UMHWPE Fixing Details
Standard Lifting Lug
Pullwire and High Burden Switch Installation Details
Pullwire Switch Installation Details
Pullwire and Blocked Chute Installation Details
Belt Drift Switches Installation Details

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Belt Conveyors
Standards Association of Australia
AS 1111
AS 1112
AS 1163
AS 1214
AS 1237
AS 1252

ISO Metric Hexagon Commercial Bolts and Screws

ISO Metric Hexagon Nuts including Thin Nuts, Slotted Nuts and Castle Nuts
Structural Steel Hollow Sections
Hot-dip Galvanised Coatings on Threaded Fasteners
Flat Metal Washers for General Engineering Purposes
High-Strength Steel Bolts with Associated Nuts and Washers for Structural
Engineering
Conveyor Belting Textile Reinforced
Conveyor Belting of Elastomeric and Steel Cord Construction
Methods of Testing Conveyor and Elevator Belting
Rotating Electrical Machines General Requirements
Steel Sheet and Strip - Hot Dipped Zinc Coated or Aluminium/Zinc Coated
Design of Rotating Steel Shafts
Carbon Steels and Carbon-Manganese Steels Hot Rolled Bars and
Semifinished Products
Carbon Steels and Carbon-Manganese Steels Cold Finished Bars
Wrought Alloy Steels Standard, Hardenability (H) Series and Hardened and
Tempered to Designated Mechanical Properties
Cold-Formed Steel Structures Code
Covered Electrodes for Welding
Welding of Steel Structures
Hot Rolled Steel Flat Products
Fixed Platforms, Walkways, Stairways and Ladders Design, Construction and
Installation
Conveyors - Design, Construction, Installation and Operation - Safety
Requirements
Certification of Welding Supervisors Structural Steel Welding
Packaging
Roller Bearings Dynamic Load Ratings and Rating Life
SAA Wiring Rules
Structural Steel Hot Rolled Plates, Floor Plates and Slabs
Structural Steel Hot Rolled Bars and Sections
Structural Steel Welded I Sections
Vibration and Shock Balance Quality of Rotating Rigid Bodies.
Mechanical Equipment - Steelwork
Safe Guarding of Machinery Part 1: General Principles
Steel Structures
The Storage and Handling of Oxidising Agents
Hot Dip Galvanised (Zinc) Coatings on Fabricated Ferrous Articles

AS 1332
AS 1333
AS 1334
AS 1359
AS 1397
AS 1403
AS 1442
AS 1443
AS 1444
AS 1538
AS 1553
AS 1554.1
AS 1594
AS 1657
AS 1755
AS 2214
AS 2400
AS 2729
AS 3000
AS 3678
AS 3679.1
AS 3679.2
AS 3709
AS 3990
AS 4024.1
AS 4100
AS 4326
AS 4680

Other Engineering Standards and Publications

AS/NZS ISO 9002
NFPA 490

Version No. 8.0

Model for Quality Assurance in Production, Installation and Servicing

National Fire Protection Association Incorporated - Code for the Storage
of Ammonium Nitrate

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Belt Conveyors
6.

BASIS OF DESIGN

6.1

BELT CONVEYOR DESIGN PROCESS

The belt conveyor design process is a systematic process, aimed at developing an appropriate
reliable engineering solution with optimised life cycle costs, without compromising on safety or
quality. The design process shall include the following activities:
Select belt speed in accordance with Section 6.2
Select belt width in accordance with Selection 6.3.
Select drive capacity in accordance with Section 6.4.
Carry out detail design in accordance with Sections 6.5 to 6.8 and 7 to 25.
Carry out design reviews in accordance with Section 6.9.

WARNING

SPECIAL DESIGN CONSIDERATION SHALL BE GIVEN TO CONVEYORS IN AN

AMMONIUM NITRATE SERVICE.
LOCATIONS WHERE AMMONIUM NITRATE COULD COLLECT AND BE CONFINED
UNDER HIGH PRESSURE ARE AN EXPLOSION HAZARD IN THE EVENT OF A FIRE.
COMPONENTS SHALL BE DESIGNED SO THERE ARE NO HOLLOW SPACES IN
AMMONIUM NITRATE CONVEYORS.

6.2

BELT SPEED

Belt speeds shall be selected as appropriate to the application and shall avoid the possibility of
spillage and excessive power consumption.
Unless otherwise specified, the following maximum belt speeds shall normally apply:
For short in-plant connecting / feed belts
For medium transfer belts
For long interplant / storage bin belts

6.3

- one (1) m/s

- two (2) m/s
- three (3) m/s

BELT WIDTH

Unless otherwise specified in the Works, or agreed to by the Superintendent, the belt width shall be
selected based on a design capacity of 200% (2 times), the maximum rated process capacity.

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Belt Conveyors
6.4

DRIVE CAPACITY

Unless otherwise specified in the Works, or agreed to by the Superintendent, the drive capacity
shall be based on 120% (1.2 times); the maximum rated process capacity, with due allowance for
skirt and scraper friction and the increased power requirements for belt feeders fitted under material
hoppers.

6.5

GENERAL

Belt take-ups shall not be positioned under feed or transfer points or anywhere where there is any
likelihood of spillage from other parts of the plant.
Layouts shall be designed such that in plan transfer angles, from one conveyor to another shall not
be less than 90, wherever possible.

6.6

DESIGN COMPUTATIONS

The Contractor shall supply design computations of the conveyor system to the Superintendent for
approval, if requested.
These computations shall include belt tensions, accelerating and decelerating forces and drive
horsepower, conveyor belt speed, belt type/design, friction forces and take-up weights.

6.7

FOUNDATIONS AND SUPPORTS

The Contractor shall provide all necessary equipment loading data, drawings of bolt layouts and
details of components to be built into the foundations.
All loads imposed on other structures by the conveyors shall be specified on drawings, so that the
design of the support structure can be verified.

6.8

TECHNICAL DATA

Equipment manuals, recommended maintenance schedules and spares list for all maintainable
items and technical data sheets for each item of equipment shall be prepared and supplied by the
Contractor, in accordance with the requirements of CSBP Guide Manual Technical Data
Requirements for Plant and Equipment (GM-05-043-01).

6.9

DESIGN REVIEWS

Design reviews shall be carried out in accordance with CSBP Engineering Procedure Engineering
Project Design Review (EP-08-030-19), to ensure that the design is consistent with the agreed
project criteria and it is compliant with CSBP Standards, Statutory Requirements and other
applicable codes and practices.

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Belt Conveyors
7.

DRAWINGS

7.1

GENERAL REQUIREMENTS

All conveyor layout drawings, head and tail end arrangements, take-ups, chute work, marking
plans, stairways, mechanical equipment supporting steelwork, platework and fabricated equipment
components shall be drawn, numbered and approved in accordance with CSBP Engineering
Standards:
ES-14-101-02
ES-14-101-03
ES-14-101-04

Drawing Management
Drawing Preparation
Drawing Numbering

Typically drawings shall provide complete information necessary for the fabrication and erection of
the conveyor system.
Note:

The Superintendents review, approval or acceptance of Contractor drawings, does not

relieve the Contractor of responsibility for accuracy of shop or site connection detailing,
conformance to this or referenced standards or contractual obligations.

7.2

SPECIFIC REQUIREMENTS

7.2.1

Conveyor General Arrangement

The Conveyor General Arrangement shall consist of an elevation, cross-sections at appropriate

points along the conveyor and a design information table. For typical Conveyor General
Arrangement layout refer to CSBP Standard Drawing 9900-4-0210/000.
Dependant on the size and configuration of the conveyor system or as directed by the
Superintendent, the Conveyor General Arrangement shall indicate the following where applicable:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.

location plan;
belt line, idlers and pulleys, working points and set out dimensions, idler spacing and type;
amount of take-up;
conveyor support structure;
location of run-off, under-speed and emergency stop switches;
conveyor crossovers and splicing platforms;
location of transfer station column lines and floor levels;
locations of feed points and discharge conveyor work point;
lengths of travel of trippers, where applicable;
surrounding ground level;
clearance over roads, rail tracks and access ways;
location of conveyor accessories;
diagram of running tensions;
Design Information Table comprising a schedule of belts, gearboxes, motors, reducers,
couplings, pulleys, bearings, brakes, idlers, accessories used on the conveyor system
together with conveyor and drive data.
Associated equipment drawing numbers shall be recorded wherever possible.

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Belt Conveyors
o.

Item numbers for all components listed in the Design Information Table schedule.
Item numbers shall be shown on the conveyor elevation and cross-sections adjacent to
the conveyor components.
Symbols for each idler type and conveyor accessories.
Symbols shall be shown adjacent to the item number in the Design Information Table
schedule and on the conveyor elevation and cross-sections indicating where the
conveyor components are located.

p.

In accordance with CSBP Engineering Standards, Equipment Numbering System (ES-14-101-06)

and Drawing Numbering (ES-14-101-04) the primary drawing number shall match the conveyor
equipment number.
EXAMPLE:

Conveyor Equipment Number: X0821

Conveyor General Arrangement drawing number _ _ _ _ 4 0821 / 000

If a Conveyor General Arrangement would become very complex and difficult to understand with
the amount of information to be included on a single sheet, consideration shall be given to having
additional sheets numbered 001, 002 etc.
The Design Information Table and Conveyor Profile shall always be placed on sheet 000. If, on
very long conveyors all of the profile cannot be shown on sheet 000, sheets 001, 002 etc shall also
be used. Similarly, cross-sections and other details shall be on sheets 001, 002 etc if space dictates.
7.2.1.1

Reference Drawings

Reference drawings, to be listed on the Conveyor General Arrangement shall include:

structural arrangements;
head and tail end arrangements;
take-ups;
chute work;
conveyor guarding;
standard drawings relevant to the facility;
cross-reference between the General Arrangement sheet 000 and associated sheets 001, 002
etc.

7.2.2

Structural Steelwork Drawings

Typically, drawings shall provide complete information necessary for the fabrication and erection
of all structural steelwork including member size, weight and dimensions, location, type and size of
bolts and welds, joints and splices, erection mark numbers and reference to the required steel
specification(s) and protection coating system. Additionally, reference to associated design drawing
and erection diagram drawing numbers should be made.

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Belt Conveyors

8.

CONVEYOR BELTING

The Superintendent shall approve the fabric, tensile strength, number of plies and cover of the
conveyor belting against each specific application. The preferred selections are as follows:
Fabric
Strength
No of plies

PN
150kN/m/ply
3

Top Cover
Bottom Cover -

5mm
1.5mm

Conveyor belting shall comply with the requirements of AS1332, or AS1333 if steel cord belting is
used.
Jointing of all conveyor belts shall be by hot vulcanising carried out in accordance with the belting
manufacturers instructions. Mechanical splicing is not acceptable.

9.

PULLEYS

9.1

CONSTRUCTION

Pulleys shall be welded mild steel construction with ample strength for the loads imposed by the
belt tension forces. Welding procedure shall take into consideration restraint between pulley shell
and end plates.
All welds shall be 100% visual and ultrasonic examined and permissible levels of imperfections
shall be in accordance with AS 1554.1
If post weld heat treatment (PWHT) is specified, final non-destructive examination (NDE) shall
take place after PWHT has been performed.
Crowned pulleys shall be used when no other belt tracking devices can be used or when specified
by the Superintendent.
All shafts shall normally be fitted to pulleys with Compression style locking elements e.g.
Ringfeder, except for ammonium nitrate conveyors. Refer to Sections 9.7.3 and 9.7.4 for details.

9.2

DIAMETERS

Pulley diameters shall be to suit the belting being used and the desired belt speed.
The thickness of the lagging on pulleys is to be disregarded in determining the diameter of pulleys.
Where practicable, pulley diameters shall be restricted to 480mm and 630mm.

9.3

OVERALL WIDTH AND BEARING CENTRES

Unless otherwise specified or directed by the Superintendent, pulley face widths for dry areas shall
be wider than the belt width in accordance with normal conveyor design practice.

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Belt Conveyors
Unless otherwise specified, pulley face widths for wet areas (ie. the superphosphate manufacturing
and granulation plants at CSBP Kwinana) shall be less than the width of the belt as per Table 1, so
that no spillage will fall onto the pulley.

Belt Width B in mm
300
450
500
600
750
900
1000
1200
1600
1800
2000
Table 1
Note:

9.4

Pulley Width in mm
B minus 75
B minus 75
B minus 75
B minus 100
B minus 100
B minus 150
B minus 150
B minus 150
B minus 150
B minus 200
B minus 200
Pulley Width

The bearing centres of non-driving head pulleys and snub pulleys at drives shall be the
same as for drive pulleys.

TOLERANCES

Pulley diameters shall be machined to a maximum tolerance of nominal diameter 3mm.

Concentricity with shaft centres measured as total movement on a dial type indicator, to be within
0.8mm for non-lagged pulleys and 1.5mm for lagged pulleys.
The difference in diameters as measured at opposite ends of the shell shall not exceed 0.8mm per
linear metre.
The shell thickness of the finished pulley shall be not less than the minimum calculated thickness
or 5mm, whichever is greater and shall not vary from place to place by more than 0.8mm. Shell
thickness shall be measured ultrasonically.

9.5

PULLEY LAGGING

In general all conveyor pulleys shall be rubber-lagged.

9.5.1

Rubber Lagging

Rubber lagging of pulleys shall be hot vulcanised to the pulley shells. The lagging shall be 12mm
thick, free of spiral wrap marks with hardness in the range of 50 60 Shore A Durometer hardness.
After fixing the lagging, it shall be ground to the correct size and concentricity if required to
comply with manufacturers tolerances.

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Rubber lagging on head pulleys shall be grooved in a diamond pattern.
9.5.2

Ceramic Lagging

Head pulleys in the Compound Fertiliser areas shall be ceramic lagged. Fixing to the pulley shells
shall be in accordance with the manufacturers instructions.

9.6

BALANCING

All pulleys shall be statically balanced. Additionally, when specified by the Superintendent, they
shall be dynamically balanced.

9.7

PULLEY SHAFTS

9.7.1

General

Shafts shall be designed in accordance with the requirements of AS1403.

Unless otherwise specified, shafts shall normally be manufactured from K1045 material as
nominated in AS1442, AS1443 and AS1444. Higher grade 4140 material shall be used if shaft
loads dictate.
9.7.2

Diameter Reduction

All diameter reductions must be carefully machined, all corners rounded and shoulders blended
with swept radii free of tool marks.
Where the major diameter reduction is machined using a fillet, the radius of this fillet shall be not
less than D/10 and preferably at least D/5, where D is the reduced diameter of the shaft.
9.7.3

Compression Type Locking Element Pulley Shaft Assembly

All shafts shall be fitted to the pulley with Superintendent approved compression type locking
elements such as Ringfeder 7012, Mav 2005 or Mav 1061s or equivalent, except for ammonium
nitrate conveyors or elsewhere where it is specified that a fully welded pulley/shaft assembly is
required. They shall be supported by plummer block type anti-friction bearings. Refer to Section
9.7.4 for welded assembly details.
Note:

9.7.4

Use of plummer blocks does not apply to screw take up arrangement and may not apply
to head pulleys on small to medium sized conveyors.
Welded Pulley Shaft Assembly

To prevent ingress of ammonium nitrate into the pulleys, thus reducing any potential explosion
risk, pulley and shaft assemblies for this service shall be fully welded, i.e. the shafts shall be fully
welded to the end plates, which in turn are to be fully welded to the pulley shell.

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9.8

PULLEY SHAFT BEARINGS

All pulley shaft bearings shall be of the ball or roller type with a minimum B10 life of 60,000 hours
or higher if specified by the Superintendent
Unless otherwise specified, bearing housing shall be:
a.

SKF, SNH series or equivalent from CSBP approved supplier, two bolt mounting plummer
blocks, fitted with Taconite seals for shafts up to 150mm diameter and

b.

SKF, series SD31 or equivalent from CSBP approved supplier, four bolt mounting
plummer blocks, fitted with Taconite seals for shafts over 150mm diameter.

10.

CONVEYOR IDLERS

10.1

GENERAL

Width of idlers shall be consistent with and based on pulley width, as required for wet or dry areas
(see Section 9.3).
10.1.1 Balance
All idler rolls shall be suitably balanced for operation at speeds 25% in excess of the speed shown
in the drawings, to have a maximum out of balance of 0.056Nm. Weigh idlers shall be balanced
within 0.014Nm. Maximum peripheral runout of idler shells when rotated on their own shafts shall
be not more than 0.5mm movement for rubber surface idlers, measured on the periphery of the
rubber.
In general, idlers fitted to belt scrapers shall be precision balanced types. Additional precision
balanced idlers shall be installed adjacent to the weigh idler in accordance with the weigh idler
manufacturers requirements.
10.1.2 Bearings
All bearings in idler rolls shall be of ball roller type. They shall be designed in accordance with the
bearing manufacturers catalogue ratings for a B10 life of 60,000 hours service, or higher if
specified by the Superintendent and at a continuous loading equivalent to the maximum loading
imposed by the conveyor rated load.
Idler roll bearings shall be of an approved sealed-for-life type.
10.1.3 Idler Profile
The horizontal and vertical deviations from design values shall be limited to 3mm.
Idlers installed on belt conveyors that incorporate weighing idlers shall have a profile tolerance as
specified by the weighing equipment manufacturer.

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10.2

TROUGH IDLERS

The Superintendent shall approve trough idlers, which shall be three-roll offset type. All rolls are to
be of equal length and interchangeable. Preferred troughing angle is 35.
Where necessary, adjustable trough transition idlers shall be provided over the transition length of
conveyor head and tail ends and shall be arranged to uniformly effect transition with minimal
increase in belt edge tension zone. Longitudinal buckling of the belt in the transition zone will not
be accepted. The angle of the outer roll of transition idlers shall be adjustable through a range of
10 to 35.
Trough idler rolls shall be 127mm diameter, lagged with 6mm thick, 50-60 shore A Durometer
hardness rubber, unless otherwise specified.
All types of trough idlers, for each particular belt size, shall have the same profile dimensions and
are to be interchangeable.
Spacing of trough idlers shall be to suit loading requirements of individual conveyors and shall be
spaced to give a maximum of 1.5% sag for all conveyors
Closer spacing shall be used on convex vertical curves. Graded zone spacing may be used where
approved.

10.3

TROUGH IMPACT IDLERS (IF REQUIRED)

Trough impact idlers shall be three roll offset type, heavy-duty rubber disc. All rolls are to be
interchangeable.
All impact rolls shall be positively locked into their frames and fitted under all loading points, for
sufficient distance, to ensure that all impacts on the belt are taken over the impact idlers. The
spacing of impact idlers shall not exceed 300mm centres.
Provision shall be made to install and withdraw any idler assembly without disturbing adjacent
idlers.

10.4

TROUGH TRAINING IDLERS

Trough training idlers shall be fitted with rolls interchangeable with those of normal trough idlers.
Side guide rolls shall have ball or roller bearings and shall not be less than 50mm diameter.
Trough training idlers shall be fitted to all conveyors that are twenty (20) metres or greater in
length and shall be located in the following locations where possible:
a.

Six (6) metres from head and tail pulleys.

b.

At 35 metre centres for conveyors up to 125 metres in length.

c.

At 60 metre centres for conveyors in excess of 125 metres long.

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When fitted to Reversing Conveyors, trough-training idlers shall be capable of operating in both
directions.

10.5

RETURN IDLERS

Unless otherwise specified, return idlers shall be 127mm diameter, flat roll (rubber) for fabric
belts and vee roll for steel cord belts.
Flat roll, return idler rolls shall be lagged with 6mm thick, 50-60 shore A Durometer hardness
rubber.
Unless otherwise approved by the Superintendents, spacing of return idlers shall not exceed three
(3) metres.

10.6

RETURN TRAINING IDLERS

Return training idlers shall be flat self-training idlers with rolls interchangeable with those of
normal return idlers. Side guide rolls shall have ball or roller bearings and shall be 50mm
minimum diameter.
Spacing of return training idlers shall be as per trough training idlers. Refer to Section 10.4 for
details.
When fitted to Reversing Conveyors, return training idlers shall be capable of operating in both
directions.

10.7

AMMONIUM NITRATE CONVEYORS

To minimise potential explosion risk, construction of ammonium nitrate prill conveyors have the
following special requirements.
10.7.1 Return Idlers
Return idlers shall be solid shafts with rubber discs.
Shafts shall be fixed to the conveyor stringers in such a way that there are no locations where
ammonium nitrate can accumulate.
10.7.2 Carrying Idlers
Carrying idler rolls shall be filled with expanded closed cell polyurethane foam, or another material
approved by the Superintendent.
10.7.3 Conveyor Belting
All conveyor belting shall be of fire retardant type.
Conveyor belting to be used for coated ammonium nitrate prill shall be polyvinyl chloride (PVC)
coated to resist the effects of the coating agent on normal rubber belt covers.

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Conveyor belting for inclined conveyors, used for coated prill, shall incorporate a anti-slip texture
such as scallops or a similar texture approved by the Superintendent.

11.

GEARBOXES

Gearboxes shall be shaft-mounted and supplied in accordance with CSBP Engineering Standard
Mechanical Preferred Equipment (ES-14-401-01).

12.

BELT TAKE-UP

Unless otherwise specified, gravity take-ups shall be used on all conveyors except for short
conveyors up to forty (40) metres in length, which shall use a screw take-up system. Short
conveyors incorporating a weightometer (belt scale) shall have some type of gravity take-up to
ensure the accuracy and consistency of the weightometer.
Refer to the following CSBP Standard Drawings for typical arrangement details:
9900-4-0250/000
9900-4-0251/000

Screw Take-up Arrangement

Gravity Take-up Arrangement

Take-ups shall be sized for the required belt tension and take-up travel based on the belting
manufacturers recommendations.
All conveyor gravity take-up pulleys shall be fitted with shedder plates above them to prevent
spillage wedging between the pulleys and conveyor belts.

12.1

GRAVITY TAKE-UP

Take-up side guides shall be equipped with wooden or plastic guide blocks.
Gravity take-up weights shall be constructed from steel plate filled with concrete and shall be fitted
with shedder plates to prevent accumulation of spillage from the belt. Provision shall be made for
adding or removing weight. The assembly shall be weighed by the Contractor to verify the correct
design mass. The Superintendent shall witness the weighing of the take-up and the certified mass in
kilograms shall be painted on the take-up frame in 50mm high black letters.
Lifting lugs shall be provided on the top of the structure and on the gravity take-up weight, to
facilitate lifting. For lifting lug details refer to CSBP Standard Drawing 9900-4-2400/001.
For general arrangement and details of typical gravity take-ups refer to CSBP Standard Drawing
9900-4-0251/000. The Superintendent shall specify the preferred type of gravity take-up for
relevant conveyors.

12.2

SCREW TAKE-UP

Unless otherwise specified, take-up housings shall be SKF THM 500 series or equivalent from a
CSBP approved supplier, fitted with Taconite seals for shafts up to 140mm diameter.

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Exposed thread on take-up screws shall be wrapped with Denso tape or approved equivalent in
accordance with manufacturers instructions after final adjustment of the belt tension has been
completed.
For screw take-up arrangement and details refer to CSBP Standard Drawings 9900-4-0250/000 and
9900-4-0250/001.

13.

BELT SCRAPERS

A primary belt scraper shall be provided at the head pulley of each conveyor to clean the carrying
side of the belt. Discharge chutes shall be arranged so that material scraped from belts will
discharge into chutes. Secondary scrapers shall be fitted where specified and shall scrape into
chutes too. Primary scraper blades shall be replaceable polymer sectional type and secondary
scraper blades shall be non-metallic unless otherwise specified.
Special scraper requirements exist in the wet areas of the SMP and some ammonium nitrate prill
areas. Additional information will be provided for individual projects in these areas.
Where specified, belt cleaning brushes shall be fitted. Brushes shall be used in lieu of blade type
scrapers for textured belts (eg scalloped belts), where blade type scrapers cannot be used. Brushes
shall be located to ensure all material brushed off belts falls into the associated head chute.
Where specified a plough type scraper shall be located on the inside of the return side of all belts,
close to the tail pulley. Blades of plough type scrapers shall be non-metallic to minimise the wear
inside the belt.
The proposed type and position of scrapers shall be submitted to the Superintendent and approval
obtained, before any item is fabricated or purchased.

14.

RUBBER SKIRTING

Rubber skirting shall be provided at all transfer and loading points and wherever there is any
likelihood of material spillage from the belt.
Unless specified otherwise or directed by the Superintendent, skirts and clamps shall be as shown
on CSBP Standard Drawings 9900-4-0260/000, 9900-4-0260/001, 9900-4-0260/002 or 9900-40260/003 for the relevant type of material. In ammonium nitrate despatch areas where prill is dry
and at or near ambient temperature, the skirt design on 9900-4-0260/000 shall be used. In
ammonium nitrate manufacturing areas where uncoated prill is wet and/or at elevated temperature,
the skirt design on 9900-4-0260/003 shall be used. Approval of proprietary skirting systems shall
be at the sole discretion of the Superintendent.

15.

CHUTES AND HOODS

15.1

DESIGN

Chutes and hoods shall be provided at all transfer points. For dry granular fertilisers, typical
conveyor transfer design details shown on CSBP Standard Drawing 9900-4-0500/000 shall be
used.

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Chutes shall be designed so that adequate space is available below the head pulley and conveyor to
accommodate belt scrapers, magnetic head drums with waste disposal chutes and product samplers
if used and to allow for operational headroom and maintenance service access as required.
Designs shall be such that the extremities of the material trajectory fall evenly each side of the
conveyor centre line, based on the Dunlop Methodology for Conveyor Design or a similar method.
Due to the significant potential for product build-up on surfaces and the resultant cleaning burden,
designs incorporating impact plates will not be acceptable unless approved by the Superintendent.
Where possible, chute designs shall prevent direct impact of product onto chute surfaces.
Inspection doors shall be provided in all transfer hoods and chutes, to facilitate access for cleaning
and maintenance purposes. The openings shall be as large as practicable and constructed in
accordance with CSBP Standard Drawing 9900-4-0053/001. Where maintenance and inspection
openings are intended to be used while the equipment is in operation, a guard mesh shall be bolted
into the opening to allow observation without exposing personnel to an unsafe opening.
Where chutes are provided with outlet gates, the gates shall be of arc or clamshell types. Horizontal
slide gates are not generally acceptable but may be approved by the Superintendent for particular
applications.
Chute valley angles and configurations shall be made to suit the material being handled but in
general shall not be less than 60. Where possible, chutes shall be vertical to minimise the potential
for product build-up on surfaces.

15.2

DUST SUPPRESSION

All hoods and chutes shall be designed to minimise dust movement during plant operation. The
following principles shall be observed:
a.

Material drop shall be reduced to the practical minimum.

b.

The free falling column of material shall be maintained where possible in the compressed
condition, to minimise air entrapment.

c.

Transfer points shall be fully enclosed and sealed with rubber strip curtains to prevent entry
of outside air.

d.

The downstream conveyor shall be enclosed at the outlet of the transfer point with a cover
of minimum length two (2) times the belt width and 500mm or 250% of material lump size
(whichever is the greater), above the belt at the conveyor centre-line. The whole length of
the cover shall be provided with standard rubber skirting. Refer to CSBP Standard Drawing
9900-4-0500/000 for details.

e.

Dust collection points, when installed, shall be positioned downstream of transfer points, to
maximise dust settling inside the skirted transfer point.

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15.3

CONSTRUCTION

Unless otherwise specified, chutes shall be of skeletal steel frame construction with 6mm
(minimum) thick rubber panels and hoods fabricated from 6mm (minimum) thick steel, stiffened
and supported as required. All chutes and hoods shall be designed and constructed so that they are
readily removable for maintenance purposes. Standard lifting lugs as per CSBP Standard Drawing
9900-4-2400/001 shall be provided.
Note:

16.

Where material is likely to impact the chutes, they shall be lined with UHMW
polyethylene in accordance with CSBP Standard Drawing 9900-4-0550/001.

CLEARANCES

All conveyors shall have a minimum clearance between the underside of the return belt and the
ground surface or floor of one (1) metre. Where required by design constraints, this clearance may
be reduced, with the approval of the Superintendent.
Conveyor stringer supports and transfer structures shall give clear access below the belt and
bracing. Transfer structures shall be clear to a height of three (3) metres above ground level. To
achieve this, the use of portal type structures is recommended and the use of diagonal cross bracing
shall be kept to a minimum.
Where crane or vehicle access is required under elevated conveyors, the minimum height clearance
shall be six (6) metres and the minimum width clearance shall be ten (10) metres.
Note:

Where the minimum height cannot be achieved, a low-level clearance-warning gantry

shall be installed. Refer to CSBP Standard Drawing 9900-3-0001/006 for typical details.

The minimum head clearance between a conveyor walkway, platform and any structures over the
conveyor walkway, shall be 2.2 metres.
Note:

17.

Where the minimum height cannot be achieved, low clearance warning signs shall be
clearly displayed and any low overhead structure shall be locally painted with hazard
warning 100 mm wide black and yellow diagonal stripes.

ACCESS AND MAINTENANCE FACILITIES

All walkways, platforms and stairways on conveyor structures shall be in accordance with CSBP
Engineering Standard Fixed Platforms, Walkways, Stairways and Ladders (ES-14-301-05) and
CSBP Standard Drawings 9900-3-0001/003, 9900-3-0001/004 and 9900-3-0001/006.
Wherever possible, all conveyor structures shall be designed with clear space on both sides of the
belt for idler removal, replacement and belt splicing access. The belt splicing area shall be
identified on the conveyor framework using black lettering on a yellow background, stating Belt
Splicing Area.

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When designing walkways around conveyors, a minimum walkway width of 600mm (preferably
750mm) shall be maintained, measured from the outermost part of the conveyor. If pull wires and
/or pull wire switch boxes are outside the conveyor frame then the walkway widths shall be outside
the pull wires and pull wire switch boxes. Particular attention should be made to the walkway
design around transfer points where the guarding and pull wires can be several hundred millimeters
outside the conveyor frame.
Elevated conveyors shall be provided with walkways on both sides of the conveyor. The main
walkway shall be at least 750mm wide and the maintenance walkway shall be at least 600mm
wide. These widths shall be measured as described above Crossovers shall be provided at 100
metre intervals along the belt.
Adequate lifting beams and monorails shall be built into the conveyor structures at drive and
transfer points for handling heavy components during maintenance operations. Refer to CSBP
Engineering Standard Monorails (ES-14-403-20) and CSBP Standard Drawing 9900-4-2400/001
for lifting lug details.
No pipes or cables shall be run parallel to and immediately below any belt conveyor. Where
conveyor structures are used to support pipe racks or cable ladders, the pipe racks and cable ladders
shall be positioned so they do no obstruct any conveyor maintenance operation, especially belt
changing and splicing, changing of idler assemblies and spillage clean up.

18.

SAFETY REQUIREMENTS

Conveyor components shall be designed in accordance with the safety requirements of Statutory
Authorities, AS 1755 - Conveyor Safety Code and CSBPs relevant Engineering Standards and
Standard Drawings.

18.1

CONVEYOR GUARDS

Conveyor guards shall be designed to remove any foreseeable risk of personal injury by accidental
contact with equipment. They shall be designed to enable routine visual inspection to be carried
out on the equipment without removing the guards.
Guards around transfer points and areas where adjustments are made, shall be designed where
possible to be able to be handled by one person to provide quick access to items such as idlers,
skirting and take-up adjustments. Where possible, guards at these locations should be made of
light weight material such as aluminium or plastic and not weigh more than 15kg. In these
locations guards should not have a width, length or height greater than 1000mm, to ensure they are
relatively simple to handle by one person.
It shall be possible to remove guards without having to disconnect pull wires. It is suggested that
where a guard extends vertically both above and below the pull wire by more than 300mm, the
guard be split into two separate sections with the split being directly behind the pull wire.

18.2

ANTI-ROLL BACK

All inclined conveyors shall be fitted with an anti-roll back device on the reduction gearbox shaft.

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Fitting of brakes may also be required on other conveyor types or for specific purposes eg to
prevent run on. In particular, inclined reversing conveyors shall be fitted with a brake instead of a
gearbox mounted anti-roll back device.

18.3

EMERGENCY LANYARD SWITCHES

All conveyors shall be fitted with continuous pull wires and pull wire switches in accordance with
CSBP Standard Drawings 9900-9-7011/000, 9900-9-7012/000 and 9900-9-7013/000. On elevated
conveyors with walkways on both sides of the belt, pull wires shall be provided on both sides.
Pull wires shall be installed outside of guarding and where possible at least 100 mm clearance shall
be provided between the pull wire and the guard or any other solid object. Other than where pull
wires pass through eye bolts or other guides, the clearance shall not be less than 50 mm.

18.4

MONITORING DEVICES

All conveyors shall be fitted with belt-drift detection tilt switches, or a Superintendent approved
equivalent, fitted in accordance with standard drawing 9900-9-7015/000 and as follows:
a.

On belts ten (10) metres or larger in length, four (4) switches shall be fitted. One each side
of the trough and return belt leading onto the head and tail pulleys.

b.

On belts less than ten (10) metres in length, two (2) switches shall be fitted at the head end
only.

All conveyors shall be fitted with an under-speed sensing switch. This device shall be fitted to the
tail pulley.
Where specified, conveyor discharge chutes shall be fitted with a blocked chute probe in
accordance with CSBP Standard Drawing 9900-9-7013/000.
All gravity take-up weights shall be provided with end travel, limit detection switches.
All monitoring devices shall be as specified in CSBP Engineering Standard Electrical/Instrument
Preferred Equipment (ES-14-701-01).

18.5

NOISE

No part of the conveyor system shall emit noise levels exceeding 85dB(A), at a distance of one (1)
metre from the source.

19.

IDENTIFICATION

19.1

EQUIPMENT NUMBERS

All equipment shall be assigned an identification number in accordance with CSBP Engineering
Standard Equipment Numbering System (ES-14-101-06).

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19.2

MOTOR IDENTIFICATION TAG

All electric motors shall be fitted with an identification tag in accordance with CSBP Engineering
Standard Electric Motors (ES-14-903-12).

19.3

EQUIPMENT LABELS

Equipment labels shall be manufactured and installed in accordance with CSBP Engineering
Standard Labels and Signs: Plant and Equipment (ES-14-102-09).

20.

MATERIALS

Unless otherwise specified or approved by the Superintendent all materials shall be new and
comply with the following CSBP Engineering Standards:
ES-14-302-01
ES-14-401-01
ES-14-701-01
ES-14-902-01

21.

Fabrication of Structural Steelwork

Mechanical Preferred Equipment
Electrical/Instrument Preferred Equipment
Materials and Workmanship for Electrical Installations

HANDLING OF STEELWORK AND EQUIPMENT

Care shall be taken at all times to prevent damage to steelwork, equipment and their protective
coatings.
Equipment shall be carefully packed for transportation to protect it from dust, moisture, climatic
conditions and vibration which may occur during loading and transport.
Heavy and bulky equipment shall have provision for lifting, slinging and handling during transit,
erection and maintenance periods. Any parts normally lifted during maintenance periods and
weighing one (1) tonne or more shall be marked with their weight. If spreaders are required for
slinging, a label stating the requirements shall be fitted near each lifting point.
Damaged materials and coatings shall be repaired in accordance with applicable standards and
manufacturers instructions, to the satisfaction of the Superintendent or they shall be replaced.

22.

FABRICATION

Unless otherwise specified fabrication of conveyor system steelwork and components shall be in
accordance with CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01).

23.

WELDING

Unless otherwise specified all welding shall conform with CSBP Engineering Standard Fabrication
of Structural Steelwork (ES-14-302-01) and:
a.

AS 1554.1 Category SP (Special Purpose), for all structural welding and conveyor
supporting steelwork

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b.

AS 1554.1 Category GP (General Purpose), for welding of all chutework and other
conveyor ancillary steelwork items.

24.

BOLTING

Unless otherwise specified all bolting shall conform with CSBP Engineering Standard Erection of
Structural Steelwork (ES-14-302-02) and:
a.
b.

AS 1252 Grade 8.8/TB bolts for structural bolted connections

AS 1252 Grade 8.8/S for general bolted connections.

25.

PROTECTIVE COATINGS

25.1

STEELWORK

Surface preparation and protective coating shall be in accordance with CSBP Engineering Standard
Protective Coatings (ES-14-102-12). Coating system and colour shall be as specified for the
particular area in which the conveyor is installed.

25.2

MECHANICAL AND ELECTRICAL COMPONENTS

Protective coating and finish of mechanical and electric components shall be to the manufacturers
standard except those components covered by CSBP Engineering Standard Protective Coatings
(ES-14-102-12).

25.3

BOLTS

Unless otherwise specified, all bolts nuts and washes shall be hot-dip galvanised in accordance
with AS1214.

25.4

FLOOR GRATING AND STAIR TREADS

Floor grating and stair treads shall be hot dipped galvanised in accordance with AS 4680. Unless
otherwise specified, floor grating shall be welded in place and stair treads shall be bolted to
stairway stringers.

26.

INSTALLATION

26.1

MECHANICAL/STRUCTURAL

All mechanical and structural installation activities including setting out, erection, bolting, field
welding and, grouting of steelwork and machinery base plates shall be carried out in accordance
with:
a.

the drawings;

b.

Superintendent approved Contractor erection procedures;

c.

CSBP Engineering Standards:

ES-14-202-14
Grouting

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d.
Note:

26.2

ES-14-302-02
ES-14-403-20
ES-14-301-05

Erection of Structural Steelwork

Monorails
Fixed Platforms, Walkways, Stairs & Ladders

Statutory Authorities having jurisdiction over the work site.

Prior to installation, bolt holes in chute flanges and those in equipment flanges and
supporting steelwork shall be checked for alignment accuracy. Discrepancies shall be
reported to the Superintendent and rectification work carried out to the satisfaction of the
Superintendent.

ELECTRICAL

All electrical installation activities shall be in accordance with:

a.

the drawings;

b.

Superintendent approved Contractor installation procedures;

c.

CSBP Engineering Standard Materials and Workmanship for Electrical Installations

(ES-14-902-01);

d.

Statutory Authorities having jurisdiction over the work site.

27.

INSPECTION AND TESTING

27.1

INSPECTION AND TEST PLAN

The Contractor shall submit Inspection and Test Plans (ITP), for all aspects of the work, to the
Superintendent for approval, at least 14 days prior to commencement of any work, which may be
affected. The Contractor shall not proceed with any related work until the Superintendent has
approved the ITP.
The ITP shall identify:
a.
b.
c.
d.
e.

27.2

The inspection, tests and verifying procedures to be performed, including those specified in
this Standard and any others in the Works.
The acceptance criteria for each procedure and the standard or process under which they are
to be performed.
The point, during the execution of the Works, at which the procedure is to be performed.
Who is to perform the procedure.
The procedures to be witnessed by the Superintendent and whether or not subsequent work
is to be held pending the Superintendents approval of the procedures and their results.

WELD INSPECTION AND TESTING

Weld inspection and testing shall be in accordance with AS 1554.1 and CSBP Engineering
Standards:
ES-14-302-01 Fabrication of Structural Steelwork
ES-14-302-02 Erection of Structural Steelwork.

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27.3

FABRICATED STEELWORK INSPECTION

All fabricated structural steelwork shall be inspected in accordance with CSBP Engineering
Standard Fabrication of Structural Steelwork (ES-14-302-01).

27.4

INSPECTION DURING INSTALLATION

The following areas shall be inspected and approved by the Superintendent:

a.
b.
c.
d.
e.

Surface preparation of concrete footing prior to erection of structural support steelwork.

Setting out and alignment tolerances.
Cutting, drilling and welding of existing steelwork.
Surface preparation and protective coating of remedial works and field welds.
Cleaning and surface preparation, of the underside of support column and machinery base
plates, holding down bolts and concrete foundations prior to grouting.

Inspection shall be carried out in accordance with relevant Australian Standards and CSBP
Engineering Standards:

ES-14-102-12
ES-14-202-14
ES-14-302-02
ES-14-403-20

28.

Protective Coatings
Grouting
Erection of Structural Steelwork
Monorails

COMMISSIONING

Prior to being placed into service the conveyor system shall be subject to the following
commissioning activities.

28.1

STAGE 1 - PRE-COMMISSIONING / CONSTRUCTION VERIFICATION

All components within the conveyor system shall be inspected to verify that they have been
fabricated / manufactured, supplied, installed, aligned and lubricated in accordance with:

contract drawings and documentation;

Standards and Codes specified in this Standard;

Statutory Regulations;

Manufacturers requirements.

Tests and calibrations shall be carried out to prove that all systems are operational, including
protective and measuring devices.
Testing and commissioning of all belt conveyor electrical and instrument equipment shall be
carried out in accordance with CSBP Engineering Standard Testing and Commissioning of
Electrical and Instrumentation Installations (ES-14-902-02).

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The following Stage 1 Mechanical Commissioning Inspection Reports shall be used to verify
equipment details:

SF1811
SF1812
SF1813
SF1814
SF1815
SF1816
SF1823
SF1824
SF1825
SF1850

Note:

28.2

M101
M102
M103
M104
M105
M106
M113
M114
M115
M140

General Mechanical
Fabric Carcass Conveyor
Miscellaneous Conveyor Equipment
Conveyor Idlers
Conveyor Pulley
Belt Conveyor
V-Belt Drive
Base Mounted Gear Reducer
Shaft Mounted Gear Reducer
Chute

Stage 2 Commissioning of an item of equipment shall not commence until the

Superintendent has accepted and signed off all the Stage 1 Commissioning Inspection
Reports for the item of equipment, as being successfully completed.

STAGE 2 DRY COMMISSIONING

This stage involves actual running of equipment under no-load conditions, except where
manufacturers instructions state this would be detrimental to the equipment.
Mechanical testing shall only commence after motor rotational tests and electrical control and
safety checks have been carried out. Refer to CSBP Engineering Standard Testing and
Commissioning of Electrical and Instrumentation Installations (ES-14-902-02) for details.
No-load running testing shall include:
a.

checking and recording the motor amps;

b.

checking the correct operation of the equipment;

c.

checking for evidence of misalignment, overheating or abnormal wear;

d.

measurement of bearings and gear vibrations;

e.

adjustments and correction of all faults

The plant shall be run for a sufficient length of time to establish that it is in a reliable and
serviceable condition.
The following Stage 2 Commissioning Test Reports shall be used to test equipment under no-load
condition:

SF1911
SF1912
SF1916
SF1923
SF1924

M201
M202
M206
M213
M214

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General Mechanical
Fabric Carcass Conveyor Belt
Belt Conveyor
V-Belt Drive
Base Mounted Gear Reducer

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Belt Conveyors

SF1925 M215

Note:

28.3

Shaft Mounted Gear Reducer

Stage 3 Commissioning an item of equipment shall not commence until the

Superintendent has accepted and signed off all the applicable Stage 2 Commissioning
Inspection Reports for the equipment, as being successfully completed. Only suitably
qualified and experienced personnel shall carry out testing activities.

STAGE 3 WET COMMISSIONING

This stage involves testing and adjusting equipment, with the conveyor system operating under
load condition, i.e. running material through the process equipment.
The Contractor, under the direction of the Superintendent shall carry out this work.

29.

OPERATIONAL PHASE

Flow diagram Figure 1 shows the high level activities involved in the management of a
commissioned, belt conveyor systems during the operational phase. Reference to relevant clauses
in this Standard and other CSBP documents are made.

29.1

MAINTENANCE STRATEGY

A maintenance strategy, in accordance with CSBP Departmental Procedure Developing

Maintenance Strategies (DP-05-013-05), shall be established and full details covering the belt
conveyor system, inspection and preventative maintenance requirements recorded in the JDE
Maintenance Information Management System.
29.1.1 Ammonium Nitrate Conveyors
Special consideration shall be given when developing a strategy for conveyor preventative
maintenance and replacement of equipment, in an ammonium nitrate service. Any location where
ammonium nitrate could collect and be confined under pressure is an explosion hazard in the event
of a fire.
29.1.1.1

Inspection

Frequent visual inspection shall be included in the maintenance inspection plan, to ensure that any
location that has an ammonium nitrate build-up is identified quickly and appropriate remedial
action taken.
29.1.1.2

Equipment Replacement

Pulley and shaft assembly shall be a fully welded configuration. Refer to Section 9.7.4 for details.
Return idlers shall have solid shafts and carrying idlers shall be filled with polyurethane or other
approved material. Refer to Section 10.7 for details.

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29.2

INSPECTION DURING OPERATIONAL PHASE

Inspections shall be carried out in accordance with the Preventative Maintenance Inspection Plan
and results recorded, to establish whether any remedial work is required. Areas of inspection shall
include, but not be limited to the following:
a.

Locations of ammonium nitrate build-up, in ammonium nitrate conveyor systems.

b.

Extent of corrosion and condition of protective coating on conveyor system steelwork

including; conveyor support structures, take-up structures, walkways, platforms, stairways,
platework, fabricated equipment components and connection bolts.

c.

Extent of corrosion and condition of protective coating on mechanical and electrical

components.

d.

Tightness of bolted connections especially in areas subject to vibration.

e.

Wear clearances and alignment on all moveable components being within manufacturers
limits.

f.

Condition of chains, wire ropes and slings where fitted. Refer to CSBP Guide Manual
Slings, Rigging and Lifting Equipment Safely (GM-11-038-02) and CSBP Engineering
Standard Monorails (ES-14-403-20) for requirements.

g.

Condition of electric motors, cabling, controls, lights, horns, lanyards, under speed
switches, proximity switches, electromechanical brakes, belt drift switches, blocked chute
switches, weigh frames/load cells, etc.

h.

Functioning of emergency stop and control devices.

Based on inspection findings, maintenance work shall be carried out in accordance with work
priority or if an engineering modification is required, changes shall be implemented in accordance
with CSBP Guide Manual Engineering Modifications (GM-05-050-01). All closeout details shall
be recorded in the JDE System.

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30.

RECORDS MANAGEMENT

30.1

AS - BUILT DRAWINGS

On completion of installation, testing and commissioning activities, drawings shall be upgraded to

reflect any as-built design deviations.
Drawings recording the as-built details shall be prepared/revised, numbered, approved and handed
over in accordance with CSBP Engineering Standards:

ES-14-101-02
ES-14-101-03
ES-14-101-04

30.2

Drawing Management
Drawing Preparation
Drawing Numbering

ENGINEERING PROJECT FILES

On completion of the project and handover to the Business Unit, in accordance with CSBP
Engineering Procedure Engineering Project Handover (EP-08-030-38), all relevant hard-copy
documentation shall be archived in the designated work area in numbered project files.
Records in electronic format (such as drawings and JDE data) shall be stored in the appropriate
databases and designated work area.
Refer to CSBP Guide Engineering Modifications (GM-05-050-01) and CSBP Engineering
Procedure Engineering Project Files (EP-08-030-05) for type of documents to be retained for
historical purposes.

30.3

MAINTENANCE WORK ORDERS

On completion of the maintenance work order, details shall be recorded in accordance with CSBP
Departmental Procedure Closing Maintenance Work Orders (DP-05-013-04).

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Commissioned belt
conveyor system

29.1

Develop
maintenance
strategy

29.1

Record details in
JDE maintenance
system.

29.2

Carry out inspection

according to plan.

DP-05-013-05

Equipment number
Spares requirements
Inspection
requirements etc

Yes
Accepted?

Record details in
JDE system.

29.2

End

No
Identify remedial
work required

MAINTENANCE WORK

DP-05-011-03
DP-05-013-01
DP-05-014-01

Initiate maintenance
work.

ENGINEERING MODIFICATION

Initiate engineering
work.

GM-05-050-01

Carry out design

work.
Carry out
maintenance work
Carry out
engineering work.

Close out
Record details in
JDE system.

DP-05-013-04

Close out
Record details in
JDE system.

30.2

30.3
End

Figure 1

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Belt Conveyor Maintenance Process Flow Diagram

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