2015/06 - Bullk Handling Today

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l

T O D A Y June 2015

LDV FLIPS OVER AT MINE NEW WINDER DESIGN ON THE CARDS

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The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.

Company Affliates as at May 2015 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

4 BULK TODAY 2015 Tel: (011)HANDLING 867-0902 l Fax:June (011) 867-0036 l Email: saimh@global.co.za l www.saimh.co.za

Simon Curry

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LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA

LEEASA, formed in 2003, is a division of the Chamber of Engineering Technology (COET), a non-profit organisation. The association’s objectives include, but are not limited to: the transfer of knowledge and training within the field of the Lifting Industry, to improve safety, promote the use of standards and to promote Professional and Ethical practices.

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t is represented on the Engineering Council of South Africa (ECSA) and a number of ECSA committees as well as on various task teams at the South African Bureau of Standards (SABS).

What’s in it for you:

As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year).

ECSA registered COET / LEEASA members are awarded one Continuing Professional Development (CPD) credit in category

3 each year. CPD is an ECSA requirement to retain registration.

Members obtain a discount on training and seminars validated by the association, especially useful in earning ECSA CPD credits.

Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry.

LEEASA has some 500 members (Individuals and Companies).

Tel/Fax: (011) 787-1302, Email: engineer@netactive.co.za, www.leeasa.mirrorz.com 8

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conveying excellence

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EARTHMOVING

We have chosen to establish a whollyowned subsidiary and invest in the country’s growth

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POWER TRANSMISSION

Leif Duwel, managing director of H채gglunds South Africa

The newly launched compact drive unit

The H채gglunds workshop at their facility in Johannesburg

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High-quality Gearboxes and Couplings

When failure is NOT an option, choose a Renold Quality product.

RB & PM Couplings

Now Available Ex-Stock T +27 (0) 11 747 9500 E sales@renold.co.za W www.renold.com

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Koepe Winders at Impala 16 Shaft showing the 90째 orientation for space saving

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LIFTING

A drum stress plot

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A single drum stress plot including exaggerated deflection

A specialised lifting solution at Sasol’s Secunda plant

Johnson Crane Hire assembled a sliding system inside the constrained work area at Sasol Secunda

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LIFTING

The scope of the heavy-lift operation involved the removal of three vessels for the Gas-Heated Heat Exchanger Reformer (GHHER) project at the gas reforming plant

Portable jacking-and-sliding system

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The entire team with the one-of-a-kind Rand Water crane

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LIFTING

SKF Mining Industry Solutions Harsh operating and market conditions make the mining industry a tough customer. SKF’s advanced range of products and services in the SKF Life Cycle Management approach - SKF’s proven approach for reducing Total Cost of Ownership for machinery at every stage, from specification and design to operation and maintenance, can help!

SKF solutions assist with increased productivity and profitability, improved worker safety, reduced environmental impact, cutting energy consumption and reducing unplanned downtime.

The Power of Knowledge Engineering SKF South Africa (Pty) Limited Tel: +27 11 821 3500, Fax: +27 11 821 3501, Email: sales.za@skf.com, Web: www.skf.co.za

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Figure 1. Underground conveyor belt layout at area where HPI occurred

Entity

Value

Ash Contentr

27%

C.V

21.6 MJ/kg

Abrasive Index

452 mgFe

Density

1.59 t/m3

Table 1. The values of the coal produced

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SAFECON

Figure 2. Schematic for the pulley configuration on conveyor L403 Drive with LDV crossing underneath the conveyor

Pulley No.

Pulley Position

1

HEAD PULLEY

2

SNUB PULLEY

3

DRIVE PULLEY

4

TAKE-UP PULLEY

5

TAKE-UP RETURN PULLEY

6

BEND PULLEY 1 (ON BRIDGE PIECE)

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BEND PULLEY 2 (ON BRIDGE PIECE

Table 2. Pulley positions as in Figure 2

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SAFECON

Conveyor Number/Description

L403 – Installed L403 –Required

Information for design calculations Belt width

mm

1350

1200

Belt speed

m/sec

3.10

3.10

Peak capacity

tph

2400

2000

Material density

t/m3

1.1

1.1

Angle of idlers

Degrees

35

35

Troughing idler spacing

m

1.5

1.5

Drive wrap angle

Degrees

210

210

Horizontal centre to centre distance

m

292.581

292.581

Overall lift/drop

m

9.00

9.00

Motor power (Primary)

kW

160

55

Motor power (Secondary)

kW

N/A

N/A

Motor RPM

RPM

1495

1495

15:1

15:1

Drive data

Gearbox ratio Idler data Troughing idler pitch

m

1.5

1.5

Return idler angle

Degrees

0

0

Return idler pitch

m

3

3

Counter Mass

Counter Mass

2.00

2.00

1250

1250

Take-up data Type Travel

m

Belt data Class Number of plies

-

-

Belt width

mm

1350

1200

Top and bottom cover

mm

3.0 x 2.0

1.0 x1.0

PVG

PVC

Type of rubber

Table 3. Specifications for L403 at the time of the incident as well as the expected design specifications

Figure 3. Sketch illustrating the vehicle going under the L403 Bridge

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Figure 4. Typical set up of a winch style take-up

Figure 5. Schematic illustration of how the return belt sagged as it rolled over the skewed idler causing contact with the LDV

Figure 6. Illustration showing the difference between having the idler in position and having it removed

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SAFECON

Figure 7. Image showing the bridge where the HPI took place

Figure 8. Image showing the lack of guarding at the belt bridge.

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Entity

What happened

How this affected the outcome

Change Management - Incorrect belt PVG belt installed instead of the required The PVG belting increased the frictional coefinstalled PVC belt. ficient between the drive pulley and the belt.

This allowed the drive to impart an excessive amount of power into the belt. If a PVC type belt had been installed, slip would have taken place due to the low tension levels and the drive would have shut down.

Change Management - Overpowered Larger than required motor installed.

Motor

The larger power pack imparted a force more than double than required for the correct operation of the belt. This initiated a larger than normal stretch on the

SC1-02 Copyright CMA 12

pull/entrance side of the drive and a greater If a smaller power pack had been installed, the slack on the push/exit side of the drive caus- conveyor might have been unable to overturn ing the slack at the bridge. the vehicle.

Insufficient Tension

Belt was not tensioned to the required speci- If the belt had been tensioned correctly, this fications. would have taken up any slack in the belt and prevented the belt from sagging and therefore preventing the incident.

Risk Assessment

No risk assessment had been done since If a risk assessment had been done when going into the low seam sections. the low seam section had initially been commissioned, the area crossing under bridges would have been identified as a hazardous area, and would have been addressed.

Skewed Idler

Idler was not installed correctly.

Because the idler was installed incorrectly, this imparted too much friction into the system.

Therefore when slack was created behind the drive, the first place where the conveyor was able to throw this slack was at the first ’high friction’ point, in this case the idler. Hence the reason why the dip occurred at the bridge.

Removed Idler

Idler had been removed.

With the idler in the centre of the bridge being removed, it allowed a great span for the conveyor to traverse unsupported. This caused the belt to sag much further than if there were a supporting idler in between. When the belt slacked, the increase in unsupported weight assisted in pulling the conveyor belt downwards until it came into contact with the LDV.

Guarding

The bridge was insufficiently guarded.

Adequate guarding would have prevented the belt from coming into contact with the LDV, but it would not have prevented the slack in the belt.

Table 4. Table showing a summary of the events leading to the occurrence of the HPI

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Camilla du Toit of Shepstone and Wylie Attorneys

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Megaroller’s Impact and Rubber Disc Return Rollers absorb the impact of large loads of ore falling onto conveyor belts to prevent damage.

Megaroller’s unique Multisteer conveyor belt steering frames are the key to effective conveyor belt management.

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June 2015

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June 2015

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FCB CAPE TOWN 10008448CT/E

Keeping Africa running smoothly.

Engen is committed to an African success story. In Africa, industries operate under extreme conditions different from any other place in the world. Thatâ&#x20AC;&#x2122;s why we do more to develop our tailor-made range of lubricants. We use top-of-the-line technology and only the best ingredients. The result is an advanced technology product that meets industry requirements and reliability expectations. And our dedicated team on the ground ensures that you have access to what you need when you need it.

Contact the Engen Customer Service Centre (CSC): +27 21 403 5090 or visit www.engenoil.com.

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10008448CT Engen_Africa Print Ad_Bulk Handling Today_176x130E.indd 1

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2015/02/12 2:08 PM

Pierre van Rooyen, design and administration manager

A CX 400 R3, 350 KW drive

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June 2015

A CX 620 R3, 1000 KW drive

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Visit ppsinvestments.co.za Email clientservices@ppsinvestments.co.za Call on 0860 INV PPS (0860 468 777).

Professional Provident Society Investments Proprietary Limited (“PPS Investments”) (39270), Professional Provident Society Multi-Managers Proprietary Limited (“PPS Multi-Managers”) (28733) and Professional Provident Society Insurance (“PPS Insurance”) (1044) are licensed Financial Services Providers.

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SUCCESS STARTS WITH

74497B / BP

THE RIGHT PARTNER

Achieving excellence is your number one priority. Helping you get there is ours. What makes us a leading fuel marketer is the security of supply we provide our customers through our strategic partnership with BP. By understanding your particular business needs, we are able to provide agile solutions and service, which means you can focus all your energy on achieving success, while we fuel it.

To find out about Masana, visit www.masana.biz

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Book in the August issue of “The SA Mechanical Engineer” to reach visitors to the show or pop in

V14628

to our stand at Electra Mining Botswana

Protect Your Belt Conveyors with Voith Fluid Couplings.

The Voith Fluid Coupling, type TVVS, is predominantly used in belt conveyor drives.

The coupling protects the drive against overload and dampens torsional vibrations. This protects your system and increases its productivity.

Key Benefits: • Very smooth start-up • Torque limiting up to 140% of nominal load • Automatic adjustment to different load states info.vtza@voith.com Tel: +27 11 418 4000 www.rsa.voithturbo.com

V14727 Voith MM Bulk Handling HP DH3 FEB15.indd 1

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MARKET FORUM

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► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l

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Skills on Site

Septmeber 2012

1

MARKET FORUM A fit-for-purpose fleet of equipment

Operators are trained both in operations of equipment as well as maintenance

Hoists mounted on crab unit

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MARKET FORUM

Overbelt magnets are engineered to effectively remove even the most challenging tramp metal

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MARKET FORUM

SSABâ&#x20AC;&#x2122;s hot-rolled plate and strip steels with a yield strength 600-1300 MPa (also tubes exceeding 600 MPa) and certain cold-rolled products

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MARKET FORUM

The Kubota L3200 diesel tractor, the smallest in the Kubota L-series range at 32Hp (24kW), is powerful enough to haul aeroplanes

Log onto www.promech.co.za to read this issue on-line

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June 2015

MARKET FORUM

INVEST ONCE WITH TWICE THE OPPORTUNIT Y

Visit ppsinvestments.co.za Email clientservices@ppsinvestments.co.za Call on 0860 INV PPS (0860 468 777).

Professional Provident Society Investments Proprietary Limited (“PPS Investments”) (39270), Professional Provident Society Multi-Managers Proprietary Limited (“PPS Multi-Managers”) (28733) and Professional Provident Society Insurance (“PPS Insurance”) (1044) are licensed Financial Services Providers.

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June 2015

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MARKET FORUM

Service Contracts

Tenova Takraf is supporting four continuous ship unloaders through two service contracts awarded by Italian power generation company, ENEL S.p.A. Each contract services two bucket chain continuous ship unloaders (CSUs), previously supplied by Tenova Takraf Italy, and located respectively at Civitavecchia and Brindisi to feed coal to two of the largest power plants in Italy. Both contacts are 24-month duration extensions of previous contracts.

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The service contracts are an evolution of maintenance support originally supplied by Tenova Takraf Italy for the two CSUs at Civitavecchia, with the main goal for the coal terminal being to maintain reliability and a planned annual output of 4.5 million t/yr. This has been consistently achieved at Civitavecchia, where the CSUs are the only source of input coal. At Brindisi, the CSUs are employed in replacing or jointly handling coal with grab unloaders.

The CSUs have an operating capacity of 1.5 mtph on the Civitavecchia project and 1.8 mtph at Brindisi and are able to download

vessels up to 130,000 DWT (Deadweight Tonnage). The machines are equipped with a bucket chain elevator approximately 38 m high and a slewing/lifting boom, which includes the transfer conveyor, of 42 m length. One of the major advantages of these CSUs is their low environmental impact, as the power plants are under special control and supervision of the Italian Government to update/upgrade system equipment to reduce all emissions. The CSUs minimise dust and noise emissions during the discharge cycle.

Tenova Takraf Tel: (011) 201-2300 www.takraf.com

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