Manual SCR

Project Document No. Issue Sht 1 of 27 BGR,TNEB,METTUR 1-G017-X-004582 0

SITE INSTALLATION SCHEDULE FOR BW STACKER CUM RECLAIMER

GE032 ISSUE A JUNE09

SITE INSTALLATION

PROJECT NO. G017 & G087

STACKER CUM RECLAIMER

CLIENT: BGR ENERGY SYSTEMS LIMITED

PROJECT: METTUR THERMAL POWER STATION STAGE III

MODIFICATION RECORD

Issue Modification Orig/Date Chkd/Date Appd/Date

0 First Issue. UMT 25/11/2010 AKP

25/11/2010 SSB

25/11/2010

DIST:



GE032 Issue A Jan 09

INTELLECTUAL PROPERTY

The information in this document was prepared using Intellectual Property

owned by Metso. This is confidential proprietary information and remains

the exclusive property of Metso. The document is for use solely in

connection with the performance of Metsos Contract.




CONTENTS

1. GENERAL .............................................................................................................................................................4

2. DESCRIPTION ......................................................................................................................................................4

3. STORAGE INSTRUCTIONS ...............................................................................................................................4

4. ASSOCIATED DOCUMENTS ..............................................................................................................................5

5. RECORD OF ISSUE LEVELS: ............................................................................................................................6

6. SPECIAL TOOLS..................................................................................................................................................6

7. ERECTION PROCEDURE:..................................................................................................................................7




1. GENERAL The purpose of this Erection Schedule is as follows: -

a. To instruct and advise the erection contractor such that he may assemble and erect the stacker cum reclaimer in

an accurate, safe, economical and efficient manner.

b. To enable the client to review the erection procedure and therefore to comment on any part of it prior to the erection commencing.

c. To enable the erection contractor and client to have all the materials tools cranes and other equipment available

prior to erection commencing.

d. To establish a sequence for the erection and provide a basis for a site programme.

e. To provide a means for recording the satisfactory completion of erection operations.

2. DESCRIPTION

Stacker cum reclaimer on operates on the rails and is able to stack the stockpiles and reclaim from the stockpiles. Stacker cum reclaimer has its own dedicated yard belt.

The machine is designed to operate in full manual control, or, for maintenance purposes, local control stations allow operation of various parts of the plant whilst the remainder is isolated.

The components for the stacker cum reclaimer will be delivered to site with some of the minor components already pre-assembled. Major fabrications will have been shop assembled and any matchmarks must be strictly adhered to

3. STORAGE INSTRUCTIONS

a. Storage of Drive Gear Boxes Short Term Storage Up to one year indoor. Standard factory applied preservation is effective for transport and storage in sheltered area up to one year

depending on atmospheric conditions. Units should not be stored near vibrating machines in order to avoid damage to bearings. Always store units in their original supplied shipping condition




4. ASSOCIATED DOCUMENTS

This schedule is to be read in conjunction with the following documents: - Lubrication Schedule Refer also to Master Part list (Copy attached as Appendix C).

At certain stages during this schedule structural assemblies are required to be sub-assembled on a level grillage. This assembly work may be carried out at any stage, and not in any specific order. However, it is essential that the erection of the assemblies onto their mating assemblies be carried out in the following sequence:

x Erect bogies for super structure and 4-wheel and 8 wheel equaliser beams x Erect equalising beam x Erect Undercarriage x Install slew bearing x Erect slew deck x Erect inner boom x Erect boom x Erect mast x Erect counter wt boom and counter wt boom link x Erect the boom link x Erect the partly counter weights x Erect the boom conveyor mechanical , misc items and bucket wheel chute x Erect remaining counter weights as per balancing programme x Erect central chute x Erect the tipper platform bogies and tripper platform x Erect vibrofeeder platform with bogies and vibrofeeder x Erect intermediate conveyor portal x Erect intermediate conveyor with mechanicals x Erect tipper structure with mechanical x Erect intermediate conveyor discharge chute and vibrofeeder chute




5. RECORD OF ISSUE LEVELS:

It is essential that the latest issue of all drawings is available and worked to. In order to record issue levels of the Metso design drawings; a copy of the drawing list is attached. This should be clearly marked up with the issue level of each drawing worked to on site.

6. SPECIAL TOOLS

In addition to the normal tooling requirements necessary for the type of erection covered by this document, there are Certain Special Tools, which must be available prior to the start of erection.

x Statimeters (1 x 25 T (min)) x Torque Wrenches (including calibration tools) x Hydraulic Jacks (2 x 100T with locking collar and hand pump) x SKF Hydraulic Nut No. HMV76 + 150mpa oil injection pump with gauge (with suitable

6mm pipe fitting for SKF adaptor sleeve No. OH3176H) x Matched Torque multipliers x SKF Hydro-cam (model HTA) bolt tensioners (M27 + M42) x Precision Optical level with parallel plate micrometer x Precision Engineers level x Theodilite (20 sec)

Not mandatory but strongly recommended to ensure satisfactory site election.


SITE INSTALLATION SCHEDULE FOR BW STACKER CUM RECLAIMER Work and verification operations Verification/Witness Record

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Include associated specification document numbers and details of equipment and services required. Include also for recording traceability numbers, specified data and references of associated records. Where scheduled operations apply to more than

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One item make provision for recording completion and verification for each item and operation. Mandatory sequences of completing work are to be specified. Include essential detailed safety and functional warnings.

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7. ERECTION PROCEDURE:

7.1 ESTABLISHMENT OF ERECTION AREA

x Erection of the machine shall take place

within the erection area. This should be an area where the ground adjacent to the track is suitably compacted and able to accommodate the cranage required for the erection. Over the erection area the following rail/track tolerances shall be checked and verified.

x Level along track to be +10mm over the length of the bogies (10m). Height measurements to be taken for each bogie frame.

x Level across track @ 7000 rail to rail crs

to be r10mm.

x Rail centres to be 7000 +5 over the length of the bogies.

x Prior to travelling the completed machine

during commissioning tests the entire length of track is to be checked.

x Check that the centreline of the down store (yard) conveyor is positioned correctly relative to the rails within r4mm and that the underside of the conveyor is 1000 +4 above the rail level.

For rail tolerance refer Drawing no 1-G017-G-000022 For plot plan refer Drawing no 1-G017-L-00004 (Con. #7) Drawing no 1-G017-L-00006 (Con. #9)



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7.2 ASSEMBLY & ERECTION OF BOGIES STACKER CUM RECLAIMER Drawing no 1-0000-A-000235

x Establish the centre line of slew and mark on the rails the following points:- i. East Rail - a point 6000 8 North ii. East Rail - a point 2500 4 East iii. West Rail - a point 60008North

iv West Rail - a point 25004 south

These points represent the pivot centres of the bogie main pivot brackets.

x At the points established in above build up the main bogie assemblies up to and including the pivot brackets.

x The bogies are to be locked to prevent movement along the rails. Pivot brackets are to be made stable by chocking ensuring that their upper mating faces are horizontal. (Maximum permissible slopes 1:500).

x Build the bogie sets.

a) Front Units ( at 4 wheel

equaliser beam) i. Height above rail 968 4 ii. Relative difference in height to

opposite front bogie to be no greater than 4

b) Rear Units ( at 8 wheel

equaliser beam) i. Height above rail 16184 ii. Relative difference in height to

opposite rear bogie to be no greater than 4

x To attain the above dimension use the shim provided with the pivot brackets/rocker assembly.



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x Check that the bogie pivot bracket

upper surface is level.

x Check alignment of all wheel sets. CL of 8 and 4 wheel sets to be in line with track CL to within 3mm. Check wheel sets are at the correct rail centres. The above should be repeated after the erection of the undercarriage.

x The following items are to be assembled to the main bogies after the undercarriage has been erected but not at the same time as the slew ring installation. i. Travel Storm locks ii. Earthing Shoe iii. Ploughs iv. Bogie Drives v. LT Limit Switches

7.3 ASSEMBLY & ERECTION OF EQUALISING BEAM AND UNDERCARRIAGE As per drawing no 1-0000-A-000614

x Assemble the equaliser beam, to the

bogies.

x Erect a suitable grillage to facilitate the assembly of the undercarriage structure. This support grillage must be such that each section is independently adjustable and provide access all round the joints that are to be as per Drawing.

x This structure has been trial assembled in the manufacturers workshops. It is important to maintain the overall critical dimensions shown on the relevant detail drawing and level within the tolerances stated.



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x Survey assembled undercarriage structure and release for welding. Re-survey after welding.

x The undercarriage section joints are to be HSFG bolted splices.

x Prepare and paint the site joint areas in accordance with specification (1-G017-X-000807).

x Lower the undercarriage structure, onto the bogies and equalising beam ensuring the connecting surfaces are free and clear from dirt and grit prior to assembly.

x Check top of undercarriage at the slew ring seating is at correct height of 4515mm above rail level as called for on drawing and level within r4mm over the slew ring seating area.

x Tighten the joint bolts after re-checking alignment of the bogies in relation to the rail as previous.

Note: It is critical to ensure accurate alignment of bogies and equaliser beams to eliminate machine crabbing along the tracks.

x Slew Ring Installation.

See separate installation procedure as per drawing no 1-0000-A-000643.



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7.4 ASSEMBLY AND ERECTION

OF SLEW DECK AND SLEW RING As per drawing 1-0000-A-000643

x Erect a suitable grillage to facilitate

the assembly of slew deck structure

Note : The structure is to be supported in inverted position.

x This structure has been trial assembled in the manufacturers workshops. It is important to maintain the overall critical dimensions shown on the relevant detail drawings. Pay particular attention to the alignment of the luff cylinder and luff pivot bores.

x The Slew Deck section joints are to be

HSFG bolted splices.

x Prepare and paint the site joint areas. x Refer to slew ring installation schedule

for completion. x Fit slew bearing as per drawing no

1-0000-A-000643. Install slew bearing on the top of undercarriage structure with proper care so as to reference point as shown in drawing no 1-0000-A-000614.

x Lift the slew deck structure to its correct orientation.

x Lift and erect the slew deck structure onto the undercarriage structure. Using hydraulic jacks carefully lower the slew deck structure into position on the undercarriage/slew ring



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assembly ensuring correct alignment of slew rollers. Install mounting bolts as per drawing no 1-0000-A-000643.

x Install slew lock as per drawing no 1-0000-A-003174.

x Erect lower section of slew deck chute and support beams to slew deck structure as shown on drawing. Check interface with impact table assembly

x Install the impact table as per drawing no. 1-0000-A-003058.

x Erect the idler on impact table. Ensure that the alignment of yard conveyor.

x Install the 2 slew drives and adjust height to set each pinion central to the rack. (Refer Drawing no 1-0000-A-000643). Adjust position of drives to achieve the correct backlash as per drawing.

Check alignment and meshing of drives through full rotation. When satisfactory, weld locating collars.

x Erect slew deck access and supports as per drawing no 1-0000-A-004470. Flooring panels are to be fixed to the supports. Where joints are necessary in the hand railing, these are to be made using suitable ferrules and then dressed smooth on completion.

x Erect and bolt down luff cylinder hydraulic power pack. ( * Install after erection of luffing structure).

x Check that all hydraulic pipe work, including flexible hoses has been satisfactorily flushed & tested in



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accordance with suppliers recommendations. Check that there are no apparent leaks and that pipe work is securely fixed to structure. Flexible hoses to be adequately protected.

x Install all hydraulic circuit components including hydraulic oils. The fixing of components to main structural flanges is not permitted. Any fixing to main structures to be referred to Metso for prior approval.

x Rotate slew deck such that luff pivots

are aligned parallel with centre line of machine and track, i.e., in order that boom can be erected at right angles to track. Prevent slew deck from rotating from this position by suitable means.

x Install slew end buffer as shown in

drawing no 1-0000-A-004301. It is to be install before erection of slew gear & pinion guard drawing no 1-0000-A-002634.

x Install slew limit switches and resolver.

x Check the following bores to ensure level alignment and parallelism (with shop test readings):- i. Luff cylinder bores. ii. Luff pivot bores.



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7.5 ASSEMBLY AND ERECTION OF INNER BOOM

(Refer Drawing no 1-0000-A-000617)

x Survey the inner boom check the following for alignment and parallelism:- i. Boom pivot bores ii. Luff pivot bores iii Mast pivot Note: check with shop test reading. Fit the luff pivot spherical bearing assemblies to the inner boom. Refer drawing no 1-0000-A-001751.

x Lift inner boom assembly onto slew deck. x Hold and position using the

installation cranes in order to fully assemble the boom pivot pins.

x With boom pivot pins fully assembled, lower boom onto outer boom support trestle. Check boom level across support trestle. Boom structure to be anchored to trestle.

7.6 ASSEMBLY AND ERECTION OF THE BOOM ( Refer drawing no 1-0000-A-000617)

x Erect a suitable grillage at ground

level to facilitate the assembly of the main sections of the boom structure. The support grillage must be such that each section is independently supported and adjustable and provide access to the site bolted joints. This structure has been trial assembled in the manufacturers workshops.



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x Adjust and align all sections of the

boom structure. Tighten all bolted joints in accordance with drawing requirements.

x Install boom conveyor idlers and take up arrangement along with pulley taking cares to ensure correct alignment. Ensure head pulley is at 90 to boom centreline. Ensure idlers are in line especially the impact idlers. Also assemble snub pulley.

x Install the boom conveyor tail end components (frame transition idlers, tail pulley etc.) on the inner boom structure. Ensure tail pulley is at 90 to boom centreline. Adjust packing as necessary. Note: Boom conveyor drives to be fitted later. Erect a suitable trestle to facilitate and support the outer end of the boom structure whilst assembling the boom to the pivot on inner boom.

FOR ERECTION SEQUENCE FOR BOOM AND COUNTER WT BOOM BUILDS REFER TO SECTION 7.18

x Lift the assembled boom structure and manoeuvre the boom counter wt end into position between the inner boom structures. Note: Boom to be lifted using a 2-crane lift. Spreader beams to be used to ensure a vertical lift at each lug.

x Hold and position using the

Installation cranes in order to fully assemble the boom pivot pins.



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x With boom pivot pins fully assembled, lower boom onto outer boom support trestle. Check boom level across support trestle. Boom structure to be anchored to support trestle.

x At this stage the boom support ropes can be attached to the boom.

x Install the boom conveyor drive units to the tail/drive pulley shaft. Fully tighten drive unit shaft coupling bolts in accordance with the manufacturers literature. Installs drive torque arm assemblies. Install belt scrapers and ploughs as shown to boom structure, but adjust to leave scraper blades clear of pulley.

x Install boom conveyor pulley scrapers. x Carry out survey and alignment

checks on conveyor pulleys and idlers. With particular attention to alignment tolerances required on the weigh scale idlers and transition geometry.

x Install boom conveyor take- up along with pulley.

x Join and vulcanise boom conveyor belt. Ensure that take-up pulley is at minimum take-up position prior to belt splicing.

x Tension boom conveyor belt.



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7.7 ASSEMBLY & ERECTION OF MAST STRUCTURE ( Refer drawing no 1-0000-A-000641)

x Erect a suitable grillage to facilitate the assembly of the mast structure. This structure has been trial assembled in the manufacturers workshops.

x Assemble mast components in the following sequence;

I. Assemble the lower mast and mast stay on to inner boom.

II. Pre-assemble mast head and mast stay on to inner boom.

III. Assembly upper mast on lower mast and hold in position.

x Erect the pre-assembled mast head,

mast link with the upper mast

x Survey the assembled mast

x Prepare and paint all site joints.

x Re-check the following for alignment and parallelism:-

I. Inner boom pivot bores.

II. Counter wt boom pivot bores.

III. Support ropes bores.

Note: check with shop test reading.

x Install the counter wt boom pin with the mast and, while supporting the rear of the counter wt boom, fit the support ropes.



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7.8 ASSEMBLY AND ERECTION OF THE COUNTER WT BOOM ( Refer drawing no 1-0000-A-000664)

x Erect a suitable grillage to facilitate

the assembly of the Counter wt Boom.

x Survey assembled structure.

x The counter wt boom section joints are to be HSFG bolted splices as per drawing.

x Prepare and paint the site joint areas.

x FOR ERECTION SEQUENCE FOR BOOM AND COUNTER WT BOOM BUILDS REFER TO SECTION 7.18

7.9 ASSEMBLY AND ERECTION OF THE BUCKETWHEELAND DRIVE (As per drawing no 1-0000-A-001367)

x Assemble bucket wheel shaft,

bearings, etc. to the bucket wheel structure.

x Fit the bucket wheel guide plate assembly (Refer Drawing no 3308 124) loosely into the bucket wheel structure and secure temporarily in position.

x Lift the bucket wheel and shaft

assembly into position onto the boom structure and align the shaft bearing housings using the packers provided. Fully tighten bearing house fixing bolts.

x Install the bucket wheel chute support

steelwork to boom structure. Refer Drawing no 1-0000-A-000663.



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x Install the bucket wheel chute.

x Install the ten buckets to the bucket wheel, ensuring that the bucket wheel is locked against rotation to any out of balance loads. Grease the connection pins.

x Rotate the completed bucket wheel assembly by hand to check clearance between the bucket wheel and its chute and guide plate. Adjust chute/guide plate to obtain correct clearances.

x Assemble the bucket wheel hydraulic drive to the bucket wheel shaft. Connect drive torque arm to boom structure. ( Refer Drawing no 3308 310)

7.10 ASSEMBLYAND ERECTION OF OPERATORS CABIN AND ACCESS (As per drawing no 1-0000-A-000634)

x Install operators cabin support

structures and access to the boom structure as per drawing

x Install operators cabin to the support structure.

x Install operators cabin levelling

cylinder assembly.



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7.11 ASSEMBLY OF TRIPPER PLATFORM (As per drawing no 1-0000-A-000920)

x Erect bogies for tripper platform.

Bogies are to be locked to prevent movement along the rails. Pivot brackets are to be made stable by chocking ensuring that their upper mating face is horizontal. (Maximum permissible slopes 1:500)

x Build the bogie sets.

x Check that the bogie pivot bracket upper surfaces are level.

x Check the alignment of all wheel sets.CL of wheel set to be in line with track CL to within 3mm.

x Erect the tripper platfrom /gantry structure as per drawing no 1-0000-A-000920.

x Survey complete tipper platform

structure and release for welding.

x The platform structure joints are to be NDT tested in accordance with contract Manufacturing Specification.

x Erect the tripper platfrom access.

x Assemble the front portal. Section joints are to be HSFG bolted.

x Erect the portal on tripper platform.

x Erect the electrics house base sub-

frame Note:

The following step is to be done after erection of tripper and intermediate conveyor structure.



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x Erect the electrics house onto the

gantry structure. Mark off through sub-frame onto structure and drill through to suit fixings. Do not assemble roof until all panels have been positioned and fixed.

7.12 ASSEMBLY OF VIBROFEEDER PLATFORM (As per drawing no. 1-0000-A-004462)

x Erect the bogies for vibrofeeder

platform. The bogies are to be locked to prevent movement along the rails. Pivot brackets are to be made stable by chocking ensuring that their upper mating face is horizontal. (Maximum permissible slopes 1:500).

x Erect the vibrofeeder platform /gantry structure as per drawing no (1-0000-A-004462)

x Survey complete vibrofeeder platform structure and release for welding.

x Maintain the distance (18300 mm) between single bogies of tripper platfrom and double bogies of vibrofeeder platform.

x Erect the walkway and access for vibrofeeder.

x Erection of vibrofeeder is to be done after

the erection of intermediate conveyor.

7.13 ASSEMBLY OF THE INTERMEDIATE CONVEYOR AND TRIPPER.

x Assemble the intermediate conveyor

with suitable support. Section joints are to be HSFG bolted splices.



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x Assemble idlers on intermediate conveyor.

x Erect the assembled intermediate conveyor on the tripper platfrom and vibrofeeder platfrom.

x Assemble take-up arrangement with pulley on intermediate conveyor.

x Assemble the tripper with suitable

support and section joints are to be HSFG bolted splices.

x Assemble the idlers on tripper.

x Lift the tripper structure and assemble with tripper platform and vibrofeeder platform.

x Erect walkway and access for intermediate conveyor and tripper structure.

x Assemble all pulleys for tripper and intermediate conveyor.

7.14 ASSEMBLY AND ERECTION OF AUXILIARY EQUIPMENT

x Install cable reel drums on to the

electrics trailer.

x Install Transformers on to electrics trailer.

x Install HT main isolator on to electrics trailer.

x Install HT switchgear into electrics house.



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x Install MCC panels into electrics

house.

x Install MCC panels into electrics house.

x Install slew ring & bucket wheel shaft bearing lubrication systems.

x Install long travel bogie lubrication system.

x Install long travel bogie trip wire brackets.

x Install long travel, slew and luff limit switch brackets.

x Install boom, conveyor trip wire brackets.

x Install boom conveyor belt drift, and speed switch brackets.

x Install maintenance cranes.

x Room, transformer room etc. on trailer. Install power pack on slew deck structure.

x Fix Metso nameplate & logos to both boom and counter wt boom structures.

7.15 ERECTION OF LAND MOUNTED EQUIPMENT

x Install boom storm anchoring

structures and access to prepared foundations

x Install cable reel turnover anchor into pit in foundations.

x Install land fixed long travel buffers.



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7.16 MACHINE BALLASTING

x Ensure that the luff cylinder is

detached from the inner boom, if they were fitted previously.

x Attach 1 x 25 t (minimum) rated Statimeters to the underside of the boom structure. Attach the other end of each statimeter to a ground mass of 30 tonnes minimum.

x Erect the ballast blocks onto the counter wt boom and record the mass of each block. BLOCKS MUST NOT IMPACT ONTO COUNTER WT BOOM.

Note: x During the addition of the ballast

blocks the luffing superstructure will become tail heavy and the out of balance load will be transferred to the statimeter record the statimeter readings and note what items have yet to be fitted to the luffing superstructure.

x Balancing of the luff structure is achieved with approximately 110 T of ballast; i.e. the boom will begin to lift off the trestle.

x The statimeter readings and the total

mass of the ballast blocks is to be passed to Mesto Design Office for final balancing calculations to be carried out.

x Inspect and test hydraulic luff system before extending luff cylinder piston rods and connect clevis eyes to inner boom structure.

x Luff the boom down slightly to enable the statimeters and ties to be detached.



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x DO NOT ALLOW BOOM TO REST

ON TRESTLE

x (Otherwise boom support ropes will become slack)

x (which will greatly increase the cylinder loads - )

x (Remove boom trestle if necessary to prevent )(This)

x Take cylinder pressure reading.

x Check cylinder loads. Required cylinder load = 94+2t. Compression in each cylinder with boom horizontal and machine fully assembled.

7.17 FINALINSPECTION AND DOCUMENTS REVIEW

x Carry out any repairs to damaged

paintwork caused during erection of the machine. Repair procedure to be carried out in accordance with specification.

x Carry out full inspection of the Reclaimer and ensure that all equipment is correctly fitted and that all bolts and fixings have been installed.

x Carry out a review of the Reclaimer Installation Schedule ensuring all installation verifications have been carried out and recorded and all site fault reports and any rectification work completed.



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7.18 ERECTION OF LUFFING

STRUCTURE (As per drawing no.1-0000-A-000617)

Assumed starting from a position where the inner boom structure is installed onto the slew deck structure

x Provide vertical erection support

below the inner boom and boom as per erection support drawing

x Lift the inner boom structure onto the slew deck structure.

x Lift the boom structure and pin with inner boom structure.

x Assemble the mast on to inner boom. x Lift counter wt boom into position on

the mast, and fit supporting pins of counter wt boom links.

x Whilst supporting the rear of the counter wt boom with the installation crane, fit the counter wt boom support links.

x Lift boom links and pins with Mast and lift up the boom by connection between boom and boom links. Carefully lower the boom back onto its supporting trestle. This should result in the main boom links becoming tensioned.

x Erect partly counter weights for reducing of loads on erection support at boom.

x Lift the bucket wheel at the end of main boom.



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x Lift the operator cabin assembly. x Erect partly counter weights for

reducing of loads on erection support at boom.

x Erect boom conveyor mechanical and misc items etc

x Erect remaining counter weights as per balancing programme.

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