Mechanical Design Guide

ROSIA MONTANA GOLD
CORPORATION S.A
MECHANICAL DESIGN GUIDE
1418-DC-0019
Specification No. Rev.
RORROSIA
B
1418-DC-0019
25/06/04
PRINCIPAL ENGINEERING
REV. DATE DESCRIPTION AUTHOR
ENGINEER MANAGER
A 07/4/04 Issued for Review JV DMcL KB

B 25/6/04 Issued for July 31 Estimate JV DMcL KB
Mechanical Design Guide

ROSIA MONTANA GOLD CORPORATION S.A 1418-DC-0019
TABLE OF CONTENTS
1 PURPOSE 1
2 UNITS 1
3 CODES AND STANDARDS 1
4 REFERENCE DOCUMENTS 2
5 EQUIPMENT IDENTIFICATION 3
6 GENERAL DESIGN REQUIREMENTS 4
7 OPERATING DUTY 5
8 SERVICE FACTORS 5
8.1 Overload Capacities 6
9 DRIVES 6
9.1 General 6
9.2 Base-Frames 6
9.3 Gear Reducers 6
9.4 Vee Belt Drives 7
9.5 Sheaves 7
9.6 Chain Drives 8
9.7 Sprockets 8
9.8 Bearings and Seals 8
9.9 Shafts 10
9.10 Couplings 11
9.11 Lubrication 11
9.12 Hydraulic Power And Lube Oil Systems 11
9.13 Brakes 12
9.14 Vibration Monitoring 12
10 SURFACE PROTECTION 12
Mechanical Design Guide Contents Page 1 Ausenco International Pty Ltd

ABN: 98 096 016 849
11 STANDARDIZATION OF COMPONENTS 12
12 WIRE ROPE, CHAINS AND FITTINGS 13
13 FASTENERS 13
14 LIFTING POINTS 14
15 MATERIALS HANDLING EQUIPMENT 14
15.1 Conveyors - General 14

15.2 Belt Feeders 15
15.3 Belting 15
15.4 Pulleys 16
15.5 Pulley Shafts 16
15.6 Speed Reducers 16
15.7 High and Low Speed Couplings 16
15.8 Fluid Couplings 17
15.9 Pulley Shaft Bearings 17
15.10 Take-Ups 17
15.11 Idlers 18
15.12 Backstops 18
15.13 Belt Cleaning Systems 19
15.14 Belt Safety Devices 19
15.15 Warning Lights 20
15.16 Conveyor Guards 20
15.17 Conveyor Hoods 20
15.18 Protection Beneath Conveyors 20
15.19 Conveyor Cross-Over Bridge 20
15.20 Stringers 20
15.21 Trusses and Walkways 20
15.22 Supports 21
15.23 Skirting 21
15.24 Belt Magnets 21
15.25 Tramp metal detectors 21
16 FEEDERS 22
16.1 General 22

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16.2 Feed Openings Under Hoppers or Stockpiles 22

16.3 Feeder Loads 22
16.4 Apron Feeders 22
16.5 Belt Feeders 23
16.6 Vibrating Feeders 23
17 SCREW CONVEYORS 23
18 TRANSFER CHUTES, HOPPERS AND BINS 23
18.1 DESIGN AND CONSTRUCTION 23

18.2 Linings and Wear Bars 25
19 CRANES AND HOISTS 25
20 ROCKBREAKER 26
21 WOOD PICKER 26
22 FLUID HANDLING 26
22.1 Sumps 26
22.2 Tanks 27
22.3 Launders 28
22.4 Centrifugal Pumps 29
22.5 Agitators 33
23 PRESSURE VESSELS 34
23.1 General 34
23.2 Corrosion Allowances 34
24 FLOCCULANT PREPARATION 35
25 LIME SLAKING 35
26 FANS, BLOWERS AND COMPRESSED AIR EQUIPMENT 35
26.1 General 35
26.2 General Purpose Compressed Air Systems 35
26.3 Instrument Air Systems 35
26.4 Air Blowers 36
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26.5 Air Compressors 36

26.6 Instrument Air Dryer 37
26.7 Air Receivers 37
27 DUST CONTROL EQUIPMENT 38
27.1 General 38
27.2 Dry Dust Collection Equipment 38
28 NOISE CONTROL 40
29 VIBRATION CONTROL 40
30 SAFETY FEATURES 40
30.1 Safety Signage 40

30.2 Safety Guards and Guard Rails 40
30.3 Hazardous Materials 41
30.4 Chemical Storage 41
30.5 Eye Washes And Safety Showers 42
31 UTILITY STATIONS 42
32 PLANT LAYOUT 42
32.1 Clearances And Accessibility 42

32.2 Stairs, Walkways And Ladders 43
33 PACKAGED EQUIPMENT 43
34 SHOP PRE-ASSEMBLY AND TESTING 43
APPENDIX 1 - OVERDIMENSIONAL TRANSPORT MATRIX
APPENDIX 2 - TRANSPORT ENVELOPE

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1 PURPOSE
This document is a guide to assist in the production of specifications and mechanical

designs that are safe, economical and practical, that will comply with all relevant standards
and regulations, and that will utilise standard, proven and reliable equipment wherever
practical.
It is intended that this document, together with the Mechanical Design Criteria, will form the
basis for mechanical equipment specifications and ensure consistency between the
specifications.
Whereas the requirements of the Mechanical Design Criteria are mandatory and require
project approval for any deviations, the responsible engineer / designer may choose to
deviate from the requirements of this document if considered necessary.
It is left to the discretion of the responsible engineer/designer to ensure that the specific
project requirements are met, including safety and economics.
2 UNITS
Metric Units should be used for all design work and should be shown on all drawings and in
calculations. Units should be International System (SI), with the following specific units:
• Length: mm
• Flow: m3/h
• Pressure: kPa
Imperial units would be acceptable where preferred equipment and machinery is

manufactured in countries whose standards are based on the use of such units. All
documentation should reflect the SI equivalent in brackets after the Imperial unit.
Where gas volume is nominated as ‘Normal’, units should be taken as the volume occupied
by the gas at:
• Temperature = 273.15 K (0 oC)
• Pressure = 101.325 kPa absolute
3 CODES AND STANDARDS
Design and fabrication of equipment and components should comply with codes and
standards from European organisations. Codes and standards should take preference from
the organisations in the order as listed below:
SR Romanian Codes and Standards
CEN Comite European de Nomalisation
ISO International Standards Organization
DIN Deutsch Institut fur Normung E.V. (German Standards)
Mechanical Design Guide Page 1 Ausenco International Pty Ltd

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BSI British Standards Institution
The design and fabrication of equipment and components should conform to the
requirements of Comite European de Normalisation (CEN) codes and standards. Where an
applicable EuroNorm (EN) or EuroNorm Vornorm (EVN) is not available, an appropriate
internationally recognised standard may be utilised.
In all instances, the equipment and components should meet Romanian regulations when
they are more stringent than the European or international codes and standards proposed.
The latest edition of a code or standard will govern.
For a list of standards and codes applicable to this project, refer to the List of Codes and
Standards for this project.
Equipment must carry the Conformite Europeen (CE) mark with a CE declaration of
conformity provided. Recognised third parties / Notified Bodies will need to be engaged to
carry out compliance checks and affix CE markings where suppliers are not qualified to do
so themselves.
Particular attention should be given to the following Directives:

• Machinery – 98/37/EC
• Pressure Equipment (PED) – 97/23/EC
Formatted: Bullets and Numbering
α.• For machinery, the Declaration of Conformity should be included with the Supplier’s
document submittals to the Buyer.
β.• For electrical equipment supplied with mechanical equipment packages, the Declaration
of Conformity should be retained by the Supplier and made available to the Buyer for
inspection, if required. Submission of a Declaration of Incorporation for equipment in lieu
of a CE Mark and Declaration of Conformity should only be permitted with the Buyer’s
prior agreement where there are exceptional circumstances.
δ.• The Supplier should be responsible for selection of Notified Bodies and recognized third
party organizations needed to carry out full compliance and affix CE marking.
In the absence of any specific standard, the manufacturer’s recommendations should

prevail subject to approval.
4 REFERENCE DOCUMENTS
The following documents need to be referenced and understood in relation to the design
and specification of mechanical plant and equipment:
Site Design Criteria 1418-DC-001

Process Design Criteria 1418-DC-005
Mechanical Design Criteria 1418-DC-0010
Process and Utility Piping Design Criteria 1418-DC-0013
HVAC Design Criteria 1418-DC-014
Structural Design Criteria 1418-DC-017

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Basis for Design Process 1418-DC-018

Process Description 1418-RPT-0004
List of Codes and Standards for Project
Specification for Surface Protection of Structural 1418-ES-005
Steelwork and Platework
Specification for Steel Tanks and Bins 1418-ES-006
Specification for Piping Materials and Valves 1418-ES-011
Specification for Thermal Insulation for Process 1418-ES-014
Vessels and Piping
Specification for Stainless Steel Fabrication 1418-ES-015
Specification for Lining with Rubbers 1418-ES-026
Specification for Electrical Equipment Supplied with 1418-ES-023
Mechanical Packages
Specification for Low Voltage Motors 1418-ES-031
Specification for High Voltage Motors 1418-ES-033
Specification for Instruments Supplied with 1418- ES-034
Packaged Systems
Electrical and Instrument Preferred Equipment List 1418-EL-0003
5 EQUIPMENT IDENTIFICATION
Each main item of equipment (which has an equipment number, as specified on the
equipment list and P & I D’s), will need to have two (main) nameplates of stainless steel, of
minimum 1.6 mm thick. One nameplate will be in the Romanian language and the other will
be in the English language.
The following data should be engraved and painted in black enamel on the nameplate:
• Equipment no
• Equipment name
• Manufacturer’s name
• Model no
• Date of manufacture
• Purchase order no
Equipment no. and name should have minimum 12 mm high characters. Other data should
have smaller characters, but not less than 8 mm high.
It should be left to the discretion of the equipment manufacturer to include additional

information on the nameplate, such as manufacturer’s address and company logo.
Equipment name plates should be permanently and securely attached to the equipment, in
a prominent location, by means of stainless steel screws or rivets.

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Each proprietary item of equipment, supplied as part of the equipment package e.g. motor
and gearbox supplied with an agitator, should be tagged and identified with a stainless steel
equipment name plate, including the following data, either engraved / painted in black
characters or neatly hard stamped with the equipment make, model and serial numbers
with letters not less than 8 mm high. Each nameplate should be permanently and securely
attached to the proprietary item of equipment by means of stainless steel screws or rivets,
affixed in a prominent position where possible, otherwise attached to the equipment by
stainless steel chain (preferred) or stainless steel wire.
6 GENERAL DESIGN REQUIREMENTS
All design should facilitate ease of access for handling, transportation, installation,
adjustment, control, inspection, maintenance and repair.
The equipment should be manufactured in accordance with the equipment Supplier’s

standard, robust, heavy duty design, provided this is not in conflict with the specification,
incorporating the best materials and practices in line with modern engineering concepts,
suitable for continuous operation at the specified duty.
The equipment should be designed for unprotected outdoor operation under all weather
conditions, unless otherwise specified.
Notwithstanding any other specified provisions, all work should be carried out in
accordance with sound engineering practice and to accepted industry standards, with
special emphasis on safety and reliability.
All materials used in the construction or assembly of equipment should be new, non-
defective and suitable for the duty and service.
Prior to commencement of fabrication, computations for equipment structures should be

reviewed by the responsible engineer.
Vibrating equipment should be designed to minimise the transmission of vibration to the

supporting structure. Unless the supporting structure is designed for the vibrating
equipment loads, suitable vibration isolation devices (e.g. isolation frames for vibrating
screens) should be provided.
Where practicable, access to plant and equipment should be such that all major field
maintenance can be carried out from ground or a floor level.
Clear access should be provided for the withdrawal of components for maintenance. In
general, maintenance access points should have a horizontal clearance of at least
1,000mm, where practical. When equipment is withdrawn for removal, or landed on the
platform in readiness for installation, the design should incorporate provision for safe
access around the equipment for the attachment of slings, etc.
Where practical, equipment layouts should facilitate the use of mobile cranes for removal
and installation of equipment. Where layout precludes use of mobile cranes, and regular
access is required for removal and installation of equipment and components for
maintenance, the layout should incorporate monorails.

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All conveyors and feeders should incorporate sufficient space for belt replacement. This
shall include future provision for belt reel system complete with motorised capability as
necessary.
Where electric motors are used, they should be included in the supply of mechanical
equipment. Motors should be in accordance with the project motor specification, except
where special motors are required e.g. vibrator motors for screens and brake-motors for
crane hoists.
Zinc, copper, aluminium and their alloys including brass should not be used in components
in contact with process fluids.
7 OPERATING DUTY
The equipment should be suitable for continuous operation, 24 hours per day, all year
round, under the following conditions, without excessive noise, vibration, wear, overheating,
stress or deflection:
• Continuous operation at the performance levels specified in the technical specifications.
• Continuous operation at the extremes of ambient temperature specified on the Site
Design Criteria.
• Continuous operation in an environment containing high levels of fine abrasive dust.
• Continuous operation in a dirty, wet, corrosive environment.
• Continuous operation fully exposed to the elements.
• Periodic clean up by means of high pressure hose.
The equipment should be designed to have a minimum operating life of 20 years. This
assumes that, even with the on-set of corrosion, the equipment will remain in a safe and
operable condition after 20 years of service. However, any parts subject to wear and
regular replacement, such as pump impellers, are excluded from this requirement. Careful
consideration should be given to the selection of materials, where components are
subjected to abrasion / corrosion, to minimise compnent wear rate and maintenance down-
time.
The rated capacity of an item of equipment should be stated for the most adverse demand
of the equipment, plus a suitable (design) margin to account for equipment wear and
allowance for design error, if necessary. This should apply to equipment capacity and
motor power. The margin will typically be up to 10% but will need to be determined on a
case by case basis.
8 SERVICE FACTORS
In order to ensure that all mechanical components are sufficiently robust, suitable service
factors should be applied to the nominal design loads. As a minimum requirement, the
selected service factor should give a load rating not less than 1.5 times the maximum
steady state operating torque or load of the driven equipment or 1.25 times the full load
torque or load of the drive motor or actuator, whichever is the more stringent.

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All components should be capable of transmitting the maximum overload torque or load
produced by the drive or the connected load under the most severe conditions, including
braking or other dynamic inertia effects.
Where special requirements exist, these should be stated in the individual equipment
specifications and design service factors should equal or exceed these values.
8.1 Overload Capacities
Machinery and equipment should be designed to withstand starting overloads based on the
drive characteristics and the starting methodology of the equipment. Equipment should be
capable of running at 20% overload for periods not exceeding two hours, unless determined
otherwise.
9 DRIVES
9.1 General
Rotating equipment should be clearly marked with an arrow showing the direction of
rotation
Taper lock bushes should be used for attaching pulleys, sprockets, and couplings to low
speed shafts.
9.2 Base-Frames
Base-frames should be designed to prevent undue deflection or failure under any

conditions of loading likely to be encountered.
Mounting pads on base-frames should be machined true and parallel. Allowance should be
made on the motor mounting pad for 5 mm maximum shimming and 1 mm minimum
shimming.
Where base-frames are fabricated, they should be stress relieved before machining.
Base-frames for equipment or assemblies which exceed 200 kg in weight, should have
lifting lugs and incorporate jacking lugs complete with jacking screws at each motor pillow
block mounting foot to facilitate drive alignment.
Base-frames should be designed to facilitate the drainage of moisture and spilled product
and ease of cleaning.
Where base-frames are mounted on concrete plinths, the design of the frame should
facilitate the ease of grouting of underside of frame and ensure that moisture, spilled
product and dust cannot accumulate under the base-frame otherwise ensure that
accumulated material can be easily hosed out from under the base-frame.
9.3 Gear Reducers
Gear reducers should be helical or bevel helical units selected with a conservative service
factor to allow for moderate continuous shock load and regular starting.

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Except where the use of integral motor-reducers (motors of special mounting and/or an in-
tegral part of the reducer) are required or are economically justified, separate motor and
gear reducer drive arrangements should be used.
Gearboxes should be horizontally split for dismantling purposes and should be designed to
suit oil bath lubrication of gears and splash lubrication of the support bearings.
Gearboxes should be dustproof and equipped with inspection covers, drain and filler plugs,
breathers with suitable filters, oil level indicators or dip sticks and lifting lugs, as required.
Preference should be given to gear reducers that have a thermal rating such that auxiliary
coolers are not required.
Gear quality level should be Qv 10 or better as per ANSI/AGMA 2001-C95, and gear life
should have a design value of 10 years as per the same standard.
Gear strength factors should not be less than 2.0, and durability factor not less than 1.5.
Shaft mounted speed reducers should be arranged for standard shaft mounting using
flanged or expanded shaft connections.
Speed reducers should have anti-friction bearings and taconite shaft seals, where possible,
to prevent dust and moisture from entering the bearings.
Where taconite seals are unsuitable, and, in particular, where shaft speed exceeds 15 m/s,
labyrinth seals should be used.
Gearbox ball or roller bearings should be seated in full ring cartridge type housings, suitably
located on the split of the gearbox.
Magnetic drain plugs should be provided to remove any metal particles in the oil.
9.4 Vee Belt Drives
V-belt drives should be complete with sheaves, taper lock hubs, matched V-belts and drive
guards.
V-belt drives should be in accordance with the European Metric ISO standard 4184 using
SPZ, SPA, SPB, or SPC V-belt cross sections. A minimum of two belts should be provided
on each drive.
Service factors should be 1.5 minimum, 24 hours per day, for appropriate driven equipment
based on motor horsepower.
To minimise spares inventory of matching V-belts, standard lengths should be used, where
practical.
Drive motors should be mounted on slide or pivoted bases allowing sufficient adjustment for
correct belt tensioning according to the manufacturers requirements. Bases should
incorporate jack screws with lock nuts for tensioning adjustment.
9.5 Sheaves
Sheaves should be equipped with de-mountable compression-type hubs except when used
for small power or auxiliary equipment drives.

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For belt speeds up to 25 metres per second, sheaves and hubs should be statically
balanced.
For belt speeds over 25 metres per second, sheaves and hubs should be dynamically
balanced. Refer to the MPTA standard ‘Balancing Power Transmission Pulleys (SPB)’ for
dynamic balancing requirements.
Drive and driven sheaves and sprockets should be installed with a minimum of overhang on
the shaft, to minimise shaft loads.
9.6 Chain Drives
Roller chain drives should only be used where other drive types cannot be used.
If chain drives are used, they should use a minimum of 15 mm duplex chain and sprockets.
Chain and sprockets should be of similar hardness materials.
Chain drives should be complete with sprockets, taperlock hubs and bushings, roller chain
with at least 6 cottered links plus one spare offset link and guard or oil tight and dust-tight
split chain with dipstick, filter cap and drain plug.
Sufficient take-up allowance should be provided on the motor mounting to take up two full
chain pitches. Where take-up allowance is not possible due to fixed shaft centres, an
adjustable chain wheel idler should be incorporated.
9.7 Sprockets
Drive and driven sheaves and sprockets should be installed with a minimum of overhang on
the shaft to minimise shaft load.
Sprockets should be standard ANSI steel with hardened teeth and tapered hubs with split
compression type bushings keyed to shaft.
9.8 Bearings and Seals
Bearings should be mounted in standard proprietary housings, with positive sealing on the
bearing assemblies to prevent contamination. Bearings should be spherical roller type
unless otherwise recommended by the manufacturer.
Bearings, other than for proprietary motors, gear reducers, pump spindles and the like,
should be mounted in plummer block type housings.
Plummer block bearings should be of the self-aligning, double row, spherical roller, adapter
mount type, in split, ductile iron housings.
Where ever possible, plummer block mounted bearings should use ‘Taconite” type seals.
Where taconite seals are unsuitable, in particular, where shaft speed exceeds 15 m/s,
labyrinth seals, per manufacturer’s recommendations, should be used.
Plummer block housings should be fitted with 6mm button head type stainless steel grease
nipples. The lubrication points should be readily accessible and positioned to allow greasing
whilst equipment is operating.

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Where the rotating equipment is supported between the bearings (e.g. pulley), there should
be a fixed bearing and an expansion type bearing. Fixed bearings should be mounted on
the drive end of any drive shaft.
Where the shaft does not extend through the pillow block, a housing end enclosure or cap
should be provided.
Plummer block housing should be mounted such that applied loads cause no increase in
cap bolt tension.
The supporting steel work should also be provided with adjusting screws for longitudinal
adjustment of plummer blocks.
Equipment bearings should be selected to ensure long life. Bearings should be selected for
a minimum L-10 life1, to ISO 281, as indicated below, where possible:
Mechanical Equipment Minimum L-10 Life

Trolleys and hoists 3,000 hours
Gear drives and reducers 80,000 hours (Except as per Note 2)
Blowers 80,000 hours
Pumps 80,000 hours
Conveyor idlers 60,000 hours
Conveyor pulleys 80,000 hours
Feeders 80,000 hours
Vibrating screens 80,000 hours
Compressors, process fans and turbines 100,000 hours
Agitator shaft bearings 200,000
Other equipment Select on individual basis
Notes:
1. L-10 life, as per 1S0 281, is defined as the number of service hours, at a constant
speed and rated load, that ninety percent of the bearings will provide before showing
evidence of fatigue.
2. There are practical / economic restrictions in achieving L-10 life of 80,000 hours life for
intermediate bearings of gearboxes. For example, Lightnin can offer gearboxes with
output bearings with 80,000 hour L-10 life, however intermediate bearings will only have
32,000 hour L-10 life as heavier bearings would compromise the overall integrity of
their gearboxes.
Where required by design considerations, well lubricated, non-ferrous bushings and

bearings may be used.
Where phosphor bronze bearings are used the quality should be to SAE 64 or equivalent.
The supplier should be required to provide details of specification number and analysis of
metals used. This requirement will also apply to the use of white metal.
'Sealed for life' type bearings may be used for special applications, ie conveyor idlers.

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Self-lubricating graphite or compound bearings should not be used unless specifically

recommended by the Supplier.
Plummer blocks should be installed such that the loads pass through the base and not the
cap. Deviations from this arrangement for practical reasons should be subject to approval
and accompanied by design calculations.
Bearing housings should be of cast steel, good quality cast iron or fabricated to
specification and accurately machined where necessary. Special precautions should be
taken during packing to prevent damage during transportation
9.9 Shafts
Heavy duty shafting should be forged carbon steel, turned, ground and polished. Unless
otherwise prescribed for design stress, a safety factor of 5 should be used, based on the
yield stress for steel in the normalised condition.
Design allowance should be made for combined bending and torsion stress. Suitable fillet
radii should be provided at changes in diameter and shaft ends should be chamfered.
Changes in diameter and keyways should not coincide. Unless otherwise prescribed or
allowed in relevant codes, calculated stresses should not exceed 1/5 of the minimum yield
stress for the chosen material
Light duty shafting should be hot rolled polished mild steel or cold rolled mild steel. Cold
rolled shafting should be subject to approval.
All shafts should be metric or, if unavoidable, imperial dimensioned shafts turned down at
the bearing seats to the following diameters (in mm’s) with tolerances appropriate to the
particular bearings employed:
16 50 115 220
20 60 125 240
25 70 140 260
30 80 160 280
35 90 180 300
40 100 200
Shafts should be supplied with keysets and keys. If a fastening method other than by key is
used, any such proposed fastening should be submitted together with design calculations
for the engineer’s approval.
Shafting should be free of any sharp corners and all shaft ends should be chamfered.
All shafts should be straight within limits of the tolerance of applicable standards.
Turned down shaft ends should have fillet radius of at least half the difference in diameters.
Turndown should not exceed 25mm. A factor of 1.5 for bending at turndown for stress
concentration should be used.
To allow the use of bearing end caps, shaft ends should not protrude from the bearing
unless required for power transmission.

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9.10 Couplings
Couplings should be radially and torsionally flexible, and should incorporate a suitable
resilient element to damp out impact or shock loads. Couplings should preferably be of a
non-lubricated design.
Rigid couplings are appropriate for applications where direct mounting to drive shafts (such
as for conveyor drives) are used.
9.11 Lubrication
The minimum design temperature for this project is minus (-) 21°C. The oil or grease has to
be suitable for start-up at this temperature. Synthetic oils should be used in preference to
mineral oils.
Where bearings are grease lubricated, the lubricant should be delivered into ball and roller
bearing housings via an annular groove on the bearing centreline. Housings for non-
locating bearings should have suitable internal grooving to allow for axial float of the
bearing within the housing.
In order to allow lubrication while the unit is operating, lubrication points should be readily
accessible outside the equipment casing or guards. Grease nipples should be mounted on
plates at conveniently accessible locations.
Stainless steel tube and compression type fittings should be used for all remote lubrication
piping. Piping should be neatly routed in a manner that allows drive guards or other
adjacent components to be removed without disconnecting the lubrication piping.
All remote lubrication points should be provided with a stainless steel label which should
clearly identify the point being lubricated.
Grease fittings should be button head type, with stainless steel nipples, easily accessible
for greasing without removing guards.
Gearing and chain drives should have fully enclosed oil bath lubrication except where a low
peripheral velocity requires grease lubrication. Where the peripheral velocity of gearing
exceeds 750m/min, forced feed lubrication should be provided.
As far as is practical, a centralised lubrication system should be considered where multiple

points of lubrication of equipment are necessary. Such centralised systems should have
the approval of the equipment supplier.
9.12 Hydraulic Power And Lube Oil Systems
Reservoirs for hydraulic power systems should be sized for at least twice their respective
system volume.
Hydraulic systems should have adequate provisions for cooling and heating, as applicable,
to assure proper operation under continuous duty at the specified extreme ambient
temperature conditions.
Accumulators for the hydraulic cylinders should be locally installed near the hydraulic
cylinders.

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Hydraulic power and lube oil units should be supplied pre-assembled on skids and should
be fully shop tested at the manufacturer’s works.
Hydraulic and lube oil lines, of carbon steel piping material, should be pickled, neutralized
and sealed before shipment and should require a minimum of field fit.
9.13 Brakes
Brakes should be adequately sized for the load characteristics and heat dissipation.
For hoisting, or where the brake is holding back a continuous applied load, thrust or
releasing shoe brakes should be used with weight or spring actuated operation, such that
loss of power will result in fail-safe (hold load) operation.
Brakes should be fitted to the coupling at the input shaft of the reduction unit where
practicable
9.14 Vibration Monitoring
Where ever practical, especially on high speed bearings, such as on gear boxes and fan
plummer block bearings, condition monitoring studs should be installed. The studs should
be the SPM Type and be installed on two perpendicular radial axes of gear box bearings.
10 SURFACE PROTECTION
External non-corrosion resistant metal surfaces, including 3CR12, should be treated and
protected from corrosion in accordance with the applicable system nominated in the project
specification for surface treatment.
Proprietary equipment, such as gearboxes, may be to the Supplier’s proprietary paint

system. However, such a system should be suitable for the operating environment and
should be approved by the responsible engineer.
Galvanising should not be used for corrosion protection unless appropriately grit blasted
and coated with an approved project coating system. Stainless steel items need not be
painted.
In specifying surface protection systems, particular attention should be paid to the masking
of machined surfaces, and exclusion of blasting grit and paint from terminal boxes, glands,
seals, breathers, and the like, where entry of grit and paint would be detrimental.
Exposed machined surfaces should be coated with a suitable corrosion inhibitor compound
and protected against damage during transport and storage.
11 STANDARDIZATION OF COMPONENTS
Where possible, standard, readily available components should be used from reputable
manufacturers who have stock carrying distributors in Romania and other neighbouring
countries.
Where possible, sizes should be limited, i.e. shaft sizes, bearings, sheaves, V-belts, pulley
sizes, belt widths, screw conveyor diameter, etc., to reduce spares inventory.

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The manufacturer, type, size and ratio of speed reducers should be limited to reduce
spares inventory.
12 WIRE ROPE, CHAINS AND FITTINGS
Ropes, whether fixed suspension or for general use, should comply with the appropriate
Statutory Regulations.
Wire rope fittings should be securely attached to the ropes, preferably with terminal splicing
standard spelter fittings or approved swaged fittings. All rope slings should be tested to
twice the required working strength. Spelter fittings should not be used for high temperature
applications.
Lifting tackle should be supplied with valid test certificates.
Wire rope slings for general use should be fitted with a metal tag indicating the safe working
load.
Sockets, thimbles, rigging screws, stretching screws, eyebolts etc, should have a safe
working load of not less than that for the attached rope or chain.
Chains should comply with the appropriate Statutory Regulations and be stamped with the
safe working load.
13 FASTENERS
Fasteners will need to be readily available from Romanian suppliers. Fasteners, using
hexagon head bolts, nuts and screws, will therefore need to comply with ISO codes 4014,
4017, 4032 and 4033.
Bolts should be supplied and installed complete with hexagon nut, and flat washer under
the nut. Non-painted threads should be coated with a proprietary anti-seize compound
before assembly. Bolts should be supplied in standard lengths so that after tightening:
• Not less than one full thread is exposed beyond the face of the nut.
• Not more than three full threads are exposed beyond the face of the nut.
When bolting onto parallel surfaces, nuts should be fitted with plain parallel washers except
where the machinery is subject to vibration or movement. Then spring washers, nylon
insert locknuts or tack welding should be used. Where nut adjustment is required (eg
bearing take-up), castellated nuts with split cotter pins should be used. For thread
diameters of 10mm and under, the use of tab washers is acceptable.
The fastening of equipment to steelwork or to concrete, in areas subject to spillage of

corrosive solutions or exposed to corrosive vapours, should use of 316 stainless steel bolts
with 304 stainless steel nuts (to prevent galling).
Bolting for the fastening of equipment to steelwork or to concrete, in areas not subject to
spillage of corrosive solutions or exposed to corrosive vapours, should be hot dipped
galvanized.

ABN: 98 096 016 849
14 LIFTING POINTS
Suitable lifting points should be provided on all equipment components which exceed 20 kg
in weight. Lifting lugs should be positioned so that the equipment can be slung safely at the
required attitude for installation without the need for special lifting frames or spreaders.
Lifting lugs should be designed and certified by suitable qualified personnel.
Lifting lugs should be designed and located for lifting in balance without equipment
damage.
15 MATERIALS HANDLING EQUIPMENT
15.1 Conveyors - General
Suitable standards for the design of conveyors include CEMA and ISO 5048. Conveyor
suppliers have their own preference. However, the engineer needs to ensure that edge
clearances and maximum power requirements should be based on 85% loading of the belt
at the specified design capacity (wet t/h of material).
Design all belt conveyors handling crushed ore based on maximum 85% loading of belt at
design capacity.
Conveyors should be designed for continuous 24 hour operation.
Belt speed for conveyors should be determined by the application. However, belt speed
should be kept below 3 m/s.
In general all conveyors should have well-lighted walkways. Clear distance between
conveyor stringers and closest obstruction on the main walkway side should be 800mm
minimum.
Standardization should be considered in the selection of components.
Plugged chute alarms should be provided at each transfer point.
The minimum material depth at the hopper outlet should be the greater of the following two
cases: two times the largest lump size or one third of the hopper opening width.
Concave vertical curve radii should be calculated to prevent belt lifting off the idlers. Empty
belt weight, (including an allowance of 20% belt mass reduction for worn belt) should be
used in the calculations with the belt loaded to the tangent point of the curve. Acceleration
factors of 2 to 2.5 for DOL motor starting, and 1.3 to 1.6 for soft starting should be applied.
Convex curves should be calculated to impose lower load than the idler load rating.
Reduced idler spacing should be computed for the selected curve radius.
Take-up travel for conveyor belting should include sufficient length to allow for one splice.
Additional travel, due to belt sagging between idlers, temperature variation and elastic
stretch, should be allowed in the take-up travel distance. Take-up tension requirement for
conveyors installed with winch or screw type tensioning device should be two times the
average tension. Ample room should be provided for belt stretch.

ABN: 98 096 016 849
Maximum inclination of conveyor belts should be 15 degrees on carrying runs and not more
than 7 degrees at load points. Inclination of conveyor belts carrying “pebbles” should be
less than 13 degrees.
Conveyor drives, should consist of an electric motor, traction type fluid coupling or
electronic soft starting gear and a shaft mounted helical gear reducer.
Conveyor drives should utilise shaft mounted gear reducers.
The following minimum clearances between conveyor components and items which should
be allowed for:
Belt and chute 75 mm
Return strand and grade level 700 mm
Belt laterally to any structure 200 mm
Belt to any overhead structure 1,000 mm
Under tail pulley to any structure and grade 500 mm
15.2 Belt Feeders
Belt feeders should be considered as an integral part of the bin and feeder system. The
discharge opening of the bin or hopper should be large enough to ensure passage of the
material at the required maximum discharge rate which should be throttled by the feeder.
Therefore the feeders should serve as flow regulators and should never be used as flow
promoters.
15.3 Belting
Selection of belting should be based on operating and design conditions. The selection of
carcass and breakers should satisfy maximum tension, minimum plies for load support,
maximum plies for empty belt troughing, pulley sizes, impact and other operating
conditions. Standardization for maintenance and inventory should be considered in the
selection of belting.
Top and bottom cover quality should be Grade M. Top and bottom cover thickness should
not be less than 6 mm and 3 mm respectively.
Belts should be of synthetic fabric construction unless otherwise recommended by the

Supplier.
Belt splices should be vulcanized. Cold vulcanized joints are acceptable on small
conveyors and feeders.
Belt with rip detection filament should be provided where an electronic rip protection system
is required.

ABN: 98 096 016 849
15.4 Pulleys
Pulleys should be heavy duty design supplied complete with shaft, hub connection, lagging,
plummer blocks and bearings. Pulleys should be live shaft type and designed to operate at
full belt tension, and be attached to the shafts by Ringfeder or equivalent locking assembly.
Pulley face width for conveyor belts ≤ 1,000 mm wide should be 100 mm wider than the belt
width. Pulley face width for conveyors > 1,000 mm wide and ≤ 1,500 mm should be 150
mm wider than the belt width. Pulley face width for conveyors > 1,500 mm wide should be
200 mm wider than the belt width.
Drive pulleys should have 12 mm thick rubber lagging with 6 mm diamond pattern grooves,
66-65 durometer hardness (Shore A). Other pulleys should have 10 mm thick plain rubber
lagging, 45-55 durometer hardness. Lagging should be vulcanised to the pulley.
All drive pulleys should have a minimum angle of wrap of 180 degrees. The use of snub
pulleys should be restricted and used only when deemed essential by the Buyer’s engineer.
15.5 Pulley Shafts
Drive pulley shafts should be machined from Grade 4140 steel or equal and other shafts
should be machined from Grade K1045 steel.
Pulley shafts should be designed to safely withstand the maximum force that can be
imposed during acceleration, braking or motor stalled conditions and for infinite life under
design running conditions based upon the endurance limit of the shaft material.
Pulley shafts should be designed to limit the deflection at the locking element such that the
slope does not exceed the manufacturers specified maximum under all load conditions.
15.6 Speed Reducers
All speed reducers should be of standard design for the specified duty.
Speed reducers larger than 55 kW should be parallel-shaft or concentric-shaft type with

anti-friction bearings throughout and direct-coupled high and low speed shafts.
Speed reducers up to and including 55 kW should be shaft-mounted.
Shaft mounted reducers may be hollow shaft shrink disk type or solid shaft rigid coupling
type.
15.7 High and Low Speed Couplings
Couplings should be flexible type, capable of accepting angular and parallel offset
misalignment of shafts.
Special attention should be given to assembly and removal features when the coupling is
used in conjunction with a fluid coupling.
Maximum bore diameter should be based on the use of a standard square key.
Each half of the coupling should be shop mounted to its shaft before shipping to site.

ABN: 98 096 016 849
15.8 Fluid Couplings
Fluid coupling should be used as an alternative to variable speed drives or electronic soft-
start units, to limit the torque during starting and prevent lifting of belt off the idlers at the
concave curve section of conveyors.
Fluid couplings can be used for soft starting conveyors with high inertia loads, for drives
55kW and larger.
Fluid couplings should be of the fixed filled and traction type.
Fire resistant fluid should be used for fluid coupling fill.
15.9 Pulley Shaft Bearings
Shafts should be supported by plummer block bearings, except for take-up shafts which
should be supported by take-up block bearings.
Pulley shaft plummer block bearings should be the heavy duty, double row self-aligning,
spherical roller, four bolt type with split housings.
Pulley shaft plummer block bearings should have one fixed and one expansion type
bearing, the fixed bearing being on the drive end of any driven shaft.
Seals should be replaceable, grease purged, “taconite” type, comprising two seals with an
intermediate cavity with a grease fitting
Where shafts terminate at bearings, the bearings should be equipped with dust-tight end
discs.
15.10 Take-Ups
Gravity take-ups should be provided on all conveyors over 30m long. Counterweights
should be steel boxes filled with steel punchings or alternatively concrete and steel plates.
Gravity take-ups should include provision for hanging counterweights on the take-up frame.
High overhead counterweights should be avoided by the use of suspension cables. Safety
guards or fences should be furnished to close off areas immediately under the
counterweights. Provision should be made to prevent counterweight cables from coming
off their sheaves.
Horizontal gravity take-ups should have V-grooved wheels, and rails should be self-
cleaning (inverted angle). Hold downs should be provided to prevent the wheels from
jumping off the rails. Counterweights should be attached to the horizontal take-up frames
by means of cables and sheaves.
Screw take-ups should be used on conveyors up to 30m long.
Screw take-ups should be protected screw type with double roller bearings with dust covers
one side except where shaft must be extended for mounting attachments.
Screw take-ups for large belt feeders should be of hydraulically assisted type. They should
have manually operated hydraulic cylinders, mounted on a grease container, and stainless

ABN: 98 096 016 849
steel screws to retain the force generated hydraulically. Each cylinder should have a gauge
to monitor the pressure during the tensioning operation.
15.11 Idlers
Idler design and selection should be in accordance with the minimum requirements
recommended by the latest ISO standard for Continuous Mechanical Handling Equipment
for Loose Bulk Materials.
Idler frames should be designed to readily shed spilled material.
Triple labyrinth seals should be used. The seals should be effective against dust and
moisture entering the bearings.
All Idlers should have “Sealed for Life” type lubrication.
In general, all carrying idlers should be of the troughed belt type, having three equal length
interchangeable rolls with end rolls inclined at 35o, unless special considerations dictate
otherwise.
Minimum roll diameters should be 150mm.
The maximum spacing for all idlers should be limited by load rating of the idler and the
specified maximum belt sag, but should not exceed idler manufacturer’s recommended
spacing.
Idler spacing should be based upon a maximum sag allowance of 2% of idler spacing.
Bearings should be retained on the shaft by a positive mechanical locking device such as a
snap ring.
Impact idlers or impact beds, as found to be appropriate for the particular application,
should be used at loading and transfer points.
Impact tables should be designed to enable in-situ removal of mounting frames. Impact
bars (wear strips) should be of fully replaceable HDPE material, or other suitable material
as recommended by the Supplier.
Flat, plain, vee return idlers should be used on the return side, except where vee return
idlers are needed to assist in belt tracking.
Return idlers for conveyors handling abrasive or sticky material should be the multiple
rubber disc self-cleaning type.
Training idlers should be used on all conveyors 50m and longer. They should be located
within 9m of both the head and tail pulley ends.
Transition troughing idlers should be used at the tail and head terminals.
15.12 Backstops
Holdbacks (backstops) should be used on inclined conveyors.
Braking systems can be used in lieu of hold-backs.

ABN: 98 096 016 849
Drives with motors up to and including 55 kW may have internally mounted holdbacks on
the high speed shaft.
Drives larger than 55 kW should have externally mounted holdbacks.
15.13 Belt Cleaning Systems
A multiple-cleaning system consisting of a primary scraper and secondary scraper should

be applied.
Access to maintain belt scrapers should be of prime consideration. The design should
allow for ease of withdrawing of scraper assemlies and should ensure that the scraped
material / dribble is appropriately contained within a dribble chute.
Vee ploughs should be installed prior to any tail pulley or area where spillage could cause
damage when caught between the belt and pulley face.
Return belt ploughs should have a three points suspension system and should be securely
mounted by chains or cables to the conveyor stringers to minimise the risk of ploughs
breaking loose.
15.14 Belt Safety Devices
Safety devices should be provided for the protection of operating personnel and equipment.
Where required, belt conveyors should have proximity type motion sensing control switches
to detect belt slippage.
Conveyors should be electrically interlocked for sequential starting and stopping. Motor
control circuits should be de-energised when speeds drop below a preset point. Start-up of
the feed conveyor should ensure that transfer of material does not take place until the
receiving conveyor is running at design speed.
Safety devices for personnel protection should include:

• Horns and rotating beacon red lights to provide a warning that a stationary belt is about
to be set in motion.
• Pull cords for emergency stop switches extending the full accessible length of both sides
of each conveyor. Single and double-ended units should be used to avoid pulling
against a stationary point. The pull cords should be located high enough above the belt
to prevent miss-operation due to material falling off the belt, but not less than 300 mm
above the belt line. Maximum spacing between switches should be 30 metres. For long
conveyors employing more than one stop switch, an indication as to which switch is
pulled should be provided.
• Any other devices and protection required by Statutory Authorities.
Safety devices for equipment protection should include:

• Belt drift switches to detect excessive belt misalignment. For long conveyors with
multiple side travel switches, indication should be provided as to which switch is tripped.
• Zero speed or minimum speed detectors, mounted preferably on tail pulley.
• Blocked chute detectors.

ABN: 98 096 016 849
• Belt rip protection devices, as required.
Where required by the project a tramp metal detecting device and / or tramp collecting
magnet should be installed.
15.15 Warning Lights
A conveyor start-up warning system should be provided.
Warning lights should flash and the siren should sound for at least fifteen (15) seconds prior
to the start-up of the electric motors.
Warning lights should be capable of being seen, and warning siren capable of being heard,
along the complete length of the conveying system.
15.16 Conveyor Guards
Refer to Section 35.2 for safety guard requirements.
15.17 Conveyor Hoods
Consideration needs to be given to climatic conditions (snow and ice) and the need for
weather covers over conveyors. Where covers are deemed necessary, the design of
covers should allow for ease of maintenance and simplicity of construction. A fixed, semi-
open cover design should be used wherever possible, rather than a (more expensive and
complicated) cover design with hinged panels.
15.18 Protection Beneath Conveyors
Conveyors which cross over roads and pedestrian paths should be provided with underside
protection to catch material falling from the belt.
15.19 Conveyor Cross-Over Bridge
Safe crossing points should be provided where required.
15.20 Stringers
Where Ausenco is carrying out conveyor design, stringers should be made in sections with
maximum length of six (6) meters and should be made of rolled steel sections with
minimum size as follows:
• 150mm deep channel for conveyors up to 500mm wide
• 200mm deep channel for conveyors up to 1000mm and wider.
Where conveyor supplier is responsible for the design, stringer and truss design will be to
his own standards. The selection of stringer/truss length will generally be determined by
transport/shipping considerations.
15.21 Trusses and Walkways
Elevated outdoor conveyors should have open truss sections with walkways as follows:

ABN: 98 096 016 849
• Minimum 800mm wide walkway on one side, for conveyors with up to and including
950mm wide belts.
• Minimum 800mm wide walkway on one side and 600mm squeeze way on other side, for
conveyors with over 950mm wide belts.
15.22 Supports
Truss sections should be supported by trestles made of standard structural sections and
made in sections suitable for shipping.
Belt feeder frame should be rigidly supported to take the impact load, material shear and
pressure head load from the feed bin or hopper.
15.23 Skirting
Width between skirts should be nominally 2/3 of the belt width.
Skirtboards should be 10mm thick mild steel for conveyors handling crushed ore and 6mm
thick plate for conveyors handling pebbled ore.
Skirtboards should be lined with 12mm thick AR steel wearliners with a minimum hardness
of 500 BHN plug welded to the skirtboard.
Skirt rubber seals should be easily removable and minimum 12mm thick 70 Durometer
hardness rubber. Skirting should have rubber dust curtain at termination and back spill
rubber at feed.
The height of the skirt board must be sufficient to contain the material volume and at least 2
times the maximum material lump size on the belt.
The skirt board should have a minimum length of 1000mm for each 1m/s of belt speed
measured from the end of the loading area.
15.24 Belt Magnets
Belt magnets should nominally be self-cleaning, suspended electromagnets complete with

an adjustable cable sling designed for a one point suspension.
The preferred installation of a suspended magnet is over the trajectory of material

discharge from the belt conveyor. Provision should be made to adjust the location of the
magnet to suite the trajectory of the material. A non-magnetic pulley is required.
For a belt magnet installed across the conveyor belt, the magnet should be centred over the
width of the conveyor and the face (bottom) should be parallel to the slope of the conveyor.
Conveyor idlers beneath the magnet should be made of rubber, polyethylene or other
nonmagnetic material.
15.25 Tramp metal detectors
Tramp metal detectors should be installed on belt conveyors as indicated in the flowsheet
and layout drawings, to detect tramp metal on the moving material, mark its location, trigger
an alarm and stop the conveyor. The tramp metal is either picked up manually or with the
use of a magnet to prevent it from going into and damaging the equipment downstream.

ABN: 98 096 016 849
No metal decking, cross bracing or return idlers should be installed between and below
carrying idlers adjacent to the receiver antenna.
Idlers adjacent to metal detectors should be of the rubber impact type.
16 FEEDERS
16.1 General
Plugged-chute alarms should be provided to prevent damage to feeder parts and drive.
Variable-speed drives should be considered for control of feed rates.
Feeder speed should be kept below 0.25 m/s to minimise component wear.
16.2 Feed Openings Under Hoppers or Stockpiles
Draw-down holes should be as large as possible, with chute or rockbox configurations

designed to minimize direct static load on the feeder.
No feed slot over a feeder should be less than two and one-half times the maximum lump
size except that for run-of-mine ore the width of the opening may be twice the maximum
lump size.
Edges should be protected by wear bars and where necessary, provision made for blocking
off the opening with spile bars, timber or a gate.
When loading a belt a tapered reclaim slot (increasing in width) with a self-relieving incline
in the direction of feeder travel should be provided.
16.3 Feeder Loads
The design static loading should be determined by the feeder designer, and should
consider stockpile and feeder geometry, and ore characteristics.
16.4 Apron Feeders
Apron and pan feeders should generally be installed horizontally except where design
considerations dictate an incline.
To prevent cascading when the feeder is stopped, the headshaft centerline (projected up to
the pan line) should be located downstream of the feed opening by 1.5 times the maximum
lump size beyond the toe of the material repose angle.
Feeder skirtboards should be approximately 150mm higher than the material bed depth and
be located to allow at least 50mm or Supplier's recommended clearance within pan flanges
on either side. The skirtboards should be heavily reinforced and provided with liners.
All feeders should have a continuous pull cord connected to limit switches. Switches
should be two direction pull type with no dead end tie-downs. Limit switches should be
provided on both sides of feeders.

ABN: 98 096 016 849
The discharge chute, heavily reinforced and lined, should have a cross-section at least 1.5
times that of the material bed on the feeder. A dribble conveyor or dribble chute should be
provided to direct fines to subsequent equipment.
16.5 Belt Feeders
The design requirements for feed slot, feeder length, skirts and discharge chutes as
described for apron feeders should be observed for belt feeders.
The belt for slot-fed belt feeders should be wide enough to prevent spillage without using
skirts, and be supported on impact beds beneath feed slot.
16.6 Vibrating Feeders
The skirts should be tapered away from bottom of feeder for a future increase or decrease
of feeder slope from normal position of 6 degrees.
Skirts and discharge chute should be reinforced and protected by liners.
When equipped with a grizzly section, the fingers should consist of manganese bars, self
relieving in direction of flow.
A minimum 50mm clearance between the vibrating frame and all discharge chutes or
hoppers should be maintained.
17 SCREW CONVEYORS
Design capacity should be based on 45 percent loading of trough cross-sectional area for
non-abrasive material, 30 percent for moderately abrasive material and 15 percent for
highly abrasive material. The latter requires hard-surfaced flights or abrasion resistant
alloys.
Modifications of the basic helical screw should be used to supplement conveying with other
desired treatment of the load in transit, e.g.: either notched flights or paddles for a moderate
mixing action, notched and folded flights for agitation and aeration, tapering flights for fri-
able lumpy material or to draw material uniformly from the entire length of the hopper
opening, long pitch flights for rapid conveying of free flowing material, or double-flight short-
pitch screws to deter flushing of very fluid material. Wherever possible, intermediate
bearings should be avoided.
18 TRANSFER CHUTES, HOPPERS AND BINS
18.1 DESIGN AND CONSTRUCTION
Steel chutes, hoppers and bins should be welded construction with bolted connections for
installation and loose flanges where necessary for field fitting and adjustment.
Material should be mild steel plate of a minimum thickness of 6mm. Connecting bolts
should be M16 diameter min. unless otherwise specified

ABN: 98 096 016 849
Chute design and dimensions should be based on the material trajectories. The calculation
should take into account, material size distribution, maximum lump dimension, adhesion
between the crushed ore and the conveyor belting, and air resistance to material flow. The
outer limit of the trajectory path should follow that of the largest size lump to ensure that
material does not impact on the unprotected faces of the head box or the chute.
Head chutes should be designed to withstand impact and wear without deformation or
failure of structural steel members or platework.
Head chutes should completely enclose the head pulleys, snub pulleys, and belt scrapers.
Chutes should be designed to collect and shed all carryover and fines dropping from the
head pulley, snub pulley, and the belt, and deposit it onto the receiving belt.
Head chutes should be designed so that there should be no leakage or spillage of the
conveyed material.
Chutes should be designed to load material centrally on the receiving belt.
The first point of impact of ore on the receiving belt should be midway between two impact
idlers.
Chutes should be designed for the freeflow of material without arching, ratholing, bridging,
plugging, or otherwise constricting the flow of material.
Chutes should be designed so that material impacts and flows on areas protected by liner
plates, rock boxes, heavy chains, or grizzly bars only.
Chutes should be designed so that the ore trajectory on leaving the head pulley strikes the
material contained in the rock box.
Chutes should be self supporting for a fully plugged condition. Chutes and the support
structure should be designed to support the weight of the chute with liners, attachments,
and the weight of ore equal to that of the plugged chute volume. The chute and support
structure design should also take into account impact loading.
Minimum chute angles should be as follows:

• Minimum sliding angle TBAo
• Minimum valley angle 55o
• Minimum dynamic angle of repose for rock boxes TBAo
Provide all areas of the chute subject to wear with 500 BHN abrasive resistant liners of the
following thickness: For chutes handling crushed ore use 20mm thick and for chutes
handling pebbled ore use 12mm thick. Design liner plates for easy replacement. Install
liners on the inside of the chute with counter sunk bolts and make them in sections with a
maximum weight per liner of 30kg.
Minimum inside widths of head chutes should be not less than pulley width plus 100mm.
Chutes should be provided with inspection doors. Inspection doors should be mounted on
fabricated hinges and fitted with latches and dust-tight gaskets.
Chutes should be equipped with rubber dust curtains at the chute entrance.

ABN: 98 096 016 849
Chutes should have flanged joints to facilitate installation, and maintenance of all conveyor
equipment and plate work with minimum disturbance to surrounding equipment, structures,
and plate work.
Each chute should be fitted with plugged chute detector.
18.2 Linings and Wear Bars
In general, 500 Brinell hard steel plate with a minimum thickness of 12mm should be used,
but other materials such as dual-layer composite metal carbide plate (e.g. Duaplate),
rubber, ceramic, or UHMW polyethylene lining material may be used in specific
applications.
Ease of replacement of liners should be considered in high wear areas.
In general, hard steel wear bars should be used in applications involving run of mine or
coarse crushed rock.
Bolted liners should be fastened with M16 or M20 countersunk flat head bolts, except non-
impact steel wear plate (linings) may be welded.
Weight of any wear plate (liner) to be handled manually should not exceed 30kg and should
have a minimum of four bolt holes. Liners weighing less than 15kg should have at least two
bolt holes.
Consideration should be given to providing lined chutes with at least one side bolted for
removal and access to liners.
19 CRANES AND HOISTS
Cranes and hoists should comply with the relevant Romanian and European codes and
regulations.
Cranes and hoists lifting capacity should be sized to suit the heaviest component of the
equipment they service for maintenance purposes.
The safe working load of the cranes and hoists should be clearly displayed on both sides of
the hook blocks and crane girders.
All like parts should be interchangeable, where possible.
Electric overhead travelling cranes should be supplied with hoist overload protection and
impact absorbing bumpers.
Electric overhead travelling cranes should include, but not limited to the following major
components:
• Wire rope type hoists.
• Trolley, as required.
• Bridge and full length service platform for all cranes.
• Brake system.

ABN: 98 096 016 849
• Main conductor bar system for all cranes.

• Festoon cable cross conductor system for hoists and cranes.
• Bridge mounted crane lighting system.
• Pendant control system.
• Control panel.
• Fused disconnect and main line contactor.
• Bridge and trolley travel limit switches.
Service hoists should be motorized for lifts of over 3m; trolleys may be hand-operated for
short runs or occasional usage. Monorail beams equipped with trolleys for use with
portable hoists, should be supplied where suitable.
Provision should be made for access to all cranes and hoists. Particular attention should
be given to access to overhead travelling crane bridge, for maintenance and repair work, for
the full range of longitudinal crane travel.
20 ROCKBREAKER
A rock breaker should service the dump hopper. The rock breaker should be capable of
reaching all corners of the dump hopper, breaking oversized pieces of rock and driving
them through the gyratory crusher opening, without the help of any other tool or
mechanism.
The rock breaker horizontal coverage should be 180-degree as a minimum.
The rock breaker should be mounted on one edge of the dump hopper situated over the
gyratory crusher. The design of the foundation of the rock breaker should ensure that loads
are transmitted directly to ground and not to adjacent structures.
A hydraulic power unit should be provided common to the rock breaker and the wood
picker.
21 WOOD PICKER
A wood picker should also service the dump hopper. The wood picker should be capable of
reaching all corners of the dump hopper and picking up waste wood and lumber that comes
with the ore.
The wood picker should have a hydraulically operated boom and grapple and should be
powered by the hydraulic power unit common to the rock breaker and the woodpicker.
22 FLUID HANDLING
22.1 Sumps
Sumps refers to in ground storage applicable to sump pumps.

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Process sumps should be sized for the larger of;

a) Minimum of one (1) minute of retention capacity based upon the maximum design pump
flowrate, or
b) To contain the total volume of process fluid returning to the sump, following a pump
stoppage.
The design of sumps should aim for a minimum freeboard of 300 mm above the maximum
overflow level.
Process sumps may be constructed of concrete or carbon steel. Where required, sumps
should be suitably lined to protect against corrosive and / or abrasive fluids.
Process sumps should be designed with the maximum possible specific gravity of the slurry
in a sanded condition.
22.2 Tanks
22.2.1 General
The live capacity of vertical cylinder tanks should be calculated from the bottom of the
overflow weir or nozzle to the minimum level required to submerge the discharge line for
gravity or pumped flow without vortexing at the outlet nozzle.
Tankage should be designed with the maximum possible specific gravity of the contained
solution but in no case less than 1.0.
The design of tanks should aim for a minimum freeboard of 300 mm above the maximum
overflow level.
Tankage design should take into consideration the magnitude and direction of external
loads and restraints.
Steel tanks should be designed and fabricated in accordance with European standard ENV
1993-4-3, STAS 1606-73, API 650 or other appropriate standard, and comply with
Romanian statutory requirements.
GRP tanks should be designed and fabricated in accordance with the requirements of BS
or other appropriate European standard which meets Romanian statutory requirements and
structural needs for the application.
GRP and plastic tank agitators should be supported from steelwork above the tanks, thus
limiting the static and dynamic loads on the tanks.
Where it is essential that shop fabricated tanks be accurately installed with vertical walls,
tanks should be supported by ring beams around the full circumference of the tank. This
will facilitate site installation by use of wedges and packers.
Hold-down bolt hole arrangement should ensure that holes are appropriately oversized /
slotted to account for hold-down bolt location tolerances.
Man-way and access hatches should be incorporated into all tank designs in order to
facilitate maintenance and inspection functions.

ABN: 98 096 016 849
Slurry tanks should have clean out doors at floor level. Tank overflows should be piped to
approx 300 mm above ground. Ends of the overflow pipes should have 45o elbow pointing
in the direction of the sump or floor slope and directed to the nearest sump.
Overflow pipes should ensure the discharge clears the tank foundation to avoid splashing.
Unlined tanks and pump boxes should have a minimum of 2 mm corrosion / abrasion
allowance added on the wetted surfaces.
Tank pipe connection flanges should be per SR ISO 1092, flat faced, or should be
compatible with SR ISO 1092 flat face flanges. Flange rating should be PN10.
22.2.2 Tank Shop Fabrication Versus Field Fabrication Criteria
The size of shop fabricated tanks will be dependent on transportation limits. Refer to
Appendix 1, Transport Envelope, which gives guidelines for size restrictions for transport of
equipment to site.
Shop fabricated tanks should fit within an envelope of 4.5 m high (from road level to top of
highest point of tank on truck / trailer) x 4.5 m wide. The maximum practical transport length
is 30m (from front of truck to back of load), however, length of tank pre-assemblies should
be kept below 12m wherever possible.
Tanks not able to fit within this envelope should be field erected.
Shop fabricated tanks should be fully tested prior to shipment.
22.2.3 Agitated Slurry Tanks
Tankage should be designed with the maximum possible specific gravity of the slurry in an
unsuspended or bogged condition.
Where necessary, tanks should employ a steady ring fitted to the bottom of the tank to
prevent radial deflection when running with the bottom impeller unsubmerged.
Concentrate storage tanks should be lined with 6 mm thick rubber on the sides and 20 mm
thick rubber on the bottom.
22.3 Launders
22.3.1 General
Intertank launders should be of open launder design.
Pipes should be used in the following applications:

• cyclone overflow
• cyclone underflow
• steep slopes or changes in direction where splashing or spillage may occur
• tank overflows

ABN: 98 096 016 849
Open launders may be with rectangular or rounded bottom. Rectangular launders are
preferred for course materials and round launders for fine materials.
Open launders should be designed so that the level of slurry does not exceed 25 percent of
the overall launder depth at normal operating conditions or 50 percent at maximum flow
conditions.
Closed launders should be designed so that the level of slurry does not exceed 50 percent
of the pipe diameter at normal operating conditions or 65 percent at maximum flow
conditions.
Launder sizes and slopes should ensure the prevention of sanding / deposition conditions
in the launder.
22.3.2 Junction Boxes and Distributors
Junction boxes with step-downs should be used in preference to 90 degree direction

changes in open launders.
Junction boxes should be sized with enough volume to absorb and dissipate excessive
kinetic energy in the entering streams while maintaining the slurry solids in suspension.
Freeboard above maximum flow condition should be a minimum of 300mm.
A distributor may be used where it is necessary to divide a process slurry stream into two or
more streams of specified proportions having the same solids concentration, sizing and
composition as the original stream.
22.4 Centrifugal Pumps
22.4.1 Pump Duty

Refer to Piping Design Criteria section on Pump Duty Selection regarding
recommendations for pump duty requirements. In addition, the following requirements for
calculation and specification of pump flow-rates and heads should apply:
• Normal (nominal) operating duty, maximum duty and minimum duty flow-rates, as
applicable, will be nominated by the process engineer and / or specified on the process
drawings. The responsible engineer should ensure that seal flow, as applicable, is
accounted for in the specified flow-rates.
• The responsible engineer should calculate and specify the required pump heads for the
flow-rates nominated.
• For fixed speed sump pumps and pumps emptying tanks, where pump flow-rate is a
function of sump / tank level, the responsible engineer should nominate a nominal flow-
rate and pump discharge head duty based on an average pump sump / tank level. The
minimum and maximum flow-rates will be a function of the sump / tank minimum and
maximum levels, respectively. The responsible engineer will need to ensure that the
pump and motor selection meets NPSHA and power limitations (at minimum sump / tank
level) and that ‘run-out’ does not occur with slump/tank at maximum level. Where
required, it may be more appropriate to revise the discharge pipe design to restrict flow-
rate rather that select another pump if initial design results in run-out conditions.

ABN: 98 096 016 849
The maximum power absorbed by the pump (for new pump condition) should be
established over the full range of pump operation, based on design impeller diameter,
including the maximum flow condition.
22.4.2 Basis for Pump Selection

Refer to Piping Design Criteria section on Pump Duty Selection regarding
recommendations for pump selection requirements. In addition, pumps should be selected
on the following basis:
• The pumps should be selected from the Supplier’s standard range.

• The pump characteristics should exhibit decreasing head with increasing flow, with a
maximum head at shut-off.
• Pump design should ensure stable flow / avoid occurrence of run-out (cavitation) at
maximum flow conditions. Pumps should therefore be capable of delivering at least 10 %
more flow than the specified maximum flow-rate.
• Casing design pressure should be greater than the sum of maximum suction pressure
and differential pressure at shut off, with maximum sized impeller.
• Pump NPSHR should be < NPSHA - (20% NPSHA or 1 metre, whichever is the lesser),
under all operating conditions
• Pumps should operate as close as possible to, and preferably to the left of, the best
efficiency point (BEP), under normal duty.
• Pump minimum allowable flow-rate should be at least 10% less than specified minimum
flow condition.
• Pump materials should be selected to suit the fluids being handled with particular regards
to corrosion, abrasion and temperature.
• Aluminium, zinc and copper base alloys should not be used on any wetted parts, nor
should materials containing asbestos be used on any part of the pump assembly.
• Fixed speed pump impeller diameters should be no larger than 90% of the maximum
size impellers designed for the pump casings. [This will enable larger impellers to be
installed should operating conditions require increased flow-rates.]
• Variable speed pump impeller diameters should be the maximum size impellers
designed for the pump casings.
• Impeller diameter should not be less than the minimum diameter shown on the
manufacturer’s published curves.
• The pump shaft and impeller should be balanced, and critical speed should not occur
within the operating speed range of the pump.
• Pump connections to Buyer’s pipework should have DIN standard flanges, otherwise
suitable mating flanges will need to be supplied for field match-ups.
• Variable speed pumps should be directly coupled to motors via mechanical couplings,
except where belt drive arrangements are more suitable / economical.
• Direct drive couplings should be flexible, non-lubricated type, where available. For motor
sizes 45 kW and below, couplings may be elastomeric type. It is intended that the make /
model of couplings will be rationalised across the plant, and therefore the supplier will
have to provide the selected make / model of couplings.

ABN: 98 096 016 849
• For direct drive, back-pullout pump arrangement, couplings should be spacer type.
• Where mechanical seals are used, the supplier of the mechanical seals must have
considerable experience with the type of fluid being pumped and should recommend the
type of mechanical seals.
• Pumps with mechanical seals should be provided with a protective splash and shaft
guard that covers the open areas between the bearing housing and the casing. The
guard should deflect fluid spray from malfunctioning seals to protect personnel and
rotating parts.
22.4.3 Basis for Motor Selection
Rated capacity of motor should be greater than maximum power required for the pump-set,
under all operating conditions.
22.4.4 Centrifugal Slurry Pump Features
The following features should be incorporated:

• Pumps should be of horizontal arrangement, complete with drivers on common base-
frames.
• For V-belt driven slurry pumps, motor arrangements should be as follows:
For motors < 55kw : CV or ZV arrangement
For motors > 55kw up to 150kw : ZV arrangement
For motors > 150kw up to 350kw : Preferably direct coupled, but side by
side is suitable
For motor sizes > 350kw : Pumps should be direct coupled to

motor on coupled via gearbox
• External adjustment of impeller clearance, for wear, should be provided. The shaft and
bearing assembly should be able to be axially moved to adjust the impeller clearance
without having to adjust the individual bearings.
• Shafts should be rigid, heavy duty with short overhang to limit deflection and minimise
vibration. Where mechanical seals are to be fitted, to obtain satisfactory mechanical seal
performance, the shaft stiffness should limit the total deflection to a value that the pump
supplier can guarantee pump and seal reliability.
• Impeller tip speeds should be limited to reduce impeller wear, based on industry
accepted limits and good engineering practices. Preference should be given to slurry
pumps operating at less than 1,000 rpm or tip speeds less than 25 m/s.
• Pump design should be such that reverse rotation will not cause impeller or other parts to
loosen.
• Pump casings should be of heavy-duty construction, designed to ensure against cracking
/ breakage failure in the event of excessive pipe loading of suction and discharge
nozzles. Cast iron casings should not be used.

ABN: 98 096 016 849
• Pumps should rotate clockwise viewed from the coupling end (counter clockwise if
viewed from the suction end).
• Pump casings should be suitable for orienting pump discharge nozzles in at least four
positions on small pumps (up to 80 NB suction size) and at least eight discharge
positions on larger pumps (> 80 NB suction size).
• Suction and discharge flange drilling should conform with DIN standard, pressure class
rating to suit the pump design pressure and temperature. The minimum flange rating
should be Class 150. Unless otherwise specified, flange adapters, to match the above
standards, should be provided if pump flanges have other dimensions.
• Where replaceable casing liners are employed, casing design should ensure against the
leakage of pumped fluid after liners have worn through. Liner fasteners should not be
exposed to the pumped fluid.
• Bearing assemblies should be of cartridge design. Grease lubricated bearings should
have taconite seals with grease purged labyrinths and “A” series V-rings fitted onto the
shafts, to protect against the ingress of slurry, dust and moisture. Oil lubricated bearings
should have taconite seals with grease purged labyrinths and back-up double lip seals to
prevent grease entry into housings.
• Pump shafts should have replaceable shaft sleeves at the pump glands. Shaft sleeves at
impeller end should be sealed to prevent leakage and stress corrosion of shafts.
• Stuffing boxes should be capable of accepting both compression packing and
mechanical seals.
• Where mechanical seals are employed, they should be of cartridge design, selected by
the seal manufacturer for the particular slurry application. Where the leakage of slurry
presents a safety hazard, double-mechanical seals should be used.
• Packed pumps should be furnished with alloy shaft sleeves with a minimum hardness of
450 BHN. Sleeves should have corrosion resistance equal to or greater than pump
wetted parts. Packed pumps should be furnished with lantern rings that should be
arranged for minimum gland seal water usage. Packing should be die-formed type
rather than of braided rope. Packing glands should be split arrangement for ease of
maintenance.
• Where employed, cooling passages and jackets for stuffing boxes, bearings and
pedestals should have a minimum design pressure of 600 kPag.
22.4.5 Centrifugal Liquor and Process Water Pump Features

a) Chemical and Fuel Pumps
Chemical and fuel pumps should be end suction type to ANSI B73.1M.
b) Water and Solution Pumps
Wherever possible, water pumps should be double entry suction arrangement to the
manufacturer’s standard, otherwise pumps should be end suction type.
Solution pumps should be end suction type.
End suction water and solution pumps should be to ISO 2858.
Water pumps should be supplied with vents (unless pumps are self venting) and
drain connection.

ABN: 98 096 016 849
c) Common Features
The following features should be incorporated into centrifugal liquor, solution and
water pumps:
• 2 pole motors should not be used, except for special duty and high pressure (low
flow) duty pumps, such as multi-stage booster pumps and gland water supply
pumps.
• Means for external adjustment of impeller clearance, for wear.
• Impeller balance should be in accordance with ISO 1940 G6.3 minimum.
• Cartridge type mechanical seals for water pumps.
• For liquor pumps, cartridge type mechanical seals. Where the leakage of liquor
presents a safety hazard, double-mechanical seals or magnetic drives should be
used.
• Bearings should be oil lubricated and supplied with a guarded bottle oiler.
• Replaceable shaft sleeves should be supplied for all pumps.
• All casing openings (e.g. vents drains, etc.) should be plugged with non-galling
materials with corrosion resistance equal to or greater than the casing.
22.4.6 Vertical Centrifugal Sump Pump Features

The following features should be incorporated:
• Sump pumps should be vertical cantilevered shaft design, complete with motor and drive
system.
• Sump pumps should be able to handle froth, and be able to run dry and operate in
“snore” (low to empty sump) conditions, and reprime with not more than 100 mm rise in
sump level.
• Inlet strainer should be incorporated on the pump, to prevent larger particles from
clogging the impeller.
• Pump bearings should be grease lubricated and have grease purged seals to prevent the
ingress of fluid in the event of submergence of the pump.
22.5 Agitators
The agitator / tank design, both by way of geometry and agitation intensity, should be
capable of resuspending solids settled from a full tank during a shutdown of up to 24 hours
duration. The re-suspension, to the point where the size of the bottom corner fillets does
not exceed 15% of the tank diameter, should be accomplished within 15 hours of impeller
rotation being able to start.
Agitators in tanks containing slurry should be top mounted.
Preference should be given to agitator shafts that are removable from the drive system
without disassembly of the gear casing or bearing pedestal shaft.
Impeller assemblies or blades should be removable from the agitator shaft and, when
impeller diameter exceeds 1.5 m, individual blades should be removable.

ABN: 98 096 016 849
The design of agitator shaft and impeller assemblies should ensure that the assemblies are
not subjected to critical speeds and that deflections are kept to within acceptable limits.
Impellers and shafts should be coated, or be of suitable materials, to protect against

abrasion and corrosion.
23 PRESSURE VESSELS
23.1 General
Pressure vessels must comply with Romanian statutory requirements and the
requirements of the Pressure Equipment Directive 97/23/EC. Appropriate European
pressure vessel codes that should be referred to include EN 13445 Parts 1 to 6 (- part 3 for
design of pressure vessels).
Material selection should take consideration of the internal media (corrosion and abrasion)
and external environment (corrosion) and economics. For example, selection of rubber
lined carbon steel versus stainless steel.
Vessels with vertical shells should be supported by ring beams around the full
circumference of the vessel. This will facilitate site installation by use of wedges and
packers.
Hold-down bolt hole arrangement should ensure that holes are appropriately oversized /
slotted to account for hold-down bolt location tolerances.
23.2 Corrosion Allowances
The following corrosion allowances should apply:

• For unlined carbon steel vessels, subjected to non-corrosive / non-abrasive internal
media, painted externally: Allow 0 mm for internal corrosion.
• For carbon steel vessels, internally protected with suitable paint system, subjected to
mildly corrosive / non-abrasive internal media, painted externally: Allow 3 mm for
internal corrosion.
• For carbon steel vessels, internally protected with lining system suitable to protect
against corrosive / non-abrasive internal media, painted externally: Allow 1 mm for
internal corrosion.
• For carbon steel vessels, internally protected with lining system suitable to protect
against corrosive / abrasive internal media, painted externally: Allow 6 mm for
internal corrosion and abrasion.
• For carbon steel vessels, externally painted, in a non-corrosive atmospheric
environment: Allow 1 mm for external corrosion.
• For carbon steel vessel, externally painted, in a corrosive atmospheric environment,
e.g. where there are corrosive vapours present: Allow 2 mm for external corrosion.
• For vessels manufactured of corrosion resistant materials (e.g. stainless steel, FRP),
with non-abrasive internal media: Allow 0 mm for external corrosion, 0 mm for
internal corrosion.

ABN: 98 096 016 849
24 FLOCCULANT PREPARATION
Dry flocculant should be supplied in (about 25kg) bags for make-up into dilute aged
flocculant solution by an automatic package system, including metering pumps and post
dilution.
25 LIME SLAKING
Quicklime should be supplied in bulk truck delivery. The lime slaking should be done in an
automatic package system.
26 FANS, BLOWERS AND COMPRESSED AIR EQUIPMENT
26.1 General
General purpose compressed air and instrument air will be provided by separate systems.
26.2 General Purpose Compressed Air Systems
A detailed plantwide air demand investigation of all known, as well as anticipated air users
will need to be performed in order to establish the necessary plant compressed air system
capacity.
The air system will be designed to provide between 800 kPag at the compressor discharge
and 600 kPag air at the furthest point from the compressor while supplying air for as many
tools and equipment which may be in use at any one time. The main air supply line should
be sized to carry the average air demand of all users with a pressure drop through the main
(including all fittings) not exceeding 20 kPa. Branch lines from the main should be sized to
carry the maximum air demand of the number of outlets in use at any one time for a
particular branch line with a pressure drop through the branch lines not exceeding 20 kPa.
Feeder lines from the branch lines should be sized to carry the maximum air demand for as
many tools which may be connected at any one time with a pressure drop through the
feeder lines not exceeding 10 kPa.
Branch lines should be taken from the top of the mains and the feeder lines should be taken
from the top of the branch lines. The mains and branches should be sloped toward low
points. All low points should be drained with drip legs using automatic moisture traps,
insulated and heat traced.
26.3 Instrument Air Systems
The air system will be designed to provide between 600 kPag at the compressor discharge
to 500 kPag air at the furthest point from the compressor. The main air supply line will be
sized to carry the average air demand of equipment with a pressure drop through the main
(including all fittings) not exceeding 20 kPa. Branch lines from the main will be sized to
carry the maximum air demand of the number of outlets in use at any one time for a
particular branch line with a pressure drop through the branch lines not exceeding 20 kPa.
Feeder lines from the branch lines will be sized to carry the maximum air demand for
equipment which are connected with a pressure drop through the feeder lines not
exceeding 10 kPa.

ABN: 98 096 016 849
Branch lines will be taken from the top of the mains and the feeder lines will be taken from
the top of the branch lines. The mains and branches will be sloped toward low points. All
low points will be drained with drip legs using automatic moisture traps, insulated and heat
treated, if outdoors.
26.4 Air Blowers
Process air should be provided by positive displacement blowers. The blowers should be
fitted with a noise attenuation hoods, and be located inside a dedicated room to further
attenuate noise from the process building.
26.5 Air Compressors
General purpose air compressors should be centrifugal type or oil-free rotary screw type air
compressors. There should be one / two operating (whichever is the more economical
arrangement) compressors and one (identical) stand-by compressor.
Instrument air compressors should be heavy-duty, packaged oil-free, rotary screw type air
compressors. There should be one / two operating and one stand-by compressor.
Air compressors should be supplied as complete pre-assembled packages, with the

following features:
• Compressor motors should be sized for operating conditions described in the
specification.
• Suitable drive, necessary couplings and coupling guards.
• Integral base plate for compressor, inter-cooler, after-cooler, lubrication and motor.
• Inter-cooler between stages and after-cooler, complete with moisture separation
facilities and traps to allow efficient removal of condensate.
• Inter-coolers and after-coolers should be designed for maximum discharge ambient
air temperature (as specified).
• Air compressor discharge by-pass lines should also pass through an after-cooler.
• Inlet air filter and silencer.
• Sound attenuating enclosure.
• Pressure relief valves.
• Dry contacts for status & alarms to plant control system.
• Blow-off silencer mounted on blow-off valve for installation remote from air
compressor and outdoors.
• Flexible connection / expansion joints for air compressor discharge piping.
• Instrumentation and controls.
• Compressor control panel, complete with motor starters, stop / start controls and
protective devices.
• Main incoming disconnect switch or breaker.

ABN: 98 096 016 849
26.6 Instrument Air Dryer
Dryer should be heatless, regenerative type, with twin towers, one regenerating while the
other is on drying cycle. Shifting operation should be carefully programmed to assure
correct pressurization and prevent bad disturbance and desiccant attrition at any stage of
the change-over.
The air dryer package should be pre-assembled and should include the following:
• Twin tower with desiccant.
• Safety relief valves.
• Switch over valves, purge valves, purge flow indicator.
• Common base for total package.
A stainless steel screen should be provided to prevent desiccant from blowing into the lines.
All valves should be non-lubricated.
Dryer operation should be fully automatic on a timer cycle. The following instrumentation
and controls are required:
• Pressure gauge on each tower.
• Pressure relief valve on each tower.
• Purge meter.
• Hydrometer control.
• Switching failure alarm contact.
• Loss of power alarm contacts.
• Indicating lights for power on/off.
• Dry contacts for communication with plant control system.
26.7 Air Receivers
Separate air receivers should be provided for each of the Plant and Instrument Air systems.
Air receivers should be of carbon steel, welded construction and should be supplied
complete with:
• Pressure gauge.
• Safety Relief valve.
• Automatic condensate drain line with manual shut-off valve, insulated and heat traced
if outdoors.
• Manual drain valve and drain line, insulated and heat traced if outdoors.

ABN: 98 096 016 849
27 DUST CONTROL EQUIPMENT
27.1 General
Dust control systems will be installed at points where dust is generated and it is practical to
control the emissions to meet local Romanian emission requirements.
Where it is necessary to return the dust product to the process, dry dust collection systems
will be employed.
Where it is not necessary to return the dust product to the process, wet dust collection /
scrubbing systems should be used where possible. The waste product will be appropriately
disposed of or recycled back into the process.
27.2 Dry Dust Collection Equipment
27.2.1 Dust Collectors
Dust Collector(s) should be of bag pulse jet cleaning type with access to clean air plenum
for bags removal. Hopper should be designed for 640mm water column negative pressure
and hopper full of dust. Housing should be designed for 640mm water column negative
pressure.
27.2.2 Rotary Air Locks
Rotary Air-lock should be of plate fabricated construction and be supplied with outboard
bearings, speed reducers and chain sprocket or V-belt drives. Rotor should be supplied
with six (6) blades minimum and be supplied with adjustable wipers.
27.2.3 Screw Conveyors
Screw Conveyor should be of plate fabricated construction and be supplied with outboard
bearings, speed reducers and chain-sprocket or V-belt drives.
Motor should be sized to start with Dust Collector hopper full of dust. Common drive
arrangement should be used for screw conveyor / rotary airlock combination.
27.2.4 Exhaust Fans
Exhaust Fan should be of Industrial Centrifugal type with V-belt drive arrangement and
common support frame/base for Motor/Fan mounting complete with vibration isolators.
Fan motor should be sized for ‘cold’ start with Damper in open position and minimum 25%
above the fan brake kW.
27.2.5 Ductwork
Ductwork should be designed for minimum turbulence, minimum friction loss and minimum
wear.
Supports should be designed and spaced so that sagging does not occur, allowing for a
normal dust load, or 10% fill with water and should be structurally adequate allowing for a
dust filled plugged duct.

ABN: 98 096 016 849
After erection of ducting and the installation of dust extraction units, the complete system
should be tested, balanced and blast gates locked or tack-welded in place.
For non-corrosive applications, ducting should be manufactured from carbon steel.

Minimum wall thickness of ducting should be 3 mm.
Ducts in corrosive service should be FRP (fiber-reinforced plastic) or stainless steel.
Ducts handling hot off-gases should be constructed of materials suited to their individual
conditions of temperature, corrosion and abrasion.
Temperature of gases in unlined carbon steel ducts should be kept above the dew point to
preclude corrosion of the ducts.
Ducting flanges should be of a suitable thickness for the diameter but should not be less
than 3mm.
Flanged connections should be complete with matching gaskets made from material
suitable for the needs of the process.
Ducting should be designed to allow access for wash down and draining of ducts.
Systems should be designed to balance with no dampening, if possible, or a minimum of

damper throttling.
Natural rubber lining should be employed, where there is likelihood of abrasion of elbows
and other areas, where gas temperatures do not exceed 60o C. Minimum thickness of
rubber should be 6 mm, where required.
27.2.6 Dampers and Gates
Dust control systems should be designed to balance within 10 percent without blast gates.
If blast gates are necessary they should incorporate polyurethane, UHMW polyethylene or
ceramic wear protection. Butterfly dampers should not be used.
Louver dampers of the opposing blade type should be employed for clean air stream
modulation applications.
27.2.7 Expansion Joints
Systems operating at other than ambient temperatures should be analyzed for expansion-
contraction requirements. Expansion joints should be located so that compound movement
is minimized.
Expansion joints should be installed between fans and ductwork.
27.2.8 Fans
When calculating power requirements for fans, temperature and elevation variations must
be considered.
Power requirements should be calculated for the lowest temperature expected.

ABN: 98 096 016 849
28 NOISE CONTROL
Noise level should be considered when selecting and arranging equipment.
Except for crushers and mills, maximum permissible sound power level from equipment,
when operating under normal operating conditions, should be no more than 83 dBA,
measured one metre from the source of noise, in accordance with ISO 7574. This should
include adjacent equipment.
29 VIBRATION CONTROL
In cases where rotating machinery must be located on structural steel supports, care should
be taken to isolate equipment vibrations from piping, ducting, or other resonating material.
Isolation mounts and/or flexible joints should be used.
30 SAFETY FEATURES
30.1 Safety Signage
Signs will need to be provided to alert all personnel of the need for protective clothing such
as steel cap boots, hard hats, safety glasses, etc.
Signs will need to be provided where a specific hazard exists, such as live conductors, high
noise levels, low head clearance, trip hazard, traffic hazard, acid spillage, hot surfaces,
nuclear source etc.
30.2 Safety Guards and Guard Rails
Equipment should be provided with suitable guards in accordance with Romanian

requirements for guarding of machinery.
Guards for components which are subject to splashing / loss of lubricant or oil, such as
chain drives and fluid couplings, respectively, should be of fully enclosed sheet metal
construction to prevent the spillage of lubricant / oil. Such guards should include be
adequately sealed to prevent the ingress of airborne contaminants and should include
provision for drainage.
Guards for components which require lubrication without removal of guard, such as for
chain drives, should incorporate such provisions as required. For example, a chain drive
may require a connection for drip feed lubrication of chain and a small inspection hatch for
manual lubrication of chain by oil can.
One piece guards should be fabricated from perforated plate material. Such guards should
be painted safety yellow.
Mesh guards should have a skeletal frame fabricated from either angle or tubular members.
All edges of the mesh should be attached to this frame. Such guards should have a mesh
aperture size not more than 30 mm. Guards should be painted black (for ease of visibility
through guards) with yellow (safety) bands.

ABN: 98 096 016 849
Safety guards should be provided to enclose all rotating and moving parts. Safety guard
design should incorporate the following requirements:
• Guards should be securely fixed in position and, for the purpose of maintenance, be
capable of removal and replacement, without dismantling any other part, while the
machine is at rest and isolated.
• Guards, other than those designed to contain lubricant / oil spillage, should be designed
to provide clear visibility to components within the guard.
• Ease of removal of the entire guard using normal maintenance tools.
• Lubrication of enclosed parts without dismantling or removal.
• Where it is intended for guards to be removed without the assistance of overhead hoists,
mobile cranes or lifting devices, guards / sections of guards should not exceed 20 kg in
weight.
• Each section of guard to be man handled or lifted, should include lifting lug or provision
for safe lifting with eye bolt.
• Adjustment of distance between shaft centres on pulley drives, and provide for obtaining
tachometer readings on each shaft without removing guards.
• Human traffic: Where it possible that maintenance personnel may stand on the guard
during maintenance shut-downs, machinery guards will need to be designed to cope with
the weight of at least one person (150 kg), without permanent deformation.
Fencing of machinery areas may be provided in lieu of individual guarding, but only when
such machinery operates as a single unit and access to the area is provided with a lock-up
gate
30.3 Hazardous Materials
The following materials should not be used:

• Asbestos and compounds thereof.
• Poly-Chlorinated Bi-phenyl (PCB’s) and compounds thereof.
• Chloro-fluorocarbons (CFC’s) and compounds thereof.
The following materials should not be used without specific approval:

• Ceramic fibres.
• Radioactive materials unless as part of instrumentation system.
30.4 Chemical Storage
Chemicals reagents will be delivered to site by road either in disposable containers or in

bulk tankers. Chemical storage on site is to take cognisance of the following:
• The chemical inventory system is to adequately address and categorise hazardous
materials into incompatible groups (oxidising agents, flammable substances, explosive
substances, strong acids, etc.).
• Hazardous areas will be classified and have sufficient area to segregate incompatible,
hazardous materials and to avoid overlap of these areas.

ABN: 98 096 016 849
• Sufficient area must be designated for the safe storage of hazardous substances at low
flash points and/or of an explosive nature.
• The designated plots for containing hazardous substances will be sited on impervious
ground with adequate drainage slopes and bunds, and these bunds must be sufficient to
contain a maximum volume of spillage from a hazardous chemical vessel.
• Provision of safety showers/eye wash stations as required.
30.5 Eye Washes And Safety Showers
Eye wash units and safety showers should be located at convenient locations. Safety
showers will be supplied with eye wash units as combined units. However, eye wash units
may be supplied without safety showers. Where installed above ground level, containment
of wash/shower water will need to be considered.
31 UTILITY STATIONS
Utility stations include compressed air service outlets and wash-down outlets.
Compressed air outlets, for connection of air powered tools and other air operated
equipment, should comprise a 25 NB Minsup fittings and 25 NB ball valve.
Wash-down outlets should comprise Camlock fittings and ball valves as follows:
• 50 NB outlets for ground level and bunded areas (e.g. on concrete floors, above
ground level) where regular cleaning is necessary.
• 25 NB outlets in other areas requiring wash-down outlets e.g. head-end of conveyors
where cleaning of blocked chutes is required.
32 PLANT LAYOUT
32.1 Clearances And Accessibility
The design should allow for maximum accessibility to moving and wearing parts for
inspection and replacement.
Platforms and walkways should be provided wherever access is required for regular
inspection, lubrication or operation of machinery or equipment.
Stairways will be provided rather than ladders except in cases where space is not available
or usage will be very infrequent.
Where clearance is required from piping, structures and platforms for operating or
maintenance access, the following minimum clearances should be provided where
possible:
a) Overhead Clearance:
Over pumps and drives : 3,000 mm
Over walkways, passageways and

ABN: 98 096 016 849
platforms to nearest obstruction : 2,200 mm
Bobcat Clearance : 2,500 mm
b) Horizontal Clearance:
At driver end of equipment : 1,200mm
At non-driving end of equipment : 1,000mm
In front of manways : 1,000mm
For passageways and elevated

walkways : 750mm
Where occasional access is required: 600mm
Bobcat clean-up access : 2,000mm
Other requirements may be needed for specialised equipment and should be assessed
individually.
32.2 Stairs, Walkways And Ladders
Refer to Structural Design Criteria for the requirements of stairs, walkways and ladders.
33 PACKAGED EQUIPMENT
Self-contained packaged equipment and ancillaries should be supplied as follows:

• Instrumentation, electrical devices and wiring should be factory installed. Wiring and
conduit should be brought to properly identified terminals housed in terminal boxes
suitable for field terminations by others.
• Integral piping systems should be factory installed, and arranged for a minimum number
of field connections by others.
• All components, including equipment, piping, electrics and instrumentation, should be
located for convenient operating and maintenance access.
34 SHOP PRE-ASSEMBLY AND TESTING
Equipment should be factory assembled to the greatest extent practical for handling and
shipping.
Where complete factory assembly and testing is specified and the equipment has to be
disassembled for shipment, sub-assemblies should be checked for fit and match-marked
prior to dis-assembly, for the purpose of ease of re-assembly in the field.
The extent of pre-assembly and works testing should be determined by the Total Installed
Cost (TIC) of the equipment, taking into consideration the costs of shop assembly, transport
and site work necessary to complete the installation and testing. The extent of pre-

ABN: 98 096 016 849
assembly of large assemblies will therefore need to be a matter for agreement between the
Supplier and the Buyer.
In general, the extent of shop assembly will be largely determined by transport size
restrictions. Refer to Overdimensional Transport Matrix and Transport Envelope,
Appendices 1 and 2, respectively, which give guidelines for size restrictions for transport of
equipment to site.
Shop assemblies will need comply with Overdimensional Transport Matrix and Transport
Envelope. In general, for preliminary design purpose, shop assemblies, other than for
specialised large equipment such as mills, should fit within an envelope of 4.5 m high (from
road level to top of highest point of tank on truck / trailer) x 4.5 m wide. The maximum
practical transport length is 30m (from front of truck to back of load).
Assemblies not able to fit within this envelope should be field erected.
Shop assembled equipment should be shop tested prior to shipment.
Electrical equipment and instrumentation should be fully tested and calibrated, as

applicable, prior to shipment.

ABN: 98 096 016 849
APPENDIX 1 - OVERDIMENSIONAL TRANSPORT MATRIX
6 5 0 0 L O A D E D H E IG H T S U B J E C T O F A S T U D Y
ESTIMATED MAXIMUM
5 5 0 0 L O A D E D H E IG H T
ALLOWABLE HEIGHTS
AND WIDTHS WITH SOME
4 5 0 0 L O A D E D H E IG H T
INFRASTRUCTURE SUCH
AS OVERHEAD WIRES,
SIGNAGE AND ROAD
IMPROVEMENT
(WIDENING,
COMPACTION ETC.)
MINIMAL INFRASTRUCTURE PROBLEMS.

I.E. NO ELECTRICAL SUPERVISION REQUIRED.
4500 OVERALL WIDTH

6000 OVERALL WIDTH
SUBJECT TO DETAILED STUDY
From our experience 6m maximum height is achievable from Constanta to Rosia Montana, but
* only with road works, especially railway crossings. Only if the top part of the piece is round.
* Loads of correct
With the over 6mconfiguration
wide are achievable on single
of axles and carriageways
suitable dimensionsbutof are site dependant
the piece (enough length, no
big height), 200t net loads will not encounter major problems till Sebes. Further, a road study nust
* be issued. Even the first part is subject to re-checking by a specialised company.
Electrical overheads are either minor - requiring the lifting of wires up to about 5.5m or major -
* requiring the disconnection or alteration to the transmission lines.
* All movements are subject to weather conditions
Mechanical Design Guide Ausenco International Pty Ltd

ABN: 98 096 016 849
APPENDIX 2 - TRANSPORT ENVELOPE
Pilot Lifting Disconec Avoiding

Route Length (m) Width (m) Height (m) Weight (t) Vehicles Police Over heads wires ting wires bridges
Constanta to >4.0<4.5 No No Permit No No No
Rosia Montana >4.5<4.8 Yes No Permit Yes No No
>4.8<6.0 Yes No Permit Yes Yes Yes
Max 6.5 site and shape of the piece Yes Yes Yes Yes Yes
>2.5<3.2 No No Permit
>3.2<4.5 1 No
>4.5<5 2 No
>5.0 2 1
Max 7.5 wide site dependant and piece shape
<16.5 No No
>16.5<30 No No
>30.0 2 No
>45 Special assessment No
<200t no problem till Sebes. After, suject of study
NOTE:
1 The usual route from Constanta is: Constanta - Slobozia - Bucharest - Pitesti - Sibiu - Alba Iulia - Rosia
2 Due to the relief, a combination of dimensions (big height AND width or length) can reduce the alowed convoy dimensions
Mechanical Design Guide Ausenco International Pty Ltd

ABN: 98 096 016 849

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ROSIA MONTANA GOLD

Specification No. Rev.

A 07/4/04 Issued for Review JV DMcL KB

Mechanical Design Guide

3 CODES AND STANDARDS 1

6 GENERAL DESIGN REQUIREMENTS 4

8.1 Overload Capacities 6

Mechanical Design Guide Contents Page 1 Ausenco International Pty Ltd

12 WIRE ROPE, CHAINS AND FITTINGS 13

15 MATERIALS HANDLING EQUIPMENT 14

15.1 Conveyors - General 14

Mechanical Design Guide Contents Page 2 Ausenco International Pty Ltd

16.2 Feed Openings Under Hoppers or Stockpiles 22

18 TRANSFER CHUTES, HOPPERS AND BINS 23

18.1 DESIGN AND CONSTRUCTION 23

19 CRANES AND HOISTS 25

26 FANS, BLOWERS AND COMPRESSED AIR EQUIPMENT 35

26.5 Air Compressors 36

27 DUST CONTROL EQUIPMENT 38

30.1 Safety Signage 40

32.1 Clearances And Accessibility 42

34 SHOP PRE-ASSEMBLY AND TESTING 43

APPENDIX 1 - OVERDIMENSIONAL TRANSPORT MATRIX

APPENDIX 2 - TRANSPORT ENVELOPE

Mechanical Design Guide Contents Page 4 Ausenco International Pty Ltd

This document is a guide to assist in the production of specifications and mechanical

Imperial units would be acceptable where preferred equipment and machinery is

3 CODES AND STANDARDS

CEN Comite European de Nomalisation

ISO International Standards Organization

DIN Deutsch Institut fur Normung E.V. (German Standards)

Mechanical Design Guide Page 1 Ausenco International Pty Ltd

BSI British Standards Institution

The latest edition of a code or standard will govern.

Particular attention should be given to the following Directives:

In the absence of any specific standard, the manufacturer’s recommendations should

Site Design Criteria 1418-DC-001

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Basis for Design Process 1418-DC-018

It should be left to the discretion of the equipment manufacturer to include additional

Mechanical Design Guide Page 3 Ausenco International Pty Ltd

6 GENERAL DESIGN REQUIREMENTS

The equipment should be manufactured in accordance with the equipment Supplier’s

Prior to commencement of fabrication, computations for equipment structures should be

Vibrating equipment should be designed to minimise the transmission of vibration to the

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8.1 Overload Capacities

Base-frames should be designed to prevent undue deflection or failure under any

9.3 Gear Reducers

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9.4 Vee Belt Drives

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9.6 Chain Drives

9.8 Bearings and Seals

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