Report - Maintainability Design Review

Quality Management System Document No: MH0074-EM-IS-001
Report Project No: MH0074

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Maintainability Design Review Date : 2012-03-04
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PROJECT SASOL IMPUMELELO MATERIALS

MH0074 PROJECT TITLE
NUMBER HANDLING SYSTEM
CLIENT SASOL MINING
LOCATION SECUNDA, SOUTH AFRICA
REV DATE DESCRIPTION ORIG CHK’D Q.A. P.E.
A 2013-03-04 REVIEW AND COMMENT DDN AF JS PG
APPROVALS
FULL NAMES SIGNATURE DATE
ORIGINATING
DOUW DE NECKER
ENGINEER
ENGINEERING
PAUL GRAYLIN
MANAGER
QUALITY
LANCE CHIVELL
MANAGER
PROJECT
MANNY MARQUES
MANAGER
CLIENT
(OPTIONAL)
Copyright in this document vests in ELB Engineering (Pty) Ltd, and no part thereof may be reproduced without the consent of the copyright holder.
Print Date: 2013-03-15
Template No: E-EN-SP-045 Rev 0 Effective Date: 2012-06-20
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TABLE OF CONTENTS
1. INTRODUCTION ...................................................................................................................................... 3
2. SCOPE ..................................................................................................................................................... 3
3. ABBREVIATIONS ..................................................................................................................................... 4
4. REFERENCED DOCUMENTS ................................................................................................................. 4
5. REFERENCED DRAWINGS .................................................................................................................... 5
6. MAINTAINABILITY PHILOSOPHY ........................................................................................................... 7
7. DESIGN REQUIREMENTS ...................................................................................................................... 9
8. METHODOLOGY OF ASSESSMENT .................................................................................................... 10
9. TECHNICAL DESCRIPTION .................................................................................................................. 10
10. SAFETY INFORMATION.................................................................................................................... 20
11. COMPONENT MAINTENANCE ......................................................................................................... 20
12. MAINTAINABILITY DESIGN REVIEW ............................................................................................... 20
13. RECOMMENDATIONS ...................................................................................................................... 76
14. RAMBO CHECKLISTS ....................................................................................................................... 89
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1. INTRODUCTION
The purpose of this document is to show the results of the Maintainability Review during
design phase as required by The Contract. Each area of the materials handling system
will be assessed separately. All drawings applicable to maintainability for each area will
be reviewed in detail and will be checked against our RAMBO Procedure.
This review analysis will be used to identify and assess potential safety hazards,
operating and maintenance problems. These identified problems will be properly
evaluated and appropriate measures put in place.
2. SCOPE
This report is applicable to the Sasol Impumelelo Mining Materials Handling System,
which includes the following areas:
1 500t Underground Bunker
Incline Conveyor – CV6 INA
Impumelelo Tripper Conveyor – CV6 ITA
15 000t Surface Bunker – BU2304
Impumelelo Reclaim Conveyor – CV2303
Overland Conveyor, including the following:
• Overland Conveyor Belt Turnover and Tail End
• Overland Conveyor Mid Station / Belt Storage
• Overland Conveyor Head End
SCS Tripper Conveyor – CV2302
4000t Surface Bunker – BU2305
SCS Reclaim Conveyor (Initial) – CV2307
SCS Connecting Conveyor – CV2308
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3. ABBREVIATIONS
Abbreviations may be used throughout the report, and are defined below:
Abbreviation Connotation
CV Conveyor
SCS Sasol Coal Supply
BU Surface Coal Bunker
RAMBO Reliability, Accessibility, Maintainability,

Buildability, Operability and Price
OLC Overland Conveyor
SWR Steel Wire Rope
SWL Safe Working Load
GA General Arrangement
PFD Process Flow Diagram
MFD Mechanical Flow Diagram
P&ID Piping and Instrumentation Diagram
4. REFERENCED DOCUMENTS
As part of the review, the following documentation were used as a reference in the
respective areas:
• MH0074-EM-CH-003 Rev. 04 – Design Report for Impumelelo Reclaim Conveyor
• MH0074-EM-CH-002 Rev. 04 – Design Report for Tripper Conveyor
• MH0074-EM-CE-045 Rev. G – Gearbox Ratio Data Sheet
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• MH0074-EM-PL-001 Rev. A – Gearbox Orientation Schedule
• MH0074-EM-CH-070 Rev. G – Pulley Standardisation Schedule
• MH0074-EM-CH-072 Rev. A – Idler Standardisation Schedule
• MH0074-EM-IN-009 Rev. L – Crane Schedule
• MH0074-EM-CH-056 to 064 – Winch Calculations
• MH0074-EM-CH-001 Rev. C – Mechanical Equipment List
• MH0074-EM-RP-022 – Materials Handling System – Hazop Analysis
• MSTMMG000016 Rev. 01 – Materials Handling System Specification
• 02060003-O 04-SOW-04-0002 Rev. I – Impumelelo MHS SOW
• MH0074-EM-SP-007 Rev. 0 – Design Criteria Mechanical
• SA Mines Health and Safety Act
• Act 85 (1993) – Occupational Health and Safety Act
5. REFERENCED DRAWINGS
As part of the review, the following drawings were used in the respective areas:
• MH0074-030-GN-0000-F-001 – Material Flow Diagram
• MH0074-030-GN-0000-F-002 – Process Flow Diagram
• MH0074-022-CV-2303-L-001 – Reclaim Conveyor CV2303 - Layout (1800 Wide

Belt)
• MH0074-022-CV-2303-S-001 – Reclaim Conveyor CV2303 – Tail Frame Details
• MH0074-022-CV-2303-S-031 – Reclaim Conveyor CV2303 – Head Frame Details

and Stringer
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• MH0074-022-CV-2303-S-029 – Reclaim Conveyor CV2303 – Counterweight Tower

Arrangement
• MH0074-022-CV-2303-S-004 – Reclaim Conveyor CV2303 – Transfer Tower Floor

Plans
• MH0074-022-TT-2303-M-001 – Reclaim Conveyor CV2303 – Transfer Tower

General Arrangement
• MH0074-022-TT-2303-S-001 – Reclaim Conveyor CV2303 – Transfer Tower

Elevations
• MH0074-022-CV-2303-S-021 – Reclaim Conveyor CV2303 – Tail Pulley and Crawl

Support Details
• MH0074-022-CV-2303-S-024 – Reclaim Conveyor CV2303 – Take-Up Trolley

Details
• MH0074-022-CV-2303-S-001 – Reclaim Conveyor CV2303 – Tail Frame Details
• MH0074-022-CV-2303-S-031 – Reclaim Conveyor CV2303 – Stringer and Head

Frame Details
• MH0074-022-CV-2303-S-039 – Reclaim Conveyor CV2303 – Horizontal Take-Up

Structure
• MH0074-022-CV-6ITA-M-001 – Tripper Conveyor CV6 ITA - General Arrangement

Drawing
• MH0074-022-CV-6ITA-S-001 – Tripper Conveyor CV6 ITA – Tail Frame Details
• MH0074-022-CV-6ITA-S-018 – Tripper Conveyor CV6 ITA – Take-Up Guide Posts
• MH0074-022-CV-6ITA-S-023 – Tripper Conveyor CV6 ITA – Tripper Head Frame
• MH0074-022-CV-6ITA-S-031 – Tripper Conveyor CV6 ITA – Fixed Tripper Details
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• MH0074-011-TT-6INA-S-005 – Decline Conveyor CV6 INA – Drive House Building

– Elevations and Floor Plans
• MH0074-022-CV6ITA-S-014 – Tripper Conveyor CV6 ITA – Take-Up Tower Layout

– Elevations on Gridlines A, C & D.
6. MAINTAINABILITY PHILOSOPHY
The Operating and Maintenance Manuals will be supplied in Link One Software format in
accordance with Sasol Mining Specification MSTMMG000015.
As far as reasonable practical, all structures shall be designed such that maintenance
can be carried out without dismantling any structure to perform maintenance activities.
The design shall be done to ensure maintainability and/or removal of all mechanical
equipment in the least possible time (4 hours) with the least amount of handling, without
as far as possible dismantling any structure especially for maintenance. Spare item shall
be available, preferably in the same vicinity to promote and speed-up the replacement
turn-around time. Typical areas where time would be of the essence are on top of the
surface bunkers. Support structures and flooring shall be designed to accommodate
spare pulleys and drive arrangements.
Safe access to every maintenance item shall be provided by means of walkways and
stairs. Means of access shall also be provided to crawls with trolleys to latch-on any
manual –or electric hoists.
Where return idlers are higher than 2m from ground level, baskets or platforms shall be
provided underneath every return idler, suitable for a person to safely stand or lay on
when idlers are replaced. The basket shall allow fine spillage to fall through it.
It is preferred that all drives should be on the ground level.
The number of pulleys shall also be optimised and standardised as more pulleys result in
higher capital cost and maintenance cost.
In the areas where the drives and pulleys are situated, overhead cranes shall be provided
to be able to lift and replace heavy pulleys and drive components. Cranes shall extend
over an area where a vehicle can be positioned so that the equipment can be lifted and
placed onto a truck for transportation thereof. The crane shall be designed for the
heaviest load it has to lift. The overhead crane shall be electrically driven.
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Underground, crawl beams and hoists must be installed at conveyor drives, tail and head
pulleys, especially head pulleys at bunkers.
As far as possible, equipment shall be designed with standard parts readily available
within South Africa.
Lifting lugs must be provided on the luffing chutes as well as the supporting structures to
allow for the manual opening and closing of the chutes with a chain and a lever hoist.
This will also be used for locking out inadvertent movement during maintenance.
Lifting lugs must be provided on sections of chutes or structures that need to be lifted and
removed to gain access to maintenance items such as pulleys. Pulling lugs must also be
provided in areas where the conveyor belt needs to be pulled away from a pulley to gain
access and clearance between belt and pulley. This access will be used to rig a spreader
bar or C-clamp arrangement in between the belt and the pulley to facilitate sideways
removal of pulley from underneath the belt and/or structure.
Lifting lugs must be provided on all base plates of drives that will be replaced as
complete units during maintenance. These baseplates include drive assemblies such as
132kW and 315kW drives. The total mass of the drive must be marked on the base plate.
Lifting lugs must be provided on all electrical motors, gearboxes, winches, and bearing
pillow blocks.
A means of replacing idlers shall to be provided. This shall include equipment for lifting
the belting. In places where the belt cannot be lifted (below chutes) retractable idler
frames must be provided.
Facilities and procedures for pulling in new belting in a controlled manner (for the first
installation, and subsequent replacement of portions of belting) must be provided. These
must include, stands for new belting, guide rollers and pulleys, special tools, clamping
facilities, and splicing areas. If a vehicle is to be used for belt pulling operations, a 600m
length of gravel road shall be provided.
In cases where standard bearings cannot be easily replaced on pulley shafts, due to
shaft extensions with couplings for drives, hold-backs or brakes, or if there are space
limitations which make it impossible to replace standard bearings (for instance, on take-
up trolleys), the design of pulleys and sole plates shall make provision for the possibility
that the standard SKF spherical bearing be removed (by cutting off the bearing sleeves)
and be replaced with equivalent split roller bearings, in case of bearing failures. SKF
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bearings (SNL housings) shall be specified as well as the equivalent SRB split bearings
on the design drawings. Initially, the pulleys shall be installed with standard SKF
spherical bearings, to save capital cost. Should the bearings fail during the operation of
the conveyors, it will be replaced with split roller bearings.
The facilities shall be designed such that the replacement of maintenance items (such as
drives and pulleys), can be performed within 4 hours, provided that the spare items are
available.
Belt storage for the full length of belt and loading/unloading facilities at the incline shaft
surface workshop must be provided.
A safe means of inspecting the incline conveyor’s idlers, while the belt is in motion, must
be provided.
The take-up of the incline conveyor should preferably be located on surface, close to the
drives, to simplify lock-out and maintenance.
Three sets of belt clamps (a set is capable of clamping the bottom and top belts). The
clamps must not damage the belt and the design must be approved by the Client.
A means of relaxing the tension in the belt at the splicing area and at the pulleys at the
head end must be provided.
At the incline conveyor a system must be provided to retrieve belting, in case of a failure
that caused it to run down the incline shaft, i.e. a belt recovery winch or Capstan brake
winch.
Handrails (both sides of the walkway) shall be provided along the side of the incline
conveyor for personnel using the incline shaft for access. However, safe access for idler
replacement must still be possible.
7. DESIGN REQUIREMENTS
The design requirements for the Sasol Impumelelo Materials Handling System are
provided in the following design criteria specifications:
• MH0074-EN-SP-004 Rev. B – Civil and Structural Design Criteria
• MH0074-EM-SP-007 Rev. 0 – Mechanical Design Criteria
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8. METHODOLOGY OF ASSESSMENT
Each area will be assessed from an operations and maintainability aspect. Detailed
drawings of each area will be used as part of the assessment and the relevant RAMBO
check sheets will be completed for each area.
9. TECHNICAL DESCRIPTION
The technical description and process flow of the Sasol Impumelelo Materials Handling
System is summarised in the respective process flow diagram (PFD) below. Extracts were
taken from the PFD for the different areas for easy identification.
1 500t Underground Bunker
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Stream # 1
Description Units
Feeder Discharge
Conveyor Start Time Sec. -

Conveyor Operational Stop Sec. -
Conveyor Emergency Stop Sec. -
Belt Width mm -
Belt Length m -
Belt Detail - -
Conveyor Length m -
Conveyor Lift m -
Installed Power kW 2x 2x 7.6
Material - Coal
Bulk Density kg/m³ 950
Volumetric Density kg/m³ 850
Particle Size mm -240
Design Capacity tph or t 2100
Minimum Operating Capacity tph 850
Maximum Operating Capacity tph 2100
Gearbox Ratio p.u. -
Minimum Speed Hz or m/s 20.2Hz
Belt Fill @ Max Capacity % -
Maximum Speed Hz or m/s 50Hz
Material Mass kg/m -
Flooded Mass kg/m -
Incline Conveyor (CV6 INA)
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Stream # 2
Stream CV6 INA
Description Units
Incline Conveyor
Conveyor Start Time Sec. 20 Dwell, 60 Ramp

Conveyor Operational Stop Sec. 6
Conveyor Emergency Stop Sec. 6
Belt Width mm 1800
Belt Length m 2064
Belt Detail - ST3150, 7/7, Grade F
Conveyor Length m 1043
Conveyor Lift m 250.1
Installed Power kW 3x 1000
Material - Coal
Maximum Operating Capacity tph 3500*
Gearbox Ratio p.u. 20:1
Minimum Speed Hz or m/s 4.66
Belt Fill @ Max Capacity % 65
Maximum Speed Hz or m/s 4.66
Material Mass kg/m 188.5
Flooded Mass kg/m 516.3
* Surge Capacity for 20 seconds only
Impumelelo Tripper Conveyor (CV6 ITA)
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Stream # 3 4 5
Stream TBA Stream TBA Stream CV6 ITA
Description Units Screen Oversize - Screen Undersize -

Tripper Conveyor
HOLD HOLD
Conveyor Start Time Sec. - - 45

Conveyor Operational Stop Sec. - - 4.3 - 20
Conveyor Emergency Stop Sec. - - 4.3 - 20
Belt Width mm - - 1800
Belt Length m - - 826
Belt Detail - - - 1250/4, 4/2, Grade F
Conveyor Length m - - 382
Conveyor Lift m - - 28.3
Installed Power kW Hold Hold 2x 315
Material - Coal Coal Coal
Bulk Density kg/m³ 950 950 950
Volumetric Density kg/m³ 850 850 850
Particle Size mm +100 -100 -150
Design Capacity tph or t 3350 3350 3500
Minimum Operating Capacity tph 509.53 2390.47 2900
Maximum Operating Capacity tph 614.95 2885.05 3500
Gearbox Ratio p.u. - - 20:1
Minimum Speed Hz or m/s - - 4.03
Belt Fill @ Max Capacity % - - 78
Maximum Speed Hz or m/s - - 4.03
Material Mass kg/m - - 239.8
Flooded Mass kg/m - - 437.2
15 000t Bunker (BU2304) and Reclaim Conveyor (CV2303)
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Stream # 6 7 8
Stream BU2304 Stream BU2304 Stream CV2303
Description Units 15000t Bunker 15000t Bunker

Reclaim Conveyor
Luffing Chutes Luffing Chutes
Conveyor Start Time Sec. - - 45

Conveyor Operational Stop Sec. - - 5.7 - 9.4
Conveyor Emergency Stop Sec. - - 5.7 - 9.4
Belt Width mm - - 1800
Belt Length m - - 479
Belt Detail - - - 800/4, 4/2, Grade M
Conveyor Length m - - 225
Conveyor Lift m - - 4.5
Installed Power kW - - 1x 132
Material - Coal Coal Coal
Bulk Density kg/m³ 900 900 950
Volumetric Density kg/m³ - - 850
Particle Size mm -150 -150 -150
Design Capacity tph or t 15000t 15000t 2400
Minimum Operating Capacity tph 1000t/Chute - 1000
Maximum Operating Capacity tph 2400t/Chute - 2400
Gearbox Ratio p.u. - - 20:1
Minimum Speed Hz or m/s - - 1.5
Belt Fill @ Max Capacity % - - 78
Maximum Speed Hz or m/s - - 2.8
Material Mass kg/m - - 239.8
Flooded Mass kg/m - - 446.8
Overland Conveyor (CV2301)
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Stream # 9
Stream CV2301
Description Units
Overland Conveyor
Conveyor Start Time Sec. 70 Dwell, 600 Ramp

Conveyor Operational Stop Sec. 100
Conveyor Emergency Stop Sec. 100
Belt Width mm 1200
Belt Length m 53877
Belt Detail - ST2000, 7/5, Grade M
Conveyor Lift m -55
Installed Power kW 4x 1000, 2x 450
Material - Coal
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SCS Tripper Conveyor (CV2302)
Stream # 10
Stream CV2302
Description Units SCS Tripper

Conveyor
Conveyor Start Time Sec. 60

Conveyor Operational Stop Sec. 3.9 - 8.6
Conveyor Emergency Stop Sec. 3.9 - 8.6
Belt Width mm 1500
Belt Length m 515
Belt Detail - 800/4, 4/2, Grade M
Conveyor Lift m 24.4
Installed Power kW 1x 315
Material - Coal
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4 000t Surface Bunker (BU2305)
Stream # 11
Stream BU2305
Description Units 4000t Bunker Luffing

Chutes
Conveyor Start Time Sec. -

Conveyor Operational Stop Sec. -
Conveyor Emergency Stop Sec. -
Belt Width mm -
Belt Length m -
Belt Detail - -
Conveyor Length m -
Conveyor Lift m -
Installed Power kW -
Material - Coal
Volumetric Density kg/m³ -
Design Capacity tph or t 4000t
Minimum Operating Capacity tph 2000t/Chute
Maximum Operating Capacity tph 2400t/Chute
Gearbox Ratio p.u. -
Minimum Speed Hz or m/s -
Belt Fill @ Max Capacity % -
Maximum Speed Hz or m/s -
Material Mass kg/m -
Flooded Mass kg/m -
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SCS Reclaim Conveyor (Initial and Future) (CV2307)
Stream # 12 12a
Stream CV2307 Stream CV2307
SCS Reclaim
Description Units SCS Reclaim
Conveyor (Future
Conveyor
Extension)
Conveyor Start Time Sec. 20 20
Conveyor Operational Stop Sec. 7 - 10 4.9 - 18.4
Conveyor Emergency Stop Sec. 7 - 10 4.9 - 18.4
Belt Width mm 1800 -
Belt Length m 809 1190
Belt Detail - 800/4, 4/2, Grade M 1250/4, 4/2, Grade M
Conveyor Length m 377 565
Conveyor Lift m 4.9 23.5
Installed Power kW 1x 315 1x 132, 1x 315
Material - Coal Coal
Bulk Density kg/m³ 950 950
Volumetric Density kg/m³ 850 850
Particle Size mm -150 -150
Design Capacity tph or t 2400 2400
Minimum Operating Capacity tph 1000 1000
Maximum Operating Capacity tph 2400 2400
Gearbox Ratio p.u. 20:1 20:1
Minimum Speed Hz or m/s 1.5 1.5
Belt Fill @ Max Capacity % 76 86
Maximum Speed Hz or m/s 2.8 2.8
Material Mass kg/m 232.9 266.7
Flooded Mass kg/m 434 437.2
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SCS Connecting Conveyor (CV2308) and Existing Brandspruit Conveyor
Stream # 13 14
Stream CV2308 Stream Existing
Description Units SCS Connecting Brandspruit

Conveyor Conveyor
Conveyor Start Time Sec. 20 -

Conveyor Operational Stop Sec. 5.3 - 12.3 -
Conveyor Emergency Stop Sec. 5.3 - 12.3 -
Belt Width mm 1500 1350
Belt Length m 167 -
Belt Detail - 800/4, 4/2, Grade M -
Conveyor Length m 79 -
Conveyor Lift m 5 23.5
Installed Power kW 1x 132 -
Material - Coal Coal
Bulk Density kg/m³ 950 950
Volumetric Density kg/m³ 850 850
Particle Size mm -150 -150
Design Capacity tph or t 2400 2200
Minimum Operating Capacity tph 2000 1800
Maximum Operating Capacity tph 2400 2200
Gearbox Ratio p.u. 20:1 -
Minimum Speed Hz or m/s 3.9 2.9
Belt Fill @ Max Capacity % 79 94
Maximum Speed Hz or m/s 4.02 3.6
Material Mass kg/m 183.9 -
Flooded Mass kg/m 434 -
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10. SAFETY INFORMATION
The purpose of this report is to show the results of design assessments conducted and to
identify possible hazardous safety issues, operating problems and maintainability problems
during design phase only.
It is assumed that during any maintenance activity, all mandatory code of practices will be
followed, all risk assessments will been done, proper lock-out procedures will be followed
and the required permits to work will be in place as required by Law.
It is imperative that lockout / tag-out regulations be followed before undertaking

maintenance activities. Failure to comply with the lockout / tag-out procedures exposes
workers to uncontrolled behaviour of the conveyor belt. Severe injury or death can result.
11. COMPONENT MAINTENANCE
Component maintenance procedures for equipment are not addressed in this document.
Component maintenance manuals will be provided by the different suppliers of equipment.
These manuals associated with operation, maintenance and training will be prepared in a
format compatible with Mincom LinkOne software.
12. MAINTAINABILITY DESIGN REVIEW
This section of the document addresses the findings regarding maintainability. Mechanical
equipment such as idlers, mechanical drive arrangements, pulleys, belting, winches,
magnets, scales, bearings etc. have been reviewed to ensure these items are
maintainable and the removal and installation processes are achievable and practical as
designed and drawn.
Special attention is given to equipment such as pulleys and drives, to ensure that these
items can be removed and replaced within a four (4) hour turn-around time.
Every mechanical item on every conveyor is looked at in isolation (considered as a node)

to ensure that all required pulling points, special tools, clearances; lifting points, crawls,
cranes, hoists etc. have been allowed for, to facilitate ease of removal and replacement.
The review on all conveyors and applicable areas are provided below, with the necessary
back-up information and review checklists (RAMBO).
Any change/s and/or recommendation/s are provided under each section.
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12.1 Impumelelo Reclaim Conveyor (CV2303)
On the Impumelelo Reclaim Conveyor, the following mechanical items have been
identified and to ensure it is maintainable and can be replaced with ease:
12.1.1 Pulleys,
12.1.2 Drive Assembly,
12.1.3 Idlers,
12.1.4 Belting,
12.1.5 Winches and Sheaves,
12.1.6 Chute Liners,
12.1.7 Belt Magnets,
12.1.8 Weigh Scale,
12.1.9 Crane / Hoist
12.1.10 Guards / Plummer Blocks / Greasing Points / Vibration Monitoring
12.1.1 Pulleys
Refer below the pulleys locations and technical data.
Pulley Locations
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Technical Data
Motor 1 - Backstop 1 1 HT 800 R/C 12 824 2000 2600 240 200

Pulley 2 2 MT 630 R 12 654 2000 2600 220 180
Pulley 3 2 MT 630 R 12 654 2000 2600 220 180
Pulley 4 2 MT 630 R 12 654 2000 2600 220 180
Take-up Pulley 2 MT 630 R 12 654 2000 2600 220 180
Tail Pulley 2 MT 630 R 12 654 2000 2600 220 180
Motor 1 – Backstop 1 Pulley
• Release the conveyor belt tension by eliminating the tension of the conveyor take-
up system. It must be stressed that a zero tension must exist before any work is
performed on any pulley in the conveyor system. This can be achieved by raising
the counterweight. By raising the counterweight, the horizontal take-up carriage will
move forward towards the head end of the conveyor. Sprag the counterweight so
that the tension is removed off the winch. Release winch steel wire rope from the
counterweight. Qualified personnel must clamp the conveyor belt.
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• Remove head chute and scrapers.
• Clamp the conveyor belt with a channel clamp as shown below to prevent belt
movement when belt is pulled to create clearance between belt and head pulley.
Utilise lugs / pulling points as provided.
• Clamp a channel clamp to the carry side. Attached a turfer to the channel clamp
and head frame to pull belt for clearance. Utilise lugs / pulling points on the head
frame. Lugs are also added to the column of the transfer house to assist with lifting
belt from pulley so that a c-clamp can be moved in between the pulley and belt for
easy removal of drive pulley.
• Disengage low speed side coupling from pulley shaft.
• Remove low speed side holdback arm.
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• Attached suitable slings to the c-clamp and use overhead crane with c-clamp and
move clamp in between the belt and pulley.
• Sling pulley and ensure the slack in the pulley is taken out before the plummer
block bolts are released.
• Release plummer block bolts and use crane to manoeuvre pulley to the side, i.e.
opposite side of drive assembly.
• The crane can be used to lower pulley through floor opening provided directly onto
a truck.
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The assembly installation would be similar to the removal process working in reverse for
all pulleys as described below.
Pulley 2
• The tension release and the belt clamping would be the same as explained for the
removal process as for the Motor 1 – Backstop 1 pulley.
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• Ensure enough belt slack and use lug on head frame to lift belt of bend pulley and
to keep the belt in position.
• For this pulley removal, attach a spreader bar to the crane as shown.
• Lower slings past conveyor stringer and sling pulley.
• Take-up the tension in the sling before plummer block bolts is released.
• Slide-in the angle iron skid frame (special tool provided for maintenance) below
pulley and bolt frame to floor cross beam members. Place piece of off-cut belting
on the angle iron frame to prevent any damage to pulley lagging when pulley is
pulled out from the side. A typical photograph is shown below.
• Loosen plummer blocks and lower pulley onto frame.
• Release the overhead crane.
• Attach an eye bolt to pulley shaft end and use turfer attached to the column and
eye bolt to pull pulley out, using the frame and off-cut conveyor belting as a sliding
surface. The replacement of the pulley is done using the same method. Use pulling
point on the opposite side column. This pulling point is lower down so that sling or
chain pass underneath the drive.
• Once pulled out from underneath, the overhead crane can be used to lift pulley and
move it out to the opening in the floor to lower directly onto a 5t truck.
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Pulley 3
• The tension release will be the same as explained for the removal process as for
Motor 1 – Backstop 1 pulley.
• Clamp carry belt as shown with channel clamp.
• Secure channel clamp before pulley 3 as illustrated and use a turfer to pull belt
away as shown.
• For this pulley removal, the crawl beam above should be utilised.
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• Two trolleys to be used, each with a chain block.
• Sling pulley to the chain blocks.
• Take-up the tension in the chain block before plummer block bolts is released.
• Loosen bolts and lift pulley with chain blocks and move out towards the side onto
the back of a truck.
Take-Up Pulley
• The tension release will be the same as explained for the removal process of Motor
1 – Backstop 1 pulley.
• Move take-up carriage into extreme slack position where the crane and crawl beam
can reach it. It may be necessary to remove a floor panel to access the pulley
down below.
• Sprag belt with a channel on carriage frame support.
• Lower the chains of the crane through the upper level grating and sling pulley.
• Once plummer blocks are loose, raise pulley such that it is close to and in line with
the crawl beam.
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• Use two trolleys with chain blocks on crawl beam and double sling the pulley onto
the chain blocks.
• Take-up any slack in the slings. Release the crane from the pulley and move pulley
out on crawl beam. Lower directly onto truck situated on the outside underneath
the crawl beam overhang.
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Pulley 5
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• Move take-up carriage such that the belt wrap is still 180 degrees in order to
facilitate a proper belt pull.
• Pull belt from each column as shown to get maximum belt release, i.e. utilise 4m
from the take-up release.
• Fold belt over as far as possible and secure belt in position.
• Use two trolleys with chain blocks on crawl beam and double sling the pulley onto
the chain blocks.
• Take-up any slack in the slings. Move pulley out on crawl beam. Lower directly
onto truck situated on the outside underneath the crawl beam overhang.
Tail Pulley
• The tension release will be the same as explained for the removal process of the
• Clamp return belt with a channel clamp and steel wire rope as shown.
• Clamp the carry side with a turfer to pull belt for clearance.
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• Use crawl beam above tail pulley and latch a hoist onto beam trolley.
• Attach c-clamp to electric hoist.
• Move c-clamp in between the belt and pulley.
• Sling pulley to c-clamp.
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• Take-up and slack in the hoist chain and loosen plummer blocks.
• Move pulley out to the side of the crawl beam and load directly on truck.
12.1.2 Drive Assembly
Technical Data
kW Input rpm VFD Hz Pulley Output rpm Ratio Belt speed G/Box
132 1270 42.3 824 65 19.548 2.8m/s QHRH3
The drive assembly components such as couplings, electric motor, holdback and gearbox
are easily assessable through the overhead crane and auxiliary hoist. The entire drive
assembly can be replaced without removing individual drive components, i.e. crane
suitably sized. Lifting lugs for motor, gearbox and baseplate will be supplied for easy lifting.
Jacking bolts in axial and radial planes will be provided for alignment purposes.
The transfer tower floor loading has been designed to cater for placement of equipment
directly onto the floor without lifting it to ground floor first. The floor also caters for the
removal of the head chute. Sufficient area has been allowed for to place equipment whilst
disassembly is taking place.
12.1.3 Idlers
Technical Data
Series 30 Series 30 Series 30

Carry Return Carry at Loading Point
3 2 5
35 10 60
1.5 4.5 0.5
152 HDPE 152 HDPE 152 HDPE
6306 6306 6306
30 30 30
660 965 400
35° Carry Idlers
All 35° carry idlers can be easily removed with the Flexco Belt lifter as illustrated below.
This belt lifter is placed below the belt line on the stringer top girders, in between two
adjacent carry idler sets. The scissor lifting arrangement is lifted by means of a suitable
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heavy duty ratchet. This will raise the belt of the rollers to gain access during the removal
process.
35° carry idlers within the transfer house can be also accessed by placing one half of the
channel clamp underneath the belt and lifting it to a suitable height with the crane auxiliary
hoist.
60° Carry Idlers
The carry idlers installed at the luffing chute loading areas are retractable idler frames, and
can be removed sideways.
10° Return Idlers
The majority of all return idlers for this conveyor are accessible from ground level. Five
return idlers must be enclosed with guards as shown, to prevent a person from getting
grabbed as shown below.
These four (5) idlers are indicated below.
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1st 2nd 3rd 4th 5th
12.1.4 Belting
Technical Data
Belt Type – Plied Belt
Belt Mass – 26.1kg/m
Belt Class – 800N/mm
Belt Width – 1800mm
Number of Plies – 4 Ply
Top Cover Thickness – 4mm
Bottom Cover Thickness – 2mm
Cover Grade – M
Conveyor Tape Length – 459m
Pulley Centre Distance – 224.2m
Belt Order Quantity – 480m
Number of Rolls – 2 off / 240m of Belt per Reel
Approximate Roll Mass – 8t
Approximate Roll Diameter – 2.1m
Number of Splices – 2 off
Roll Lay-off - Both rolls will be supplied in the same configuration, i.e. wound in the factory
with belt top cover on top, heat 1, outside, when viewed by the splicing crew. The leading
edge of the belt will reel off the top of the reel.
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Initial Belt Pull Method Statement
1. Place both belt rolls at the tail end of the conveyor, i.e. roll 1 and roll 2.
2. Both rolls should be placed such that the leading edge is coming off the top of the
reel, with the top cover of the belt facing upwards.
3. Set-up the splice table behind the conveyor tail pulley, i.e. between the tail and the
first reel. The first roll should be placed at approximately 14m behind the tail pulley,
which will allow a 2m leading edge at the head when the entire roll is pulled in.
4. Fit a belt clamp to the leading edge of the first roll.
5. The leading edge of the belt can be cut, so that both sides of the leading edge are in
a “v”-shape towards the centre line of the belt.
6. A suitably sized hydraulic winch and rope to pull the entire 480m of belt will be used
(~1.2t pull force required).
Belt Mass 26.1 kg/m

Belt Length: 480 m
- Straight Section 176.298 m
- Incline Section 58.939 m
- Return Side 224.237 m
Inclination Angle 0.122 rad
Friction Factor 0.03 p.u.
Rope Nominal Diameter 24 mm
Rope Mass 2.316 kg/m
F = W(µ x Cos ø + Sin ø) + Fh + Fr + Fb + Rope

F = 936.9532 kg
Contingency Factor 1.2 p.u.

Pulling Force Required: 1124.344 kg
Round Up 1200 kg
Required Winch Pull 1.2 ton
7. The winch will be positioned at ground level in front of the transfer house. A snatch
block will be mounted on the transfer structure to divert the rope to the winch when
the belt is pulled, ~1m above the head pulley centre line.
8. The speed of the hydraulic winch will be approximately 0.07m/s (4m/min) and the
speed can be varied with a flow control valve, especially when going around the
pulleys. A load cell for safety precautions can be fitted to the leading edge to monitor
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the tension. The tension in the cable will be monitored continuously by a spotter
walking alongside the leading edge. The spotter will be in radio contact with the winch
operator and personnel further down the conveyor for safe operating and pulling.
9. The weight of the belt from the top of the reel combined with the pull from the winch
will un-reel the belt from the let-off station.
10. Belt roll 1 will be pulled to the head end of the conveyor. At this point, the pulling crew
will secure the belt to the head frame of the conveyor.
11. The splicing crew will then remove the vacant roll 1, unroll belt 2, and splice it to the
lagging end of belt 1. While this is happening, the winch operating team will
disconnect the belt clamp from the leading edge of roll 1 and wind-up the cable onto
the winch drum. The winch will be moved to the tail, behind the second roll for the
cable to pass underneath the roll. A snatch block may need to be attached to the
reel’s support to clear rope with belt. Also during this time, the rope will be reeved
from the tail on the return side through all the pulleys and attached to the leading
edge of belt roll 1.
12. The pulleys must be protected against the clamp and cable, either by leaving the
suppliers strapping on (tin strapping) or by enclosing and strapping it with off cut
belting. The clamp will be covered in a similar fashion, to protect pulleys against any
possible damage.
13. Once all crews have completed their tasks, roll 1 and 2 will be pulled through to the
tail end of the conveyor.
14. Once the second roll’s leading edge passes the tail end, the pulling activity is
stopped, and both rolls’ loose ends, i.e. leading end of roll 1 and lagging end of roll 2
should be at the tail ready for the final splice.
15. Before the final splice is performed, the take-up trolley shall be moved into the correct
position and the correct belt length to perform the final splice shall be cut and spliced.
Belt Repair Method Statement
1. Belt repair need to take place from the tail pulley of the conveyor. We have allowed
for sufficient space, 9m x 6m, for splicing, 2off strobe lights and a movable closure
and an A-frame support for the reel.
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2. Any length of belt can therefore be replaced by cutting and splicing it at the tail to the
spare roll and by using the drive to pull in the new length of belt and un-reeling the old
belt at the same time.
3. Once the repaired length is replaced with a new length of belt, the roll is cut and the
final splice is carried out.
4. During a belt snap situation, which is more likely to happen in the area of the drive,
i.e. T1 tension, facility is provided on the head frame of the conveyor to pull the two
ends of the belt closer, take up belt slack and perform a belt insert splice. A
temporary splice can also be made and by setting the VFD to a lower speed, the belt
can be cycled with the motor such that a proper splice can be carried out at ground
level behind the tail pulley. The VFD can be set as low as 6Hz. Refer curve below.
The load curve is still within the motor force ventilation curve.
5. The supplier is recommending a 300m spare belt.
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12.1.5 Winches and Sheaves
Technical Data
Counterweight
Mass (Ton) Required Counterweight Recommended
2 x T2 = Ttu = (Ttu/9.81) x ROPE Required Winch Take-Up Pulley Mass Travel in Travel Allowance Winch Winch Capacity
(kN) reeving ratio Capacity Displacement (A) Tower (B) in Tower (B) Model
44.00 4.49 2.49t 4.45m 4.45m 5.45m 5000S 3.5t
Winch
Motor Power Rope Dia Rope Capacity Sheave
(kW) (mm) (m) Root Dia
2.2kW, 2.6m/min 16.00 63 280
For any maintenance activity, the take-up tension can be released through the 5000S
winch. The winch shall be raised the full travel distance (4.45m) to allow sufficient slack on
the belt. At this point, a locking mechanism will be used to lock the carriage in place at that
specific level. Access to this level will be via a cat ladder, onto a landing, surrounding the
take-up tower so that the locking mechanism can be installed on both sides of the take-up
carriage.
For sheave inspection and maintenance, we have allowed access via cat ladders onto a
platform (landing). The winch can be inspected and maintained from ground level. This
particular winch has a mass in the region of 200kg. A small swing JIB crane to be installed
for removal of winch.
12.1.6 Chute Liners
Chute will come complete with proper inspection hatches for ceramic wear inspection.
Chute will be designed such that it can be easily split into different sections for scheduled
repairs. These flanges will be located at appropriate floor levels. At these flanges,
provision will be made for the insertion of scaffolding pipes so that a platform can be
constructed on the inside of the chute to enhance ceramic liner repair when necessary.
12.1.7 Belt Magnets
The belt magnets will have a designated area for maintenance, on the same support
structure (similar to Thubelisha). Once the magnet is pulled back on the support structure,
a low bed suitable for a static load of 33.4t can move in underneath the magnet for
loading.
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12.1.8 Weigh Scale
The weigh scale is situated at ground level, and will be aligned with the conveyor stringer
and welded. No provision is therefore made in terms of lifting crawl beams for lifting out the
weight scale frame. Equipment such as the load cell can be easily removed by a Manitou
type crane. Suitable access is available for a Manitou crane.
Any crane maintenance activities can take place from a platform provided. If a suitably
sized crawl is preferred for servicing the drive pulley and drive pack, the same platform
can be used for gaining access to the hoist for hooking of lifting equipment and to perform
scheduled inspections such as certifying authority inspections on crawl beam, hoist and
trolleys.
The detailing of the magnet and horizontal take-up guards will be done by using Clear
View type guarding. Panels to be kept to 25kg and shall be raised approximately 200mm
above ground level.
The tail frame guards will be detailed such that the plummer blocks are outside the guard,
to facilitate greasing without removing any guards, as well as enhancing vibration
monitoring. When removing the guards, the grease point will therefore not interfere with
the removal process. Refer to pictures below for two options available.
At horizontal take-up carriage, the grease point of the take-up pulley must be extended to
outside the clear view guard arrangement.
Option 1
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Option 2
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12.2 Impumelelo Tripper Conveyor (CV6 ITA)
On the Impumelelo Tripper Conveyor, the following mechanical items have been identified
and to ensure it is maintainable and can be replaced with ease:
12.2.1 Pulleys (including tripper car pulleys)
12.2.2 Two Drive Assemblies - Primary and Secondary,
12.2.3 Idlers (including Tripper Car Idlers / Carry Idlers on Tripper Car Support
Structure above 15 000t Bunker)
12.2.4 Belting,
12.2.5 Winches and Sheaves,
12.2.6 Transfer Chute Liners & Tripper Car Transfer Chute and Liners
12.2.7 Cranes / Hoist
12.2.9 Tripper Car Equipment:
12.2.9.1 Travel Drive Assembly
12.2.9.2 Calliper Brake Assembly
12.2.9.3 Couplings / Chain Sprockets / Chain Idlers / Shafts / Chains
12.2.9.4 Tripper Car Festoon and Runners
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12.1.1 Pulleys
Refer below the pulleys locations and technical data.
Pulley Locations
Technical Data
Motor 1 1 HT 1000 R/C 12 1024 280 240

Motor 2 - Backstop 1 1 HT 1000 R/C 12 1024 280 240
Pulley 3 2 LT 630 R 12 654 220 180
Pulley 4 3 MT 800 R 12 824 240 200
Pulley 5 3 MT 800 R 12 824 240 200
Head Pulley 4 MT 800 R 12 824 240 200
Pulley 7 5 MT 630 R 12 654 240 200
Take-up Pulley 5 MT 630 R 12 654 240 200
Pulley 9 5 MT 630 R 12 654 240 200
Tail Pulley 5 MT 630 R 12 654 240 200
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• Release the conveyor belt tension by eliminating the tension of the conveyor take-
up system. It must be stressed that a zero tension must exist before any work is
performed on any pulley in the conveyor system. This can be achieved by raising
the counterweight. Sprag the counterweight so that the tension is removed off the
winch. Release winch steel wire rope from the counterweight. Qualified personnel
must clamp the conveyor belt.
• Remove fixed tripper transfer chute and scrapers.
• Clamp the conveyor belt with a channel clamp as shown above, using the pulling
lugs provided on the pulley support frame. The belt can be spragged on the carry
side between a vertical and diagonal brace using a channel clamp on the actual
stringer. This is done to prevent belt rotation around the pulley, so that sufficient
slack is obtained.
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• The crane can be used to lower pulley to ground level directly onto a truck, through
the crane lifting well provided, prior to the first box trestle support.
The assembly installation would be similar to the removal process working in reverse for
all pulleys as described below.
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removal process of the Motor 1 – Backstop 1 pulley.
• To pull the belt at the drive bend pulley, use pull structure below elevated stringer
as shown.
• Ensure enough belt slack is obtained. Sprag belt down in between the beams at
floor level such that the pulley will clear belt when pulled out to the side.
• For this pulley removal, attach a spreader bar to the overhead crane.
• Lower slings past conveyor stringer and sling pulley on both shaft ends.
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pulley and bolt frame to the cross beams above floor level. Place piece of off-cut
belting on the angle iron frame to prevent any damage to pulley lagging when
pulley is pulled out from the side. A typical photograph is shown above for pulley 2
removal of the Impumelelo Reclaim Conveyor.
• Release plummer block bolts and use crane to lower pulley onto the angle iron skid
frame.
• Attach an eye bolt to pulley shaft end. Sling pulley to the lug provided on the cross
beam between the two building columns. Use a turfer or puller to pull pulley out,
using the frame and off-cut conveyor belting as a sliding surface. The replacement
of the pulley is done using the same method. Use lug on opposite side cross beam
between the two building columns and repeat exercise to pull pulley back into
position. For the replacement of the pulley, longer slings will be needed.
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move it out to the crane lifting well.
Pulley 3
• For this pulley removal, attach a spreader bar to the overhead crane.
• Lower slings past conveyor stringer and sling pulley on both shaft ends.
• Loosen plummer block bolts and raise pulley of the stools with overhead crane. The
belt running over this pulley will be raised as well. While the belt and pulley is lifted
in this position, secure a beam clamp to the beam above pulley and use a sling to
secure belt in position.
• Loosen plummer block stools and remove stools completely.
• Ensure enough belt slack is obtained. Sprag return belt down in between the
beams on top of the floor, such that the pulley will clear belt when pulled out to the
side.
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pulley and bolt frame cross beams above floor level. Place piece of off-cut belting
on the angle iron frame to prevent any damage to pulley lagging when pulley is
pulled out from the side. A typical photograph is shown above for pulley 2 removal
of the Impumelelo Reclaim Conveyor.
• Lower pulley onto skid frame.
• Attach an eye bolt to pulley shaft end. Sling pulley to the lug provided on the cross
beam between the two building columns. Use a turfer or puller to pull pulley out,
using the frame and off-cut conveyor belting as a sliding surface. The replacement
of the pulley is done using the same method. Use lug on opposite side cross beam
between the two building columns and repeat exercise to pull pulley back into
position. For the replacement of the pulley, longer slings will be needed.
move it out and to lower it from the bunker directly onto a 5t truck.
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Pulley 4
• Remove tripper car transfer chute top half and scrapers.
lugs provided on the pulley support frame. The belt can be spragged on the carry
side between a vertical and diagonal brace using a channel clamp on the actual
stringer. This is done to prevent belt rotation around the pulley, so that sufficient
slack is obtained.
• Release plummer block bolts and use crane to manoeuvre pulley to the side.
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Pulley 5
• To pull the belt, a cross member is placed at an upper level between two vertical
channels.
• For this pulley removal, attach a C-clamp to the overhead crane.
• Remove the entire floor panel to gain access with the c-clamp as indicated below.
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• Release plummer block bolts and use crane to manoeuvre pulley to the side.
move it out to the crane lifting well in front of the head pulley area.
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Head Pulley
• Remove chute and/or guard enclosure.
lugs provided on the pulley support frame.
• Clamp bottom belt to prevent belt rotation around pulley.
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• The crane can be used to lower pulley to ground level directly onto a truck, through
the structure opening in front of the head pulley.
Pulley 7 & Pulley 9
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• The bend pulleys can be accessed from the top floor of the take-up structure.
• Remove guard enclosure.
• Use overhead crane with a spreader bar and attach suitable slings.
• Lower slings down to the pulley and sling pulley.
• Take-up any slack on the slings before the bend pulley frames are loosened.
• Loosen pulley frame from floor beam which can be reached from the same level.
• Once loose, lower pulley down to second floor.
• Release crane.
• Use pulling lugs on the building columns, and pull pulley out towards the side.
Once pulled out, roll pulley to the lifting well opening.
• Use overhead crane to lower pulley down.
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Take-Up Pulley
• Move take-up carriage into extreme slack position. Mechanically, lock the take-up
carriage in place, both sides of carriage, front and back.
• A platform shall be provided on the left hand side with a cat ladder to access crawl
beam to get the lifting hooked on.
• The crawl beam shall be placed ~100mm off the centre line of the pulley (front
side), to prevent a clash with the winch ropes.
• Pulley plummer blocks can be access from the floor level. Sling pulley and move
pulley out to the right on the curved crawl beam to the crane lifting well.
• At the crane lifting well, the crane can be used to lift pulley to ground level.
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Tail Pulley
• The tension release will be the same as explained for the removal process of the
• Pulling provision shall be provided on the floor beam as shown, approximately

4.2m behind tail pulley, to enable belt pull and to facilitate enough belt slack.
• Cast in plates with pulling lugs shall be provided on the concrete pillars, so that belt
can be pulled and flipped over to the one side to gain better access to sling the
pulley.
• Dual crawl beams above tail pulley will be supplied to facilitate a better rigging
process for the tail pulley. These crawl beams will run to the outside of the transfer
house to lower pulley down onto a truck.
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12.1.2 Drive Assembly (Primary and Secondary Drives)
Technical Data
kW Input rpm VFD Hz Pulley Output rpm Ratio Belt speed G/Box
2x 315 1515 50.5 1024 75.2 20.134 4.03m/s QHRH2
There are two drive assemblies, both situated at the fixed tripper. One drive arrangement
is situated on the right hand side of the head pulley and the other drive on the left hand
side of the bend pulley. Both drive assembly components such as couplings, electric
motors, holdbacks and gearbox are easily assessable by the overhead crane and auxiliary
hoist. The entire drive assembly can be replaced as a unit on a common baseplate. The
crane is sized for a SWL of 10t. Lifting lugs for motor, gearbox and baseplate will be
supplied for easy lifting. Jacking bolts in axial and radial planes will be provided for
alignment purposes.
The transfer tower floor loading has been designed to cater for placement of equipment
directly onto the floor without lifting it to ground floor first. A spare drive assembly and/or
fixed tripper pulley can be placed on top of the bunker to shorten the down time in a
breakdown situation. The floor also caters for the removal of the fixed tripper transfer chute
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to gain access to the fixed tripper head pulley. Sufficient area has been allowed for the
placement of equipment whilst disassembly is taking place.
12.1.3 Idlers (incl. tripper car idlers and carry idlers on tripper car support structure
above 15 000t bunker)
Technical Data
1 2
Series 35 Series 30
Carry Return
3 2
35 10
1.5 4.5
152 Steel 152 Steel

6307 6306
35 30
660 965
3 4
Series 35 Series 35
Carry at Loading Point Carry at Inclines
3 3
45 45
0.5 1.5
152 Steel 152 Steel
6307 6307
35 35
660 660
35° & 45° Carry Idlers
All 35° and 45° carry idlers can be easily removed with the Flexco Belt lifter as illustrated
below. The belt lifter is adjustable for the different trough angles. This belt lifter is placed
below the belt line on the stringer top girders, in between two adjacent carry idler sets. The
scissor lifting arrangement is lifted by means of a suitable heavy duty ratchet. This will
raise the belt of the rollers to gain access during the removal process.
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35° carry idlers within the vicinity of the overhead crane can be also accessed by placing
one half of the channel clamp underneath the carry belt and lifting it to a suitable height
with the crane auxiliary hoist.
35° carry idlers on top of the bunker can also be serviced by parking the tripper car over
and above the required carry idler set. This idler set can be reached by means of the
access platform on the tripper car.
45° carry idlers at the loading zones must be supplied with retractable frames for easy
removal without dismantling the bottom piece of chute to enable belt lift for idler roll
access.
10° Return Idlers
All return idlers are situated 2m and above ground level. All the return idlers will be
equipped with baskets below each idler set, whereby a person can crawl in underneath the
idler, lie on his back and replace idler rolls as and when required. On each side of the
gantry, two fall restraint hooks will be provided to secure a fall arrest harness, while sliding
with your back onto the basket to gain access underneath the idler. Refer to drawing
extract below.
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A typical basket is shown above below return idler set.
A typical basket viewed in plan.
The return idlers on top of the bunker can be accessed by removing a diagonal brace on
the side of the support structure, as all these braces are bolted. With the aid of ropes and
a person pulling from the top, the roll can be unhooked from the idler bracket and dropped
down on to the basket, whereby it can be pulled out to the side. To replace the roll, a rope
can be tied to the roll and lifted from the top while another person guides the locating shaft
ends into the idler bracket.
Bolted Diagonal Brace.
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12.1.4 Belting
Technical Data
Belt Type – Plied Belt
Belt Mass – 28.62kg/m
Belt Class – 1250N/mm
Belt Width – 1800mm
Number of Plies – 4 Ply
Top Cover Thickness – 4mm
Bottom Cover Thickness – 2mm
Cover Grade – F
Conveyor Tape Length – 826m
Pulley Centre Distance – 388.9m
Belt Order Quantity – 857m
Number of Rolls – 3 off / 2x 286m of Belt per Reel and 1x 285m of Belt per Reel
Approximate Roll Mass – 10.2t
Approximate Roll Diameter – 2.4m
Number of Splices – 3 off
Roll Lay-off - Both rolls will be supplied in the same configuration, i.e. wound in the factory
with belt top cover on top, heat 1, outside, when viewed by the splicing crew. The leading
edge of the belt will reel off the top of the reel.
Initial Belt Pull Method Statement
1. Place belt roll 1 to straddle conveyor on top of the bunker, ~82m away from where the
take-up structure starts. The same A-frame can be used (provision we need to make
for each conveyor) as the one which will be installed at the tail end of the conveyor for
future belt replacement and repair.
2. All rolls should be placed such that the leading edge is coming off the top of the reel,
with the top cover of the belt facing upwards.
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3. Set-up the splice table behind roll 1. The roll is positioned such that when the first roll
is pulled down the incline completely, the leading edge of the belt at the tail pulley will
be approximately 2m past the tail pulley.
4. A suitably sized hydraulic winch and rope to pull the entire 857m of belt will be used
(~2.4t pull force required). Place this temporary belt pulling winch behind the
conveyor tail frame at the incline transfer house. Reeve the winch cable through to
the top of the bunker. The pressure can be set on the winch to prevent over tension
on the cable. The tension will only be set for the required belt pull as a safety
precaution.
Belt Mass 28.62 kg/m

Belt Length: 857 m
- Straight Section 223.738 m
- Incline Section 189.162 m
- Return Side 413.1 m
Inclination Angle 0.262 rad
Friction Factor 0.03 p.u.
Rope Nominal Diameter 24 mm
Rope Mass 2.316 kg/m
F = W(µ x Cos ø + Sin ø) + Fh + Fr + Fb + Rope

F = 1930.345 kg
Contingency Factor 1.2 p.u.

Pulling Force Required: 2316.414 kg
Round Up 2400 kg
Required Winch Pull 2.4 ton
5. Install a manual belt clamp at the start of the decline on the carry side, prior to the
take-up structure.
6. Fit a belt clamp to the leading edge of the first roll.
7. The leading edge of the belt can be cut, so that both sides of the leading edge are in
a “v”-shape towards the centre line of the belt.
8. The speed of the hydraulic winch will be approximately 0.07m/s (4m/min) and the
speed can be varied with a flow control valve, especially when going around the
pulleys and down the decline. A load cell for safety precautions can be fitted to the
leading edge to monitor the tension. The tension in the cable will be monitored
continuously by a spotter walking alongside the leading edge. The spotter will be in
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radio contact with the winch operator and personnel further down the conveyor for
safe operating and pulling.
9. The weight of the belt from the top of the reel combined with the pull from the winch
will un-reel the belt from the let-off station.
10. The belt clamp is used to control the decline feed of roll 1 and to safely pull the
remainder of the belt. The clamp will be set in such a way that the clamp friction
control a slow feed down the decline, even if the belt is pulled by the winch.
11. Once the leading belt edge reached the tail pulley and passes the tail pulley by
approximately 2m, the clamp is engaged. A channel clamp is fixed to the lagging end
of the roll one and secured to the tripper car support structure. The splicing crew will
then remove the vacant roll 1, lift roll 2 up to the bunker and position in the same
location as roll 1. Roll 2 must however be rotated 180 degrees, so that the leading
edge of the belt faces the head pulley. The top cover of the belt will still face upwards.
While this is happening, the winch operating team will disconnect the belt clamp from
the leading edge of roll 1 and reeve the cable through the return side of the conveyor
to the top of the bunker.
12. Clamp the leading edge of roll 2 and attach the cable to the clamp.
13. The pulleys must be protected against the clamp and cable, either by leaving the
suppliers strapping on (tin strapping) or by enclosing and strapping it with off cut
belting. The clamp will be covered in a similar fashion, to protect pulleys against any
possible damage.
14. Once all crews have completed their tasks, roll 2 will be pulled through the full 286m.
Once completely pulled in on the return side, the leading edge will still be on the top
of the bunker. The lagging end of roll 2 will be at the splice table. No need for
clamping this roll.
15. The splicing crew will then remove the vacant roll 2, lift roll 3 up to the bunker and
position in the same location as roll 2. Roll 3 must however be rotated 180 degrees,
so that the leading edge of the belt faces the head pulley. The top cover of the belt
will still face upwards. While this is happening, the winch operating team will
disconnect the pull rope from the belt clamp of roll 2’s leading edge. This is to prevent
any unforeseen pull on belt 2 while the splicing is taking place between the lagging
end of belt 2 and the leading end of belt 3.
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16. Splice roll 2 and roll 3 together. While the splicing is taking place, the manual belt
clamp is installed on the return side, prior to the take-up structure.
17. Once the splicing crew completed the first splice, the pull cable will be attached to the
clamp on belt 2’s leading edge. Both belt 2 and belt 3 will be pulled through to the tail
on the return side. Care should be taken when the belt passes the clamp at the
decline. Once the belt passes the clamp, the winch should be stopped and the clamp
set to enable a controlled pull, and to prevent any run-away of the belt down the
decline.
18. Once the third roll’s leading edge passes the tail end, the pulling activity is stopped.
The lagging end of roll 3 should then be spliced to the free end of roll 1 on top of the
bunker. This will be the second splice. The third and final splice between roll 1 and 3
will be at the tail pulley of the conveyor.
19. Before the final splice is performed, the take-up carriage shall be moved into the
correct position. The loose ends of the belts shall be flipped over one another and the
correct belt length shall be determined to perform the final splice.
20. The polyline below is an illustration of the 3 different rolls pulled in.
Belt Repair Method Statement
1. Belt repair need to take place from the tail pulley of the conveyor. We need to allow
for sufficient space, 9m x 6m, for splicing, 2off strobe lights and a movable closure
and an A-frame support for the reel. Since the tail end of the tripper conveyor is within
the incline transfer tower and no space available behind the tail pulley of the tripper
conveyor, the provision for the afore-mentioned may be required on a level higher.
Detail of this still need to be finalised, as the incline conveyor is a lesser priority at this
stage. This may even require deflector pulleys to guide belt down and onto the tripper
conveyor.
2. Any length of belt can therefore be replaced by cutting and splicing it at the tail to the
spare roll and by using the drive to pull in the new length of belt and un-reeling the old
belt at the same time.
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3. Once the repaired length is replaced with a new length of belt, the roll is cut and the
final splice is carried out.
4. During a belt snap situation, which is more likely to happen in the area of the drives,
i.e. T1 tension, a facility needs to be provided to prevent complete belt run back. The
drives are situated at the fixed tripper, and the probability of a belt break will then be
on the incline portion of the belt. To prevent run back, one directional carry idlers may
need to be installed on the incline portion. A temporary splice insert can also be made
and by setting the VFD to a lower speed, the belt can be cycled around with the
motor to the tail, where a proper splice can be carried out. The VFD can be set as low
as 6Hz. The motor is fitted with force ventilation which ensures constant cooling. By
setting it to 6Hz, the load curve is still well within the motor force ventilation de-rating
curve. Refer curve below (red line compared to green line).
5. The supplier’s recommendation for spare belt is 300m.
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12.1.5 Winches and Sheaves
Technical Data
Counterweight
Mass (Ton) Required Minimum Recommended Winch
2 x T2 = Ttu = (Ttu/9.81) x BELT Required Winch Take-Up Pulley Travel Allowance Winch Safe Working
(kN) reeving ratio Capacity Displacement (A) in Tower Model Load
110.00 11.21 3.12t 6.89m 7.89m 8000S 5.4t
Sheave
Motor Rope Winch Root
Power Diameter Rope Capacity Diameter
(kW) (mm) (m) (mm)
2.2kW, 1.3m/min 20.00 94 350
For any maintenance activity, the take-up tension can be released through the 8000S
winch. The winch shall be raised the full travel distance (6.89m) to allow sufficient slack on
the belt. At this point, a locking mechanism will be used to lock the carriage in place at that
specific level. Access to the take-up carriage is accessible through the take-up tower. The
take-up carriage shall be locked on both sides of the carriage, in front and at the back.
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For sheave inspection and maintenance, these are serviceable from the second and fourth
level of the take-up structure. The sheaves are enclosed with proper guards. The winch
can be inspected and maintained from the third level of the take-up structure. This
particular winch has a mass in the region of 300kg. The same crawl beam installed for the
removal of the take-up pulley can be used for the removal of the winch.
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The crawl beam shall be constructed with a curve to divert the winch and the pulley
directly to the open area next to the stairs for the overhead crane to reach.
12.1.6 Transfer Chute Liners & Tripper Car Transfer Chute and Liners
Chute will come complete with proper inspection hatches for ceramic wear inspection.
Chute will be designed such that it can be easily split into different sections for scheduled
repairs and in situ removal of equipment. These flanges will be located at appropriate floor
levels. At these flanges, provision will be made for the insertion of scaffolding pipes so that
a platform can be constructed on the inside of the chute to enhance ceramic liner repair
when necessary.
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Access to the crane for maintenance is provided as part of the escape route. This access
is at the beginning of the tripper car maintenance parking bay.
The hoist schedule for this conveyor to follow after discussion with Client and official
approval is granted. Working platforms shall be provided to access all crawl beams to
enable hooking of lifting equipment onto the crawl beams.
The tail frame guards will be detailed such that the plummer blocks are outside the guard,
to facilitate greasing without removing any guards, as well as enhancing vibration
monitoring. When removing the guards, the grease point will therefore not interfere with
the removal process. Refer to pictures below for two options available.
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Option 1
Option 2
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12.1.9 Tripper Car Equipment
12.1.9.1 Travel Drive Assembly
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The drive assembly is serviceable from the tripper car bottom platform. Access to this
platform is via a cat ladder. The drive assembly can be lifted straight up with the overhead
crane. This activity can only happen in the dedicated maintenance area for the tripper car.
The floor panel above the drive must be removed to enable a direct upward lift. Refer
picture above.
12.1.9.2 Caliper Brake Assembly
The caliper brake assembly on the opposite side to the drive is also serviceable from the
tripper car bottom platform. Access to this platform is via a cat ladder. The brake assembly
can be lifted straight up with the overhead crane. This activity can only happen in the
dedicated maintenance area for the tripper car. The floor panel above the brake assembly
must be removed to enable a direct upward lift. Refer picture above.
12.1.9.3 Couplings / Chain Sprockets / Chain Idlers / Shafts / Chains
The couplings, chain sprockets, chain idlers and drive shafts are serviceable in the same
fashion as described above for both the drive –and brake assembly.
The chain and support brackets can be inspected by walking along the maintenance
walkway. The chain will be located in a 100mm long channel (152 x 76) positioned at
every vertical support leg. The channel will be supported to the leg by means of an angle
iron. The collection of dust within the channel is therefore eliminated and would be self-
cleaning as the chain runs through these intermittent channel supports.
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12.1.9.4 Tripper Car Festoon and Runners
The festoon cable and flat bar runners are all accessible from the main walkway. The
height is currently at 1.8m as illustrated above.
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13. RECOMMENDATIONS
The following is recommended based on the design assessment:
• Special tools shall include
o C-Clamp designed and certified as lifting equipment for 1800mm wide

conveyor belt.
o Spreader bar designed and certified as lifting equipment for 1800mm wide
conveyor belt.
o Angle iron skid frame required for pulley 2 removal.
o 2 sets of channel clamps, one set for holding belt from rotating, the other
set for pulling belt to gain clearance between conveyor belt and pulley.
o Flexco belt lifter shall be used for lifting belt off idler rolls.
o A-frame shall be designed and installed at the tail end of the conveyor for
belt maintenance.
o For belt splicing maintenance activities, 2off strobe lights and moveable
closure shall be procured. This equipment shall be kept in the store and
used as and when required.
• Pulling points are required as highlighted below.
o 2off lugs on conveyor head frame, to assist with belt pulling to gain
clearance between conveyor belt and pulley.
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o 1off lug on transfer tower cross beam between the columns, approximately
1m above centre line of pulley. This lug will be used for the initial belt pull, to
secure a snatch block.
o A cross beam to be installed between column 1 and column 2, with a lug in

line with pulley 2 shaft. This lug will be used to pull pulley from underneath
the conveyor structure from the angle iron skid frame. A similar set-up is
required on the opposite side for pulling the pulley back in position. This lug
however must be lower down on the cross beam so that the steel wire rope
clears the drive assembly.
o A cross beam is needed between the first two columns respective. The
cross beam between columns two will be used for clamping the belt to
prevent belt rotation when clearance is required. The cross beam between
columns one will be used to pull the belt away from pulley 5 so that enough
take-up slack is achieved. This will allow enough belt length to facilitate with
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folding the belt over to the side at pulley 5 to gain access with the slinging
process.
o 3off lugs on conveyor tail frame, to assist with belt pulling to gain clearance
between conveyor belt and pulley.
All pulling points and crawl beams must have clear SWL identification and shall be
stated on the GA.
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• The 60° luffing chute idlers must be ordered with retractable bases for easy
removal of rolls.
• A small overhead crawl suitable for lifting ~200kg must be added above take-up
winch to facilitate complete winch removal.
• An A-Frame for a belt reel (300m spare belt) to be designed and shown at the tail
end of the conveyor.
• 4off Return idler guards to be called-up as indicated (refer idler section).
• Fall protection constraints needed for pulley 5. Alternatively, a possible access

platform above horizontal take-up to get access to pulley 5 during maintenance.
• Allow sufficient access space underneath counterweight for cleaning, ~200mm.
• Allow for mechanical lockout on both take-up carriage and structure at both front
and rear to prevent unintended movement of take-up carriage during maintenance
activities.
• Rubber buffers to be added on horizontal take-up carriage, at clearance position.

Carriage mechanical lockout facility to be provided during maintenance, to prevent
movement of carriage.
• Raise crawl beam level high enough for sufficient vertical clearance for chain block
and slings.
• A complete list of crawls and hoists with safe working load and position to be called
up on final general arrangement drawing. A crawl schedule is enclosed at the end
of this report.
• Extend take-up pulley greasing point to outside the clear view guard arrangement.
• All guards shall be designed such that the pulley plummer blocks are outside of the
guard.
• Pulley 2 to be ordered with the shaft ends drilled and tapped for M16 eyebolt. This
is required for pulling the pulley from underneath the conveyor structure.
• All pulleys must be protected against possible lagging damage during the initial belt
pull.
• All gantries shall where return idler baskets are situated shall be supplied with 2off
fall restraint hooks on both sides of the walkway, to secure a fall arrest harness.
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• All mechanical equipment shall be ordered with lifting lugs.
• All drive assemblies shall be supplied with axial and radial alignment facilities on
the baseplates.
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The following is recommended based on the design assessment:
• Special tools shall include
o C-Clamp designed and certified as lifting equipment for 1800mm wide

conveyor belt.
o Spreader bar designed and certified as lifting equipment for 1800mm wide
conveyor belt.
o Angle iron skid frame required for drive pulley and snub pulley removal.
o 2 sets of channel clamps, one set for holding belt from rotating, the other
set for pulling belt to gain clearance between conveyor belt and pulley.
o Manual belt clamp which will be used for the initial belt pull excerise.
o Beam clamp to assist with the removal of snub pulley.
o Flexco Belt Lifter
o A-frame for initial belt pull. The same A-frame will be used for belt
maintenance by the Client.
o For future splicing, allow for 2off strobe lights and movable closure, which
will be kept in the store and used as and when required by the Mine.
• Pulling points are required as highlighted below.
o 2off lugs on fixed tripper support frame, to assist with belt pulling to gain
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o Support frame to facilitate belt pull from fixed tripper bend pulley.
o To facilitate the bend drive pulley removal at the fixed tripper, the stairs
need to be moved out for proper clearance. Since this is only required on
one side, the best would be to do it both sides to keep the platform the
same.
o A cross beam is needed between the two columns as shown, on both sides
of the bunker. Two pull points need to be added to each cross beam, to
allow pulling the drive bend pulley and snub pulley out from underneath the
conveyor stringer and fixed tripper platform.
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o 2off lugs on tripper car head pulley frame, to assist with belt pulling to gain
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o 4off lugs on head pulley support frame, to assist with belt pulling and belt
clamping to gain clearance between conveyor belt and pulley.
o 2off lugs on floor beam at incline conveyor transfer tower, to assist with belt
pulling at the Tripper conveyor tail pulley, to gain clearance between
conveyor belt and pulley. Cast in plates need to be allowed for in the
concrete pillars with pull points which will be used to pull and twist belt over
to one side in order to gain access to both sides of the pulley, preventing
double slinging. Dual crawl beams to be provided.
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o At the floor below the bend pulleys, allow for 2off lugs on the columns as
shown below. This will be used for pulling pulleys 7 & 9 to the side first, to
roll them to the open crane lifting well as indicated below. The crawl for
servicing the take-up pulley can also be used for lifting of pulley 7. This
crawl runs to the actual lifting well, where the overhead crane can be slung
to the pulley to lower it straight down to ground level.
o For servicing the take-up pulley, a crawl is required below the top floor, i.e.
below the bend pulleys. This crawl shall be offset from the centreline of the
pulley by 100mm, to clear the maintenance winch cables. The clearance
between the belt and the crawl will be 150mm. The crawl must run in front
of pulley 7 and will clear the take-up winch and building column as shown
below and will end at the lifting well.
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o Add cross beam for belt pull at tripper bend pulley as indicated below.
All pulling points and crawl beams must have clear SWL identification and shall be
stated on the GA.
• All carry idlers underneath chute discharges must be ordered with retractable
bases for easy removal of rolls.
• An A-Frame for a belt reel (300m spare belt) to be designed and shown at the tail
end of the conveyor. This belt reel may have to be placed at a level higher at the
incline conveyor transfer house to facilitate belt repair. Sufficient space shall be
provided for splicing, i.e. ~9m x 6m. Detail to be finalised with possible bend
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pulleys to guide belt onto tripper conveyor. The same A-frame must be able to
straddle the support structure on top of the bunker for the initial belt pull.
• Fall protection constraints needed on tripper car at the removable floor panels. It is
also required at the platform for maintaining carry idlers on the tripper support
structure.
• Allow for mechanical lockout on both take-up carriage and structure at both front
and rear to prevent unintended movement of take-up carriage during maintenance
activities.
• A complete list of crawls and hoists with safe working load and position to be called
up on final general arrangement drawing. Schedule enclosed at the end of this
report.
• Extend take-up pulley greasing point to outside the clear view guard arrangement.
• The secondary drive pulley and snub pulley to be ordered with the shaft ends
drilled and tapped for M16 eyebolt. This is required for pulling the pulley from
underneath the fixed tripper structure.
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• Tripper car floor panel to be removable, so that a c-clamp can reach the tripper car
bend pulley. Hand rail clamp to be installed to clamp together both enclosures.
• Platforms shall be provided to access the tail pulley crawl beam and the take-up
pulley crawl beam.
• The crane shall be capable of lifting the entire torque arm drive assembly.
• All mechanical equipment shall be ordered with lifting lugs.
• Drive assemblies shall be ordered and specified with jacking screws in axial and
radial planes for alignment purposes.
• All gantries where we have return idler baskets shall be provided with 2off fall
restraint hooks on both sides of the walkway to secure a fall arrest harness.
• Diagonal braces on tripper car support structure shall be bolted to facilitate return
idler roll replacement.
• All pulleys must be protected against possible lagging damage during the initial belt
pull.
• All guards must be detailed such that the pulley plummer blocks are on the outside
of the guard.
• Tripper car chain to be located in 100mm long channel sections. No continuous

channel shall be used.
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14. RAMBO CHECKLISTS

MH0074-EM-
Quality Management System Document No:
CH-040
Project No: MH0074
Revision: 0
ELB ENGINEERING SERVICES (PTY) LTD

ELB RAMBO Checklist
Impumelelo Reclaim Conveyor Date : 2012-02-07
CV2303
Page No: 89 of 94
Reliability Accessibility Maintainability Buildability Operability and Price
Aim: The aim of this checklist is to highlight the RAMBO principle and to ensure that the
elements of RAMBO have received due consideration
Procedure: The following Checklist shall be completed during the review phase of each
drawing. The checklist is to be completed by the design engineer responsible for
reviewing the drawing. Notes to support the checklist items shall be made as
appropriate to support the checklist items.
Assessment done on drawing:
MH0074-022-CV-2303-L-001
Overland Conveyor System
Reclaim Conveyor CV2303
General Layout
1. RELIABILITY YES NO
• Is the device/item being applied to a service for which it is designed? Yes

• Is the device/item operating within its normal designed operating
Yes
parameters?
• Is the device/item built from appropriate materials considering
Yes
strength, wear and corrosion?
• Is the device/item lined with appropriate wear resistant material
Yes
considering the application?
• Is the surface protection specification called for appropriate to the
Yes
duty? On General Notes Drawing.
• Does the device/item require protection from impact due to vehicles? No
• Does the device/item require special consideration due to its being
Yes
essential to prevent injury or death to personnel?
• Have the worst case process conditions been defined and addressed? Yes
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2. ACCESSIBILITY YES NO
• Can all parts requiring regular service be reached safely without the
use of other supplementary access devices? Special tools for
No
pulleys and idler removal. Refer recommendations in
maintainability design review report.
• Can all parts requiring infrequent access be reached without
Yes
excessive disassembly or unsafe work practices? See note above.
• For activities working at height without fall protection, have fall
restraint provisions been provided? Pulley 5, gantries at return idler Yes
baskets. Possible platform to pulley 5.
• Is the device/item likely to be classified as a confirmed space? No
• If the device is likely to be classified as a confined space has provision
No
been made to account for this?
• Is there adequate room around the device for clean up? Yes
3. MAINTAINABILITY YES NO
• Can all frequent maintenance be performed without recourse of

Yes
unsafe work practices?
• Are lifting facilities available to allow frequent maintenance activities to
Yes
be easily performed without recourse to elaborate rigging practices?
• Can infrequent maintenance activities be performed without recourse
Yes
to unsafe work practices?
• Can wearing parts be easily accessed for replacement/repair? Yes
YES NO
4. BUILDABILITY
• Can the device/item be installed without recourse to unsafe work
Yes
practices?
• Can the device/item be installed with the lifting equipment available on
Yes
site?
• Is it necessary for the device/item to be installed in a specific
Yes
sequence?
• Should lifting lugs be incorporated into the design? Yes
5. OPERABILITY NO
• Is this device readily available to an operator? Yes

• Can the operation of the device be easily inspected by an operator? Yes
• Are controls for the device located for ease of operation? Yes
• Are there adequate controls/instruments provided to allow for
Yes
satisfactory operation of the device?
YES NO
6. COST AND SCOPE IMPLICATIONS
• Are the item quantities similar to the estimate allowance? No
• Is the lining the same as the specification or original estimate? N/A
Insert any comments required to clarify or expand on any of the above points
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Comments:
Accessibility – Require special tools for pulley removal.
Pulling points required at various positions. Refer to Maintainability Design Review Report.
60 Degree luffing chute idlers to be retractable for easy roll replacement.
Pulley plummer blocks to be located outside the tail guard. At horizontal carriage, the take-up pulley
grease point to be extended outside the clear view guard arrangement.
Tail frame guard drawing required for review and sign-off.
Rubber buffers on horizontal carriage. Allow mechanical lock-out on horizontal carriage.
Belt reel support to be provided at conveyor tail end.
Crawl required above winch.
Where incline starts, 5off return idlers to be enclosed with guards.
Allow sufficient space for cleaning at take-up area between clear view guard and floor level.
Provision to sprag counterweight when maintenance is carried out. This will enable the tension
release on the winch.
Check Sheet Completed:
Name Discipline Sign Off
Douw de Necker Mechanical Engineer

………………………………… ……………………………………
………………………………… ……………………………………
………………………………… ……………………………………
………………………………… ……………………………………
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MH0074-EM-
Quality Management System Document No:
CH-038
Project No: MH0074
Revision: 0
ELB ENGINEERING SERVICES (PTY) LTD

ELB RAMBO Checklist
Impumelelo Tripper Conveyor Date : 2012-02-07
CV6 ITA
Page No: 92 of 94
Reliability Accessibility Maintainability Buildability Operability and Price
Aim: The aim of this checklist is to highlight the RAMBO principle and to ensure that the
elements of RAMBO have received due consideration
Procedure: The following Checklist shall be completed during the review phase of each
drawing. The checklist is to be completed by the design engineer responsible for
reviewing the drawing. Notes to support the checklist items shall be made as
appropriate to support the checklist items.
Assessment done on drawing:
MH0074-022-CV-6ITA-M-001
Overland Conveyor System
Tripper Conveyor CV6 ITA
Mechanical Layout
1. RELIABILITY YES NO
• Is the device/item being applied to a service for which it is designed? Yes

• Is the device/item operating within its normal designed operating
Yes
parameters?
• Is the device/item built from appropriate materials considering
Yes
strength, wear and corrosion?
• Is the device/item lined with appropriate wear resistant material
Yes
considering the application?
• Is the surface protection specification called for appropriate to the
Yes
duty? On General Notes Drawing.
• Does the device/item require protection from impact due to vehicles? No
• Does the device/item require special consideration due to its being
Yes
essential to prevent injury or death to personnel?
• Have the worst case process conditions been defined and addressed? Yes
2. ACCESSIBILITY YES NO
• Can all parts requiring regular service be reached safely without the No
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use of other supplementary access devices? Special tools for

pulleys and idler removal. Refer recommendations in
maintainability design review report.
• Can all parts requiring infrequent access be reached without
Yes
excessive disassembly or unsafe work practices? See note above.
• For activities working at height without fall protection, have fall
restraint provisions been provided? Gantries at return idler baskets,
Yes
at tripper car removable panels, at tripper car maintenance
platform to service carry idlers.
• Is the device/item likely to be classified as a confirmed space? No
• If the device is likely to be classified as a confined space has provision
No
been made to account for this?
• Is there adequate room around the device for clean up? Yes
3. MAINTAINABILITY YES NO
• Can all frequent maintenance be performed without recourse of

Yes
unsafe work practices?
• Are lifting facilities available to allow frequent maintenance activities to
be easily performed without recourse to elaborate rigging practices? Yes
Specific requirements are made under recommendations.
• Can infrequent maintenance activities be performed without recourse
Yes
to unsafe work practices?
• Can wearing parts be easily accessed for replacement/repair? Yes,
the requirement of pulling points, access and crawls have been Yes
taken into consideration.
YES NO
4. BUILDABILITY
• Can the device/item be installed without recourse to unsafe work
practices? Possibility of mine activity when this conveyor needs
Yes
to be erected. An assessment needs to be done to establish the
consequences.
• Can the device/item be installed with the lifting equipment available on
Yes
site?
• Is it necessary for the device/item to be installed in a specific
Yes
sequence?
• Should lifting lugs be incorporated into the design? Yes
5. OPERABILITY NO
• Is this device readily available to an operator? Yes

• Can the operation of the device be easily inspected by an operator? Yes
• Are controls for the device located for ease of operation? Yes
• Are there adequate controls/instruments provided to allow for
Yes
satisfactory operation of the device?
YES NO
6. COST AND SCOPE IMPLICATIONS
• Are the item quantities similar to the estimate allowance? No
Doc
Revision: A
Page No: 94 of 94
• Is the lining the same as the specification or original estimate? N/A
Insert any comments required to clarify or expand on any of the above points
Comments:
Accessibility – Require special tools for pulley removal.
Pulling points required at various positions. Refer to Maintainability Design Review Report.
Carry idlers under chute discharge to be retractable for easy roll replacement.
Pulley plummer blocks to be located outside the tail guard. Grease points to be extended outside
the guards and should not interfere when a guard needs to be removed.
All guard drawings required for review and sign-off.
Allow mechanical lock-out on vertical take-up carriage.
Belt reel support to be provided at conveyor tail end.
Crawl required above tail pulley and take-up pulley. Height of crawl at tail pulley to be increased.
Allow sufficient space for cleaning at take-up area.
Provision to sprag counterweight when maintenance is carried out. This will enable the tension
release on the winch.
Secondary drive pulley and snub pulley to be ordered with drilled and tapped shaft ends to enable
pulley removal.
Special pulley skid frames to be made up for secondary drive –and snub pulley removal.
Tripper car floor panel to be made removable to gain access to tripper car bend pulley.
Fall restraint hooks needed for certain areas, such as at tripper car and gantries at return idler
baskets.
A-frame required for belt pull. The same A-frame to be used for belt maintenance.
Working platforms to all crawl beams shall be provided.
Check Sheet Completed:
Name Discipline Sign Off
Douw de Necker Mechanical Engineer

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What areas of the materials handling system will be assessed?

What areas of the materials handling system will be assessed?

Quality Management System Document No: MH0074-EM-IS-001

Report Project No: MH0074

PROJECT SASOL IMPUMELELO MATERIALS

REV DATE DESCRIPTION ORIG CHK’D Q.A. P.E.

A 2013-03-04 REVIEW AND COMMENT DDN AF JS PG

4. REFERENCED DOCUMENTS ................................................................................................................. 4

5. REFERENCED DRAWINGS .................................................................................................................... 5

6. MAINTAINABILITY PHILOSOPHY ........................................................................................................... 7

7. DESIGN REQUIREMENTS ...................................................................................................................... 9

8. METHODOLOGY OF ASSESSMENT .................................................................................................... 10

9. TECHNICAL DESCRIPTION .................................................................................................................. 10

10. SAFETY INFORMATION.................................................................................................................... 20

11. COMPONENT MAINTENANCE ......................................................................................................... 20

12. MAINTAINABILITY DESIGN REVIEW ............................................................................................... 20

13. RECOMMENDATIONS ...................................................................................................................... 76

14. RAMBO CHECKLISTS ....................................................................................................................... 89

1 500t Underground Bunker

Incline Conveyor – CV6 INA

Impumelelo Tripper Conveyor – CV6 ITA

15 000t Surface Bunker – BU2304

Impumelelo Reclaim Conveyor – CV2303

Overland Conveyor, including the following:

• Overland Conveyor Belt Turnover and Tail End

• Overland Conveyor Mid Station / Belt Storage

• Overland Conveyor Head End

SCS Tripper Conveyor – CV2302

4000t Surface Bunker – BU2305

SCS Reclaim Conveyor (Initial) – CV2307

SCS Connecting Conveyor – CV2308

SCS Sasol Coal Supply

BU Surface Coal Bunker

RAMBO Reliability, Accessibility, Maintainability,

OLC Overland Conveyor

SWR Steel Wire Rope

SWL Safe Working Load

PFD Process Flow Diagram

MFD Mechanical Flow Diagram

P&ID Piping and Instrumentation Diagram

• MH0074-EM-CH-003 Rev. 04 – Design Report for Impumelelo Reclaim Conveyor

• MH0074-EM-CH-002 Rev. 04 – Design Report for Tripper Conveyor

• MH0074-EM-CE-045 Rev. G – Gearbox Ratio Data Sheet

• MH0074-EM-PL-001 Rev. A – Gearbox Orientation Schedule

• MH0074-EM-CH-070 Rev. G – Pulley Standardisation Schedule

• MH0074-EM-CH-072 Rev. A – Idler Standardisation Schedule

• MH0074-EM-IN-009 Rev. L – Crane Schedule

• MH0074-EM-CH-056 to 064 – Winch Calculations

• MH0074-EM-CH-001 Rev. C – Mechanical Equipment List

• MH0074-EM-RP-022 – Materials Handling System – Hazop Analysis

• MSTMMG000016 Rev. 01 – Materials Handling System Specification

• 02060003-O 04-SOW-04-0002 Rev. I – Impumelelo MHS SOW

• MH0074-EM-SP-007 Rev. 0 – Design Criteria Mechanical

• SA Mines Health and Safety Act

• Act 85 (1993) – Occupational Health and Safety Act

Impumelelo Reclaim Conveyor – CV2303

• MH0074-030-GN-0000-F-001 – Material Flow Diagram

• MH0074-030-GN-0000-F-002 – Process Flow Diagram