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exxaro
POWERING POSSIBILITY
MECHANICAL ENGINEERING STANDARD
EXX-EME-STD-0008
FOR
EXXARO
EXX-EME-STD-0008
COMPILED BY:
TITLE DATE
DOCUMENT APPROVALS
#
PRINCIPAL MECHANICAL
ENGINEER
HENNIE FOURIE
4/t;J/6
I~
DOCUMENT CONTROL
DOCUMENT INFORMATION
INFORMATION
DOCUMENT HISTORY
The following acronyms are applicable to this document: For more details, please consult the
Glossary.
ACRONYM DESCRIPTION
DEFINITIONS
The definitions listed below apply to this document. For more details, please consult the
Glossary.
TERM DEFINITION
REFERENCES
The following documents are either Applicable Documents - applicable to the extent
specified herein and thus forming part of this document. The applicability will generally relate
to the Project in terms of policy, procedures, standards, qualification, etc.; or Reference
Documents - where the information concerned has been fully extracted from the reference
document and added to this document, or where the reference document contains
information relevant to this document, or for information only.
ISO 8501-1: Preparation of steel substrates before application of paints and related Applicable
products - Visual assessment of surface cleanliness
DOCUMENT DISTRIBUTION
This document is available for internal and external use at Exxaro Resources Technology
and related projects.
TABLE OF CONTENTS
1. PURPOSE ......................................................................................................................................7
2. SCOPE DEFINITION .....................................................................................................................7
3. BATTERY LIMITS..........................................................................................................................7
4. EXCLUSIONS ................................................................................................................................7
5. DEFINITIONS AND ABREVIATIONS ...........................................................................................7
6. RESPONSIBILITIES ......................................................................................................................7
7. REQUIREMENTS FOR WEAR LINING ........................................................................................8
7.1 GENERAL ............................................................................................................................8
7.2 WEAR LINING REQUIREMENTS FOR SPECIFIC APPLICATIONS .................................9
7.3 CERAMIC WEAR LINERS .................................................................................................10
7.3.1 General .................................................................................................................10
7.3.2 Standard ceramic tiles...........................................................................................11
7.3.3 Engineered tiles ....................................................................................................11
7.3.4 Liner thickness ......................................................................................................12
7.3.5 Surface preparation for ceramic tiling ...................................................................12
7.3.6 Ceramic tile layout .................................................................................................12
7.3.6.1 General .................................................................................................12
7.3.6.2 Protection of epoxy adhesives .............................................................12
7.3.7 Permanent marking of ceramic lined plate work ...................................................14
7.4 REQUIREMENTS FOR STEEL LINERS ...........................................................................15
7.4.1 General .................................................................................................................15
7.4.2 Steel lining layout ..................................................................................................16
7.4.3 Steel lining fixing requirements .............................................................................18
7.4.4 Surface preparation for steel liners .......................................................................20
7.4.5 Steel liners in dead box areas ...............................................................................20
7.5 Lip liners .............................................................................................................................20
8. MANUFACTURING REQUIREMENTS .......................................................................................20
9. PACKING, DELIVERY, OFF LOADING AND STORAGE ON SITE ..........................................20
10. ASSEMBLY, INSTALLATION, ERECTION AND CONSTRUCTION REQUIREMENTS ...........21
10.1 CERAMIC TILES................................................................................................................21
10.1.1 Attachment of tiles.................................................................................................21
10.1.2 Erection and installation of ceramic lined components .........................................21
10.2 INSTALLATION OF STEEL LINERS .................................................................................21
11. COMMISSIONING REQUIREMENTS .........................................................................................21
12. PROJECT DOCUMENTATION ...................................................................................................22
12.1 DRAWINGS .......................................................................................................................22
FIGURES
TABLES
1. PURPOSE
This Exxaro Wear Protection for Plate Work and Chutes (number EXX-EME-STD-
0008) states the standard requirements for metallic and ceramic wear lining for
plate work and chutes in abrasive environments. The life cycle phases covered
are from design up to commissioning.
2. SCOPE DEFINITION
This specification details the requirements for metallic and ceramic wear lining for
plate work and chutes in abrasive environments. The specification covers chutes,
bins and underpans as well as plate work surfaces of vibrating feeders and screen
underpans requiring wear lining. It includes the specification, design and
installation of wear lining. It also informs designers of plate work and chutes of the
lining requirements to be provided for in the design phase.
3. BATTERY LIMITS
This specification is applicable to all wear areas that will be lined with steel or
ceramic liners, excluding pipe work.
4. EXCLUSIONS
The specification is limited to wear lining and excludes the specification, structural
and functional design requirements of the components to be lined.
6. RESPONSIBILITIES
The Exxaro Principal Mechanical Engineer is responsible for this standard.
7.1 GENERAL
The type of lining specified dictates the design of the equipment being lined. The
designer must make provision for the thickness of the lining when specifying inside
dimensions of components to be lined.
The mass of the lining material and the stiffness requirement for lining shall be
taken into account by the designer when designing components requiring lining.
The designer shall ensure that the lined components are of suitable section sizes
to be installed and handled safely during construction and maintenance.
Lined items shall be designed to ensure safe maintenance access for replacement
of liners or panels.
150 100 6 24
150 100 12 48
150 100 20 75
150 100 25 96
The thickness, type of lining material and area to be lined shall be indicated on
detail drawings.
Welding shall be done on the outside of the component and not on the side that
must be lined. Where internal welding is required, it shall be grinded flush to
prevent interference with the installation of tiles.
Where internal welds cannot be removed to ensure the structural integrity of the
component, liners shall be chamfered to accommodate the weld. This is
applicable for all corners, angles and joint sections as shown in Figure 1.
All work executed shall satisfy the requirements contained in the approved Quality
Control Plan, by the engineer.
Alternative lining materials than that specified may be offered for consideration by
Exxaro. Such requests shall be accompanied by full technical details of the
material and evidence that the proposed alternative shall be more cost effective
than the material specified by Exxaro. Alternative proposals shall only be
implemented after obtaining approval from the Exxaro engineer.
Table 2 indicates the lining requirement for plate work components in different coal
applications. Wear liners shall be designed considering high and low wear areas.
The designer shall specify liners considering cost and wear patterns.
ROM 50 25 25
Product 1 6
Dribblings 1 6 20
Screen underpans 10 25
Mixing box 25
Cones:
50 12
Vertical section
25
Conical section
Cones:
6
Vertical sections 4
12
Conical sections
7.3.1 GENERAL
Standard tiles rather than engineered tiles shall be used wherever possible.
The epoxy adhesive shall have minimum 38MPa tensile strength and 80MPa
compressive strength. The supplier shall specify the adhesive best suited for
application on passivated 3CR12 plate work.
The ceramic tile supplier will be required to provide product and workmanship
guarantees for each application.
Backing plates and stiffeners shall be the same material as the plate work.
Ceramic lining shall be done in the workshop or on site and shall be carried out in
a controlled environment under cover. Very large components can be lined in situ
with the approval of Exxaro. Lined items shall be devided into sections to ensure
transport of lined panels from fabricators to site as far as practically possible.
Tile layout drawings with unique numbers per item shall be provided for all tiled
surfaces on the Exxaro drawing template.
The layout of the tiles shall be detailed and submitted to Exxaro for approval. Liner
designs shall be done to minimize the use of special tiles as far as practically
possible to the discretion of the engineer.
The weight of the complete assembly, including backingplate and liner materials
shall be clearly shown on the drawing.
Standard ceramic tiles 6, 12, 20, 25 or 50 mm thick shall be used. Standard tiles
shall be rectangular, starting from 100 x 25 mm to 150 x 100 mm in the thickness
specified. The maximum tile size shall be 100 x 150 mm. The maximum tile size
shall be used wherever possible on large flat surfaces.
Engineered tiles shall be used for specific applications like square to round
sections where the use of standard tiles is not feasible.
A distinction shall be made in the tile thickness between the impact areas and the
non-impact zones of plate work as indicated in Table 2.
All surfaces shall be properly prepared before tiling in accordance with ESP-XX-
0016-01. Steel surfaces to be lined shall be ground flush. No weld beads shall
protrude on the inside of the steelwork.
Bins and chutes fabricated from 3CR12 will require sandblasting to Standard Sa
2½ as per ISO 8501-1 before application of tiles. Tiling shall cease when
discolouration of the steel is noticed. When discolouration is noticed, the remaining
area to be tiled will be sandblasted again before tilling continues.
7.3.6.1 General
Each tile shall be in intimate contact with the adjacent tile. In exceptional cases a
maximum joint width of 3 mm shall be allowed, provided that such tiles are in direct
contact for at least 90% of the length of the contact area.
The maximum allowable height variation (step) between adjacent tiles shall be 2
mm.
The bottom edge of a chute shall have a steel lip protruding to provide additional
tile support and prevent chipping of tiles.
Supporting bars shall be fitted inside large plate lining areas where support is
required.
Tiling on inspection and maintenance doors shall be flush with the lining of the
main platework.
a. Tiles shall be staggered to ensure that the epoxy route ends at a T-piece. The
shortest side of the tile shall always be in the direction of the flow as indicated
in Figure 2.
Material
flow
direction
d. Material flow shall be distributed over the largest area to minimise localised
wear when viewing a section of a chute.
Unacceptable
Acceptable
Stiffeners
All components lined with ceramic tiles shall have a permanent and clearly visible
warning stating
and stenciled onto the exterior of the component, on all sides visible from
walkways.
7.4.1 GENERAL
Where the use of steel liners is indicated, VRN 500 or approved alternative of the
specified thickness shall be used.
Liners shall be a maximum size of 300 mm x 300 mm. The maximum diagonal
dimension of any liner plate shall be less than the minimum chute outlet dimension
to ensure that dislodged liners can be discharged through the chute. The
maximum weight of a liner shall be limited to 25kg for liners with limited
maintenance access for rigging equipment.
A detailed drawing of the chute face shall be made, indicating the following:
Liner plates shall be arranged on any chute face in staggered rows across the flow
of material. No long joints will be permitted in the direction of the flow of material.
This must be achieved through a combination of square and rectangular (triangular
where applicable) plates fitted in a staggered pattern from row to row. Figure 6
shows a typical staggered arrangement.
Steel liners shall be mounted in intimate contact with the chute, bin or hopper
steelwork.
Liners shall overlap each other in corners. Liners shall be chamfered to clear welds
in internal corners. The correct and incorrect placement of liners in corners is
indicated in Figure 7 below.
The liner plates will be attached to the chute or bin plate work by means of
countersunk-head nib bolts as specified in SANS1143: “Countersunk and
Mushroom Head Bolts”, Table 2.
All nuts shall be easily accessible for liner replacement. Outside stiffener positions
must be taken into account for liner spacing and layout. Cutting away or removal of
stiffeners to accommodate fixing holes and/or nuts shall not be allowed.
Bolt holes shall be such that no two holes on the same or adjacent plates are
closer than 80 mm.
Countersunk bolt holes for the fixing of liner plates of various thicknesses shall be
as indicated in Figure 8.
There shall be no distinction between liners in dead box areas and normal flow
areas.
Lip liners shall generally be of the same material as the adjacent liners, i.e.
ceramic lip liners shall be used where the adjacent plate work is lined with ceramic
tiles and steel liners used where the adjacent plate work is lined with steel liners.
The chute designer shall confirm the suitability of the material for the specific
application, dependent of material abrasiveness, size and impact energy.
Lip liners mass must not exceed 25kg per individual section to ensure ease of
replacement. In large chutes this will require that a lip liner consist of multiple
sections.
8. MANUFACTURING REQUIREMENTS
Specific manufacturing requirements will be determined during detail design, if
required.
The ceramic tiles shall provide a complete lining system, thus preventing any
ingress of moisture through gaps between tiles. The epoxy adhesive shall be used
solely for adhesion of tile to substrate and tile to tile, and not for filling gaps
between tiles. A proper wear resistant epoxy shall be used to fill all gaps between
liners.
Due care shall be taken to prevent damage to ceramic lining during installation of
lined components. Additional stiffeners shall be used to prevent flexing of the
components if necessary.
Installation of steel liners shall be done in accordance with the approved Quality
Control Plan and detail drawings, after approval by the Exxaro Engineer.
12.1 DRAWINGS
Material data sheets and batch test certificates shall be submitted for all liners on
delivery, including backing material and epoxy and adhesive information.