This table provides a list of contract inclusions that should be reviewed for a bulk material handling project .This table of items could be considered a check list of key project considerations, before , during and on completion of a bulk materials handling project.
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Geotechnical survey and site survey
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Operational spares
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Belt rip protection systems
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Centralized lubrication
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Compressed Air
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Area lighting, high mast lighting etc.
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HAZOP studies and resultant design changes.
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Clearing of construction area of all debris, material , existing steelwork , civils etc. To allow for all new construction work.
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First fill of lubricants.
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Fire hydrants or fire extinguishers .
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All transportation of conveyor equipment on site.
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Belt magnets for tramp metal removal.
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Mechanical and structural engineering design and drafting
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Lighting on conveyors and in transfer stations
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Electrical work other than on-board conveyor electrical equipment
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Transformers
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Testing and commissioning of the equipment.
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All civil work installation required for the installation of the equipment.
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All equipment safety signage.
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Conveyors at river crossings are fully enclosed.
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Transfer points are enclosed and fitted with dust suppression systems to minimise dust pollution.
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No transfer points, loading points or discharge points are located within wetlands.
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Belt scales.
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All splicing , joining and repair of belting.
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Spares holding optimization
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Potable water.
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All area separation , including vehicle gates, pedestrian gates , fences etc.
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Interlocking Industrial Paving
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Surface conveyors without dog housing to have hold down points for wind on the head and tail frame.
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Conveyors are fitted with HDPE idlers to minimize noise.
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Spillage handling
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Drainage
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Conveyor dynamics analysis
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LV lighting and small power transformers
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Dust suppression
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Power conditioning and power factor correction equipment
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Integration to higher level PLC and SCADA systems
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Trenching
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Access and haul roads
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Packing, marking and transport of all material and equipment to site.
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Corrosion protection and touch up paint.
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Compliance with site safety and environmental training requirements prior to commencing work, personnel medical and safety inductions.
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Conveyor motor cabling and mini substations mounted on skid frames.
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All civil work design required for the installation of the equipment.
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All civil work precast fabrication required for the installation of the conveyor.
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Procurement of equipment, spares and sub-contactors
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An overall width of 8 m for single conveyors and 20 m for dual conveyors has been allowed for. This makes provision for the conveyors and associated service roads. The service roads will have gravel surfacing. The conveyors have generally been located above the natural ground level (i.e. on fill) and along the alignment of existing roads, where possible.
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For service roads across wetland areas, culverts will be placed at regular intervals (maximum spacing of approximately 50 m) to allow the through flow of surface runoff.
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Relocation of Existing Services
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Modifications to Existing Site
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Material flow testing
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Diversion of roads, haul roads, pipelines, rivers etc.
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Water management, process water, sewage etc.
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Civil work including clearing, earthworks, design and grouting
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Motor control center or programming of MCC components
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Fiber optic or copper cable to PLC / SCADA system
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Variable speed drives
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All underground flame proof equipment.
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Any blasting, cutting or trimming of underground rock or coal.
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Supply of all fasteners, gaskets, packers, shims, masonry anchors and loose fittings as required to do the installation of the works.
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Mobilization of all supervision, labour, materials, power supply, tools, construction plant and equipment, transport necessary for completion of the work.
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Detailed conveyor structural loadings and bolt loadings.
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Fire detection and/or suppression systems.Gantries elevated more than 7m should make an allowance for fire suppression at the head end of the conveyor. Water bowsers to be used for fire suppression on the ground level.
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Rationalization for drives , gearboxes , pulleys , belting or idlers.
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Site Surveying
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Surface runoff at transfer points are locally contained by means of bund walls linked to silt traps. Silt traps with drying pads are provided at all transfer points.
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Considerations are to be made for conveyors crossing wetlands.
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All lifting and rigging equipment.
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Underground personal safety devices ( Lamp , emergency rescue pack and battery pack )
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Personnel protective equipment
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Toilets
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Site Security and equipment lock-up.
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Communications Underground
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Washing down of area to clear spillage.
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Considerations for the support of the mass of conveyor drives during maintenance on the low speed coupling.
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A risk of water collecting on the belt – belt slipping is eminent and require that the design must make sure that water can run off from all the belt's tail pulleys
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Belt snapping at the highest point of tension and risk for the inclined conveyor feeding the silo which may result in potential structural damages which requires the inclusion of belt arrestors with run back idlers
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Fire booster water truck points.
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Programmable Logic Controller (PLC) and SCADA software development
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All drawings and documents available will be made available in native format and only minor changes to these documents and drawings will be necessary to finalise the design
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Structural Steel Detailing
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No allowance is made to changes to the current concept design. The contractor does not necessarily agree with the concept.The impact of such a change can only be verified after the re-design and selection of the updated concept design.
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The standard drawings produced by the FEL3(BFS) contractor are acceptable and can be used without significant modification by the successful FEL4 contractor.
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No time allowed for Environmental Services
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Costs related to vendor/contractor visits and assessments (including Quality teams)
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Hydro-geological or mine exploratory geotechnical investigations
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Any negotiations with Eskom or Transet.
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Any time for As Built drawings , or offsite support for construction managamenet.
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All site rigging points, including working at heights rigging locations and lifting points for mechanical and electrical equipment maintenance.
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Substation airconditioning design , UPS for AC and redundancy requirements.
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Some coal tipper trucks make use of auto-tarpaulin closing systems, these systems have larger clearance heights. Designs for loading equipment to cater for these additional clearance heights.
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