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283003 HOISTING EQUIPMENT : WINDERS

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283003 HOISTING EQUIPMENT : WINDERS2830

    ANGLOGOLD ASHANTI SPECIFICATION

HOISTING EQUIPMENT : WINDERS

     283/3 ISSUE 1 PAGE 1 OF 25 UNDER LICENCE FROM AAC APPROVED 1998-08-20

     CONTENTS PAGE

1.0 SCOPE 2

    2.0 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2

3.0 DEFINITIONS 2

4.0 REQUIREMENTS 3

4.1 General 3

    4.2 Design 3

    4.3 Material 4

    4.4 Construction 4

    4.5 Welding 5

    4.6 Surface texture 5

    4.7 Drumshafts 5

    4.8 Drumshaft bushes 6

    4.9 Drum and sliders 6

    4.10 Drum sleeves 6

    4.11 Brakes 6

    4.12 Fabricated brake rigging 7 4.13 Forged brake rigging 7 4.14 Bearings 7

    4.15 Bearing housing and sole plates 7 4.16 Clutch 7

    4.17 Spragging gear 8

    4.18 Brake engine 8

    4.19 Bolts nuts and locking device 9

5.0 QUALITY ASSURANCE PROVISIONS 9

6.0 TEST AND INSPECTION METHODS 9

    6.1 Tests on material receipt 9 6.2 Tests during and after manufacture 9 6.3 Weld examination 13

7.0 MARKING AND PACKING 14

7.1 Marking 14

    7.2 Packing 14

APPENDIX A : RELATED DOCUMENTS 15

    APPENDIX B : RECORD OF AMENDMENTS 17

    APPENDIX C : MATERIAL CLASSIFICATION SCHEDULE 18 APPENDIX D : DATA SHEET (TO BE COMPLETED BY THE ENGINEER) 19 APPENDIX E : DATA SHEET (TO BE COMPLETED BY THE CONTRACTOR) 22

ANGLOGOLD ASHANTI SPECIFICATION

HOISTING EQUIPMENT : WINDERS

     283/3 ISSUE 1 PAGE 2 OF 25 UNDER LICENCE FROM AAC APPROVED 1998-08-20

1.0 SCOPE

     This specification details the requirements for winders and their mechanical components used

    for hoisting and shaft sinking operations.

     THIS SPECIFICATION DETAILS THE REQUIREMENTS FOR SAFETY "CRITICAL" ITEM

    (See AngloGold Ashanti QSP 100).

2.0 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

     The following requirements shall be specified on every invitation to tender, contract or order.

     Title, number, date and issue of this specification.

     The performance and operating data as specified in the AngloGold Ashanti data sheet

    (see Appendix D).

     If required the name of the independent Quality Assurance Representative (see AngloGold

    Ashanti QSP 100).

3.0 DEFINITIONS

     For the purpose of this specification, the following definitions shall apply:

     APPROVED : Approved by, and acceptable to the Engineer in writing

     ASME : American Society of Mechanical Engineers

     AWS ; American Welding Society

     BS : British Standard

     CRITICAL : An equipment or a component of an equipment, the failure of which, by

    analysis, judgement and experience, is likely to result in hazardous or

    unsafe conditions for individuals using, maintaining or depending upon it

     OR

     an equipment or a component of an equipment, the failure of which is

    likely to very significantly affect the performance

     OR

     and equipment essential to production or safety that uses any

    component requiring 24 hours or more to replace or repair.

     DATA BOOK : A hard cover, loose leaf book containing a record of identification

    markings, heat treatments, mechanical, chemical and NDE certification

    and any other certification requirements of this specification.

     DIN : Deutsches Institut fur Normung.

     MAJOR : Equipment or a component of an equipment the failure of which is likely

    to materially reduce production performance.

ANGLOGOLD ASHANTI SPECIFICATION

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     MINOR : Equipment or a component of an equipment the failure of which is not

    likely to materially reduce production performance.

     MPI : Magnetic particle inspection.

     QSP : An AngloGold Ashanti Quality System Procedure.

     RT : Radiographic testing.

     SABS : South African Bureau of Standards.

     UT : Ultrasonic testing.

     VISUAL : Unaided vision, except normally used personal sight aids.

     The following terms are defined in the General Conditions of Contract:

     AngloGold Ashanti, Company, Contractor, Engineer

4.0 REQUIREMENTS

4.1 General

     Materials and structural sections shall be specified on the relevant drawing(s). Substitution of

    specified material or structural sections without Approval is not permitted. Additional costs of

    approved substitution shall be borne by the Contractor.

4.2 Design

     The winder design shall be capable of the performance specified in the AngloGold Ashanti data

    sheet (see Appendix D) when exposed to the operational environment.

     The Contractor shall determine from the Engineer at the time of tender, any further details not

    specified in the data sheet.

     The equipment shall be designed to conform to the required layout and operational parameters

    supplied by the Engineer.

     The requirements of the South African Minerals Act shall apply.

    4.2.1 Factors of safety: for items subjected to fatigue load shall not be less than the following,

    based upon the nominal or normal load.

     Unscrewed elements: for all elements not having a screwed thread in the load path, or after a

    sharp change of section shall be 10 : 1 based upon the ultimate tensile strength of the material.

     OR

     A factor of safety of 2 : 1 based upon the rope breaking strength whichever is the greater.

     Screwed elements: for all elements with a screw thread or other sharp change of section in

    the load path 15 : 1 based upon the thread root diameter.

ANGLOGOLD ASHANTI SPECIFICATION

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    4.2.2 Torsional vibration: all mechanical drive systems shall be designed and controlled so that

    the range of torsional vibration superimposed on the mean driving torque does not exceed

    25% of the mean driving torque.

     Should any of the commissioning tests show torsional oscillations in excess of 25%, the

    Contractor shall apply corrective measures. The costs of these corrective measures and any

    further testing to verify these corrective measures shall be borne by the Contractor.

4.3 Material

     Unless otherwise specified in this specification the Contractor shall specify on every invitation

    to tender, contract or order the material proposed for each component of the winder and its

    category (i.e. critical or major). This shall be in the format as shown in Appendix C.

    4.3.1 Steel fabrications: shall be fabricated from steel which complies with the requirements of BS

    4360 grade 43C unless otherwise specified in this specification. The steel shall be non-

    destructively examined for surface and subsurface defects before manufacture commences.

    Non-destructive examination methods shall comply with the requirements of Clause 6.1.

    Acceptance criteria shall comply with the requirements of BS 5996 L1C1E.

     Steel fabrications shall be stress relieved after all welding has been completed.

     WELDING AFTER FINAL STRESS RELIEVING IS NOT PERMITTED.

    4.3.2 Steel castings: shall comply with the requirements of BS 3100 grade A2, fully annealed after

    casting unless the requirements of the design dictate otherwise or unless specific in this

    specification. In this case the material shall be specified in detail in accordance with the

    requirements of Appendix C.

     Weld repair procedures for castings shall be submitted for Approval at the time of tender.

     Upgrading of castings by welding requires prior Approval and shall be controlled by the

    Contractor's quality assurance function.

     Casting repairs not controlled as specified in this specification shall be cause for rejection and

    the replacement cost of the item shall be born by the Contractor.

     Details of casting repairs, including sketches shall be recorded by the Contractor in the Data

    Book.

    4.3.3 Forgings: shall comply with the requirements of AngloGold Ashanti specification 281/9 unless

    specified otherwise in this specification.

     WELD REPAIR OF FORGINGS IS NOT PERMITTED.

4.4 Construction

    4.4.1 Dimensions and tolerances: shall be as specified on the relevant drawing(s). All structural

    sections and plate before and after fabrication shall be straight, free of twist and buckling

    unless otherwise specified on the relevant drawing(s).

    4.4.2 Holes for fasteners: shall be drilled to standard diameters, back marks or cross centres

    unless otherwise stated on the relevant drawing(s). Rags and burrs shall be removed.

ANGLOGOLD ASHANTI SPECIFICATION

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     Where possible all holes shall be reamed after assembly to avoid overlapping of holes prior to

    bolting.

     FLAME CUTTING OF HOLES FOR FASTENERS IS NOT PERMITTED

    4.4.3 Cuttings: components shall be cut to size by means of shearing, cropping, sawing or flame

    cutting. Components produced by flame cutting shall be so proportioned to allow the material

    to be dressed back to bright metal.

     When visually inspected after finish machining there shall be no evidence of flame cutting.

4.5 Welding

4.5.1 Welder qualification and weld procedures: shall comply with the requirements of SABS 044

    Part III.

     Details of welding procedure, showing the build up of all main welds together with details of

    manufacture, classification, code and size of electrodes to be used shall be submitted for

    Approval at time of tender.

    4.5.2 Weld repair procedures: shall be submitted to the Engineer for approval at time of tender.

    Weld repairs shall not be conducted without Approval.

    4.5.3 Weld acceptance criteria: all welds shall be free from defects in accordance with the

    requirements of BS 2790 for volumetric examination and AWS D1.1 section 9 for surface

    examination unless otherwise specified.

     The extent of the weld examination shall comply with the requirements of Table 3 (see Clause

    6.3).

     WELDING AFTER FINAL STRESS RELIEVING IS NOT PERMITTED

4.6 Surface texture

     After final heat treatment component surfaces shall be machined to size in accordance with the

    dimensional requirements of the relevant approved drawing(s) and to the degree of finish as

    follows, in accordance with the requirements of the Ra series of BS 1134.

4.6.1 General surfaces: as specified on the approved drawings.

4.6.2 Pins, bores and radii: shall be finish machined to Ra 1.6mm.

     PLATING OF COMPONENTS IS NOT PERMITTED.

4.7 Drumshafts

     Drumshafts shall comply with the requirements of AngloGold Ashanti specification 283/1.

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4.8 Drumshaft bushes

     Drumshaft bushes shall be a copper alloy that complies with the requirements of BS 1400

    grade PB2 or an approved equivalent.

     The bushes shall be cast in halves and be of flanged design. The design shall accommodate

    an automatic lubrication system that will provide adequate lubrication between the drumshaft

    and the bushes of the drum(s) during the un-clutched operation. Tests and inspections shall

    comply with the requirements of Clause 6.1 and 6.2.

     The design of the bushes shall be such that they can be removed without dismantling the drum.

4.9 Drums and sliders

     Drums and sliders shall be manufactured in halves with machined faces that bolt together and

    shall be manufactured using one of the following methods.

    4.9.1 Cast: shall be steel in accordance with the requirement of BS 3100 grade A2 and shall be

    normalized before machining.

    4.9.2 Fabricated: shall be steel in accordance with the requirements of BS 4360 grade 43C and

    stress relieved before machining.

4.9.3 Tests and inspections: shall comply with the requirements of Clause 6.1 and 6.2.

     Material properties shall comply with the requirements of the relevant material specification

    (see Clause 4.3.1 and 4.3.2).

4.10 Drum sleeves

     Drum sleeves shall comply with the requirements of AngloGold Ashanti Specification 283/7.

     Drum sleeves shall not provide any structural enhancement to the drum. The drum shall be

    structurally designed without considering the sleeve.

4.11 Brakes

    4.11.1 General: brake paths and linings shall be protected from contamination by oil, water and

    grease. The brake paths shall have sufficient thermal capacity to enable all duties of the

    winder to be conducted, including rope changing. The brake paths shall also be able to absorb,

    without undue distortion or detriment to any of the equipment, the maximum energy from the

    winding system following three emergency trip outs in quick succession. This condition shall

    apply at the designed mechanical retardation rate with the full load descending near the shaft

    bottom. The time between each emergency trip shall be a maximum of 3 minutes.

    4.11.2 Calliper shoe brakes: shall be cast steel in accordance with the requirements of Clause 4.3.2

    or fabricated steel in accordance with the requirements of Clause 4.3.1. The brake paths shall

    be manufactured in halves from material which complies with the requirements of BS 3100

    grade A4. There shall be no discontinuities in the path except for the joint faces. Tests and

    inspection methods shall comply with the requirements of Clause 6.1 and 6.2.

    4.11.3 Disc brakes: shall comply with the requirements of AngloGold Ashanti specification 283/5.

4.12 Fabricated brake rigging

ANGLOGOLD ASHANTI SPECIFICATION

HOISTING EQUIPMENT : WINDERS

     283/3 ISSUE 1 PAGE 7 OF 25 UNDER LICENCE FROM AAC APPROVED 1998-08-20

     Fabricated brake rigging material shall comply with the requirements of Clause 4.3.1 and shall

    be tested in accordance with the requirements of Clauses 6.1, 6.2 and 6.3.

4.13 Forged brake rigging

     Forged brake rigging shall comply with the requirements of AngloGold Ashanti specification

    283/2.

4.14 Bearings

    4.14.1 General: bearings shall be self-aligning and ring oiled and shall be capable of supporting the

    drum shaft assembly. Each bearing housing shall have a horizontal split across its diameter

    and shall be mounted on sole plates. Alternatively, Approved roller bearings may be used.

     Fail safe protection shall be provided for bearings overheating and for the failure of oil to flow to

    any bearing.

    4.14.2 Bearing housing: shall be cast steel in accordance with the requirements of Clause 4.3.2 or

    fabricated steel in accordance with the requirements of Clause 4.3.1.

    4.14.3 Bearing bottom half shells: shall be white metal in accordance with the requirements of

    SABS 695 grade WM 90.

    4.14.4 Bearing top half shells: shall be white metal in accordance with the requirements of SABS

    700 grade WM 40.

    4.14.5 Test and inspection methods: shall comply with the requirements of Clause 6.1, 6.2 and

    where applicable 6.3.

4.15 Bearing housing and sole plates

     Bearing housings shall seat on machined sole plates and shall be supported uniformly.

     The bearing housing holding down bolts and nuts shall be accessible for maintenance

    purposes.

     Sole plate test and inspection methods shall comply with the requirements of Clause 6.1 and

    6.2.

4.16 Clutch

     The clutch shall comprise of a slider, collar, inner ring and outer ring. The inner ring shall be

    flange mounted onto the shaft and shall have external teeth. The outer ring shall be bolted to

    the outer drum slider and shall have internal teeth.

    4.16.1 Slider: shall be cast iron in accordance with the requirements of BS 2789 grade 420/12.

    4.16.2 Collar, inner and outer rings: shall be cast steel in accordance with the requirements of

    Clause 4.3.2.

    4.16.3 Test and inspection methods: shall comply with the requirements of Clause 6.1 and 6.2.

ANGLOGOLD ASHANTI SPECIFICATION

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    4.16.4 Clutch control: shall be such that the clutch can only be withdrawn when all of the following

    conditions are met.

     : The brake is in the full on position. If the brake is in any other position a mechanical

    interlock shall prevent movement of the clutch lever past the ultimate braking position

    (i.e. the clutch cannot be withdrawn).

     : The full braking force is applied by the brake engine. A pressure switch shall signal

    that the brake engine is at stop.

     : Initial movement of the clutch lever positively exhausts the brake engine. Further

    movement of the clutch lever will only effect clutch withdrawal if the brake engine is

    fully exhausted.

     : When the clutch is in the disengaged position, the lever moved to the 'clutch in'

    position, normal brake control will not be restored before:

     - The clutch slider has moved to the fully engaged position.

     - The clutch cylinder pressures are such that the clutch is held in the engaged position.

     - The sprag is fully engaged.

    4.16.5 Alternative clutch designs: shall be fully detailed and submitted for Approval at the time of

    tender.

4.17 Spragging gear

     A guided pin shall mesh with drilled holes in the drum cheek and shall act as a sprag.

     The sprag shall be hydraulically activated and interlocked to prevent the clutch being

    withdrawn before the sprag is engaged.

     The spragging gear shall be capable of withstanding without any damage or distortion a torque

    equivalent to a fully loaded conveyance at the bottom of the shaft with an applied shock factor

    of two.

     The spragging pin shall be manufactured from steel that complies with the following

    requirements and shall further comply with the requirements of AngloGold Ashanti specification

    281/9.

    4.17.1 Chemical composition: shall comply with the requirements of BS 970 Part 1 grade 826M40.

    4.17.2 Mechanical properties: shall comply with the requirements of BS 2772 Part 2 1977 grade

    826M31.

     Test and inspection methods shall comply with the requirements of Clause 6.1 and 6.2.

4.18 Brake engine

     The braking force shall be adjustable to produce the required braking torque. Plates shall be

    fitted on the operator side of the brake engine to indicate the position of the brake pistons.

ANGLOGOLD ASHANTI SPECIFICATION

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    4.18.1 Spring nest top plate, Spring nest bottom plate, Brake engine bottom plate and the

    Brake engine anchor bracket: if steel fabrications, shall be in accordance with the

    requirements of Clause 4.3.1. If steel castings, shall be in accordance with the requirements of

    Clause 4.3.2.

    4.18.2 Brake engine guide rods: shall be in accordance with the requirements of BS 970 grade

    070M20 Table 2.

4.18.3 Brake engine tie rod, centre nut and bottom pin: shall be in accordance with the

    requirements of AngloGold Ashanti specification 283/2.

    4.18.4 Manifold blocks: shall be in accordance with the requirements of BS 4360 grade 43A or

    SABS 1431 grade 300WA.

    4.18.5 Test and inspection methods: shall comply with the requirements of Clause 6.1 and 6.2.

4.19 Bolts, nuts and locking devices

     All components classified as critical shall be manufactured from steel as specified below and

    shall further comply with the requirements of AngloGold Ashanti specification 281/9.

    4.19.1 Chemical composition: shall comply with the requirements of BS 970 Part 1 grade 826M40.

    4.19.2 Mechanical properties: shall comply with the requirements of BS 2772 Part 2 1977 grade

    826M31.

    4.19.3 Dimensions: unless the design dictates otherwise shall comply with the requirements of

    SABS 136.

    4.19.4 Test and inspection methods: shall comply with the requirements of Clause 6.1 and 6.2.

5.0 QUALITY ASSURANCE PROVISIONS

     The Contractor's quality management system shall comply with the requirements of AngloGold

    Ashanti QSP 100.

6.0 TEST AND INSPECTION METHODS

6.1 Tests on material receipt

     Tests to be conducted on the items detailed in this specification shall comply with the

    requirements of Table 1. These tests shall be conducted on the material as received by the

    Contractor or where appropriate after the final heat treatment but before any manufacturing

    processes are conducted.

     The physical sequence of the test(s) shall be detailed on the approved quality plan.

6.2 Tests during and after manufacture

     Test to be conducted on the items detailed in this specification shall comply with the

    requirements of Table 2.

     These tests shall be conducted on the material during and after manufacture as required. The

    physical sequence of tests shall be detailed on the approved quality plan.

ANGLOGOLD ASHANTI SPECIFICATION

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     TABLE 1: TESTS TO BE CONDUCTED ON MATERIAL

     RECEIPT AND/OR AFTER FINAL HEAT TREATMENT

     ITEM *C TENSILE IMPACT HARDNESS UT MPI 1.1 Drumshaft C 283/1 283/1 283/1 283/1 283/1

    SABS 1.2 Drumshaft Mi

    ISO 6892 bushes

    SABS SABS ISO BS 5996 1.3 Drum-fabricated C

    ISO 6892 148 L1C1E

    SABS SABS ISO 1.4 Drum-cast C

    ISO 6892 148

    SABS ISO SABS ISO 1.5 Brake path C

    148 6506

    BS 5996 1.6 Brake rigging C L1C1E : fabricated 283/2 : forged C 283/2 283/2

    1.7 Disc brakes C 283/5 283/5 283/5 283/5 283/5 1.8 Bearing housing

     : top M SABS Cont.

     : bottom M ISO 6892

    SABS

    ISO 6892

    1.9 Bearing shells

     : top M SABS

     : bottom M ISO 6892

    SABS

    ISO 6892

    SABS 1.10 Bearing sole Mi

    ISO 6892 plates

    1.11 Clutch

     : slider M SABS

     : collar Mi ISO 6892

     : inner ring C SABS

     : outer ring C ISO 6892

    SABS

    ISO 6892

    SABS

    ISO 6892

    SABS SABS ISO SABS ISO 1.12 Spragging gear C

    ISO 6892 148 6506 pin

For continuation of Table 1 see next page

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