T11M408 I1 Takraf 03910 Vdcme02 P1me01 004

Construction Manual - Mechanical
TAKRAF GmbH
Product:
Conveyor CV -11
Extension of conveyor CV-11
Document:
T11M408-I1-TAKRAF-03910-VDCME02-P1ME01-004
Seller:
TAKRAF GmbH
Torgauer Strae 336
04347 Leipzig
Federal Republic of Germany
Client:
CORPORACIN NACIONAL DEL COBRE DE CHILE (CODELCO)

Divisin El Teniente
Santiago, Chile 11 Regin, Chile
TAKRAF Project-No.:
G0268
Year of Construction
2014
Prepared by:
DB Andr Kreter
Prepared on:
Aug. 2013
2013-08-26
Revision: B
Project:
Document:
Subject:
G 0268 EL Teniente - Nuevo Nivel Mina

Construction Manual Conveyor CV-11
Record of Revisions
ISSUE
DATE
26.08.2013
2013-08-26
Revision: B
EFFECT ON
PAGE
PARA
All
All
DESCRIPTION
ISSUED FOR APPROVAL
Construction Manual - Mechanic

2
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Subject:

The text, drawings/sketches and all attachments of this technical documentation are protected by the
suppliers copyright.
The receiver is entrusted with this documentation for personal use only.
Without the suppliers written approval, it must not be copied or otherwise reproduced, passed on to
third people, in particular competitors, or misused in any other way.
Illegal use by the receiver or third persons will have consequences under civil law and criminal law.
This order-related documentation is available in German language. The German version shall apply in
case of any problems in formulation and understanding.
TAKRAF GmbH
Torgauer Strae 336
04347 Leipzig
Federal Republic of Germany
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Table of Contents
1
General Mechanical Installation................................................................................... 5
1.1
Installation description .................................................................................................... 5
1.2
1.3
Installation procedure ..................................................................................................... 5

Field joints and connections ............................................................................................ 6
1.4
Temporary supports ........................................................................................................ 6
1.5
Securing of structure during construction period ............................................................. 6
1.6
Lifting appliances ............................................................................................................ 7
1.7
Storage & handling of supplies ....................................................................................... 9
1.8
General requirements ..................................................................................................... 9
Guideline for Construction description..................................................................... 11
Construction Description ........................................................................................... 12
3.1
3.2
General conditions Construction Yard........................................................................... 12

General Remarks for Installation and Commissioning ................................................... 12
3.3
General Arrangement Drawings.................................................................................... 13
3.4
List of Weights* ............................................................................................................. 14
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.6
Tail Station Installation .................................................................................................. 15

Main Frame Installation................................................................................................. 15
Motor Unit Installation ................................................................................................... 16
Take-up Station Installation .......................................................................................... 19
Walkway Installation ..................................................................................................... 22
Loading Module CV-4A to CV-11 Installation ................................................................ 22
3.7
Loading Module CV-10 to CV11 Installation.................................................................. 23
3.8
3.9
Head Return Station Installation ................................................................................... 23

Conveyor Module Installation ........................................................................................ 24
3.10
3.10.1
3.10.2
3.10.3
3.10.4
3.11
Equipment Installation................................................................................................... 25
Hydraulic and Lubrication Systems ............................................................................... 25
Belt Scraper Installation ................................................................................................ 25
Mechanical Equipment / Monitoring Devices ................................................................. 25
Safety Guards Installation ............................................................................................. 26
Belt Installation ............................................................................................................. 27
Attachments ................................................................................................................ 28
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General Mechanical Installation
1.1
Installation description
The present document gives only a general description of the installation procedure as of July 2013,
which shall be understood in the context of the applicable local regulations and must be detailed on the
basis of the lifting appliances and installation tools actually and workforce available with the erection
company. The individual working operations shall be described in detail by the erection company.
In order to ensure adequate performance of the installation work, all drawings mentioned in the list of
applicable drawings shall be complied with.
This also includes the adequate preparation of the erection yard and equipment used by the erection
company.
ATTENTION!
The erection company has to check carefully this manual and all
documents within prior erection starts. If something missing or not clear
the erection company has to request the missing documents or information
from TAKRAF immediately.
1.2
Installation procedure
The Installation procedure described below shall be strictly complied with as it ensures the stability of
the main structures and units to be pre-assembled throughout all phases of construction process.
The weights of the assembly groups must not be exceeded so that lifting appliances in order to avoid
overload affecting lifting tackles, temporary supports, piles of wooden sleepers/steel bars, etc.
Major deviations from the installation sequence and technical specifications must be agreed with the
TAKRAF design department or site management.
The receiving and processing of transmitted modification report during installation duration should be
documented by TAKRAF Supervisor. After end of installation all documents should be transmitted to
the responsible employee of the TAKRAF Erection Department.
Possibly, adaptations will have to be made on site, e.g. of the frames arranged the truss structures,
TAKRAF supplies to be integrated in the units, etc. The erection contractor shall be responsible for the
execution of all the above adjustments.
The above provisions and subsequent agreements between TAKRAF and the customer shall be
observed by the contractor and complied with.
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1.3

Field joints and connections
All joints and connections of steel structures to be bolted or welded on site, e.g. bracings, truss
structures and platforms, shall be aligned, reamed and bolted, respectively welded before lifting the
respective structure to the mounting position.
Bolted joints and structures to be connected only in their mounting position, shall be reamed and bolted
when in place. The joints shall be locked in their position by setting plugs or tacking bolts.
This provision similarly applies to the welded joints of each individual steel structure (held by splicing
plates).
Individual members shall be connected applying the full torque specified by the supplier/manufacturer,
using fitted bolts, setting plugs or splicing plates, before suspending them from the lifting appliance.
After completion of the bolted joints, the butt joints (on top and lateral) shall be sealed. Silicon paste or
other elastic sealing materials may be used for this purpose (for additional information see QM 36-15307).
For execution of high-tension and friction-grip connections the QM 36-09-1202 shall be considered
For all site welding the QM 36-09-2004 shall be considered.
1.4
Temporary supports
The contractor shall provide temporary supports.

They shall be selected on the basis of the assumed maximum load, overload and adequate safety
factor.
They shall be tied town to prevent turnover.
The hydraulic jacks to be arranged under the supports or on the piles of wooden sleepers or steel bars
(with setting ring and crowned thrust piece) shall be arranged in central position, generally.
Example:
Load center
Steel plate
0,0
Piles of wooden sleepers, if serving as support, shall be suitably structured (crosswise arrangement of
sleepers) to meet the maximum load. Sleepers or timber bars must be arranged perfectly horizontal
resting safely on each other. The piles shall be loaded with the load imposed on the centre of each pile,
generally.
Wooden piles shall suitably protect to avoid fire, if welding work or flame cutting is to be performed on
them (impregnation, sand or similar).
Lifting platforms, scaffolds, ladders and similar shall be employed in accordance with the legal
provisions applicable to this respect in the country where the construction takes place.
1.5
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Securing of structure during construction period

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Following safety measures should be done to prevent damages and accidents:

Secure travel mechanism against moving (inclination of runway and wind loads)
Secure superstructure to undercarriage against rotation (wind loads)
Blocking of gear rim
Fixing of storm anchors
Installation of chain hoists (crosswise) between superstructure and undercarriage
Anchoring of boom structures (crosswise) with tie ropes

Secure Temporary construction supports (Wind loads)
Installation of knags between machine structure and supports head section)
Bracings between single supports
Anchoring of supports with tie ropes

All provisions should be coordinated with TAKRAF engineering department.
Lifting platforms, scaffolds, ladders and similar shall be employed in accordance with the legal
provisions applicable to this respect in the country where the construction takes place.
1.6
Lifting appliances
The lifting appliances planned to be employed in the construction process must be released by the
competent technical control board or inspection board in the country where the construction takes
place.
It is a general requirement that the sling points, lifting eyes, lugs, etc. indicated in the specifications
must be used. The lifting schemes shown in the drawings shall be adhered to. These schemes shall be
revised and presented to the manufacturer if, due to the progress of construction work (level of
completion of the units), other than the specified loads or centre of gravity are applicable. The lifting
beams and spreaders shall be provided by the construction company. Wherever slinging work is
applicable, the sling points shall be lined carefully with timber, whereas sharp edges must be covered to
protect the lifting ropes/tackles (e.g. shaped plate, rubber, timber etc.). The sling points must be slipproof so as to prevent deformation of the items to be lifted.
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Example:
Edge protection
Square timber
The erection contractor shall be responsible for all slinging and lifting work, including monitoring and
supervision of heavy loads lifting operations, in general.
Prior to each lifting, the lifting accessories such as ropes, belts, chains and shackles shall be checked
as follows:
Visual inspection for damage
Check of test date on inspection plate

If the lifting weight is > 10 t, then a trial suspension of at least 10 min shall be carried out prior to the
heavy load lifting operation.
The trial suspension shall be as follows:
Lift the component evenly until there is a distance of about 10 cm to the pile
points.
Trial suspension of at least 10 min.
Check the suspended loads (e. g. by means of the existing crane displays)
In case of any deviations of the suspended load, they shall be corrected.

Prior to each heavy load lifting operation, the personnel involved shall be trained and instructed on
record.
The instruction record shall include the following:
Lifting appliances involved and their manning as well as reserve crane drivers
Supervisor of heavy load lifting operation
Communication by means of radiotelephony and commands
Performing of lifting appliance movements
Safety guards
Behavior in case of irregularities

The work to be performed during the heavy load lifting operation shall be monitored by a supervisor
from a central location. This person shall be in direct contact with the employed lifting appliance
operators via radiotelephony.
Before starting the heavy load lifting operation, information on the general weather situation shall be
obtained.
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The erection company shall be responsible for all slinging and lifting work, including monitoring and
supervision of heavy loads lifting operations, in general.
1.7
Storage & handling of supplies
All supplies shall be stored on pads (sleepers, concrete blocks and similar) to protect them from
damage, corrosion, extreme dirt prior until the moment of installation
Structural parts shall be inserted without constraint or deformation. Holes in the main structure must not
be closed by welding!
Damaged parts must not be installed. The manufacturers design department shall decide whether they
can be installed or must be repaired.
Damaged paint coats, if any, shall be touched up, and rust shall be removed. All items stored on site
shall be protected from dirt (dust and weather protection). Surfaces that will be inaccessible after the
mounting shall be coated prior to that applying the paint system specified for this purpose.
Protective covers and sleeves, if any, shall be removed before installing each item.
Mechanical parts, bolts, shafts, axles and sliding surfaces, if not otherwise specified must be grease
prior to installing them. The instructions for treatment with molybdenum sulphide powder shall be strictly
adhered to, where applicable to the mechanical parts.
Inflammable items (cables, conveyor belts, timber frames) shall be suitably protected before performing
welding work or flame cutting.
1.8
General requirements
The erection company shall appoint a coordinator for the implementation of the project (site
planning and organization, monitoring of time schedules, etc.), who will be at the disposal of the
TAKRAF supervisor for settling all questions.
The quality documents including measurement reports and test records requested by TAKRAF
shall be submitted to the customer / TAKRAF at the dates fixed.
Any work beyond the scope of supplies and services shall be subject to prior agreement with the
customer / TAKRAF and their written approval.
In the event of any damage, malfunction, non-conform execution or delay, the erection company
shall subject itself to the judgment of the customer / TAKRAF within its scope of supplies and
after joint assessment. The customer / TAKRAF shall have the right to define actions for
eliminating this situation. Any delays and costs arising from this shall be borne by the erection
company. It shall be fully responsible for keeping the deadlines agreed in the contract.
Immediately after becoming aware of circumstances interfering with the smooth execution of the
project the erection company shall inform the customer / TAKRAF about such circumstances
and arrange with the customer / TAKRAF about the measures to be initiated.
Corrosion protection instructions shall be prepared and submitted to the erection company in
due time. Erection Company shall be responsible to apply the finish coat and repair any damage
of the coat caused during transport and / or erection. Damage due to transport, handling and
storage to parts supplied by TAKRAF shall also be repaired by Erection Company. Sufficient
paint will be supplied to the erection company.
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The field joints (welded or bolted) specified in the design drawings shall be made accessible by
scaffolds complying with the regulations.
The tacking bolts required for the erection shall be supplied by the erection company.
Attaching and removing of weld backups and end crater plates to and from field joints are
included in regular erection work and shall be allowed for by the erection company.
The erection company shall provide a material guard / warehouse man for monitoring the
incoming and outgoing goods.
Complying with the regulations, the erection company shall provide heatable quivers as well as
drying ovens for the electrodes.
For the machines the temporary supports shall be fabricated or adapted according to the
position / load as per drawings and provided with regard to deadlines.
Modification work up to 5 % of the overall scope shall not be deemed as additional work but
shall be part of the normal tasks of the erection company. This may also include the necessary
indirect material such as plates, angles, beams etc.
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Guideline for Construction description
Purpose of this construction manual

The purpose of this document is to give a general guideline on how to assemble and erect the delivered
components to a functional unit to allow the safe operation under the specified conditions.
For planning and execution of any work all information given in this manual, its attachments and related
documents of the suppliers documentation must be considered. These documents shall be checked
carefully and be understood in full prior to the start of any work and if required clarifications shall be
requested.
This manual does not relieve the responsible construction company to plan in detail all aspects of the
required works, in particular the site preparation, the sequences of pre-assembly and final assembly,
also the selection, timely availability and use of required tools, devices and cranes.
All instructions given by TAKRAF and sub-supplier must be followed.
All work must be done in conformance with all applicable technical and safety standards.
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Construction Description
3.1
General conditions Construction Yard
Existing obstacles, if any and where these interfere with construction shall be relocated. All electrical
supply and control cables for the lights and temporary substations shall be buried.
The Construction pad shall be levelled and compacted according drawing (position and condition of
pre-assembly and construction areas will be agreed before start of construction) and the conditions for
the storage of mechanical and electrical supplies as specified by the manufacturer / supplier shall be
met.
Materials sensitive to temperature variations (e.g. coating materials, certain electrical items, conveyor
belt splice kits) shall be stored in air-conditioned storage rooms which are to be provided in the
construction yard or nearby. Temporary substations shall be provided in the construction yard for
connecting of electrical tools.
3.2
General Remarks for Installation and Commissioning
In generally erection company should take into consideration all additional assembly instructions at
design drawings. In addition to these requirements the following works are part of the normal
construction scope:
Testing (UT, X-ray, red-white test) of all site welds (if necessary) according TAKRAF
requirements (design and quality assurance drawings)
Correct installation and fine adjustment of idler (height tolerance idler to idler max. 3mm), belt
cleaner, wear plates, chute side walls and sealing
Installation of brackets for final assembly of cable trays, piping etc.
Correct installation and alignment of belt pulleys pay attention to tooth disc location in regard
to limit switch position or sensor connection
Position of take-up pulley (installed on take-up carriage) before and after final belt vulcanization
and/or applying of final belt tension
Adaptation of gratings, railings and kick-plates (where necessary)
Seal welding of all field joints at walkway railings (use connection pieces)
Installation (drilling and welding) of limits switches incl. brackets and ruler
Installation of protection guards and covers drilling and welding could be necessary
Final alignment of conveyor modules (highness, side)
Installation of liner plates and lip liners at site
Adaptation and additional installation of wear plates during commissioning
Adaptation of staircase to ground level (if necessary)
Alignment of drive (motor, brakes, gear box) components
Function test of mechanical parts incl. adjustment and re-adjustment if necessary
Installation of lubrication and hydraulic systems incl. all piping works cover these installation
areas to keep it clean
Cleaning and flushing (if necessary) of hydraulic and lubrication pipe system
Filling of hydraulic and lubrication system according TAKRAF instruction (oil and lube type,
cleanliness of oil
Touch-up painting of transport and construction damages
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Installation of hand fire extinguisher, warning and company signs and warning coat
NOTE!
All equipment installed during shut-down has to be pre-assembled to the
highest possible degree. The final degree of preassembly as well as the
sequence should be determined between client, erection company and the
TAKRAF Supervisor and depending on the detailed shut-down schedule.
3.3
General Arrangement Drawings
For general arrangement and overview for conveyor CV 11 see:

General Overview drawings:
o GA conveyor CV-11, Dwg. 49046335
o GA Belt line CV-11, Dwg. 49046334
o GA - Drive/ Take-up station CV 11, Dwg. 49046328
o GA Transfer CV4A to CV 11, Dwg. 49046329
o GA Transfer CV 10 to CV 11, Dwg.49046345
o GA Standard Ground Module, Dwg. 49046326
o GA Head return station, Dwg. 49046336
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3.4

List of Weights*
Ass.Group
Designation
1000
1110
1120
1410
1510
1610
1910
2000
2110
2210
2230
2510
3000
3210
3910
4000
4110
4120
4140
4150
4210
4240
4250
5000
8000
Drive / Take-up station

Steelwork Drive / Take-up station
Walkways and Podests Drive / Take-up station
Drive Units
Drive Pulleys
Belt Cleaner Drive / Take-up station
Small Parts Drive / Take-up station
Head Return Station
Steelwork Head Return Station
Walkways and Podests
Discharge Chute
Pulleys Head Return Station
Conveyor Route
Conveyor Modules
Safety Guards
Loading Module
Loading Module CV-4A to CV-11
Steelwork Loading Module
Walkways and platforms
Loading Chute and Skirt Boards
Safety Guards Loading Module
Loading Module CV-10 to CV 11
Steelwork Loading Module
Loading Chute and Skirt Boards
Safety Guards Loading Module
Take Up Device
Steel structure - Take Up Device
Mechanical parts - Take Up Device
Equipment
Total weight
(ton)
205,05
29,96
14,93
89,24
68,63
0,36
1,93
37,26
8,85
0,12
11,95
16,34
15,83
10,74
5,09
54,51
41,95
12,92
13,74
12,66
2,63
12,56
3,88
8,24
0,40
21,27
19,67
1,52
----
As of Aug. 2013
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3.5
Tail Station Installation
3.5.1
Main Frame Installation

NOTE!
Before the construction starts, survey protocol for tail station foundations
shall be available and cross checked with steel work anchoring points!
Mark the Conveying center line before start main frame installation
NOTE!
Accurately marking of conveyor center line is essential for alignment!
For tail end assembly see assembly drawing drive / take-up station CV 11, Dwg. 49046337!
Installation of Main frame drive / take-up station, Dwg. 48029224, Group 1110, ~ 23,63ton
o Main frame will be delivered in three parts
o Start installation with front ( ~ 11,7ton) and rear part (~ 8,1to) to the foundations on
ground, exact height according Dwg. 49046340 - Foundation loads tail drive station
o Installation of Main frame middle part (~ 3,4ton) to front and rear part Bolted
connection as per drawing 48029224!
o Installation of diagonals between main frame parts (bolted)
o Levelling and aligning of main frame as accurately as possible to conveyor line
o Grouting of the foundations of the main frame before proceed with the next step
o Installation of wedge box for drive puley, Dwg. 49047381, Group 1510 for Pulley
adjustment
o Installation of drive pulleys, Dwg. 42016580, Group 1510, ~27,3ton to main frame
Fasteners for pulley, Dwg. 49047383, Group 1510
Levelling and aligning drive pulleys as accurately as possible as per pulley
drawing
NOTE!
Levelling and alignment of Main Frame and Pulleys on Main frame is
essential for the exact positioning of the Motor base plates and the Motor
unit too!
Installation of primary drive unit, Dwg. 49046344 consisting of:

o Disc Brake BSFK535DS, Dwg. 59046488, Group 1410
o SOBO Controller, Dwg. 59046489, Group 1410
o Hydraulic power unit, Dwg. 59046490, Group 1410
o Flexible coupling, Dwg. 59046492, Group 1410
o Shim plates, Dwg. 49047377, Group 1410
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Installation of brake unit future secondary drive, Dwg. 49047380, Group 1410, ~1,25ton
consisting of:
o Disc Brake BSFK535DS, Dwg. 59046488, Group 1410
o Hydraulic power unit, Dwg. 59046494, Group 1410
o Shim plates, Dwg. 49047377, Group 1410
3.5.2

Motor Unit Installation

Installation of Baseplates Dwg. 42016509, Group 1410 for Motor Unit Installation:
NOTE!
The drive motors come to site complete with the base frames attached. The
total weight is 75 tons.
The base plates for the motors are part of the foundation. They need to be
set attached to the dummy frame. The dummy frame keeps the base plates
in their correct position to each other and in the same plane.
The final setting and grouting of the base plates should be done only after
the drive pulley has been set.
The accuracy for the foundation is high and difficult to accomplish without
installing the pulley first. The fact that it is a combination of foundation
(civil) and structural tolerances (main support structure) makes matters
worse.
Therefor it is advisable to set the main conveyor structure first and align the
pulley before final setting/alignment and grouting the base plates for the
motor. This sequence should allow achieving the tolerances as shown in the
sketch below. As better the system is aligned as less wear the flexible
coupling will see.
o
o
o
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Install all four baseplates to the dummy frame, Dwg. 42017085, Group 8390
Installation of dummy frame to foundation
Levelling and aligning of baseplates to conveyor center line and to pulley center line (see
Fig. 1, Dwg. 42017487)

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Fig. 1 Baseplates alignment
Grouting of baseplates with concret

NOTE!
Before motor unit installation starts baseplates shall be grouted!
The Motor unit, Dwg. 42016940, Group 1410, ~ 71,7ton consisting of:
o Motor with frame, Dwg. 42016530
o Spindle for height adjustment, Dwg. 42016510
o Adjusting cleat left side, Dwg. 42016511
o Adjusting cleat right side, Dwg. 42016512
o Threaded bolt, Dwg. 52016695
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NOTE!
For installation / lifting of motor unit see erection manual of ABB for electrical
equipment too!
Installation of spindle for height adjustment pos. 4, Dwg. 42016940 to motor unit
Adjustment / Alignment of motor unit according Motor unit drawing 42016940, coupling
drawing 59046492 and sub-supplier documentation!
o Check the levelness of the motor unit standing surface (baseplates) to each other
o Mark the middle lines on the baseplates in X-Y layer (Fig. 2)
Fig. 2 Marked Baseplates
Mark the X-Y layer on motor unit frame
Fig. 3 Marks at motor unit

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o
o
o
o
o
Grease contact area between baseplate and height adjusting spindle

Installation motor unit to baseplates & align motor unit on baseplate as accurately as
possible while installation of motor unit by crane (Rough alignment)
Installation of adjusting cleats (Pos 2 & 3, Dwg. 42016511 & 42016512) to baseplate
welding according Dwg. 42016940, sheet 2 Check adjusting cleats after welding
and regrease if necessary!
Leveling and align motor unit with the cleats in X Y Layer and the adjusting spindle for
adjusting in Z - direction
After height adjusting install shim plates Pos. 8 Dwg. 42016940 below contact area and
retract spindle
NOTE!
The Crane shall be used to supporting adjustment / alignment works by
taking over a part of the weight of the motor unit!
After adjustment install threaded rods to fix motor unit to ground, Use Primerless
Threadlocker Loctite 243 or similar to secure rods!
NOTE!
Erection Company has to prepare a test record about the alignment of the
coupling / motor unit! (See Inspection and Test Plan)
NOTE!
For further mounting instructions of the drive & motor units see subsupplier documentation too!
3.5.3
Take-up Station Installation

Take-up station will be delivered fully assembled, ready for installation, with the following parts:
o Take-up carriage, Dwg. 48029298, Group 5200, ~5,4ton
o Carriageway support, Dwg. 48029300, Group 5200, ~ 9,3ton
o Locking pins, Dwg. 49047390, Group 5300
o wedge box for take-up puley, Dwg. 49047382, Group 1510
o Take-up pulley to take-up carriage, Dwg. 42016717, Group 1510, ~ 13ton
o Fasteners for pulley, Dwg. 49047383, Group 1510
o Take-up trestle to carriageway support, Dwg. 48029299, Group 5200 (secureed with
locking pins)
o Take-up spindle, Dwg. 49047387, Group 5300 to take-up trestle, Dwg. 48029299, Group
5300 See notes on spindel drawing for details!
o Hydraulic cylinder, Dwg. 49047389, Group 5300
Installation of take-up station to main frame drv. / take-up station
o Figures 3, 4, shows details about Take-Up station lifting
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After installation take-up carriage and trestle shall be in the upper position for belt
installation and first startup (installed hydraulic system can be used for this operation)
Fig. 4 Lifting Scheme for Transportation
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Fig. 5 Lifting Scheme for Installation
Fig. 6 End Position of Take-up Carriage for Belt Installation
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NOTE!
3.5.4
Carriageway is temporary protected with tectyl. Before move the takeup carriage to the upper position clean carriageway completely with
cleaning solvent.
After belt installation removing the locking pins in take-up carriage!
Check the alignment of the Take-up pulley after Installation (For
details see Pulley Drawing.
Walkway Installation
Installation of stair and walkway sec. drive pulley, Dwg. 48029229, Group 1120, ~3,7ton
Installation of walkway at carriageway support, Dwg. 48029227, Group 1120, ~5,3ton
Installation of support for flexible cable routing, Dwg. 49047391, Group 5900
Installation of walkway at motor frame primary drive, Dwg. 48029230, Group, 1410, ~4,5ton
Installation of idler support beam, Dwg. 48029225, Group 1110, ~6,4ton
o Installation of idler stations to beam according GA Beltline CV-11, Dwg. 49046334
Installation of walkway at idler station support beam, Dwg. 48029226, Group 1120, ~ 6,0ton
3.6
Loading Module CV-4A to CV-11 Installation
See following drawings for further details:

o GA Drawing 49046329
o Assembly Transfer CV4A to CV-11 Drawing 49046338
Installation of loading chute support structures:
o Support structure CV-1, Dwg. 48029265, Group 4110, ~4,3ton
o Support structure CV-2, Dwg. 48029266, Group 4110, ~4,3ton
o Installation of idler station to support structures according GA Belt line CV-11, Dwg.
49046334
Installation of loading chute support structure, Dwg. 48029236, Group 4110, ~4,3ton to
foundations
Installation of idler stations to support structure according Dwg. 49046334 - GA Belt line CV11
Installation of liner plates Dwg. 48029235, Group 4140 to feeding box, Dwg. 48029233, Group
4140
Installation of feeding box to support structure (~ 5,4ton)
Installation of liner plates Dwg. 48029234 Group 4140 to loading hopper Dwg. 48029232, Group
4140, ~5,7ton
Installation of loading hopper to support structure
Installation of platform for intermediate chute, Dwg. 48029239, Group 4120, ~13,1ton
Installation of walkways and stairs, Dwg. 48029241, Group 4120, ~ 0,6ton
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3.7

Loading Module CV-10 to CV11 Installation

NOTE!
Description of the dis-assembly of existing structure is not part of this
manual!
Adaption works between existing structures and new parts delivered by
TAKRAF GmbH may become necessary and are in the responsibility of the
client!

o GA Drawing 49046329
o Assembly Transfer CV4A to CV-11 Drawing 49046338
Drilling of holes as per drawing 48029296, sheet1 into existing supports
Installation of liner plates, Dwg. 48030196 to loading chute, Dwg. 48029296
Installation of liner plates, Dwg. 48030197 to skirt boards, Dwg. 48029297
Installation of skirt boards to loading chute
Installation of fully assembled loading chute to existing structure (~7,3ton)
Installation of support for rope winch to existing structure, Dwg. 48029319, Group 4280
o Welding of supports as per drawing sheet 2
Installation of rope winches, Dwg. 49047408, Group 4280 to supports and connect the rope to
the skirt boards and lift skirt boards by using of the winches
Drilling of holes as per drawing 48029294, sheet1 into existing supports
Installation of main beam for idler stations, Dwg. 48029294, Group 4210, ~3,7ton to existing
structure
Installation of support for idler station, Dwg 48029295, Group 4210, ~0,2ton
Installation of idler stations according drawing 49046334 - GA Belt line CV-11 to main beam
3.8
Head Return Station Installation

o GA Head return station, Dwg. 49046336
o Assembly Head return station CV-11, Dwg. 49046339
NOTE!
Description of the dis-assembly of existing structure is not part of this
manual!
Adaption works between existing structures and new parts delivered by
TAKRAF GmbH may become necessary and are in the responsibility of the
client!
Installation of steel structure support for belt scale, Dwg. 48030190, Group 3210
Installation of supports for snub pulley and rollers, Dwg. 48029293, Group 2110 to head return
station main frame, Dwg. 48029246, Group 2110 before install the main frame to transfer
tower
Installation of head return station main frame, Dwg. 48029246, Group 2110 to transfer tower
Installation of return pulley, Dwg. 42016717, Group 2510 to main frame
NOTE!
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See Pulley Drawings for Mounting Instructions!
Installation of snub pulley, Dwg. 42016874, Group 2510

Use fasteners, Dwg. 49047384 and wedge boxes, Dwg. 49047382 for installation!
Pre-assembly of discharge chute, Dwg. 48029247, Group 2230

o Discharge Chute consisting of three parts: bottom part, upper front part and upper rear
part
o Installation of wear liners, Dwg. 48029248, Group 2230 to bottom and upper rear part
Installation of discharge chute, Dwg. 48029247, Group 2230 to head station
o Installation shall be carried out in three steps:
Bottom part
Upper rear part
Upper front part (after belt installation)
Installation of idler station support, Dwg. 48029249, Group 2110
Installation of idler station according GA Belt line CV-11, Dwg. 49046334 to idler support
station
Installation of support frame for calibration equipment, Dwg. 48030198, Group 2110
Installation of calibration equipment to support frame ( see Sub-Supplier Documentation)
3.9
Conveyor Module Installation

For See following drawings for further details:
o Assembly Conveyor CV-11, Dwg. 49047450
o GA Belt line CV-11, Dwg. 49046334
Pre-assembly conveyor modules according to drawings:
o Standard module, Dwg. 48029245, Group 3210
o Reinforced module, Dwg. 48029267, Group 3210
o Special module, Dwg. 48029268, Group 3210
o Pull cord hook, Dwg. 48029261, Group 3210
NOTE!
Using of an assembly rig for conveyor module assembly is recommended!
Installation of pre-assembled conveyor modules according Assembly Drawing Conveyor CV11, Dwg. 49047450
Check alignment of idler stations according Sketch 01, Attachment 5.1
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3.10
Equipment Installation
3.10.1
Hydraulic and Lubrication Systems
See Piping Specification for general information!

Installation of Hydraulic Routing for disc brakes according sub-supplier documentation
Installation of lubrication systems for pulleys and motor unit according sub-supplier
documentation
3.10.2
Belt Scraper Installation

Installation of cleaners (after belt installation):
o V-Plow 1, Dwg. 49046350, Group 1610 to take-up station
o V-Plow 2, Dwg. 49046351, Group 1610 to take-up station
o Primary belt scraper, Dwg. 49047385, Group 2610 to head station (Fasteners, Dwg.
49047401)
o Secondary belt scraper, Dwg. 49047386, Group 2610 to head station (Fasteners, Dwg.
49047401)
3.10.3
Mechanical Equipment / Monitoring Devices

Installation of rip detection system, Dwg. 490473940, Group 8205
Installation of cord monitoring system, Dwg. 49047416, Group 8205
Installation of splice elongation system, Dwg. 49047417, Group 8205
Installation of Mobile thickness system, Dwg. 490470418, Group 8205
Installation of Mounting for pull-rope switches old modules, Dwg. 48029302, Group 8210
Installation of Mounting for pull-rope switches new standard modules, Dwg. 48029303, Group
8210
Installation of Mounting for pull-rope switches new reinforced modules, Dwg. 48029304, Group
8210
Installation of Mounting for pull-rope switch and start-up warning old modules, Dwg. 48029305,
Group 8210
Installation of Mounting for pull-rope switch and start-up warning new standard modules, Dwg.
48029306, Group 8210
Installation of Mounting for pull-rope switch start-up warning new reinforced modules, Dwg.
48029307, Group 8210
Installation of Mounting for belt misalignment switch head end, Dwg. 48029308, Group 8210
Installation of Mounting for belt misalignment switch tail end 1, Dwg. 48029309, Group 8210
Installation of Mounting for belt misalignment switch tail end 2, Dwg. 48029310, Group 8210
Installation of Mounting for material build-up probe, Dwg. 48029311, Group 8210
Installation of Mounting for ultrasonic belt rip detection, Dwg. 48029312, Group 8210
Installation of Mounting for electronic cord monitoring, Dwg, 48029313, Group 8210
Installation of Mounting for electronic splice elongation monitoring, Dwg. 48029314, Group 8210
Installation of Mounting for speed monitoring HOG16, Dwg. 48029315, Group 8210
Installation of Mounting for speed monitoring at drive pulley, Dwg. 48029316, Group 8210
Installation of Fixing plates for bypass switches, emergency push buttons, local push buton
stations and junction boxes, Dwg. 48029317, Group 8210
Installation of Mounting microwave sensor for material build-up probe, Dwg. 48030191, Group
8210
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3.10.4

Safety Guards Installation

Installation of Safety guards (before commissioning / start-up):
Drive / Take-up Station:
o Safety Guards around prim. drive pulley, Dwg. 48029290, Group 1910
o Safety Guards at Walkway sec. drive pulley, Dwg. 48029291, Group 1910
o Safety Guards brake disc, Dwg. 48029288, Group 1910
o Safety Guards for standard module carry strand type1, Dwg. 48029260, Group 1910
o Safety Guards for transition area, Dwg. 48029287, Group 1910
o Shaft end cover primary drive unit, Dwg. 48030186, Group 1910
o Shaft end safety cover secondary drive unit, Dwg. 48030187, Group 1910
o Safety Guards at disc brake type 1, Dwg. 48030188, Group 1910
o Safety Guards at disc brake type 2, Dwg. 48030189, Group 1910
Head Return Station:
o Safety Guards for transition area, Dwg. 48029252, Group 2210
Conveyor Route:
o Safety Guards for standard module carry strand type 1, Dwg. 48029260, Group 3910
o Safety Guards for standard module return strand, Dwg. 48029262, Group 3910
o Safety Guards for standard / special module return strand type 1, Dwg. 48029263,
Group 3910
o Safety Guards for reinforced module return strand, Dwg. 48029264, Group 3910
o Safety Guards for special module on concrete type 1 return strand, Dwg. 48029269,
Group 3910
o Safety Guards for standard / special module return strand type 2, Dwg. 48029270,
Group 3910
o Safety Guards for standard / special module carry strand, Dwg. 48029271, Group 3910
o Safety Guards for standard module carry strand special type 2, Dwg. 48026617, Group
3910
o Safety Guards for standard module return strand type 3, Dwg. 48026618, Group 3910
o Safety guard special size type 1 carry strand, Dwg. 48030170, Group 3910
o Safety guard special size type 1 return strand, Dwg. 48030173, Group 3910
Loading Module CV-4A to CV-11:
o Safety guards, Dwg. 48029238, Group 4150
o Safety guards, Dwg. 48029320, Group 4250
o Safety guards future conveyor 1, Dwg. 48030142, Group 4150
o Safety guards future conveyor 2, Dwg. 48030143, Group 4150
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3.11

Belt Installation
NOTE!
The belt pulling is not part of TAKRAF`s scope. However for safety reasons
we would recommend that TAKRAF should review the final procedure to
ensure that it is compatible with the overall conveyor design.
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Attachments
01: Procedure of Site Handling
02: Instruction for greasing of sliding bearings
03: Fastening Connections
04: Guideline for design, workshop & erection
05: Drawings and Sketches
06: Work and Test Instructions
07: Inspection & Test Plan
08: Corrosion Protection Specification
09: Belt Installation
10: Piping Specification
11: Tools List
12: Labour Qualification
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Attachment 01: Procedure of Site Handling
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Attachment 02: Instruction for greasing of sliding bearings
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Attachment 03: Fastening Connections
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Attachment 04: Guideline for design, workshop & erection
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Attachment 05: Drawings and Sketches
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Attachment 06: Work and Test Instructions
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Attachment 07: Inspection & Test Plan
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Attachment 07.1 Completion Certificate
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Attachment 08: Corrosion Protection Specification
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Attachment 09: Belt Installation
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Attachment 10: Piping Specification
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Attachment 11: Tools List
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Attachment 12: Labour Qualification
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--END OF DOCUMENT--
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Construction Manual - Mechanical

CORPORACIN NACIONAL DEL COBRE DE CHILE (CODELCO)

G 0268 EL Teniente - Nuevo Nivel Mina

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

General Mechanical Installation................................................................................... 5

Installation description .................................................................................................... 5

Installation procedure ..................................................................................................... 5

Temporary supports ........................................................................................................ 6

Securing of structure during construction period ............................................................. 6

Lifting appliances ............................................................................................................ 7

Storage & handling of supplies ....................................................................................... 9

General requirements ..................................................................................................... 9

Guideline for Construction description..................................................................... 11

Construction Description ........................................................................................... 12

General conditions Construction Yard........................................................................... 12

General Arrangement Drawings.................................................................................... 13

List of Weights* ............................................................................................................. 14

Tail Station Installation .................................................................................................. 15

Loading Module CV-10 to CV11 Installation.................................................................. 23

Head Return Station Installation ................................................................................... 23

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

General Mechanical Installation

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

Field joints and connections

The contractor shall provide temporary supports.

Securing of structure during construction period

G 0268 EL Teniente - Nuevo Nivel Mina

Following safety measures should be done to prevent damages and accidents:

Blocking of gear rim

Fixing of storm anchors

Installation of chain hoists (crosswise) between superstructure and undercarriage

Anchoring of boom structures (crosswise) with tie ropes

Installation of knags between machine structure and supports head section)

Bracings between single supports

Anchoring of supports with tie ropes

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

Visual inspection for damage

Check of test date on inspection plate

Trial suspension of at least 10 min.

In case of any deviations of the suspended load, they shall be corrected.

Supervisor of heavy load lifting operation

Communication by means of radiotelephony and commands

Performing of lifting appliance movements

Behavior in case of irregularities

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

Storage & handling of supplies

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

Construction Manual - Mechanic

G 0268 EL Teniente - Nuevo Nivel Mina

Guideline for Construction description

Purpose of this construction manual