Förderanlagen Magdeburg

Teleservice

Kick-Off-Meeting 24/25.03.2015
FAM Project 123099 Minera Radomiro Tomic
DESIGN and ERECTION
of BWR SR800P9
General Arrangement
Förderanlagen Magdeburg

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Förderanlagen Magdeburg
 Technical Data
Förderanlagen Magdeburg

in accordance to KAPROIN-DSH-001_Hoja_Datos_Rotopala_Rev_0

FAM type SR 800 P9

Design capacity stacking wet 14500 t/h density wet = 1,5 (1,8) 9666 m³/h
nominal capacity as basic for all design and efficiency calculation
Height of pad 10 m
Number of slices 1
Nominal depth of cut 2,2 m
Maximal depth of cut 2,7 m

max. average ground pressure in operation < 14 t/m²

max. crawler speed (transport) 15 m/min
nominal crawler speed (operation) 7-8 m/min

Qth vol/1.5t/m³/60/dxh/break-up factor1=

14500 t/h : 1.5 : 60 : 2x10 : 1= 8.05 m/min

total weight: approx. 850 t

length of conveyor BWB: approx. 40 m
track pitch of crawlers: approx. 9 m (sprocket-return wheel)
total height: approx. 15 m
max. slope of machine (boom + crawler direction) 10% (only for transportation)
max. slope of machine in operation (boom+crawler direction) 7% 3
 Technical Data
Förderanlagen Magdeburg

installed power bucket wheel 1000 KW

installed power belt conveyor 500 KW
installed power hydraulic unit (hoisting cyl.) 160 KW
installed power crawler drives 3x160 KW (120)
total installed power approx. 2400 KW
required during operation approx. 2000 KW

Crawler track assembly

crawler track arrangement equalized 3- crawler system
hydraulical steering system
number of track rollers 16(8) (each crawler)
number of support rollers 4 (each crawler)
crawler tread width approx. 2,40 m
distance drive to return sprocket approx. 9,30 m
distance between both crawler tracks 10,00 m (9)

Wheel boom, belt conveyor

belt width 108”= 2750 mm
belt speed 4,2 m/s
belt quality 2750 EP 800/4-22/8 MFV AEP
(low wear, acid resistant)
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Technical Data
Förderanlagen Magdeburg

V – plow 1
Belt scale 1 Multibelt 2xBED27
troughing angle 35°
inclination of bucket wheel chute approx. 70°(60°)

Bucket wheel
diameter approx. 19 m
elevation range of wheel approx. 1,50 m
(relation lower cutting circle to ground position) -0,5 m
number of buckets 16
designed bucket wheel volume incl. 50% ring 2,5 m³
used 2,0 m³
number of dumps 65
(Qvol = 2,5 m³ x 65 /min x 60 min/h = 9750 m³/h)
Fill factor 80%
drive power for mechanical drive 1000 KW
spec. cutting force approx. 360 N/cm
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 Förderanlagen Magdeburg

DESIGN SR800P9
1. basics for design

2. presentation of essential reclaimer components

general design description

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Basics for design
Förderanlagen Magdeburg

Design tools
Catia V5 3D
Autocad 2013 2D+3D
Inventor 3D

Other documents compiled by design department

Bill of material (like all processes based on SAP.)
Request of change
Deviation permit
Test reports for weldings, measurement test sheets
Test certificates
Project dwgs (acc. doc.schedule)
Sketches (as temporary information, not subjected to change system)

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 Basics for design
Förderanlagen Magdeburg

Structural calculations:
KRASTA 9.6 Modelling and analysing framework program for BWB
RSTAB 6 Modelling and analysing framework program
Especially for fatique calculation
COSAR FEM – Calculation
RFEM FEM – Calculation
for Bucket Wheel and Buckets

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 Basics for design
Förderanlagen Magdeburg

Main standards for calculation and design

- ISO 5049 – 1 of 1994 “Mobile equipment for continuous handling of bulk material”
Part 1: “Rules for the design of steel structures”
- FEM 2.131/132 Grundlagen zur Berechnung verfahrbarer Stetigförderer für Schüttgut/
Rules for the design of mobile equipment for continuous handling of bulk materials

- NCh 2369.Of 2003 “Earthquake-resistant design of industrial structures and facilities

on behalf of metacontrol INGENIEROS S.A. (Santiago-Chile)
-ASCE 7-05 “Minimum Design Loads for Buildings and Other Structures”
Chapter 6 “Wind Loads”
- NCh 3171.Of 2010 “Structural design – General dispositions and combination of load”
Chapter 9.2 “Combining Nominal Loads using Allowable Stress Design”

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Basics for design
Förderanlagen Magdeburg

Seismic Calculation
Metacontrol (Chile)

The loads due to earthquake are determined due to the Chilean standard
NCh2369.Of2003. The general requirements given by KAPROIN documents
are as follows
- Seismic Zone: 2
- Classification: category C1

The following values are determined:

Conveyor Calculation
Main Calculation (FAM – calculation programm)
Dynamic Calculation ( IFF – calculation programm)
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 Basics for design
Förderanlagen Magdeburg

DEM SR500R4_feeding_wallcoh_off - Verknüpfung.lnk

PFC 3D von Itasca

SR500R4_back_wallcoh_off - Verknüpfung.lnk
- ring chute and feeding chute will be
designed in accordance to DEM results
- angle of chute wall should be >60°
- angle of slide plate follows DEM
results (option: adjustable slide plate)

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General design-
Crawler + undercarriage Förderanlagen Magdeburg

curves will be realized by steering

system with crawler tongues 12
Crawler + undercarriage
Förderanlagen Magdeburg

- 3 equalized crawlers, all driven

with approx. 160 KW
- steering between both crawlers
on bucket wheel side
- substructure as rigid triangular
frame

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 Crawler - undercarriage
Förderanlagen Magdeburg

- FAM own fabrication of crawler frames with purchased crawler components

- Crawler pad width approx. 2400mm; distance sprocket return tumbler
approx. 9300mm (resultant ground pressure approximately 14 t/m²)
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 Bucket Wheel Boom
Förderanlagen Magdeburg

RAL-Radomiro.pdf

Steel structure design regarding structural calculation, counterweight boom

2 compact main walls with framework for lower and upper chord
Upper belt run with feeding garland idlers, others with fixed idler stations
Lower belt runs inside of wheel boom
Walkways on both sides of the boom
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Bucket Wheel Boom
Förderanlagen Magdeburg

Calculation for fatigue strength (class B)

steel structure will be designed for high dynamic stress
Main walls and all main structure will be fabricated in
constructtion qualification “E”
lower and upper chord are designed with cross profiles
for diagonal framework members
(instead tubes with worse notch effect)
Node plates need to be welded with full penetration
free of notches and without sharp edges

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 Bucket Wheel Boom
Förderanlagen Magdeburg

- levelling was designed and realized for some

other FAM-machines like mobile conveyor
bridges, discharge booms and so on

- levelling by 2 hydraulic cylinders

- ball and socket joints, free of constraints
- redundant circuit, one cylinder is able to
hold the system

basically sketch without scale only

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 Bucket wheel support
Förderanlagen Magdeburg

- bucket wheel shaft with flange coupling for bucket wheel connection and shrinking
disc for bucket wheel drive
- shaft material: heat-treated, special qualities and high-grade steel
for example: 30CrNiMo8+QT EN 10083;
yield strength 700N/mm²/ tensile strength 950-1100N/mm²
- soft thickness variations with large radius
- floating and locating bearing, self-aligning roller bearing with clamping set
- central lubricated, temperature control 18
 Belt Conveyor
Förderanlagen Magdeburg

Belt width 108” = 2750 mm

Belt speed 4.2 m/s
Belt utilization 70 %
Drive power 500 KW – 2 x 250 KW

Belt scale – weighing 2-idler station

brands Schenck, ThermoFischer, or similar
Belt quality 2750 EP 800/4-22/8 MFV AEP
(low wear, acid resistant)
Belt steering station
Pulleys dia 800/630mm with lagging
Rigid idler stations, roller dia 152 mm

Partial material guides on both ends

Auxiliary frames for belt assembly and vulcanizing 19
 Belt Conveyor
Förderanlagen Magdeburg

provided belt cleaner: brand-

IFT, Martin, Hosch, Technipak
or similar pre-separator

pre-belt scraper

belt scraper

inner belt cleaner

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Auxiliary devices for belt change
Förderanlagen Magdeburg

auxiliary equipment for belt

vulcanization

design having regard to

- enable access for maintenance
- control of belt runs
- overflow avoiding
- safety
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 Hoisting cylinders BWB
Förderanlagen Magdeburg

2 hoisting cylinder DZE/E 420/280-1200, under each main wall

Alternative 1 hoisting cylinder mounted in system centerline
max. Pressure in operation 350 bar, test pressure 420 bar
max. Compression force TBD, with buckling safety of >3,5
v= 1m/min
stroke approx. 1200mm

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Bucket Wheel & Chute
Förderanlagen Magdeburg

BW-diameter approx. 19 m

Volume of buckets approx. 2,5 m³

Quartered cutting edges, reinforced

Wearing material mosaic ceramics,

Chutes and Buckets
Wearing material PU on guide plates
Wearing material armored plates
on ring chute

Picture – example bucket wheel

and feeding chute RC-001

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Mounting wheel boom
Förderanlagen Magdeburg

Pre-assembly of wheel boom, 3 parts, welded joints

Mounting of completed boom with conveyor components, wheel shaft and walkways (partly)
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 Feeding chute
Förderanlagen Magdeburg

- flow contour was designed in accord. to results of DEM

- to avoid backing of material
- wear material (oxid ceramic) for longer maintenance
intervals

- Slide plate will be

adjustable,
with angle range between
approx. 60° and 70°

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Wear plates chute
Förderanlagen Magdeburg

For fixing of nuts use stickum (glued nuts)

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Bucket Wheel option
Förderanlagen Magdeburg

Radomiro_Tomic_SchaufelRadmSchaufel.pdf

Radomiro_Tomic_SchaufelRadSB.pdf

Wear protection where necessary with Vautid

(or similar) manganese hard welded plates

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Bucket - cutting edges
Förderanlagen Magdeburg

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 Buckets - design
Förderanlagen Magdeburg

Knifes quartered approx. 3m³ volume, cutting depth 2,5m,

long cutting edges quartered and bolted,
mosaic ceramic wear plates

see picture/ drawing

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Ring chute
Förderanlagen Magdeburg

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 Förderanlagen Magdeburg

Bucket Wheel calculation

z.B.: Nominell
Qth = 14500 t/h
V = 14500 t/h / ( 10 m x 2,2 m x 60 min/h * 1,5 t/m³)
V = 7,3 m/min

height m 10 10 10 10 10

Depth o.cut m 1,6 1,8 2,0 2,2 2,5

area m² 16 18 20 22 25
density t/m³ 1,5 1,5 1,5 1,5 1,5

capacity t/h 14500 14500 14500 14500 14500

travel speed m/min 10,1 8,95 8,05 7,3 6,45

Crawler drive speed

as a function of dump/cutting measurements

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Bucket wheel drive connection
Förderanlagen Magdeburg

Planetary-bevel spur gear with

shrinking disc
Hydraulic unit + hydraulic piping
Förderanlagen Magdeburg

Hydraulic unit – power approx. 160 kW

1 hydraulic pump for hoisting device, wheel boom levelling and crawler
steering device, max.pressure 350 bar during operation

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Diesel power unit
Förderanlagen Magdeburg

Diesel power unit as container cell

supported on substructure 34
 New design - advantages
Förderanlagen Magdeburg

Structural measures bucket wheel boom:

- Dimensionierung und Berechnung des Radauslegers auf der Grundlager der Kriterien für Tagebaugroßgeräte,
Material S355J2+N = A572 grade 50
die Schweißkonstruktion der Hauptträger des Radauslegers wird fertigungstechnisch quasi kerbfrei
gestaltet (beschleifen von Schweißnähten, Einhaltung von Mindestradien, Dickenübergänge mind.
1:3, usw.)
- In der Fachwerkkonstruktion des Radauslegers werden auf Grund des schlechten Kerbfalles keine Rohre als
Verbandstab eingesetzt
Stabquerschnitt aus Winkelprofilstahl,
Knotenbleche werden dynamisch gestaltet
(ausgerundet, Stumpfnahtanschluss und beschliffen)

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 New design - advantages
Förderanlagen Magdeburg

Structural measures bucket wheel:

- Einscheibenschaufelrad mit Doppelkonus und Torus
quasi kerbfrei und damit langlebig
flexibel
Doppelkonus nach außen weisend, daher ununterbrochene Schaufelradschurre möglich
Geradzahlige Schaufelzahl
Der Innen- und Aussenkonus des Schaufelrades, sowie die Verbindung zur Nabe werden durch
FEA mit ausreichender Sicherheit nachgewiesen
- Das Material und die Schweißnähte entsprechen höchsten Qualitätsanforderungen
3.1, US-Test, S355 (A572 grade 50) Z35
- Die Flanschverbindung wird den hohen dynamischen Belastungen entsprechend dimensioniert
- Die max. Reißkraft des Schaufelrades wird auf das 1,3-fache begrenzt

- FEA for wheel body

- Shop fabrication FAM-Magdeburg
- 3 transport units,
one part hub and inner cone shell
two parts outer cone
- Pre-assembly and adjustment in shop
- Assembly on site with auxiliary
mounting elements
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 New design - advantages
Förderanlagen Magdeburg

Adjustment of both unit with assembly elements

Weldings during assembly
In shop already adjusted units are fixed in the
original position with those elements.
Assembly element
To remove after welding.

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New design - advantages
Förderanlagen Magdeburg

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 New design - advantages
Förderanlagen Magdeburg

Schaufelradantrieb:
- Planeten-Stirnrad-Kegelradgetriebe namhafter Hersteller (z.B. Flender Siemens, Eickhoff, etc.)
- Lamellen-Sicherheitskupplung
- VFD zur Optimierung der Nenndrehzahl und zum Wartungsbetrieb mit geringer Geschwindigkeit
- Abstützung Drehmomentenstütze mit Pendellager (keine Verklemmungsgefahr)
- Zusätzliche Lastkontrolle mit Lastmessachse in Pendelstütze
- Anordnung auf Welle derart, das Schrumpfscheibe auf der Seite des Abtriebs liegt.
- Kein „Reiten“ der Nabe auf der Welle, siehe Skizze oben

Schaufeln: Sehr große Spantiefe möglich (theoretisch bis 3 m), dadurch:

langsame Fahrgeschwindigkeit, günstiges Verhältnis von Fahrzeit zu Kurvenzeit,
hohe Effizienz des Betriebes möglich, seltenere Wendemanöver
- Bauart der Schaufeln derart, dass:
Keine Ecken nur Rundungen dadurch Vermeidung von Anbackungen
Gutes Entleerungsverhalten, Auswechselbare extra lange Schneidmesser,
vierteilig, Schneiden geschmiedet aus vergütetem borlegiertem Feinkornstahl.

Schaufelradschurre:
Durchgehende Seitenwand (Keine Raddurchdringung),
Abweiskante am Ende der Schurre

Bandanlage:
Geringe Gurtausnutzung (ca. 70%)
- Große Gurtbreite 2750 mm
- Moderate Gurtgeschwindigkeit ca. 4,2 m/s
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 New design - advantages
Förderanlagen Magdeburg

Slope of bucket wheel around vertical axis

- 1. vertical=lower torsional moment

- 2. horizontal=isn‘t necessary because of
large wheel diameter

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General Arrangement – 3D
Förderanlagen Magdeburg
 Questionary
Förderanlagen Magdeburg

- General Form of documents – FAM standard

List of documents and drawings (mechanical)
General Notes for design and fabrication, walkways
Test report for measurement and welding – FAM standard
TAG-No. Client
Document-No. Client
Proposals for purchased items like conveyor and other equipment (spare parts)
- Interfaces+design Arrangement and Geometry of stockpile – drawing (DWG or
STP-data) – inclination 7% constant or +/- variable?
Arrangement and geometrie of mobile conveyor bridge (DWG or STP-data) –
distance and tolerances between crawlers of new reclaimer-existing conveyor
bridge?
Reclaiming capacity 14500 t/h designed and realized – what is the range of
reclaiming capacity because of subsequent feeding chutes and conveyors
(different material flow, range for VFD for crawler, bucket wheel and belt conveyor
drive?)
- Transport Approval for the list of oversized structures (created by FAM)
Track width of crawlers will be approx. 10 m (2,40m shoes) – need to be confirme
distances for transport mounting area – operation area
Timing for reclaiming circle (change of stockpile sides)?
- Erection Ground pressure for erection area need to be 300 KN/m²
area for storage, pre-assembly and erection
power, water-connections ….
others
 Förderanlagen Magdeburg

Fin de la presentación
Gracias por su atención

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