Page 1 of 16 Section 14557 1. GENERAL.1 DESCRIPTION.1 a. The Manufacturer shall design, and supply a drag chain conveyor for the product(s) specified, in accordance with this Section 14557..2 REQUIREMENTS.2 The equipment supplied by the Manufacturer is generally: - Motor and drive assembly - Chain, paddles, and chain connecting links - Sprockets, shafts and bearings - Head assembly, tail assembly and trunking.1 All machinery and components installed must conform to all applicable codes, and standards and as specified herein..2 The Conveyor Manufacturer shall obtain the following information in writing from the Owner prior to quoting a price: a) The average annual throughput in metric tonnes for the conveyor b) The type of duty and use to which the conveyor is to be subjected c) The minimum and maximum ambient operating temperatures that the conveyor must operate in.3 APPROVAL DRAWINGS.1 The Manufacturer shall submit approval drawings to the owner or the designated owner s representative prior to fabrication of work. Approval Drawings shall include, as a minimum, the details as listed in APPENDIX A Drawings..2 Approval Drawings shall be submitted as self contained (i.e.: XREFS,
Page 2 of 16 Blocks, and Text Styles used) AutoCAD 2000, *.dwg (writable) files to the owner. File names shall conform to the format specified in APPENDIX A - Drawings..4 RECORD DRAWINGS The Manufacturer shall submit as-built drawings and drawing files of all approval drawings. All Record Drawings shall meet the same content and format requirements as specified for Approval Drawings.5 MANUALS The Manufacturer shall submit installation, start-up, and operation and maintenance manuals to the Owner. 2. PRODUCTS.1 HEAVY-DUTY CONVEYOR (Capacities Over 250,000 tonnes/year or 400 tonnes/hour).1 TYPE Conveyors shall be drag chain type, manufactured to the following specifications..2 CAPACITY.1 Conveyor capacity shall be as shown on the flow diagram, and based on one specific product, and product density, as defined by the Owner..2 Where conveyors and/or bucket elevators feed one another the actual design capacities shall be such that succeeding pieces of equipment are not overfed..3 Conveyor shall be dust tight, enclosed, and weatherproof where outside..4 Chain speed shall not exceed 43 m/minute (140 ft/minute) at rated capacity without prior written approval from the Owner.
Page 3 of 16.5 Inclines over 5 degrees shall be allowed for in capacity calculations. Inclines in excess of 7 degrees shall not be allowed without prior written approval from the Owner..3 DRIVE.1 Power to suit length, and capacity of conveyor and be sufficient to start fully loaded at a maximum overloaded belt condition. If calculated kw or horsepower is within 5% of motor nameplate rating, upsize to next larger motor..2 Drive shall have a 1.4 service factor (AGMA Class II) using a product density based upon the highest density product to be conveyed at rated capacity. Reducer to shaft fit must not be an interference fit. Dimensions and tolerances shall be shown on approval drawings..3 All electric motors are to be either Explosion-Proof or TEFC, depending on the area classification. Motors shall be Toshiba EQPIII-XS - TEFC Premium Efficiency, or Toshiba EQPIII - XP Premium Efficiency, or approved equal, up to and including 447Tframe. For explosion-proof applications over 447T-frame discuss with Owner. If approved by local regulations TEFC motors may be used in Class II, Grp G, Div 2 location (per US or Canadian Electrical Code) provided the motor is equipped with an approved thermal cut-off device, drain holes are plugged, and the motor nameplate has a temperature code appropriate for the location. All motors, which are directly connected, shall have ball bearings (no roll bearings). Motor voltage, phase and hertz as required to match existing electrical system, or as otherwise specified in writing by the Owner..4 Motor mounts for drive assemblies shall be constructed for ease of adjustment such that coupling or belt alignment and belt tension are independently adjustable, via a sliding and/or rotational movement controlled through the use of screw adjustments.
Page 4 of 16.5 Couplings shall be FALK WrapFlex except where higher torque requirements necessitate an alternative, which shall be a SteelFlex type grid coupling, or approved equals..6 Reducers 60kW (75 hp) and larger shall be shaft mounted direct drive, preferably with C or D-flange motor mount as available, Falk Drive One or approved equal. Reducers less than 60kW (75hp) may be shaft mounted with primary synchronous drive belt, with the motor mounted on top of the reducer if 15kW (20hp) or less, Falk Quadrive or approved equal, or right-angle helical bevel shaft mounted with C-flange mount motor, Falk Ultramite UB type or Drive One, or approved equal. If the cost for a shaft mounted direct drive is within US$3,000 of a synchronous belt driven shaft mounted reducer, furnish the shaft mounted direct drive. Electric cooling fans shall not be used, however, shaft mounted cooling fans are acceptable. All reducers shall have the Falk Cargill Reliability package, or approved equal. For belt drives where a motor is not mounted on the reducer, a reduced clearance torque arm assembly shall be used for the reducer, as generally shown in APPENDIX B, to minimize torque arm play and its affect upon drive belt tension..7 Primary drive belts for motor input shaft shall be a synchronous belt with a minimum service factor of 1.8 at rated water level bucket fill capacity, Goodyear Eagle Pd (preferred), Gates Polychain, or approved equal. Maximum reduction shall be 2.5 to 1. Drives must withstand maximum torque capability of prime mover without drive slippage or damage occurring..8 A drive analysis and recommendation report, computer generated by the belt manufacturer s software, and obtained directly from the drive belt manufacturer, the manufacturer s distributor, or the conveyor manufacturer, shall be submitted to the Owner for approval prior to construction..9 Belts and other moving parts shall be guarded. Guards shall be steel, enclose belts on back as well as on front and sides, such that full protection is provided. Belt guards shall have a bolted
Page 5 of 16 removable front for easy removal of pulleys and belt. Guards shall also have a removable section on one side that may be removed without tools, and located over the center of the belt to allow the insertion of a spring-type belt tension measurement tool to measure belt tension..10 Lubrication for drive components shall meet OEM requirements for the extreme high and extreme low ambient temperature range within which the equipment is intended to operate, without changing the lubricant. The maximum allowable pour point shall be 5 C below the lowest ambient operating temperature, and the minimum allowable viscosity shall be 20 cst at 38 C above the highest ambient operating temperature. Reducer lubricant shall be synthetic Mobil SHC 600 series for all reducers, unless otherwise approved in writing by the Owner..4 HEAD AND TAIL.1 Head and tail sections shall be "split" design..2 Sprockets shall be of "split" design. Head sprockets shall be heat treated..3 Conveyor shall have hinged head and tail access doors and end relief door in head with "go" limit switch..4 Bearings to be pillow block bearing mounted in compression. Flange bearings are not acceptable. Bearings shall be mounted a minimum of 4 cm (1.5 in) from the casing..5 Bearings to be with pillow block with insert/adapter, and split housing (4 bolt where possible), Dodge Imperial up to 12.7 cm (5 ), ISAF self- aligning with Trident seals, up to and including 17cm (7 ) diameter, or approved equal. Over 17cm (7 ) use USAF split housing, self-aligning with Triple-Tech seals, or approved equal. Bearings shall have a minimum L10 life of 30,000 hrs..6 Slack chain detector with a temperature and humidity compensated inductive proximity switch, GO switch, or Turck, or approved equal.
Page 6 of 16.7 Head section shall always include a discharge rated at full capacity of conveyor. A drag conveyor shall be designed with a head discharge into downstream equipment. A manual emergency discharge gate must be provided to allow emptying of the conveyor where an unplanned situation can occur resulting in a full conveyor with no place for the product to discharge..5 SPEED.1 Speed not to exceed 43m/minute (140 ft/minute) without written approval..6 SECTIONS.1 Conveyors shall have bolted flat removable liners/bottoms with a depth no greater than 1.5 times the width. Bottoms shall not be welded to other parts of the conveyor. Any tack welds from shop assembly shall be removed in the shop..2 Drag side sections shall be 10 ga. with 1.9cm (3/16") AR 220 liner to full material depth. Liner thickness shall be 95mm (3/8") on bottom. The minimum bottom liner hardness shall be 360 Brinell..3 Drag top cover shall be 14 ga. minimum with quick removal fasteners and gaskets. Top shall be of peaked design unless otherwise approved, weatherproof, and self-draining, where conveyors are outside. Interior conveyors shall have flat dust tight covers..4 Welds shall be fillets except where engineering analysis requires another type. Welds on outside of casing shall be continuous. Stitch welds will not be accepted. This is to prevent rusting of the casing..5 Chain shall have carry-back cups if conveyor has intermediate discharge gates. Chain return will be double 360 AR slide rails 63.5 mm (3/16 ) thick mounted on 2 x 2 x ¼ angles. Rail shall be angled (herringbone) to provide full wear on flight. Chain shall be standard WH series manufactured by Webster, Rex, or Union.
Page 7 of 16 No proprietary chain shall be used. Minimum service factor for chain shall be 6 to 1, maximum working load to ultimate strength..6 Flights shall be white "virgin" UHMW 1.6cm (5/8 ) minimum thickness bolted to backers. Backers shall be bars equal in thickness to chain sidebar, 6mm (1/4 ) minimum for conveyors up to 61cm (24 ) wide. Over 61cm (24 ) wide shall have angle backers with a minimum thickness of 6 mm (1/4 ). All flights, or every tenth flight at minimum, shall be of one-piece design such that the bottom of trough under chain is swept clean..7 INTERMEDIATE DISCHARGE GATES.1 Stub discharge, full section width inline gate..2 Minimum gate length shall be 92cm (36 ) minimum, or longer as required to minimize carryover past the gate..3 Drop type discharge gates WILL NOT be permitted. Gates shall be rack and pinion horizontal slide style with an Electro- Sensors absolute encoder to determine gate position where an automated system is available, otherwise inductive proximity limit switches shall be used, GO switch or approved equal..4 Gate drives shall be either manual or electric direct drive rack & pinion, or hydraulic, or pneumatic, as specified in writing by the Owner. Electric gate drives shall consist of a C-flange motor driving either a solidly mounted in-line, or right-angle reducer driving the pinion shaft of a rack and pinion slide gate via a flexible coupling, or a pinion shaft mounted reducer anchored with a torque arm which allows sufficient movement for runout and alignment tolerances..5 Electric gate motors shall be Explosion-Proof if within the plant, or TEFC if exterior. Toshiba EQPIII - Explosion Proof Premium Efficiency, Toshiba EQPIII-XS - TEFC Premium Efficiency, or if fractional hp TEFC - Toshiba 51C with cast junction box, or approved equals.
Page 8 of 16.8 INLETS.9 PAINT.1 Conveyor shall use controlled feed inlet(s) with raised inlet bonnets or shall use bypass inlet(s) where flood feed may result in conveyor problems. Where necessary, feed inlets shall be equipped with a bolted removable scalper bar assembly to prevent foreign material for getting into conveyor. Scalper bars shall be 127 mm (½ in) thick spaced so the minimum opening width is 1 inch..2 All inlets shall be designed for full rated flow and proper feeding of the conveyor under the actual operating conditions, be it choke or controlled feed..3 Inlets shall be located far enough from the head and tail to ensure that product flow due to the angle of repose or the action of the chain, does not engage the sprocket, and in no case shall be less than 89cm (35 ) horizontally from the closest end of the inlet box to the closest sprocket tooth, unless approved in writing by the Owner. All chain conveyors shall be suitably coated at the Manufacturer s factory prior to shipment. All exterior surfaces shall be cleaned to remove all oil or other substances, surface prepped to a Commercial Blast sspc-6 finish, prime painted with 5 dry mils of epoxy primer, and finish painted with 3 dry mils of aliphatic urethane finish..2 MEDIUM-DUTY CONVEYOR (Less Than 250,000 tonnes/year, or 400 tonnes/hour) All medium-duty conveyors shall follow the heavy-duty conveyor specifications except for the following changes..1 The maximum chain speed shall not exceed 49 m/minute (160 ft/minute) without written approval..2 The minimum liner hardness shall be 220 Brinell..3 The minimum thickness of the bottom liner shall be 6mm (1/4")..4 The minimum sideliner thickness shall be 10 gauge to the full material
Page 9 of 16 depth..5 Chain return supports shall be double 360 brinnell side rails 3/16 th inch thick (herringbone style) mounted on 1.5 x 1.5 x 3/16 th inch angles..6 Non-split head and tail sections..7 Coating system shall be: remove all oils or other contaminants from the surface, power tool clean, prime with 3 dry mils of surface tolerant alkyd or acrylic primer and 3 dry mils acrylic finish. If the elevator is installed in a climate with less than 38 cm (15 inches) of rain/year the drag may be furnished with galvanized material..3 LIGHT-DUTY CONVEYOR (Less Than 50,000 Tonnes/Year) All light-duty conveyors shall follow the heavy-duty conveyor specifications except for the following changes..1 Speed shall not exceed 55 m/minute (180 ft/minute) without written approval..2 Minimum liner hardness to be 220 Brinell..3 Liner thickness shall be 4.5mm (3/16") minimum on bottom of light-duty conveyor..4 No liner to be installed on sides of light-duty conveyor..5 Chain return supports may be be double 220 AR side rails 3/16 th inch thick (herringbone style) mounted on 1.5 x 1.5 x 3/16 th inch angles, or UHMW rollers with the shaft support on outside casing flange bearings spaced a maximum of 76cm (2-6 ) apart to minimize sag, or a continuous UHMW center support rail with provision for contraction/expansion of UHMW..6 Non-split head and tail sections..7 Tail bearings may be ball type. The tail take-up bearing may be flange mounted provided they are mounted at least 4 cm (1.5 inches) from casing.
Page 10 of 16.8 Coating system shall be: remove all oils or other contaminants from the surface, power tool clean, prime with 3 dry mils of surface tolerant alkyd or acrylic primer and 3 dry mils acrylic finish. If the elevator is installed in a climate with less than 38 cm (15 inches) of rain/year the drag may be furnished with galvanized material. 3. TESTING.1 Upon completion of the manufacturing and assembly of head section and drive, the assembly shall be thoroughly tested by the Conveyor Manufacturer who shall inspect for smooth operation, correct operating speed, alignment, and belt/chain tensions. The Conveyor Manufacturer shall also check for motor Klixons or thermistors for motors 30kW (40hp) and larger, and clearly mark the correct oil filling and oil level inspection plugs on the reducer.
Page 11 of 16 APPENDIX A - Drawings GENERAL ARRANGEMENT DRAWING: Title Block, Drawing Number & Revision Number Plus the following information: SIDE VIEW Overall conveyor dimensions & incline if req'd Head & tail lengths Trough lengths End to centre of all inlets & outlets Centre to centre of all inlets & outlets Reference to intermediate discharge gate assembly dwg, if applicable. Item numbers KEY PLAN OF DRIVE ARRANGEMENT, PLAN VIEW Drawn not to scale Locate side of drive in relationship to head & tail sections TYP. TROUGH SECTION(S) Overall trough dimensions i.d. & o.d. Conveyor Cover Bolt hole locations & diameter Associated parts (ie: chain, paddles etc.) Item numbers INLET & OUTLET FLANGE DETAIL(S) Overall flange dimensions i.d. & o.d. Bolt hole locations & diameter Item numbers DETAIL OF TAIL ASSEMBLY SIDE VIEW Overall dimensions
Page 12 of 16 Take-up Associated parts Item numbers DETAIL OF HEAD ASSEMBLY SIDE & END VIEW Overall dimensions Take-up Associated parts (ie: drive components, sprockets etc.) Item number Slack chain detector installation notes GENERAL NOTES Conveyor design capacity based on specified product Chain speed metres/minute (or FPM) Head shaft speed - RPM Paint spec. Lubrication requirements for bearings, reducer, and backstop (grease & oil) under ambient operating temperature range specified by Owner BILL OF MATERIALS Item #, Description (make & model), Part #, & Quantity Items to be included Head construction Head shaft Head bearings Head sprocket Tail construction Tail shaft Tail bearings Tail sprockets Conveyor through construction Conveyor cover construction Conveyor chain Conveyor paddles Conveyor inlet construction Conveyor intermediate outlet construction Conveyor nuts, bolts, gaskets & clamps Motor model, HP, voltage, FLA, RPM
Page 13 of 16 Drive belt & pulley model nos., accurate belt tensioning deflection at a specific force, safety factor All bolt, nut and setscrew torques INTERMEDIATE DISCHARGE GATE(S) - GENERAL ARRANGEMENT DRAWING: Title Block, Drawing Number & Revision Number (If a separate drawing from drag chain conveyor drawing) Plus the following information: SIDE VIEW Overall gate dimensions Drive arrangement KEY PLAN OF DRIVE ARRANGEMENT, PLAN VIEW Showing side of drive in relationship to head & tail sections of drag chain conveyor INLET & OUTLET FLANGE DETAIL(S) Overall flange dimensions i.d. & o.d. Bolt hole locations & diameter Item numbers GENERAL NOTES Paint spec. Lubrication requirements for bearings, reducer, and backstop (grease & oil) under ambient operating temperature range specified by Owner BILL OF MATERIALS Item #, Description (make & model), Part #, & Quantity Items to be included Frame & slide construction Slide guide construction Shaft sizes Bearings Sprockets, & chain (as applicable) Hydraulic cylinders (as applicable) Position encoders (as applicable)
Page 14 of 16 Conveyor nuts, bolts, gaskets & clamps All bolt, nut and setscrew torques Motor model, HP, voltage, FLA, RPM (as applicable) Reducer model, ratio (as applicable) TITLE BLOCK REQUIREMENTS (All Drawings): Drawing title blocks shall contain the following elements: Contractor name and address Cargill name Cargill logo (optional and available from Owner) The location and plant for which the drawing is intended Drawing title which is descriptive of the contents Contractor unique drawing number, and file/project number if applicable Date the drawing was completed Scale of the drawing (and plot scale for model space) Drawn by Approved by Revision number with a descriptive list of revisions FILE NAME REQUIREMENTS (All Drawings): Digital AutoCAD drawing file names shall use the following format: Contractor s unique drawing number, and file/project number if applicable Revision number preceded by the letter r For example: the file name 1234ABCDr3.dwg represents drawing number ABCD1234, revision 3.
Page 15 of 16 APPENDIX B Diagrams REDUCER Weld pin to clevis, both ends (typical 4 places) to prevent pin movement in clevis Torque arm with spherical tie rod ends, with or without turnbuckle & lock nuts, as required MOTOR MOUNT LOW CLEARANCE TORQUE ARM Figure 1
Page 16 of 16 This page has been intentionally left blank.