BECHTEL CHILE LTDA.

MATERIAL HANDLING DESIGN CRITERIA

24017-DM-002

FOR

MINERA ESCONDIDA LIMITADA

ESCONDIDA PHASE IV EXPANSION PROJECT

3 23/08/02 Reissued to revise Item 4.8.1-e on lagging MD AN SIGNED

2 17/07/99 Reissued for Construction, included Client CF KV FL LD CL MC SIGNED
Comments
1 1/05/99 Revised and Issued for Construction CF KV FL LD CL MC
0 15/02/99 Issued for Construction KJV JJT RKB LD CL MC MK
B 22/12/98 Issued for Approval KJV JJT RKB LD CL MC MK
A 13/10/98 Issued for Coordination KJV JJT RKB LD CL MC
REV. DATE REASON FOR REVISION BY CHECK EGS VEM PE PEM CLIENT
JOB NO. 24017

BECHTEL CHILE LTDA. SPECIFICATION NO. REV.

24017 – DM - 002 3

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TABLE OF CONTENTS

Section Description Page No.

1.0 INTRODUCTION 3

2.0 CODES AND STANDARDS 3

3.0 GENERAL REQUIREMENTS AND CONSIDERATIONS 6

4.0 BELT CONVEYORS 7

5.0 FEEDERS 23

6.0 TRANSFER CHUTES, HOPPERS, BINS, SKIRT BOARDS AND LINERS 25

7.0 VIBRATION CONTROL 27

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1. INTRODUCTION

1.1 This document establishes the design criteria, procedures and specific
requirements for the materials handling equipment for the Phase IV
Expansion Project of Minera Escondida Limitada (MEL), for Mine Site
and Puerto Coloso area, 2nd Region-Antofagasta, Chile.

1.2 Capacities for all equipment will be in accordance with the requirements
specified in the related flow diagrams, data sheets and Process Design
Criteria 24017-DF-002 and 24017-DF-004.

1.3 Layout of all facilities will allow for safe and ready access for operation and
maintenance. Provision will be made for inspection, servicing, removal and
replacement of machinery and components. Equipment and component
installations will be at sufficient distance above ground level to provide
space for cleanup and to prevent fugitive dust accumulation from creating
abrasive or harmful conditions. Space also will be made for future
expansion of all facilities as identified in project scope.

1.4 All equipment and materials will be new.

1.5 All equipment and components will be the manufacturer’s normal design
for the service specified with readily available replacement parts. However,
all drive components, compressors, hydraulic systems, etc., will be rated
for the plant elevation specified.

1.6 The criteria given in this document should be read with Mechanical Design
Criteria 24017-DM-001 and Civil/Structural Design
Criteria 24017-DC-001 for additional design requirements. Due
consideration must be given to the climatic and design data furnished
therein, particularly the plant site elevation and the seismicity of the plant
site area.

2. CODES AND STANDARDS

Work will conform to Chilean Official Standards (Norma Chilena Oficial-NCh)

including aspects related to safety, health or local and/or municipal laws or decrees.
Subjects not covered by these codes and standards will be designed, fabricated,
tested and supplied to conform to the latest applicable edition of the following codes
and standards:

ABMA American Bearing Manufacturers Association

AGMAAmerican Gear Manufacturers Association

AISC American Institute of Steel Construction

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AISE Association of Iron and Steel Engineers

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

ASME/ANSI “Safety Standards for Conveyors and Related Equipment” Standard

B.20.1 - 1996

ASTM American Society for Testing and Materials

AWS American Welding Society

CEMA Conveyor Equipment Manufacturing Association

DIN Deustche Industries Norm. Belt Conveyors for Bulk Materials

(basis for calculation and design) DIN 22101

FEM Fédération Européene de Manutention, Chapter II, Rules for

the Design of Mechanisms FEM 2132

HMI Hoist Manufacturers Institute

ISA Instrument Society of America

ISO International Organization for Standardization, including

Mobile Continuous Bulk Handling Equipment, Part I, Rules for the
Design of Structures

ISO International Organization for Standardization: Guide for

the Evaluation of Human Exposure to Whole-Body Vibration.
2631ISO 1940/-1986 (E), Mechanical Vibration of Rigid Motors.

JIC Joint Industry Council (of the National Fluid Power

Association)

MMA Monorail Manufacturers Association

MPTA Mechanical Power Transmission Association

MSHA Mine Safety and Health Administration

NCh Norma Chilena Oficial (Chilean Official Standard)

NEC National Electrical Code

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NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

NFPA National Fluid Power Association

NHS Reglamento sobre Condiciones Sanitarias y Ambientales

Mínimas en los Lugares de Trabajo (National Health Service)

NOSA National Occupational Safety Association

OSHA Occupational Safety and Health Administration

RMA Rubber Manufacturers Association

SEC Superintendencia de Servicios Eléctricos y Combustibles

SMACNA Sheet Metal and Air Conditioning Contractors National Association

SSPC Steel Structures Painting Council

UBC Uniform Building Code

UL Underwriters Laboratories

Where there are conflicts among the codes or standards, the final decision on
prevailing criteria will be made by MEL. It is the seller’s responsibility to obtain the
clarifications and or decisions regarding such conflicts.

The Seller may propose alternatives to the foregoing codes and standards.
However, Seller will demonstrate the equivalence or superiority of the proposed
alternatives to those listed for approval.

In general, in the event of a conflict between the above-listed standards, the most
stringent will apply.

3. GENERAL REQUIREMENTS AND CONSIDERATIONS

3.1 UNITS

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All calculations will be made either in SI units or English units with the
results converted to SI units.

3.2 DESIGN REQUIREMENTS

All design for mechanical equipment will consider:

3.2.1 Requirements for design production goals (maximum capacity,

operating schedule, etc.)
3.2.2 Specific characteristics of materials and products
3.2.3 Plant site characteristics (elevation, environmental conditions,
seismic conditions)
3.2.4 Provision for future expansion
3.2.5 Design capacity for continuous operation with minimum
downtime, including design allowance for variable feed rates and
surge conditions
3.2.6 All load and design calculations will take into account starting of
the equipment under fully loaded conditions after any stoppage
3.2.7 Highest practical availability of equipment and systems
3.2.8 Low capital and maintenance costs consistent with reliability and
reasonable operating costs
3.2.9 Selection of mechanical equipment with a proven record in similar
operations
3.2.10 Maintenance access platforms at all drives and walkways for
equipment maintenance, housekeeping, and safety; suspended
supports, where practical, for conveyors in tunnels and galleries to
facilitate cleaning; and tunnels with sloped floors for easy cleanup

3.2.11 Monorail locations above equipment and permanent hoists or

cranes for maintenance
3.2.12 Standardization of assemblies, components and lubricants selected
to cover a broad range of applications and/or reduce warehouse
inventory
3.2.13 Design of all equipment for maximum shop-fabricated components
and shop-assembled packages, and only disassembled for shipment
if freight handling so requires
3.2.14 Design of parts and accessories using appropriate and equivalent
materials available in Chile wherever practical
3.2.15 Compressed air outlets, power outlets, water connections and
potable water in all facilities where process requires
3.2.16 Design of each mechanical unit will be performed taking into
account the most extreme operations and climatic conditions.

4. BELT CONVEYORS

4.1 GENERAL DESIGN CONSIDERATIONS

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4.1.1 As a minimum, conveyor design will be in accordance with CEMA

or DIN standards. Where CEMA or DIN guidelines differ from
industrial heavy machinery practices, or by criteria included in the
equipment specifications, the more stringent will apply.

4.1.2 The design calculations for each conveyor will be prepared by the
Seller and submitted for engineering review prior to fabrication.
Computer programs used for conveyor design calculations will be
verified with either a manual calculation or other standard
computer programs. All input and output data will be submitted,
as well as the formulae and bases for the computations.

4.1.3 All drives for conveyors greater than 125 kW, and for conveyors
with vertical concave curves will be designed for soft starts and
smooth acceleration to prevent belt lift on concave curves and
severe shock to equipment components. Drive arrangements may
incorporate wound rotor motors, hydraulic couplings,
programmable soft start starters or variable frequency motor
drives as necessary to ensure soft starts.

4.1.4 Decelerating or coasting time will be calculated for each conveyor.

Provisions will be made to prevent transfer chutes from plugging
during stopping.

4.1.5 Accelerating time of conveyors will be set so that the peak

accelerating torque does not exceed 150 percent of the breakaway
torque.

4.1.6 Conveyors handling primary crushed ore (coarse ore) will be

designed for a maximum belt loading with 130 millimeters
minimum edge distance based on the CEMA method for the
specified ore surcharge angle.

4.1.7 Belt speeds for the in-plant conveyors will not exceed 4.85 meters
per second. The belt speed for coarse ore in pit and overland
conveyors will be 6.1 meters per second, maximum.

4.1.8 Belt speeds for pebble conveyors before the pebble crusher and for
conveyors in the Coloso Port area shall not exceed 2.0 meters per
second.

4.1.9 The incline on conveyors will be as stated in the technical

specification or on the specification data sheet, but will normally
be limited to 15 degrees maximum. The maximum slope for
downhill conveyors will be 10 degrees.

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4.1.10 Conveyors will be analyzed for running, breakaway, acceleration,

braking and nonbrake stopping tensions. A belt dynamic analysis,
including elastic consideration for the belt, will be performed for
the belt conveyor in order to:

a. Prevent excessive starting and stopping tensions being

developed from the transient forces in the belt

b. Design conveyor drives with soft start, smooth

acceleration and smooth deceleration (braking) to prevent
the belt from lifting off the idlers at concave curves, and
shock or damage to the conveyor components

c. Prevent material spillage resulting from the motion of

transient forces during acceleration and deceleration of the
belt

4.1.11 Conveyors will be analyzed for summer and/or winter

temperatures, as required, to obtain the governing parameters of
the conveyor design.

4.1.12 Curve analyses will be performed for both the carrying side and
return side of vertical curves and for all of the above belt tension
conditions.

4.1.13 Concave vertical curve radii will be sized to prevent lifting of the
belt off the idlers under any conditions. For conveyor curves, the
highest possible tension at the curve will be computed (empty and
full, winter or summer, reduced and full friction) and the worst
case scenario will be used to compute the required radius. The
lowest possible tension at the curve will be computed to maintain
the minimum edge tension in the belt. The minimum edge tension
for fabric belts will be 5.3 kN/m (30 pounds per inch width –
30 PIW).

4.1.14 Convex vertical curve radii will be sized to maintain at least

5.3 kN/m (30 PIW) in the center of the belt under all running and
transient conditions. In addition, convex curves will be sized such
that the edge tension does not exceed 100 percent of the belt
tension rating during any full or empty belt running condition. The
edge tension during any transient condition will not exceed
130 percent of the rated belt tension.

4.1.15 All conveyors will be provided with accessible areas for belt
replacement and splicing operations. Splice Stations to be in Low
Tension Areas where possible.

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4.1.16 Belt sag at design load on the carrying side will be limited to
1 percent of the carrying idler spacing for steel cord belts and
2 percent for all others. Return belt sag will be limited to
3 percent of the return idler spacing.
2
4.1.17 The design of horizontal curves will be based on good engineering
practice and manufacturers recommendations.

4.1.18 Sandwich type conveyors, tube conveyors, and conveyors using

belting with integrally vulcanized side walls and lifters, if required,
will be of Bechtel approved design and make.

4.2 ELECTRIC MOTORS

4.2.1 Refer to the following specifications: Medium Voltage Motors

(Above 150kW), 24017-GE-003 and Low Voltage Motors (Up to
150kW), 24017-GE-004.

4.3 GEAR REDUCERS

Refer to Mechanical Design Criteria 24017-DM-001.

4.4 V-BELT DRIVES

Refer to Mechanical Design Criteria 24017-DM-001.

4.5 COUPLINGS

Refer to Mechanical Design Criteria 24017-DM-001.

4.6 HYDRAULIC AND PNEUMATIC POWER SYSTEMS

Refer to Mechanical Design Criteria 24017-DM-001.

4.7 CONVEYOR IDLERS

Except for Garland type impact idlers, all idlers will be of the wide base,
rigid frame type and will be rated as severe or heavy duty, Idlers will be
with dry type seal with sealed lubricated bearings. Idler bearing selection
will be based on a minimum ABMA L10 life of 60 000 hours. Bearings will
be factory greased and permanently sealed. Idler rolls will be fitted with
end shields to protect the bearings and seals.

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The load carrying capacity of idlers will be modified for factors such as
belt geometry, vertical curves, conveyor speed, size of material lumps
being conveyed, and maintenance and environmental considerations
including dusty and abrasive conditions.

Idler rolls will have no more than 0.30 millimeter total indicator
runout (TIR) at the ends.

4.7.1 IMPACT IDLERS

a. Impact idlers or tables will be provided at all conveyor

loading points. Transfer points for overland belt conveyors
will utilize Garland type 178 millimeter or larger diameter
impact idlers suspended from rubber disc type shock
absorbers for high impact absorption, better belt cover
protection, and good load centering on the belt. For fabric
belts, rubber disc type CEMA E7 series or better impact
idlers will be used under the loading area.

b. Impact idlers when specified for conveyors carrying

material having a size less than 50 millimeters will be close-
spaced 3 roll heavy-duty CEMA E6 series or 3 roll rubber
disc type to suit the specified service.

c. Impact idlers will be spaced at 300 millimeter at loading

points. Under the skirt boards, but away from loading
points, impact idlers will be spaced at 400 millimeter.
2

4.7.2 CARRYING IDLERS

a. Carrying idlers with rigid frame, 3 -roll, 35 degree, equal

length idler rolls with CEMA E7 load rating (minimum 178
millimeter idler diameter) will be used on all high speed
and heavy duty application conveyors. These will include
all the overland belt conveyors to the coarse ore stockpile,
the primary crushed ore transfer conveyor, and the coarse
ore reclaim conveyor from the coarse ore stockpile to the
SAG mill. 2

b. Grinding ball conveyors will use CEMA E5 series idlers.

All other idlers will be in accordance with CEMA
(Conveyor Equipment Manufacture’s Association) series
load ratings.

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c. Except for Garland type idlers, idler spacing for the

overland conveyor may vary between 1000 and 1500 mm
depending on the allowable belt sag.
2
d. For all other conveyors the normal spacing will be 900
mm, 750 mm as minimum, with a spacing of 400 mm
under skirtboards.
2
4.7.3 TRANSITION IDLERS

Transition idlers will be provided at the head and tail sections.

End rolls will be adjustable in 2-1/2 degree angle increments.

4.7.4 RETURN IDLERS

a. For steel cord belts, return idlers will be 2 equal roll V-type
with a 10 or 12 degree troughing angle. Flat steel rollers
with 8 millimeter lagging and deep drop brackets will be
used for fabric belts.

b. Flat return idlers with lagging will be used at belt scrapers

and return plows.

c. Return idler frames will have a minimum belt edge

clearance of 152 millimeters on both sides. Spacing
normally will be limited to 3000 millimeters maximum.
Idlers within 30 meters from the head/discharge pulley will
be the self-cleaning type.

d. For ball loading belts, the spacing will be 3000 mm as

maximum.

4.7.5 TRAINING IDLERS

Training idlers will be provided on the return side of fabric type

belts as required. The maximum spacing of training idlers will be
60 meters. An inverted V-type return idler may be used to train
the belt before the tail pulley.

4.7.6 BELT SCALE IDLERS

Belt scale idlers will conform to the selected scale manufacturer’s
specifications.

4.7.7 BELT FEEDER IDLERS

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Belt feeder idlers will be of the picking type unless noted

otherwise. They will have unequally split impact-type center rolls
and steel side rollers mounted at a 20 and 35 degree troughing
angles. Idler frames shall be the split channel type for ease of
removal from under the chutes and skirts. Dead shaft idler rolls
will be equipped with 60mm spherical roller bearings. Where
required, special live shaft idlers will be specified. For additional
information, refer to Section 6.

4.8 PULLEYS

4.8.1 GENERAL

a. It is intended to have a minimum number of shaft and

pulley assembly sizes. Pulley assemblies will be
standardized where possible for interchangeability in
diameter, face width, shaft sizes and pillow blocks.

b. Pulley loads will be determined from the larger of either

the tension developed using the connected motor
horsepower or 75 percent of the tension developed during
acceleration.

c. Shafts and pulleys will be designed independently.

Calculations will not credit either shaft or pulley as lending
strength to the other. Neither spacer tubes nor diaphragms
will be used.

d. The face width of the pulleys will be 150 millimeters wider

than the belt width for fabric type belts that are
1200 millimeters and wider, 100 millimeters for fabric belts
below 1200 millimeters in width, and 300 millimeters for
steel cord belts.

e. All drive pulleys will have minimum of 20 millimeter thick

rubber lagging with lagging geometry to be defined by
Vendor. The rubber will have a hardness of 55 to
65 durometer (Shore A). All non-drive pulleys will have
20 millimeter thick plain rubber lagging, with 45 to 55 |3
durometer hardness (Shore A). All lagging will be of
uniform thickness and will be vulcanized to the pulley.

f. All drive pulleys will have a minimum angle of wrap

of 180 degree. The use of snub pulleys will be restricted
and used only when deemed essential and permitted by
Bechtel. All pebble conveyors before the pebble crusher
will use snub pulleys.

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g. Hubs for all pulleys with shafts 100 millimeters or above

will be solid steel, secured to shafts with Ringfeder type
locking assemblies or the approved equal. Dust shields
will be fitted to pulley hubs to protect locking devices. For
shafts less than 100 millimeters in diameter, taper-lock
hubs and bushings may be permitted on minor conveyor
pulleys on a case-by-case basis.

h. Engineered pulleys will be stress relieved after completion

of all welding, but before machining.

4.8.2 STANDARD PULLEYS

a. Standard pulleys may be used for all fabric belt conveyors having
less than 125 kN/m (700 PIW) tension rating if approved by
Bechtel.

b. Standard pulleys may have a crown or straight face. For crown

face pulleys, a taper of 5.2 millimeters per meter of pulley width
will be applied.

c. As a minimum, pulleys will be constructed to meet the tolerances

and load ratings stipulated in the ANSI Standard B105.1,
Standards for Welded Steel Conveyor Pulleys (latest edition).

4.8.3 ENGINEERED PULLEYS

a. Engineered pulleys will be used for all steel cord belting and for
fabric belting having a tension rating of 125 kN/m (700 PIW) or
greater.

b. Engineered pulleys shall be welded construction with cast or

forged steel, T-shaped end discs. The weld connection between the
shell and end discs shall be in an area of reduced stress peaks
where first class welding and testing of the seams shall be possible.
Welding shall be ground smooth to the base material.

c. Engineered pulleys will be designed by finite element computer

calculations, and will be flat face with machine-turned rims.
Concentricity about the shaft centerline before machining will be
such that the finished thickness is not less than the calculated
required thickness, nor more than 25 percent greater.
Concentricity after machining will be such that the total indicator
runout for all pulleys will not exceed 0.15 millimeter prior to
lagging, nor 0.30 millimeter after lagging, for drive pulleys, and
0.5 millimeter for nondrive pulleys.

d. Stresses in pulley end disks and rims shall not exceed

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41000 kPa (alternating range).

e. Pulleys will be statically balanced so that the total out-of-balance

torque applied to the rim will not exceed 1.5 Newton meter (Nm).

f. All welding will be as specified by AWS D1.1

Sections 2, 3, 4, and 5. Nondestructive examination will be in
accordance with the latest edition of AWS D1.1 with acceptance
levels as indicated for Dynamically Loaded Structures,
Section 9.0. All pulley welds will be examined visually and tested
in their entirety, by ultrasonic or radiography, and by the magnetic
particle method.

4.9 PULLEY SHAFTS

4.9.1 All pulley drive shafts will be designed to transmit the connected
motor horsepower, including service factor, as well as locked rotor
torque. Shafts will be designed by using the ASME code for the
design of torque transmission.

4.9.2 Shafts and pulley assemblies will be sized and selected for
maximum interchangeability. Full radius fillets will be provided
when the shaft ends are reduced in diameter for bearings or
couplings.

4.9.3 All keyways, when used, will be in-line and square. Keys will be
supplied with the shafts. Keys will be fitted to shafts and taped in
place for shipping.

4.9.4 Shaft diameters at the location of Ringfeder type locking

assemblies will be machined oversize by 0.4 millimeter (0.015
inch).

4.9.5 Pulley shafting will be made of ASTM A108 Grade C1045 steel or
other materials suitable for forging. The shear stress in combined
bending and torsion of commercial steel shafts will not exceed
55 000 kPa for shafts with keyways or 69 000 kPa for shafts
without keyways.

4.9.6 The bending stress for commercial AISI 1045 steel shafts subject
to bending only will not exceed 83 000 kPa for shafts with
keyways, or 110 000 kPa for shafts without keyways. The
bending stress for other grade steel shafts subject to bending only
will not exceed 28 percent of the ultimate tensile strength for
shafts with keyways, or 36 percent of the ultimate tensile strength
for shafts without keyways.

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4.9.7 A combined shock and fatigue service factor of Kb = 1.75 will be

applied to the computed bending moment, and a service factor of
Kt = 1.25 will be applied to the computed torsional moment of
shafts used with standard pulleys. For shafts with engineered
pulleys, service factors Kb = 2.0 and Kt = 1.5 will be applied.

4.9.8 Slope, in radians, of the shaft deflection curve at pulley hubs under
pulley design load conditions will not exceed:

a. 0.00065 radian for engineered pulleys for steel cord belts

b. 0.001 radian for engineered pulleys for fabric belts
c. 0.0015 radian for standard CEMA rated pulleys

4.9.9 All commercial sized shafting will be cold rolled turned and
polished (T&P). Shafts larger than 150 millimeters in diameter
will be of AISI 1045 or equivalent.

4.9.10 Turned down shaft ends on shafts less than 150 millimeters in
diameter will not normally be permitted.

4.9.11 Turned down shaft ends will have a finish of 0.8 micrometers or
better. Turndown radii will have a finish of 1.6 micrometers or
better and will be at least 25 percent of the minor shaft diameter or
20 millimeters, whichever is greater. Undercut at radius will not
be allowed. Shaft ends will be chamfered.

4.9.12 Unless otherwise stated all shafts 150 millimeters in diameter and
above will be nondestructively tested for flaws before and after
machining; using ultrasonic method (before) and magnetic particle
or dye penetrant methods (after).

4.9.13 Ultrasonic examination will be performed in accordance with

ASTM A388 utilizing the back reflection technique. All shafts will
be examined in the radial and axial directions (through the
diameter and end to end). Ultrasonic acceptance criteria will be:

a. No indications greater than 75 percent of the reference

back reflection
b. No areas showing a 90 percent or greater loss of back
reflection

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4.9.14 Magnetic particle examination will be performed in accordance

with ASTM E709. Acceptance criteria will be:

a. No cracks
b. No linear indications greater than 1.6 millimeters that are
oriented circumferentially
c. No linear indications greater than 25 millimeters that are
oriented axially

4.9.15 Liquid (dye) penetrant examination will be performed in

accordance with ASTM E165. Acceptance criteria will be:

a. No cracks
b. No linear indications greater than 1.6 millimeters that are
oriented circumferentially
c. No linear indications greater than 25 millimeters that are
oriented axially

4.10 BEARINGS AND PILLOW BLOCKS

4.10.1 GENERAL

Antifriction bearing pillow blocks will be provided to support all

shafts. Shaft bearings will be self-aligning spherical roller
bearings. Each conveyor pulley shaft will have one fixed and one
expansion type bearing. The fixed bearing will be installed on the
drive side.

4.10.2 BEARINGS AND BEARING HOUSINGS

Refer to Mechanical Design Criteria 24017-DM-001.

4.11 BELT TAKE-UPS

Belt conveyors longer than 33 meters and conveyors equipped with weigh
scales will have gravity or winch operated take-ups. Belt conveyors less
than 33 meters in length may be equipped with screw or hydraulic assisted
take-ups.

4.11.1 Gravity take-ups will utilize a guided frame that will be complete
with a counterweight and will be supported by steel cables and
sheaves for operation. Guide rails will be self-cleaning.

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4.11.2 A winch will be provided for lowering and raising the

counterweights of the overland conveyors during maintenance
work.

4.11.3 On long conveyors, for which a gravity type take-up may not be
practical, a motorized winch type take-up may be used. In this
case, controls for adjusting belt tension shall be in action during
start-up and shutdown cycles.

4.11.4 Screw take-ups will be of the protected screw type and be

complete assemblies consisting of frame, pillow blocks and screw
adjustment mechanism operating in tension.

4.11.5 Take-up travel will be determined in accordance with belt

manufacturer’s recommendations. For steel cable belts,
additionally, at least two splice lengths are to be included in the
travel.

4.11.6 Horizontal take-up carriage assemblies will be constructed with V-

grooved wheels supported on inverted angle tracks on one side,
and a flat rail and wheels on the other side. Rail guides will be
self-cleaning. Hold-downs will be provided to prevent the wheels
from jumping off the rails.

4.11.7 Counterweights for gravity take-ups will be attached directly to

the take-up frames or hung by means of steel cables and sheaves.
Take-up counterweights will consist of steel plates, concrete slabs
or other suitable material. Cast plates are not acceptable.

4.12 CONVEYOR BELTING

4.12.1 Selection of conveyor belting will be based upon the specified

operating and design conditions. The selection of carcass and
breakers will satisfy the requirements for maximum tension,
minimum plies for load support, maximum plies for empty belt
troughing, pulley sizes and other operating conditions.

4.12.2 Belt covers will be RMA Grade 1 or equal on all conveyors

carrying coarse ore, and RMA Grade 2 for all other conveyors
Bottom cover rubber shall be compounded for minimum
indentation at the operating temperature range.

4.12.3 Belting will provide adequate load support while allowing

sufficient transverse flexibility to provide a minimum of 50%
contact on the center roll at all times, in either the loaded or empty
condition. Climatic conditions and material characteristics will be
given careful consideration when choosing the cover material.
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4.12.4 Maximum standardization of belt rating (kN/m) and construction

will be made consistent with economy of purchase and spare
inventory.

4.12.5 To ensure standardization within each belt width, the maximum

prevailing operating tension will be used to determine the required
strength kN/m rated tension. Fabric belting will have an ultimate
tensile strength of not less than 10 times the maximum operating
tension calculated for a given belt width.

4.12.6 Steel cord belting will be selected to provide an ultimate tensile

strength of at least 5.5 times the maximum operating tension at
operating conditions and 4.8 under starting and braking conditions
for the coarse ore overland conveyors. For all other steel cable
belting, the ultimate tensile strength of the belting will be at least
6.7 times the maximum operating tension. If breaker fabric is
required, it will be installed in the top cover only. All splices shall
have a splice efficiency of at least 50% and not fail within 150,000
cycles.

4.12.7 Each roll of belting will be identified on the top cover with the
following information:

a. Manufacturer’s name

b. Brand name of belting

c. Order and serial number

d. Belt rating

e. Belt weight per unit length

4.12.8 All conveyor belting will have vulcanized splices.

4.13 BELT SCRAPERS

4.13.1 Belt conveyors will be furnished with a dual belt scraper system.
The primary scraper will be a “ Doctor blade” track type scraper.
The secondary scraper will be located inside the discharge chute
to catch fine dribble. This belt scraper will be of the multiple
tungsten blades type, Martin Engineering “Doctor Blade” scraper
or approved alternative. All belt scrapers will be designed with
suitable access for easy and safe removal and maintenance. The
material collected will be arranged to drop into the discharge
chute.

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4.13.2 All conveyors will be furnished with a V shaped, suspended plow

type scraper on the return side of the belt located near the tail
pulley. A diagonal plow may be used ahead of vertical take-ups
and intermediate drive stations.

4.14 HOLDBACKS AND BRAKES

Holdbacks or brakes will be used on all inclined conveyors to prevent

reversal of the conveyor when stopped under full design load. For shaft
mounted reducers with V belt drives, holdbacks will be integrally mounted
with the reducer high-speed shaft. For other drives over 75 kW,
holdbacks will be mounted on a pulley shaft extension opposite the drive
and will be of the overrunning clutch type, Marland or the approved
equal. Hold backs for in-plant conveyors, will be fully rated for the
nameplate torque of the motor. Brakes will be used as holdbacks on
overland conveyors for a controlled stop under all conditions.

4.15 SAFETY GUARDS

All chain and V-belt drives, couplings, shafts, pulleys, take-ups, take-up 2
carriages and other moving parts will be guarded in accordance with the
requirements of MSHA, OSHA, NOSA and Chilean Authorities. For
in-plant conveyors and feeders, wire mesh screen guards will be provided
on both sides as well as below the return idlers (on the return side) to
shield all moving parts. The screen opening for guards will be in
accordance with MEL standards, i.e. 10 mm. All guards will be fabricated
and mounted with provision for rapid and easy removal. Electrical
conduits will not be installed along conveyors except in elevated
structures where they could serve as a safety guard rail. Where allowed
on the conveyor, conduits will be affixed with C-clamps without sharp
corners. Ball loading conveyors will have 40 mm removable wire mesh
screen under the conveyor table for 2 meters, before and after the transfer
chute points (this screen has to be able to hold up to thirty 5” balls @ 9 kg
each).

4.16 WIND HOOPS

For outdoor conveyors, wind hoops may be provided if appropriate.

Wind hoops will be made of 50 millimeter diameter pipe.

4.17 TRAMP METAL DETECTION AND REMOVAL

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4.17.1 Metal detectors will be provided on the coarse ore overland

conveyor, after primary crushing and at other specified locations.
Metal detectors will be arranged to stop the conveyor and mark
the area where metal is detected in order to permit easy removal
by hand-picking.

4.17.2 To protect the downstream equipment from harmful tramp iron,

magnets will be provided at strategic locations such as the crushed
ore stream from the primary crusher, and the ore feed to the
pebble crusher. Based on specific site considerations, magnets of
the self-cleaning or suspended type will be specified.

4.17.3 Electromagnetic or permanent type magnets will be provided at

the head chutes of conveyors where specified. Discharge chutes
for captured tramp metal will be provided. Pulleys, idlers, chute
work and skirting adjacent to magnets will be nonmagnetic.

4.18 SAFETY DEVICES AND CONTROLS

4.18.1 Safety devices will be provided for the protection of operating

personnel and equipment.

4.18.2 All conveyors will be electrically interlocked for sequential starting

and stopping. Motors will be de-energized when belt speeds drop
below a preset point. Controls also will ensure that transfer of
material will not take place until the receiving conveyor is running
at or approaching the design speed.

4.18.3 Safety devices for personnel protection will include:

a. Dual horns and rotating beacons to provide a warning that

a stationary belt is about to be set in motion will be
installed at no more than 200 meter spacing along the
conveyors.

b. Pullcords for emergency stop switches (fail-safe type)

accessible to a person standing on a walkway beside a
conveyor. The allowable spacing between switches shall
be 30 m maximum. Any section of conveyor, which is
accessible from both sides, shall be protected separately on
both sides without interconnection.
In the case of very long conveyors, a numbering system
that allows the Control Room to identify which pullcord 2
switch has been tripped shall be provide.

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c. Any other devices and protection required by ANSI,

ASME B20.1 1985, CEMA, NOSA, OSHA, MSHA and
Chilean Authorities.

4.18.4 Safety devices for equipment protection will include:

a. A conveyor belt rip detection system using embedded coil

and antenna for all overland or steel cord belt conveyors

b. Belt side travel switches to detect excessive belt

misalignment for all belts. For steel cord belts proximity
type switches shall to be used to sense the steel cords. The
2
detection system shall be capable of signaling the location
of belt misalignment along the length of the conveyor to
the operator’s Control Room.

c. Take-up travel limit switch including warning switch

approximately 1 meter before limit.

d. Belt slip detector

e. Zero speed or minimum speed detectors, preferably
mounted on the tail pulley or take-up bend pulley.

f. Plugged chute detector, for high level

g. Limit switches for moveable head pulleys shall signal

normal and extreme limit of travel conditions.
2
4.19 WALKWAY AND ACCESS WAYS

4.19.1 A walkway or access way, 900 millimeter wide minimum, will be

provided on one side of all conveyors, and a 750 millimeter
minimum width walkway or access way for maintenance purposes
only will be provided on the other side of elevated conveyors.
Walkways or accesses will be complete with handrails, toe plates
and flooring as per MEL’s Safety Standard (1997). Handrails will
be mounted on support steel and not on the walkway. For
conveyor belts that are not elevated and less than 750 millimeter
wide only one 750 millimeter wide walkway will be installed.
For elevated conveyors walkways at both sides shall be provided.
2

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4.19.2 All walkways and associated access and drive platforms will be of
checker plate or grating, whichever is more suitable and safer for
each application. Disposal of accumulated dust on walkways and
access ways will be considered.

4.19.3 Conveyor cross-over bridges will be provided at suitable locations

at approximately 200 meter intervals for the safe passage of
personnel over the overland conveyors.

4.19.4 For conveyors having 10 degrees or more inclination, all walkway

gratings will have cross bars in order to avoid slippage when
walking.

5. FEEDERS

5.1 GENERAL

5.1.1 All feeders will be adjustable speed type, preferably by hydraulic

drives or alternatively by adjustable frequency drives as specified.
Hydraulic drives will be the low speed high torque type,
Hagglunds or approved equal; with high pressure, variable volume
axial piston type pumps operating at 13.6 MPa (2000 psi) and
designed for 34.0 MPa (5000 psi) system pressure.

5.1.2 The opening to each feeder will be a tapered reclaim slot

(increasing in width) with a self-relieving incline in the direction of
feeder travel.

5.1.3 All chutes to feeders will have provision to utilize spile bars to
retain-material in a safe manner during feeder maintenance.

5.1.4 Skirt boards, enclosures and feed chutes will be lined with
abrasion-resistant liners in accordance with Section 7.

5.2 BELT FEEDERS

5.2.1 Belt feeders will be of heavy-duty construction, having belts

supported on rubber-covered flat rollers or picking type idlers,
spaced as closely as possible to suit the duty and service specified.
Picking idlers will have unequally split impact type center rolls
with steel side rolls, and a split mounting frame for ease of
removal under chutes and skirts.

5.2.2 The belt may be of steel cord, complete with heavy-duty top and
bottom covers depending on tension requirements. These may be
of endless construction where space allows easy replacement in
the field.
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5.2.3 Inverted V-idlers will be used for training the return side of the
belt. Additionally, training will be by guide rollers located in front
of the tail pulley that limit side travel to  6 millimeters.

5.2.4 The inside width of skirt boards including liners will not exceed
70 percent of the belt width.

5.2.5 Belt speed will not normally exceed 0.5 meter per second (100
ft/min).

5.2.6 The power requirement for belt feeders will be calculated in

accordance with the following formula:

P
2 xC xW 2
x L x d  Té  x S
33000

where:

C: 0.8 dimensionless constant selected for starting conditions, accelerations,

breakaways and occasional large feed loads during filling

W: average width of feed hopper slot (ft)

L: length of feed hopper slot (ft)

d: maximum bulk density (lb/ft3)

Té: tension due to friction at skirt boards, pulley and belt cleaners (lb)

S: belt speed (ft/min)

P: power in horsepower

6. TRANSFER CHUTES, HOPPERS, BINS, SKIRT BOARDS AND LINERS

6.1 TRANSFER CHUTES AND SKIRTS

6.1.1 Transfer chutes will be designed to ensure a smooth material

transfer in the direction of flow. Chutes will be designed with 2 2
stage dead bed points of contact, prior to transfer onto next belt.
Incorporation of rock boxes and feed plates will be done to
minimize wear and feed material centrally on the belt. Chutes and
chute liners shall be standardized wherever possible (for liners
details see “LINER” section). The inside width of the transfer
chute shall be no less than the pulley width plus 150 millimeters.

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6.1.2 Inspection doors will be provided on both sides of all transfer

chutes. Provision will be made for suspended permanent type
tramp metal devices where required.

6.1.3 Careful consideration will be given to the design of the dust

suppression and/or collection systems at all transfer points. Where
dust collection is provided, a minimum dust settling distance equal
to 1.5 seconds of belt travel will be provided. Where dust
collection hoods are installed above the skirt board, the skirt board
height will be one-half belt width in order to provide settling
capacity for flying dust.
6.1.4 Transfer chutes will be of welded, 10 millimeter steel construction
with suitable flanged joints for easy installation and maintenance.

6.1.5 Special care shall be taken in the design and sizing of transfer
chutes in order to assure a proper transfer of the ore, so that the
chutes are not a bottle neck to material flow.
2
6.2 BINS

All bins will be designed with the live bin capacity based upon a 70 degree
draw down angle.

6.3 DUST HOPPERS

Dust hoppers will have walls with a 60 degree or greater slope from the
horizontal plane. The valley angle will not be less than 55 degrees.

6.4 SKIRT BOARDS

6.4.1 Skirt boards will be provided at all material transfer points, and
will be designed to minimize the entry of rocks or foreign materials
between skirts and conveyors. They will be complete with
adjustable rubber skirts of the quick-acting clamp type or similar
and secondary sealing for dust. Rubber hardness will be softer
than the conveyor belt.

6.4.2 Skirt boards at single loading points on horizontal conveyors will

be 0.6 meter long (measured from impact point) for each
0.6 meter per second of belt speed.

6.4.3 Conveyors with multiple loading points will be provided with a

continuous skirt board arrangement, embracing all loading points.

6.4.4 All skirt boards subject to wear from abrasive material will be
lined with abrasion-resistant liners in accordance with Section 7.5.

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6.5 LINERS

All chutes, hoppers, bins and skirt boards subject to wear will be lined
with replaceable abrasion resistant cast metal waffle back liners, as per
drawings 24017-0000-L-401, 402 and 404.
2
Wear bars shall be installed at the edges of dead bed discharge lips. All
liners will be bolted. Replaceable liners will not exceed 25 kilograms in
weight. Liners weighing 10 kilograms or less will be secured by two ball
mill liner type bolts; those weighing between 10 and 25 kilograms will
utilize four bolts. Liner sizes will be standardized to a minimum number,
and will be indicated on the drawings.

Typical liners will be as follows:

Source of wear Material

Heavy impact Chrome molybdenum cast steel (450

BHN).

High abrasion - light High chrome cast steel (700 BHN),

impact (i.e. minus 75 mm ceramic / rubber composite.
material)

Moderate to light abrasion Cast steel or abrasion resistant weldable

steel (450 BHN).

Copper concentrates Stainless steel, polyurethane or UHMW

polypropylene.

7. VIBRATION CONTROL
7.1 At all locations, transmitted vibration will be limited so as not to exceed
the general criteria specified in ISO 2631.

7.2 On line vibration monitoring of the motor and gear reducer. will be
provided , with 4-20 mA input to the PLC.

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