Monorails ES-14-403-20

This is a Controlled Document that complies with Wesfarmers CSBP Ltd formatting and Quality Control guidelines. Please check that this is the latest available version before use. Title: Number: Owner: Authoriser: Version Details:

MONORAILS ES-14-403-20
Dale Hewson Phil Talbot Revision 3. Electric hoist details deleted and reference to Engineering Standard: Electric Hoists (ES-14-403-21) added throughout the document. Independent Design Review requirements changed from ALL monorail systems to only those with SWL equal to or greater than 10 tonne. Sections 6.1, 7.5 and 11, and flow chart Figure 1 Sheets 1, 2 and 3 modified accordingly. Sections 7.4 and 12 added. Section 23.1.b and numbering changed. 23.2.a: Requirements for equipment

Section 24.5.2.1: 'Note' specifying Beam Load Testing required on ALL monorails regardless of SWL added. Referencing changed on Figures 1, 2 and 3 due to addition of Section 12.

TABLE OF CONTENTS
1. 2. 3. 4. 5. 6. SCOPE........................................................................................................................................... 4 PURPOSE ..................................................................................................................................... 4 RESPONSIBILITY ...................................................................................................................... 4 DEFINITION OF TERMS .......................................................................................................... 4 STANDARDS................................................................................................................................ 5 OVERVIEW ................................................................................................................................. 8

Version No. 3

Page 1 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

6.1 6.2 6.3 7.

DESIGN PHASE FIGURE 1 (3 SHEETS) ....................................................................... 8 INSTALLATION PHASE FIGURE 2 ................................................................................ 8 OPERATIONAL PHASE FIGURE 3 ................................................................................. 9

BASIS OF DESIGN.................................................................................................................... 15 7.1 7.2 7.3 7.4 7.5 7.6 EXISTING MONORAIL OF UNKNOWN CAPACITY .................................................... 15 CONDITION OF EXISTING STEELWORK ..................................................................... 15 DESIGN STANDARDS....................................................................................................... 15 DESIGN ............................................................................................................................... 15 INDEPENDENT DESIGN REVIEW .................................................................................. 16 STATUTORY AUTHORITY APPROVAL ........................................................................ 16

8.

DESIGN METHODS ................................................................................................................. 16 8.1 8.2 WORKING STRESS DESIGN METHOD .......................................................................... 16 LIMIT STATES METHOD ................................................................................................. 16

9.

MONORAIL SECTION SIZE .................................................................................................. 16 9.1 9.2 9.3 9.4 9.5 SAFE LOAD / CAPACITY TABLES ................................................................................. 16 FLANGE THICKNESS ....................................................................................................... 16 WEB THICKNESS .............................................................................................................. 16 DEFLECTION LIMITS ....................................................................................................... 17 LONG SPAN MONORAIL BEAMS................................................................................... 17 END STOP DESIGN............................................................................................................... 17 INDEPENDENT DESIGN REVIEW.................................................................................... 19 CALCULATIONS................................................................................................................... 19 DESIGN CALCULATIONS................................................................................................ 19 INDEPENDENT DESIGN REVIEW .................................................................................. 19

10. 11. 12.

12.1 12.2 13. 14. 15. 16. 17. 18. 19. 20. 21.

APPROVAL BY STATUTORY AUTHORITY................................................................... 20 MATERIALS AND EQUIPMENT SELECTION ............................................................... 20 ELECTRICAL CONTROLS ................................................................................................. 20 HANDLING OF STRUCTURAL STEELWORK & EQUIPMENT ................................. 20 FABRICATION ...................................................................................................................... 20 WELDING............................................................................................................................... 21 BOLTING ................................................................................................................................ 21 SITE MODIFICATIONS ....................................................................................................... 21 PROTECTIVE COATINGS .................................................................................................. 21 STRUCTURAL STEEL ....................................................................................................... 21 HOIST AND TROLLEY...................................................................................................... 21 BOLTS ................................................................................................................................. 22

21.1 21.2 21.3 22.

INSTALLATION .................................................................................................................... 22 CIVIL / STRUCTURAL / MECHANICAL......................................................................... 22 ELECTRICAL...................................................................................................................... 22

22.1 22.2

Version No. 3

Page 2 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

23.

IDENTIFICATION................................................................................................................. 22 BEAMS ................................................................................................................................ 23 HOIST AND TROLLEY...................................................................................................... 24

23.1 23.2 24.

INSPECTION AND TESTING.............................................................................................. 24 WELD TESTING AND INSPECTION ............................................................................... 24 EXISTING STRUCTURAL STEELWORK INSPECTION ............................................... 24 NEW FABRICATED STEELWORK INSPECTION.......................................................... 25 INSPECTION DURING ERECTION.................................................................................. 25 COMMISSIONING ............................................................................................................. 25 INSPECTION DURING OPERATIONAL PHASE ............................................................ 26

24.1 24.2 24.3 24.4 24.5 24.6 25.

RECORDS MANAGEMENT ................................................................................................ 28 AS - BUILT DRAWINGS ................................................................................................... 28 ENGINEERING PROJECT FILES...................................................................................... 28 MAINTENANCE WORK ORDERS ................................................................................... 28 MONORAIL SYSTEM ANNUAL INSPECTION .............................................................. 28

25.1 25.2 25.3 25.4

FIGURES
Figure 1 Monorail Design Process Flow Diagram Sheet 1 of 3 Figure 2 Monorail Installation Process Flow Diagram Figure 3 Monorail Maintenance Process Flow Diagram Figure 4 Minimum Interference between Monorail and Trolley End Stops 10 13 14 18

TABLES
Table 1 Size of Monorail Beam Identification Markings 23

Version No. 3

Page 3 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

1.

SCOPE

This Standard covers the minimum technical requirements for the design, approval, fabrication, installation, testing and commissioning, preventative maintenance and inspection, and record keeping of new and upgrades to existing monorails. Existing structures shall be analysed in accordance with the criteria established in this Standard and appropriate action taken, before upgrades to existing monorails are carried out or a new monorail is installed in an existing structure. Note: For electric hoists and motorised trolleys, this Standard is to be read in conjunction with CSBP Engineering Standard Electric Hoists (ES-14-403-21).

2.

PURPOSE

To ensure that all monorails in CSBP facilities are in compliance with WorkSafe WA regulations and other relevant codes and practices and that the companys requirements for operability, safety and reliability are assured at all times.

3.

RESPONSIBILITY

During the development phase it is the responsibility of the Superintendent to ensure that all approvals have been obtained before the Works are carried out and that the requirements of this Standard are adhered to. Following completion of project handover, it is the responsibility of each business unit to ensure that their monorails remain compliant with this Standard and are safe to use.

4.

DEFINITION OF TERMS

Contractor/Vendor The company that provides the equipment and services needed. Sub-Contractor A third party to be employed by the Contractor/Vendor, who has been approved by the Superintendent. Superintendent Functional title for the Wesfarmers CSBP Limited Officer, or authorised representative, responsible for the development and implementation of the Works, including liaison with and obtaining internal and external approvals from appropriate personnel, statutory authorities etc. CSBP Wesfarmers CSBP Limited.

Version No. 3

Page 4 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Works The scope of work that a Contractor is or may be required to execute under an agreement including variations and remedial work. Monorail Light industrial crane comprising a beam, a trolley and a hoisting device. The trolley travels along the bottom flange of the beam. Jib Crane A cantilevered monorail, that is pivoted about a vertical axis at the supported end. Verification Examination of objective evidence to determine conformity with stated requirements for that activity.

5.

STANDARDS

The Contractor shall perform the Works in accordance with this Standard, the latest issue of referenced standards and Contractor regulations for on-site work. Should there be a conflict between the Works, Statutory Requirements and the Standards, the Contractor shall notify the Superintendent in writing for resolution. In general, the most stringent requirement will prevail. CSBP Engineering Standards ES-14-101-02 ES-14-101-03 ES-14-101-04 ES-14-101-06 ES-14-102-09 ES-14-102-12 ES-14-202-10 ES-14-202-14 ES-14-302-01 ES-14-302-02 ES-14-401-01 ES-14-402-01 ES-14-402-02 ES-14-403-21 ES-14-701-01 ES-14-902-01 ES-14-902-02 Drawing Management Drawing Preparation Drawing Numbering Equipment Numbering System Labels & Signs: Plant and Equipment Protective Coatings Concrete Grouting Fabrication of Structural Steelwork Erection of Structural Steelwork Mechanical Preferred Equipment Mechanical Equipment Design, Supply and Installation Testing and Commissioning of Mechanical Equipment Electric Hoists Electrical/Instrument Preferred Equipment Materials and Workmanship for Electrical Installations Testing and Commissioning of Electrical Installations

Version No. 3

Page 5 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

CSBP Procedures DP-05-011-03 DP-05-013-01 DP-05-013-04 DP-05-013-05 DP-05-014-01 EP-08-030-05 EP-08-030-19 EP-08-030-38 CSBP Guides GM-05-043-01 GM-05-050-01 GM-10-020-04 GM-11-035-02 GM-11-038-02 Technical Data Requirements for Plant and Equipment Engineering Modification Contractors Site Instructions Basic Safety Rules Slings, Rigging and Lifting Equipment Safety Maintenance Daily Schedule Work Order Entry and Approval Closing Maintenance Work Orders Developing Maintenance Strategies Maintenance Breakdown Repairs Engineering Project Files Engineering Project Design Review Engineering Project Handover

CSBP Standard Forms ES-14-101-12 IF1463 Technical Data Sheets Mechanical, Electrical and Instrument Technical Data Sheets Hoist, Winch, Crane

Stage 1 Commissioning Inspection Reports M101 M152 General Mechanical Hoist, Monorail and/or Monorail Jib Crane

Stage 2 Commissioning Test Reports M201 M252 General Mechanical Hoist, Monorail and/or Monorail Jib Crane

CSBP Standard Drawings 9900-3-0005/001 9900-3-0005/002 9900-3-0005/003 9900-3-0005/004 Standard Beam and Bracing Connection Details Standard Beam Connection Details & Member Schedule Structural Base Plates Standard Column & Beam Bolted Splice Connection Details

Standards Association of Australia AS 1111 AS 1112 AS 1163 AS 1170 Version No. 3 ISO Metric Hexagon Commercial Bolts and Screws ISO Metric Hexagon Nuts including Thin Nuts, Slotted Nuts and Castle Nuts Structural Steel Hollow Sections SAA Loading Code Page 6 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

AS 1214 AS 1237 AS 1252 AS 1418.1 AS 1418.2 AS 1538 AS 1553 AS 1554.1 AS 1594 AS 1666.2 AS 2214 AS 2550 AS 3600 AS 3678 AS 3679.1 AS 3679.2 AS 3990 AS 4100 AS 4680 AS/NZS ISO 9002

Hot-Dip Galvanised Coatings on Threaded Fasteners Flat Metal Washers for General Engineering Purposes High-Strength Steel Bolts with Associated Nuts and Washers for Structural Engineering Cranes - General Requirements Cranes - Serial Hoists and Winches Cold-Formed Steel Structures Code Covered Electrodes for Welding Welding of Steel Structures Hot Rolled Steel Flat Products Wire Rope Slings - Care and Use Certification of Welding Supervisors Structural Steel Welding Cranes Safe Use Concrete Structures Structural Steel Hot Rolled Plates, Floor Plates and Slabs Structural Steel Hot Rolled Bars and Sections Structural Steel Welded I Sections Mechanical Equipment Steelwork Steel Structures Hot-Dip Galvanised (Zinc) Coatings on Fabricated Ferrous Articles Quality Systems Model for Quality Assurance in Production, Installation and Servicing

Other Engineering Standards and Publications AISC AISC AISC Design Capacity Tables for Structural Steel Design of Structural Connections Safe Load Tables 6th Edition 1987

Version No. 3

Page 7 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

6.

OVERVIEW

Flow diagrams Figure 1, Figure 2 and Figure 3 show the high level activities involved in the management of monorail systems through design, installation and operational phases.

6.1

DESIGN PHASE FIGURE 1 (3 SHEETS)

The process commences with an engineering project request to either upgrade an existing monorail system, or design and install a new one. If the Safe Working Load (SWL) of an existing monorail is unknown it is necessary to check through maintenance records, archived project files etc, to determine the monorails history, initial usage and whether design calculations are available. The condition of the existing monorail, connections and support structure shall be checked for corrosion, deformation etc as this could impact the design and consequently the Works. Based on findings, the SWL of existing monorail and loads on existing support structure shall be determined, enabling engineering design modifications to monorail and/or support structure to be established. ALL design work for monorail systems with a SWL of ten (10) tonne or greater shall be carried out and checked by an external engineering company / consultant. Monorail systems less than ten (10) tonne shall be either designed / checked externally or, designed internally by CSBP and checked externally by a suitably qualified and experienced structural engineer. An Independent Design Review shall be carried out on ALL monorail systems with a SWL of ten (10) tonne or greater, to ensure proposed modifications and loading conditions comply with relevant standards and regulations. Independent Design Review of monorail systems less than ten (10) tonnes shall ONLY be carried out if specified in the Works by the Superintendent. Monorail systems with a SWL of ten (10) tonne or greater shall be reviewed and approved by WorkSafe or their authorised agency, prior to commencement of fabrication or remedial work. A new monorail in an existing plant basically has the same design steps as previously outlined, whilst a new monorail with a new support structure follows normal design activities as indicated in the flow diagram. Reference to relevant clauses in this Standard and other CSBP and Australian Standards are made in Figure 1, covering design phase activities.

6.2

INSTALLATION PHASE FIGURE 2

This process commences with an approved monorail design and includes design modifications and structural strengthening of existing structural steelwork where required. Normal project development sequence activities are followed through to Customer handover and project file close out.

Version No. 3

Page 8 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Reference to relevant clauses in this Standard and other CSBP Engineering Standards are made in Figure 2, covering installation phase activities.

6.3

OPERATIONAL PHASE FIGURE 3

This process commences with a commissioned monorail system that has been handed over to the Customer. The maintenance strategy, monorail system technical details and the inspection and preventative maintenance requirements are finalised and recorded in the JDE Maintenance System, (activities commenced in the design / installation phases). Based on inspection findings, maintenance work is carried out in accordance with work priority or if an engineering modification is required, changes are implemented in accordance with Figure 1 and Figure 2. Closure details are recorded in the JDE System. Reference to relevant clauses in this Standard and other CSBP Engineering Standards and Departmental Procedures are made in Figure 3, covering operational phase activities.

Version No. 3

Page 9 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

AS3990 AS1418

Source historical info / Calculate SWL. 7.1 7.3 8. 9.

No

Eng Project MONORAILS

Exit SWL known?

Upgrade

New or Upgrade?

New

Exit struct?

No A

Yes Yes Cals for exist Structure? Yes No Calculate existing loads 9. 8. 7.3 AS4100 AS3990

24.2 7.2

Inspect existing Monorail.

24.2 Inspect existing 7.2 structure

No Extent of corrosion. Condition of end stops and connection to structure.

Condition OK? Yes Prepare layout/detail drawings.

Extent of corrosion. Condition of bolts. Extent of Structural deformation etc.. ES-14-101-02 ES-14-101-03 ES-14-101-04 ES-14-101-06 10. 9. 8. 7.4 7.3 8. 7.4 7.3

Carry out monorail calculations.

AS4100 / AS3990 AS1418

Check existing structure imposed loads.

Condition of existing structure and monorail to be factored into design.

24.2 7.2 No

Within code?

Yes

SWL 10t? Yes

No

End

Design structural stiffening. 12. 10. 9. 8. 7.4 7.3 Yes

Recheck design calculations

Yes SWL 10t? No

No

Within code?

End

Figure 1 Monorail Design Process Flow Diagram Sheet 1 of 3

Version No. 3

Page 10 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Intergrated design monorail and structure

Prepare layouts and detail drawings

ES-14-101-02 ES-14-101-03 ES-14-101-04 ES-14-101-06

12. 10. 9. 8. 7.4 7.3

Carry out design calculations

AS4100 AS1418

Within code?

Yes

SWL 10t? Yes B

No End

No
Revise design
12. 10. 9. 8. 7.4 7.3

Recheck design calculations

No

Within code?

Yes

SWL 10t? Yes B

No End

Figure 1 Monorail Design Flow Diagram Sheet 2 of 3

Version No. 3

Page 11 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Independent Design Review

7.5 11. 12.

Within code?

No

Advise Superintendent

Yes

Action as required 7.6 13.

Statutory Authority review/approval

Within code? Yes File approvals in project file

No

Advise Superintendent

Action as required

End

Figure 1 Monorail Design Process Flow Diagram Sheet 3 of 3

Version No. 3

Page 12 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Approved monorail design.

Tender, evaluate, approval to proceed, award. Prepare shop/ vendor drawing and documents. Submit and review/ approve. 24.3 24.1 23. 21. 14. ---> 19. 24.4 24.1 22. 14. ---> 19. 24.5 ES-14-101-02 ES-14-101-03 ES-14-101-04 ES-14-402-01 ES-14-902-01 ES-14-302-01 ES-14-401-01 ES-14-402-01 ES-14-701-01 ES-14-902-01 ES-14-302-02 ES-14-402-01 ES-14-902-01 ES-14-402-02 ES-14-902-02

Fabricate/ manufacture, inspect.

Install

Test / Commission

Remedial work required.

No

Accepted? Yes Finalise handover and close out documentation,

Remedial work as required

No

Customer accept? Yes File project documentation 25.2

As built Drawings MDR's Data Sheets H/O Certificate

End

Figure 2 Monorail Installation Process Flow Diagram

Version No. 3

Page 13 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Commissioned monorail system.

Activities commence in the design and installation phases as information becomes available.

Finalise maintenance strategy.

DP-05-013-05 GM-11-038-02

Complete recording details in JDE Maintenance System.

Equipment number SWL Registration numbers Hoist details Inspection Reqts etc.

25.4 24.6

Carry out inspection according to plan.

GM-11-038-02

Yes Accepted? No MAINTENANCE WORK Identify remedial work required.

Record details in JDE system.

End

ENGINEERING MODIFICATION

DP-05-011-03 DP-05-013-01 DP-05-014-01

Initiate maintenance work

Initiate engineering work

GM-05-050-01

Carry out maintenance work.

Carry out design work.

Fig 1

Carry out engineering work. Close out - record details in JDE system. 25.3

Fig 2

DP-05-013-04

Close out - record details in JDE 25.2 system. 25.1 End

Figure 3 Monorail Maintenance Process Flow Diagram

Version No. 3

Page 14 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

7.
7.1

BASIS OF DESIGN
EXISTING MONORAIL OF UNKNOWN CAPACITY

The safe working load of an existing monorail of unknown capacity shall be established by a search through existing records and/or a design check, dependant on results of search. This information search will include archived project records, maintenance, inspection and testing records in order to determine equipment history, initial and current usage and availability of original calculations. If required, design calculations shall be carried out in accordance with applicable standards and based on the properties and condition of existing structural steelwork members and the current loading requirements. Refer Sections 7.2 to 7.4, 12 and 24.2. Note: Where the strength or serviceability of an existing monorail or structure is to be evaluated, the actual properties of the existing structural steelwork shall be used, NOT the properties of sections currently available, which have replaced superseded sections.

7.2

CONDITION OF EXISTING STEELWORK

Existing structural steelwork, including monorails to be rated or upgraded, shall be inspected prior to commencement of design work for structural adequacy, as condition could impact on the extent of remedial and strengthening work that may be required. Refer to Section 24.2.

7.3

DESIGN STANDARDS

Monorails and supporting structures, including strengthening of existing steelwork members where required, shall be designed in accordance with this Standard and Australian Standards AS3990, AS4100 and AS1418.1 as applicable. Refer to Sections 8, 9, 10 and 12 for details. For free standing monorail structures concrete footings shall be designed in accordance with AS3600 and CSBP Engineering Standard Concrete (ES-14-202-10).

7.4

DESIGN

ALL design work for monorail systems with a SWL of ten (10) tonne or greater shall be carried out and checked by an external engineering company / consultant. Monorail systems less than ten (10) tonne shall be either designed / checked externally or, designed internally by CSBP and checked externally by a suitably qualified and experienced structural engineer. Note: Externally produced designs can be checked within the same organisation provided that the company has in place a QA checking process. If not, design shall be checked by a suitably qualified and experienced structural engineer from a different company.

For requirements on design calculations refer to Section 12.1.

Version No. 3

Page 15 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

7.5

INDEPENDENT DESIGN REVIEW

Completed design work for monorail systems with SWL of ten (10) tonne or greater shall be subject to an Independent Design Review. Refer to Section 11and 12 for details.

7.6

STATUTORY AUTHORITY APPROVAL

WorkSafe WA or their authorised agency shall approve all CSBP monorail systems with a ten (10) tonne or greater safe working load prior to commencement of any fabrication or remedial work. Refer to Section 13 for details.

8.
8.1

DESIGN METHODS
WORKING STRESS DESIGN METHOD

Unless directed otherwise by the Superintendent, design-involving plants installed during or before 1990 shall be carried out using the working stress design method. This shall be in accordance with the provisions of AS3990 except where specified otherwise in AS1418.1.

8.2

LIMIT STATES METHOD

Unless directed otherwise by the Superintendent, design - involving new plants, or operating plants installed after 1990 - shall be carried out using the limit states method. This shall be in accordance with the provisions of AS4100, except where specified otherwise in AS1418.1.

9.
9.1

MONORAIL SECTION SIZE

SAFE LOAD / CAPACITY TABLES

Subject to flange and web thickness and deflection checks (Sections 9.2 to 9.4 inclusive) monorail section size may be designed using: a. AISC Safe Load Tables 6th Edition 1987, for plants installed during or before 1990 using old steel grades (eg. Grade 250) and following the working stress design method of AS3990. AISC Design Capacity Tables for structural steel, for new and existing plants installed after 1990 and following the limit states method of AS4100.

b.

9.2

FLANGE THICKNESS

Flange thickness of proposed beam section; shall be checked for local buckling in accordance with AS1418.1 Clause 5.7.1.

9.3

WEB THICKNESS

Web thickness of proposed beam section shall be checked in accordance with AS1418.1 Clause 5.7.2.

Version No. 3

Page 16 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

9.4

DEFLECTION LIMITS

The calculated deflection of the beam shall satisfy the requirements of AS1418.1 Clause 5.6. 9.4.1 Cantilever Monorails

Calculations for the deflection of cantilever monorails shall include the effects of adjacent spans. 9.4.2 Jib Cranes

Jib Cranes that can rotate through 90 or more will impose torsional stresses in supporting building columns. Deflections due to torsional and other loading on building columns or structure shall be considered when calculating total effects.

9.5

LONG SPAN MONORAIL BEAMS

Strengthening of long span monorail beams, to increase lateral buckling strength and stability, can be achieved by the addition of bracing or ties to the top flange of the beam. Design shall be in accordance with Section 8.

10.

END STOP DESIGN

End stop connection to monorail beam, shall be designed to withstand dynamic loads transmitted by hoist trolley, in accordance with applicable standards. End stop shall be sized and positioned to suit the actual hoist trolley to be used, such that the calculated vertical and horizontal interference dimensions, between monorail and trolley end stops, shall not be less than those specified in Figure 4. Note: If original hoist trolley is to be replaced a verification check shall be carried out, to ensure minimum interference dimensions are maintained, PRIOR to putting the new trolley into service. End stops shall be replaced if needed. Refer to Section 24.5 for commissioning requirements.

Version No. 3

Page 17 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

MONORAIL WHEELS

MONORAIL END STOP HOIST TROLLY MONORAIL TROLLY END STOP

MONORAIL END STOP

HORIZONTAL INTERFERENCE >15mm (BOTH SIDES)

VERTICAL INTERFERENCE >15mm (BOTH SIDES)

TROLLY END STOP

TYPICAL CROSS SECTION THROUGH MONORAIL

MANUFACTURERS RECOMENDED WHEEL FLANGE CLEARANCE (BOTH SIDES)

Figure 4 Minimum Interference between Monorail and Trolley End Stops

Version No. 3

Page 18 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

11.

INDEPENDENT DESIGN REVIEW

On completion of design and checking of calculations, including details of remedial work and strengthening of existing structural steelwork where required, as per Section 7.3 and 7.4, an Independent Design Review shall be carried out for ALL monorail systems with a SWL ten (10) tonne or greater. Independent Design Review of monorails with SWL less than ten (10) tonne shall ONLY be carried out when specified in the Works by the Superintendent. The Superintendent shall nominate the type and extent of Independent Design Review activities to be carried out, on a case by case basis. For example: a. b. c. d. e. a. b. Methodology checks. Conformance with Australian Standards and good engineering practices. Analysis of design by carrying out alternative calculations or analysis methods. Engineering check of prepared design drawings and calculations. Comparison with a proven similar design. Initiate review / approval process with WorkSafe, or their authorised agency, if review outcome is satisfactory. Initiate appropriate action, if the Independent Design Review identifies problem areas such as non-conformance to standards and incorrect analysis.

Outcome of the Independent Design Review will enable the Superintendent to:

12.
12.1

CALCULATIONS
DESIGN CALCULATIONS

Copies of the checked structural design calculations for the monorail and supporting structure, and where required: concrete footing design - for free standing monorail structures; and the strengthening of existing steelwork members, shall be submitted to the Superintendent in accordance with the requirements of the Works. Calculation sheets shall reference preliminary drawings, sketches and layouts by drawing and revision number, and standards and other publications referred to in the calculations by title, author, date and publisher. All calculations shall be checked in accordance with Section 7.4, for accuracy and confirmation of technical detail. Each sheet shall have the company name and the printed name and signature of the checking engineer, and be dated. Copies submitted shall be clearly referenced legible hard copies. If calculations are computer generated, electronic copies shall be supplied in addition to the hard copy if specified by the Superintendent in the Works.

12.2

INDEPENDENT DESIGN REVIEW

Report and copy of analysis and any calculations prepared by the Independent Design Review shall be submitted to the Superintendent in accordance with the requirements of the Works. Documentation shall reference drawings and publications and shall be submitted in a similar manner as Section 12.1. Version No. 3 Page 19 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

13.

APPROVAL BY STATUTORY AUTHORITY

All new, re-rated or modified monorail systems, ten (10) tonne or greater safe working load shall be reviewed and approved by WorkSafe, or their authorised agency. No fabrication or remedial work shall commence until the Superintendent has received written approval from WorkSafe, or their authorised agency.

14.

MATERIALS AND EQUIPMENT SELECTION

All materials shall be new unless approved by the Superintendent. Unless otherwise noted on the drawings or approved by the Superintendent, materials and equipment shall comply with the requirements of CSBP Engineering Standards: ES-14-302-01 ES-14-401-01 ES-14-701-01 ES-14-902-01 Fabrication of Structural Steelwork Mechanical Preferred Equipment Electrical/Instrument Preferred Equipment Materials and Workmanship for Electrical Installations

Manual lifting equipment shall be designed and comply with the relevant section of AS 1418.1 and AS 1418.2. Power operated lifting equipment shall be designed and comply with the relevant section of AS 1418.1 and AS 1418.2, and CSBP Engineering Standard Electric Hoists (ES-14-403-21).

15.

ELECTRICAL CONTROLS

Where required, electrical controls shall comply with CSBP Engineering Standard Electric Hoists (ES-14-403-21).

16.

HANDLING OF STRUCTURAL STEELWORK & EQUIPMENT

Care shall be taken at all times during the fabrication, transportation, storage and erection of monorails, supports and equipment and where applicable the modification and strengthening of existing structures, to prevent steelwork deformation and/or damage to protective coatings. Damaged steelwork, equipment and protective coatings shall be repaired to the satisfaction of the Superintendent or replaced.

17.

FABRICATION

Unless otherwise specified, fabrication of monorails, supports and strengthening components for existing structures, shall be in accordance with CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01).

Version No. 3

Page 20 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

18.

WELDING

Unless otherwise specified, all structural welding shall conform to AS 1554.1 Category SP and CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01).

19.

BOLTING

Unless otherwise specified all structural bolted connections shall be torqued bearing type AS 1252 Grade 8.8/TB bolts, installed in accordance with CSBP Engineering Standard Erection of Structural Steelwork (ES-14-302-02).

20.

SITE MODIFICATIONS

No site modification or correction to structural steelwork, mechanical or electrical work, other than those specified on drawings or in the Works, shall be made without the approval of the Superintendent. Note: Any proposed site change shall be assessed for potential impact on the structural integrity of the monorail system, or breach of the WorkSafe license agreement. Where necessary, proposed changes shall be submitted to relevant parties for review and approval before implementing proposed changes. Refer to Sections 11, 12 and 13.

21.
21.1

PROTECTIVE COATINGS
STRUCTURAL STEEL

Surface preparation and protective coating, shall be in accordance with CSBP Engineering Standard Protective Coatings (ES-14-101-12). The monorail shall be painted Golden Yellow to AS 2700-colour code Y14. Support steelwork shall be: a. b. Note: Light Grey Blue, AS 2700 - B44 in Chemical Process Plants Cream, AS 2700 Y34 in other areas such as fertiliser plants, storage and despatch. If supporting structural steelwork has torqued friction type connections (bolts denoted as 8.8/TF), contact surfaces shall be clean as-rolled or equivalent, free from paint or any other applied finish, which will impact on the effectiveness of the friction developed between the contact surfaces.

21.2

HOIST AND TROLLEY

Protective coating and finish of mechanical and electrical trolleys and hoists shall be to the manufacturers standard unless specified otherwise by the Superintendent.

Version No. 3

Page 21 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

21.3

BOLTS

Unless otherwise specified all bolts, nuts and washes shall be hot-dip galvanised in accordance with AS 1214.

22.
22.1

INSTALLATION
CIVIL / STRUCTURAL / MECHANICAL

As applicable, all monorail installation activities including setting out, concrete footings, modification and strengthening of existing structures, steelwork erection, bolting, field welding and grouting of structure base plates shall be carried out in accordance with: a. b. c. the drawings; Superintendent approved Contractor installation procedures; CSBP Engineering Standards: Concrete (ES-14-202-10) Erection of Structural Steelwork (ES-14-302-02) Grouting (ES-14-202-14) Mechanical Equipment Design, Supply and Installation (ES-14-402-01) Statutory Authorities having jurisdiction over the work site.

d.

22.2

ELECTRICAL

Where an electric trolley and /or hoist is fitted, all electrical installation activities shall be in accordance with CSBP Engineering Standard Electric Hoists (ES-14-403-21).

23.

IDENTIFICATION

Monorail beam, hoist and trolley shall be clearly marked with their safe working load, equipment number, Statutory Authority registration number if applicable, and other identification markings in accordance with Sections 23.1 and 23.2. Note: When the safe working load of a trolley and / or hoist is not matched to that of the beam, the trolley, hoist and beam shall be marked with the lesser safe working load as appropriate.

Version No. 3

Page 22 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

23.1

BEAMS

All monorail beams shall be identified with the following information: a. Safe Working Load (SWL) shall be specified in metric units as follows: kilograms where SWL is less than 1 tonne e.g.; SWL 700kg tonnes where SWL is equal to or greater than 1 tonne e.g.; SWL 9t or SWL 9 tonne Equipment number, assigned in accordance with CSBP Engineering Standard Equipment Numbering System (ES-14-101-06) eg.; 1121L0221 For a hoist and trolley that is permanently attached to a specific monorail beam the equipment number shall cover the beam, hoist and trolley. For a hoist and trolley that is portable, the beam shall have a different equipment number to that of the hoist and trolley. c. d. Statutory Authority registration number for all monorails 10 tonne SWL or greater. Beam orientation (ie. either north-south OR east-west, as applicable) shall be clearly marked on the beam. For corresponding markings on electric control switches for motorised trolleys refer to CSBP Engineering Standard Electric Hoists (ES-14-403-21). Note: For curved monorails, marking shall be as directed by the Superintendent.

b.

Note:

Identification labelling shall be black paint stencilled lettering and numerals on both sides of the monorail. Markings shall be of sufficient size to be clearly visible and legible from the working area below the beam. The following minimum sizes specified in Table 1 shall be adhered to wherever possible. NOMINAL DEPTH of BEAM in mm 150 200 250 300 350 400 450 and larger MINIMUM HEIGHT of MARKINGS in mm (see note) 75 100 125 150 200 200 250

Note:

For short span beams, height of markings may be reduced where they cannot be accommodated over monorail length with standard size text specified above. Table 1 Size of Monorail Beam Identification Markings

Version No. 3

Page 23 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

23.2

HOIST AND TROLLEY

All hoists and trolleys shall be identified by the following information: a. Equipment number assigned in accordance with CSBP Engineering Standard Equipment Numbering System (ES-14-101-06) e.g. 1121L0221. Note: For a hoist and trolley that is permanently attached to a specific monorail beam one (1) equipment number shall be assigned to cover the beam, hoist and trolley as per Section 23.1. Hoists and trolleys that are portable ie they are not attached permanently to a specific monorail beam, shall be assigned one (1) number for the hoist and trolley and one (1) number for the beam, specific to the plant area responsible for that equipment. For identification and labelling of electric hoists and trolleys refer to CSBP Engineering Standard Electric Hoists (ES-14-403-21). b. Labelling details shall be in accordance with CSBP Engineering Standard Labels & Signs: Plant and Equipment (ES-14-102-09).

24.
24.1

INSPECTION AND TESTING

WELD TESTING AND INSPECTION

Weld inspection and testing shall be in accordance with AS 1554.1 and CSBP Engineering Standards: ES-14-302-01 ES-14-302-02 Fabrication of Structural Steelwork Erection of Structural Steelwork.

24.2

EXISTING STRUCTURAL STEELWORK INSPECTION

The following areas shall be inspected and results recorded during the design/development phase to establish the extent of remedial and strengthening work that may be required to existing structural steel. Monorail (if fitted) a. b. c. Extent of corrosion and condition of protective coating on monorail steelwork and end connection bolts. Type, size, connection details and adequacy and condition of existing monorail end stops. Monorail identification markings are on both sides of beam, are correct and clearly visible from ground level, or operating level in a multi level situation. Required markings in accordance with Section 23 to be displayed are: Safe Working Load (SWL) CSBP equipment numbers Statutory Authority registration number where applicable

Version No. 3

Page 24 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Structure a. b. c. d. Extent of corrosion and condition of protective coating on existing monorail support structure and connection bolts. Bolted connections are secure in areas subject to vibration. Supporting structure above a proposed monorail does not have excessive deflection or that supporting columns are not noticeably distorted. Extent of corrosion and condition of protective coating on existing structure that is to be used to support a proposed monorail.

24.3

NEW FABRICATED STEELWORK INSPECTION

All new fabricated structural steelwork shall be inspected in accordance with the requirements of CSBP Engineering Standard Fabrication of Structural Steelwork (ES-14-302-01).

24.4

INSPECTION DURING ERECTION

The following areas shall require inspection and approval by the Superintendent: a. b. c. d. e. Surface preparation of concrete footing prior to erection of structural support steelwork. Setting out and alignment tolerances. Cutting, drilling and welding of existing steelwork. Surface preparation and protective coating of remedial works, modifications and strengthening existing steelwork and field welds. Cleaning and surface preparation of the underside of support column base plate, holding down bolts and concrete foundation prior to grouting.

Inspection shall be carried out in accordance with relevant Australian Standards and the following CSBP Engineering Standards: ES-14-102-12 ES-14-202-14 ES-14-302-02 Protective Coatings Grouting Erection of Structural Steelwork

24.5

COMMISSIONING

Prior to being placed into service the monorail shall comply with the commissioning requirements of AS1418. 24.5.1 Stage 1 Commissioning All components within the monorail system shall be inspected to verify that they have been fabricated / manufactured, supplied and installed in accordance with: Contract drawings and documentation; Standards and Codes specified in this Standard; Statutory Regulations; Manufacturers requirements.

Version No. 3

Page 25 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

Movement of hoist and trolley shall be checked throughout their complete range in all directions under no-load condition. Stage 1 Commissioning Inspection Reports General Mechanical (M101) and Hoist, Monorail and/or Monorail Jib Crane (M152) shall be used to verify equipment details. Note: Stage 2 Commissioning, shall not commence until the Superintendent has accepted and signed off the Stage 1 Commissioning Inspection Reports, as being successfully completed.

24.5.2 Stage 2 Commissioning Monorail and hoist shall be tested in accordance with the requirements of AS1418. Results shall be recorded in the Stage 2 Commissioning Test Reports; General Mechanical (M201) and Hoist, Monorail and/or Monorail Jib Crane (M252). Note: Monorail system shall not be put into service until the Superintendent has accepted and signed off the Stage 2 Commissioning Test Reports, as being successfully completed. Beam Load Testing

24.5.2.1

Unless otherwise directed by the Superintendent, beam load testing shall be carried out with: a. b. Test load equivalent to SWL + 10% Test locations at: centre of span or end of cantilever (if applicable).

Beam deflection shall be measured at location of test load. Note: ALL beams shall be load-tested as above, regardless of the monorail safe working load. ONLY suitably qualified and experienced personnel shall carry out load testing. Test load shall be kept as close as practical to ground or operating level. The stability and deformation of supporting structure shall be monitored during testing.

24.6

INSPECTION DURING OPERATIONAL PHASE

In accordance with CSBP Guide Slings, Rigging and Lifting Equipment Safety (GM-11-038-02) and AS 2550 the monorail system, including all mechanical, electrical and structural components shall be subject to a complete and documented annual inspection. Dependant upon the environmental conditions and the type of equipment being used more frequent safety checks shall be carried out as directed by the applicable business unit. Note: The person using lifting equipment shall inspect it for safety, before each use. Any lifting equipment found to be defective, damaged or suspect shall not be used.

Version No. 3

Page 26 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

24.6.1 Inspection Plan In accordance with the Inspection Plan, the following areas shall be inspected and results recorded, to establish whether any remedial work is required. Monorail a. b. c. Extent of corrosion and condition of protective coating on monorail steelwork and end connection bolts. Condition of monorail end stops. Monorail identification markings are clearly visible from ground level, or operating level in a multi level situation.

Structure a. b. c. Extent of corrosion and condition of protective coating on monorail support structure and connection bolts. Bolted connections are secure in areas subject to vibration. Supporting structure above monorail does not have excessive deflection or the supporting columns are not noticeably distorted.

Hoist and Trolley a. Mechanical 1. 2. 3. 4. Extent of corrosion and condition of protective coating on trolley, end stops, wheels and connection bolts. Clearance between monorail bottom flange outside face and trolley wheel flange is within manufacturers limits. Actual vertical and horizontal interference dimensions, between monorail and trolley end stops are not less than those specified in Figure 4. Condition of chains, wire ropes, slings, sheaves, hook and safety latch as applicable. Refer to CSBP Guide Slings, Rigging and Lifting Equipment Safety (GM-11-03802) for requirements. Wear and clearances on all movable components are within manufacturers limits.

5. b.

Electrical Condition and operation of electrical equipment as defined in CSBP Engineering Standard Electric Hoists (ES-14-403-21).

Version No. 3

Page 27 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.

Monorails ES-14-403-20

25.
25.1

RECORDS MANAGEMENT
AS - BUILT DRAWINGS

On completion of site modifications and installation, testing and commissioning of the monorail system, drawings shall be upgraded to reflect any as-built design deviations. Drawings recording the as-built details shall be prepared/revised, numbered, approved and handed over in accordance with CSBP Engineering Standards: ES-14-101-02 ES-14-101-03 ES-14-101-04 Drawing Management Drawing Preparation Drawing Numbering

25.2

ENGINEERING PROJECT FILES

On completion of the project all relevant hard-copy documentation, in numbered project files, shall be archived in the designated work area. Records in electronic format (such as drawings and JDE data) shall be stored in the appropriate databases and designated work area. Refer to CSBP Guide Engineering Modifications (GM-05-050-01) for type of documents to be retained for historical purposes.

25.3

MAINTENANCE WORK ORDERS

On completion of the maintenance work order, details shall be recorded in accordance with CSBP Departmental Procedure Closing Maintenance Work Orders (DP-05-013-04).

25.4

MONORAIL SYSTEM ANNUAL INSPECTION

On completion of the annual inspection (or more frequently as determined by each business unit), results shall be recorded in accordance with CSBP Guide Manual Slings, Rigging and Lifting Equipment Safety (GM-11-038-02).

Version No. 3

Page 28 of 28

Document last modified: 25 June 2002. PDF Created: 10 November 2005.