ES-14-403-20

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MonorailsES-14-403-20

Version No. 3 Page 1 of 28

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

This is a Controlled Document that complies with Wesfarmers CSBP Ltd formatting andQuality Control guidelines. Please check that this is the latest available version before use.

Title: MONORAILS

Number: ES-14-403-20

Owner: Dale Hewson

Authoriser: Phil Talbot

Version Details: Revision 3.

Electric hoist details deleted and reference to EngineeringStandard: Electric Hoists (ES-14-403-21) added throughout thedocument.

Independent Design Review requirements changed from ALLmonorail systems to only those with SWL equal to or greaterthan 10 tonne. Sections 6.1, 7.5 and 11, and flow chart Figure 1Sheets 1, 2 and 3 modified accordingly.

Sections 7.4 and 12 added.

Section 23.1.b and 23.2.a: Requirements for equipmentnumbering changed.

Section 24.5.2.1: 'Note' specifying Beam Load Testing requiredon ALL monorails regardless of SWL added.

Referencing changed on Figures 1, 2 and 3 due to addition of Section 12.

TABLE OF CONTENTS1. SCOPE........................................................................... .......................................................... ...... 4

2. PURPOSE ......................................................... ............................................................ ................ 4

3. RESPONSIBILITY ...................................................... .......................................................... ...... 4

4. DEFINITION OF TERMS ...................................................... .................................................... 4

5. STANDARDS.................................................................................. .............................................. 5

6. OVERVIEW ...................................................... .............................................................. ............. 8

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6.1 DESIGN PHASE FIGURE 1 (3 SHEETS) ............................................................... ........ 86.2 INSTALLATION PHASE FIGURE 2 ....................................................... ......................... 86.3 OPERATIONAL PHASE FIGURE 3 .......................................................... ....................... 9

7. BASIS OF DESIGN........................................................................ ............................................ 157.1 EXISTING MONORAIL OF UNKNOWN CAPACITY .................................................... 157.2 CONDITION OF EXISTING STEELWORK .................................................... ................. 157.3 DESIGN STANDARDS..................................................................... .................................. 157.4 DESIGN ........................................................ ............................................................. .......... 157.5 INDEPENDENT DESIGN REVIEW ......................................................... ......................... 167.6 STATUTORY AUTHORITY APPROVAL ................................................................ ........ 16

8. DESIGN METHODS ........................................................... ...................................................... 16

8.1 WORKING STRESS DESIGN METHOD ........................................................ .................. 168.2 LIMIT STATES METHOD ......................................................... ........................................ 16

9. MONORAIL SECTION SIZE .......................................................... ........................................ 16

9.1 SAFE LOAD / CAPACITY TABLES ................................................................... .............. 169.2 FLANGE THICKNESS ......................................................... .............................................. 169.3 WEB THICKNESS ....................................................... ....................................................... 169.4 DEFLECTION LIMITS ........................................................ ............................................... 179.5 LONG SPAN MONORAIL BEAMS................................. .................................................. 17

10. END STOP DESIGN............................................................................................... ................ 17

11. INDEPENDENT DESIGN REVIEW.................... ................................................................ 19

12. CALCULATIONS.................................................... ........................................................... .... 19

12.1 DESIGN CALCULATIONS......................................................... ....................................... 19

12.2 INDEPENDENT DESIGN REVIEW ................................................................ .................. 1913. APPROVAL BY STATUTORY AUTHORITY................................................ ................... 20

14. MATERIALS AND EQUIPMENT SELECTION ............................................................... 20

15. ELECTRICAL CONTROLS.... ................................................................ ............................. 20

16. HANDLING OF STRUCTURAL STEELWORK & EQUIPMENT ................................. 20

17. FABRICATION ................................................................ ...................................................... 20

18. WELDING............................ ................................................................ ................................... 21

19. BOLTING..... ................................................................ ........................................................... 21

20. SITE MODIFICATIONS ....................................................... ................................................ 21

21. PROTECTIVE COATINGS.......................................................... ........................................ 21

21.1 STRUCTURAL STEEL ........................................................ ............................................... 2121.2 HOIST AND TROLLEY........................................... ........................................................... 2121.3 BOLTS ............................................................. ............................................................... ..... 22

22. INSTALLATION....... ................................................................ ............................................. 22

22.1 CIVIL / STRUCTURAL / MECHANICAL............................................... .......................... 2222.2 ELECTRICAL.................................. ................................................................ .................... 22

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1. SCOPE

This Standard covers the minimum technical requirements for the design, approval, fabrication,installation, testing and commissioning, preventative maintenance and inspection, and recordkeeping of new and upgrades to existing monorails.

Existing structures shall be analysed in accordance with the criteria established in this Standard andappropriate action taken, before upgrades to existing monorails are carried out or a new monorail isinstalled in an existing structure.

Note: For electric hoists and motorised trolleys, this Standard is to be read in conjunction withCSBP Engineering Standard Electric Hoists (ES-14-403-21) .

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

3. RESPONSIBILITY

During the development phase it is the responsibility of the Superintendent to ensure that allapprovals have been obtained before the Works are carried out and that the requirements of thisStandard are adhered to.

Following completion of project handover, it is the responsibility of each business unit to ensurethat 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 theSuperintendent.

Superintendent

Functional title for the Wesfarmers CSBP Limited Officer, or authorised representative,responsible for the development and implementation of the Works, including liaison with andobtaining internal and external approvals from appropriate personnel, statutory authorities etc.

CSBP

Wesfarmers CSBP Limited.

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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 alongthe 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 thatactivity.

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 conflictbetween the Works, Statutory Requirements and the Standards, the Contractor shall notify theSuperintendent in writing for resolution. In general, the most stringent requirement will prevail.

CSBP Engineering Standards

ES-14-101-02 Drawing ManagementES-14-101-03 Drawing PreparationES-14-101-04 Drawing NumberingES-14-101-06 Equipment Numbering SystemES-14-102-09 Labels & Signs: Plant and EquipmentES-14-102-12 Protective CoatingsES-14-202-10 ConcreteES-14-202-14 Grouting

ES-14-302-01 Fabrication of Structural Steelwork

ES-14-302-02 Erection of Structural Steelwork ES-14-401-01 Mechanical Preferred EquipmentES-14-402-01 Mechanical Equipment Design, Supply and InstallationES-14-402-02ES-14-403-21

Testing and Commissioning of Mechanical EquipmentElectric Hoists

ES-14-701-01 Electrical/Instrument Preferred EquipmentES-14-902-01 Materials and Workmanship for Electrical InstallationsES-14-902-02 Testing and Commissioning of Electrical Installations

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CSBP Procedures

DP-05-011-03 Maintenance Daily Schedule

DP-05-013-01 Work Order Entry and ApprovalDP-05-013-04 Closing Maintenance Work OrdersDP-05-013-05 Developing Maintenance StrategiesDP-05-014-01 Maintenance Breakdown RepairsEP-08-030-05 Engineering Project FilesEP-08-030-19 Engineering Project Design ReviewEP-08-030-38 Engineering Project Handover

CSBP Guides

GM-05-043-01 Technical Data Requirements for Plant and Equipment

GM-05-050-01 Engineering ModificationGM-10-020-04 Contractors Site InstructionsGM-11-035-02 Basic Safety RulesGM-11-038-02 Slings, Rigging and Lifting Equipment Safety

CSBP Standard Forms

ES-14-101-12 Technical Data Sheets Mechanical, Electrical and InstrumentIF1463 Technical Data Sheets Hoist, Winch, Crane

Stage 1 Commissioning Inspection Reports

M101 General MechanicalM152 Hoist, Monorail and/or Monorail Jib Crane

Stage 2 Commissioning Test Reports

M201 General MechanicalM252 Hoist, Monorail and/or Monorail Jib Crane

CSBP Standard Drawings

9900-3-0005/001 Standard Beam and Bracing Connection Details

9900-3-0005/002 Standard Beam Connection Details & Member Schedule9900-3-0005/003 Structural Base Plates9900-3-0005/004 Standard Column & Beam Bolted Splice Connection Details

Standards Association of Australia

AS 1111 ISO Metric Hexagon Commercial Bolts and ScrewsAS 1112 ISO Metric Hexagon Nuts including Thin Nuts, Slotted Nuts and

Castle NutsAS 1163 Structural Steel Hollow SectionsAS 1170 SAA Loading Code

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AS 1214 Hot-Dip Galvanised Coatings on Threaded FastenersAS 1237 Flat Metal Washers for General Engineering PurposesAS 1252 High-Strength Steel Bolts with Associated Nuts and Washers for

Structural EngineeringAS 1418.1 Cranes - General RequirementsAS 1418.2 Cranes - Serial Hoists and WinchesAS 1538 Cold-Formed Steel Structures CodeAS 1553 Covered Electrodes for WeldingAS 1554.1 Welding of Steel StructuresAS 1594 Hot Rolled Steel Flat ProductsAS 1666.2 Wire Rope Slings - Care and UseAS 2214 Certification of Welding Supervisors Structural Steel Welding

AS 2550 Cranes Safe UseAS 3600 Concrete StructuresAS 3678 Structural Steel Hot Rolled Plates, Floor Plates and SlabsAS 3679.1 Structural Steel Hot Rolled Bars and SectionsAS 3679.2 Structural Steel Welded I SectionsAS 3990 Mechanical Equipment Steelwork AS 4100 Steel StructuresAS 4680 Hot-Dip Galvanised (Zinc) Coatings on Fabricated Ferrous ArticlesAS/NZS ISO 9002 Quality Systems Model for Quality Assurance in Production,

Installation and Servicing

Other Engineering Standards and Publications

AISC Design Capacity Tables for Structural SteelAISC Design of Structural ConnectionsAISC Safe Load Tables 6 th Edition 1987

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6. OVERVIEW

Flow diagrams Figure 1, Figure 2 and Figure 3 show the high level activities involved in themanagement 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 monorailsystem, 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, initialusage and whether design calculations are available.

The condition of the existing monorail, connections and support structure shall be checked forcorrosion, 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 bedetermined, enabling engineering design modifications to monorail and/or support structure to beestablished.

ALL design work for monorail systems with a SWL of ten (10) tonne or greater shall be carried outand 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 checkedexternally 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 withrelevant 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 byWorkSafe 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 inthe flow diagram.

Reference to relevant clauses in this Standard and other CSBP and Australian Standards are madein Figure 1, covering design phase activities.

6.2 INSTALLATION PHASE FIGURE 2

This process commences with an approved monorail design and includes design modifications andstructural strengthening of existing structural steelwork where required.

Normal project development sequence activities are followed through to Customer handover andproject file close out.

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

6.3

OPERATIONAL PHASE FIGURE 3This process commences with a commissioned monorail system that has been handed over to theCustomer.

The maintenance strategy, monorail system technical details and the inspection and preventativemaintenance requirements are finalised and recorded in the JDE Maintenance System, (activitiescommenced in the design / installation phases).

Based on inspection findings, maintenance work is carried out in accordance with work priority orif an engineering modification is required, changes are implemented in accordance with Figure 1and 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 Figure3, covering operational phase activities.

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AS3990AS1418

Source historical info / Calculate SWL.

Exit SWLknown?

New orUpgrade?

Exitstruct?

A

Eng Project MONORAILS

Inspect existingMonorail.

Extent of corrosion.Condition of end stopsand connection tostructure.

Calculateexisting loads

Cals for existStructure?

AS4100AS3990

Inspect existingstructure

ConditionOK?

Prepare layout/detaildrawings.

Carry out monorailcalculations.

Check existingstructure imposedloads.

Withincode?

Design structuralstiffening.

Recheck designcalculations

Withincode?

B

B

Condition of existingstructure and monorailto be factored intodesign.

Extent of corrosion.Condition of bolts.Extent of Structuraldeformation etc..

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

AS4100 / AS3990AS1418

7.17.38.9.

24.27.2

24.27.2

12.10.9.8.7.47.3

Yes

8.7.47.3

10.9.8.

7.47.3

9.8.7.3

24.27.2

Yes

No

Upgrade New No

Yes

No

Yes

No Yes

Yes

No

SWL

SWL

10t?

10t?

Yes

Yes

End

EndNo

No

No

Figure 1 Monorail Design Process Flow Diagram Sheet 1 of 3

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A

Intergrated designmonorail and

structure

Prepare layouts anddetail drawings

Carry out designcalculations

Withincode?

Revise design

Recheck designcalculations

Withincode?

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

AS4100AS1418

12.10.

9.8.7.47.3

12.10.9.8.7.47.3

No

Yes SWL 10t? End

B

No

No YesEnd

B

No

Yes

Yes

SWL 10t?

Figure 1 Monorail Design Flow Diagram Sheet 2 of 3

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IndependentDesign Review

Withincode?

StatutoryAuthority

review/approval

Withincode?

File approvals inproject file

AdviseSuperintendent

Action asrequired

Action asrequired

AdviseSuperintendent

B

End

7.511.12.

7.613.

No

No

Yes

Yes

Figure 1 Monorail Design Process Flow Diagram Sheet 3 of 3

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Approved monoraildesign.

Tender, evaluate,approval to proceed ,award.

Prepare shop/ vendordrawing anddocuments. Submitand review/ approve.

Fabricate/

manufacture, inspect .

Install

Test / Commission

Accepted?

Finalise handoverand close outdocumentation ,

Customeraccept?

File projectdocumentation

Remedial work required.

Remedial work asrequired

As built Drawin sMDR'sData SheetsH/O Certificate

ES-14-101-02ES-14-101-03ES-14-101-04ES-14-402-01ES-14-902-01

ES-14-302-01ES-14-401-01ES-14-402-01ES-14-701-01ES-14-902-01

ES-14-302-02ES-14-402-01ES-14-902-01

ES-14-402-02ES-14-902-02

24.324.1

23.21.14. ---> 19.24.424.122.14. ---> 19.

24.5

25.2

End

No

No

Yes

Yes

Figure 2 Monorail Installation Process Flow Diagram

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Commissionedmonorail system.

Finalise maintenancestrategy.

Complete recordingdetails in JDEMaintenance System.

Carry out inspectionaccording to plan.

Accepted?

Identify remedialwork required.

Initiate maintenancework

Initiate engineeringwork

Carry out designwork.

Carry outmaintenance work.

Close out - recorddetails in JDEsystem.

Carry outengineering work.

Close out - recorddetails in JDEsystem.

End

Activities commence inthe design andinstallation phases asinformation becomesavailable.

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

Equipment numberSWLRegistration numbersHoist detailsInspection Reqts etc.

GM-11-038-02

Record details inJDE system.

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

DP-05-013-04

GM-05-050-01

Fig 1

Fig 2

End

MAINTENANCEWORK

ENGINEERINGMODIFICATION

Yes

25.3 25.225.1

25.4

24.6

No

Figure 3 Monorail Maintenance Process Flow Diagram

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7. BASIS OF DESIGN

7.1 EXISTING MONORAIL OF UNKNOWN CAPACITY

The safe working load of an existing monorail of unknown capacity shall be established by a searchthrough existing records and/or a design check, dependant on results of search.

This information search will include archived project records, maintenance, inspection and testingrecords 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 andbased on the properties and condition of existing structural steelwork members and the currentloading 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 beevaluated, the actual properties of the existing structural steelwork shall be used, NOT theproperties 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 priorto commencement of design work for structural adequacy, as condition could impact on the extentof 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 whererequired, 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 withAS3600 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 outand 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 checkedexternally by a suitably qualified and experienced structural engineer.

Note: Externally produced designs can be checked within the same organisation provided thatthe company has in place a QA checking process. If not, design shall be checked by asuitably qualified and experienced structural engineer from a different company.

For requirements on design calculations refer to Section 12.1.

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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. DESIGN METHODS

8.1 WORKING STRESS DESIGN METHOD

Unless directed otherwise by the Superintendent, design-involving plants installed during or before1990 shall be carried out using the working stress design method. This shall be in accordance withthe 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 plantsinstalled after 1990 - shall be carried out using the limit states method. This shall be in accordancewith the provisions of AS4100, except where specified otherwise in AS1418.1.

9. MONORAIL SECTION SIZE

9.1 SAFE LOAD / CAPACITY TABLES

Subject to flange and web thickness and deflection checks (Sections 9.2 to 9.4 inclusive) monorailsection size may be designed using:

a. AISC Safe Load Tables 6 th Edition 1987, for plants installed during or before 1990 usingold steel grades (eg. Grade 250) and following the working stress design method of AS3990.

b. AISC Design Capacity Tables for structural steel, for new and existing plants installed after

1990 and following the limit states method of AS4100.

9.2 FLANGE THICKNESS

Flange thickness of proposed beam section; shall be checked for local buckling in accordance withAS1418.1 Clause 5.7.1.

9.3 WEB THICKNESS

Web thickness of proposed beam section shall be checked in accordance with AS1418.1 Clause5.7.2.

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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 buildingcolumns.

Deflections due to torsional and other loading on building columns or structure shall be consideredwhen calculating total effects.

9.5 LONG SPAN MONORAIL BEAMS

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

10. END STOP DESIGN

End stop connection to monorail beam, shall be designed to withstand dynamic loads transmittedby 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 thecalculated 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 ensureminimum interference dimensions are maintained, PRIOR to putting the new trolley intoservice. End stops shall be replaced if needed. Refer to Section 24.5 for commissioningrequirements.

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MONORAILEND STOP

TROLLYEND STOP

HORIZONTALINTERFERENCE 15mm(BOTH SIDES)

MANUFACTURERS RECOMENDEDWHEEL FLANGE CLEARANCE(BOTH SIDES)

TYPICAL CROSS SECTION THROUGH MONORAIL

>

INTERFERENCE 15mm(BOTH SIDES)

VERTICAL>

MONORAIL

WHEELS

MONORAILEND STOP

HOIST TROLLY TROLLYEND STOP

MONORAIL

Figure 4 Minimum Interference between Monorail and Trolley End Stops

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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, anIndependent 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 shallONLY be carried out when specified in the Works by the Superintendent.

The Superintendent shall nominate the type and extent of Independent Design Review activities tobe carried out, on a case by case basis. For example:

a. Methodology checks.b. Conformance with Australian Standards and good engineering practices.c. Analysis of design by carrying out alternative calculations or analysis methods.d. Engineering check of prepared design drawings and calculations.e. Comparison with a proven similar design.

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

a. Initiate review / approval process with WorkSafe, or their authorised agency, if reviewoutcome is satisfactory.

b. Initiate appropriate action, if the Independent Design Review identifies problem areas suchas non-conformance to standards and incorrect analysis.

12. CALCULATIONS

12.1 DESIGN CALCULATIONS

Copies of the checked structural design calculations for the monorail and supporting structure, andwhere required: concrete footing design - for free standing monorail structures; and thestrengthening of existing steelwork members, shall be submitted to the Superintendent inaccordance with the requirements of the Works.

Calculation sheets shall reference preliminary drawings, sketches and layouts by drawing andrevision 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 thechecking engineer, and be dated.

Copies submitted shall be clearly referenced legible hard copies. If calculations are computergenerated, electronic copies shall be supplied in addition to the hard copy if specified by theSuperintendent in the Works.

12.2 INDEPENDENT DESIGN REVIEW

Report and copy of analysis and any calculations prepared by the Independent Design Review shallbe submitted to the Superintendent in accordance with the requirements of the Works.Documentation shall reference drawings and publications and shall be submitted in a similarmanner as Section 12.1.

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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 writtenapproval 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 andequipment shall comply with the requirements of CSBP Engineering Standards:

ES-14-302-01 Fabrication of Structural Steelwork ES-14-401-01 Mechanical Preferred Equipment ES-14-701-01 Electrical/Instrument Preferred Equipment ES-14-902-01 Materials and Workmanship for Electrical Installations

Manual lifting equipment shall be designed and comply with the relevant section of AS 1418.1 andAS 1418.2.

Power operated lifting equipment shall be designed and comply with the relevant section of AS1418.1 and AS 1418.2, and CSBP Engineering Standard Electric Hoists (ES-14-403-21) .

15.

ELECTRICAL CONTROLSWhere 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 theSuperintendent or replaced.

17. FABRICATION

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

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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 1252Grade 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 thanthose specified on drawings or in the Works, shall be made without the approval of theSuperintendent.

Note: Any proposed site change shall be assessed for potential impact on the structural integrityof the monorail system, or breach of the WorkSafe license agreement.

Where necessary, proposed changes shall be submitted to relevant parties for review andapproval before implementing proposed changes. Refer to Sections 11, 12 and 13.

21. PROTECTIVE COATINGS

21.1 STRUCTURAL STEEL

Surface preparation and protective coating, shall be in accordance with CSBP EngineeringStandard Protective Coatings (ES-14-101-12).

The monorail shall be painted Golden Yellow to AS 2700-colour code Y14.

Support steelwork shall be:

a. Light Grey Blue, AS 2700 - B44 in Chemical Process Plants

b. Cream, AS 2700 Y34 in other areas such as fertiliser plants, storage and despatch.

Note: If supporting structural steelwork has torqued friction type connections (bolts denoted as8.8/TF), contact surfaces shall be clean as-rolled or equivalent, free from paint or anyother applied finish, which will impact on the effectiveness of the friction developedbetween the contact surfaces.

21.2 HOIST AND TROLLEY

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

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21.3 BOLTS

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

with AS 1214.

22. INSTALLATION

22.1 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 andgrouting of structure base plates shall be carried out in accordance with:

a. the drawings;

b. Superintendent approved Contractor installation procedures;c. 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)

d. Statutory Authorities having jurisdiction over the work site.

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, equipmentnumber, Statutory Authority registration number if applicable, and other identification markings inaccordance 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 asappropriate.

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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

b. Equipment number, assigned in accordance with CSBP Engineering Standard Equipment Numbering System (ES-14-101-06) eg.; 1121L0221

Note: For a hoist and trolley that is permanently attached to a specific monorail beam theequipment 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. Statutory Authority registration number for all monorails 10 tonne SWL or greater.

d. Beam orientation (ie. either north-south OR east-west, as applicable) shall be clearlymarked on the beam. For corresponding markings on electric control switches formotorised trolleys refer to CSBP Engineering Standard Electric Hoists (ES-14-403-21) .

Note: For curved monorails, marking shall be as directed by the Superintendent.

Identification labelling shall be black paint stencilled lettering and numerals on both sides of themonorail.

Markings shall be of sufficient size to be clearly visible and legible from the working area belowthe beam. The following minimum sizes specified in Table 1 shall be adhered to whereverpossible.

NOMINAL DEPTH of BEAM in mm MINIMUM HEIGHT of MARKINGS in mm(see note)

150200250300

350400

450 and larger

75100125150

200200250

Note: For short span beams, height of markings may be reduced where they cannot beaccommodated over monorail length with standard size text specified above.

Table 1 Size of Monorail Beam Identification Markings

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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 beamone (1) equipment number shall be assigned to cover the beam, hoist and trolleyas per Section 23.1.

Hoists and trolleys that are portable ie they are not attached permanently to aspecific monorail beam, shall be assigned one (1) number for the hoist and trolleyand one (1) number for the beam, specific to the plant area responsible for thatequipment.

For identification and labelling of electric hoists and trolleys refer to CSBPEngineering 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. INSPECTION AND TESTING

24.1 WELD TESTING AND INSPECTION

Weld inspection and testing shall be in accordance with AS 1554.1 and CSBP EngineeringStandards:

ES-14-302-01 Fabrication of Structural Steelwork ES-14-302-02 Erection of Structural Steelwork.

24.2 EXISTING STRUCTURAL STEELWORK INSPECTION

The following areas shall be inspected and results recorded during the design/development phase toestablish the extent of remedial and strengthening work that may be required to existing structuralsteel.

Monorail (if fitted)a. Extent of corrosion and condition of protective coating on monorail steelwork and end

connection bolts.b. Type, size, connection details and adequacy and condition of existing monorail end stops.c. 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 inaccordance with Section 23 to be displayed are: Safe Working Load (SWL) CSBP equipment numbers Statutory Authority registration number where applicable

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Structure

a. Extent of corrosion and condition of protective coating on existing monorail supportstructure and connection bolts.

b. Bolted connections are secure in areas subject to vibration.

c. Supporting structure above a proposed monorail does not have excessive deflection or thatsupporting columns are not noticeably distorted.

d. Extent of corrosion and condition of protective coating on existing structure that is to beused 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. Surface preparation of concrete footing prior to erection of structural support steelwork.

b. Setting out and alignment tolerances.

c. Cutting, drilling and welding of existing steelwork.

d. Surface preparation and protective coating of remedial works, modifications andstrengthening existing steelwork and field welds.

e. Cleaning and surface preparation of the underside of support column base plate, holdingdown bolts and concrete foundation prior to grouting.

Inspection shall be carried out in accordance with relevant Australian Standards and the followingCSBP Engineering Standards:

ES-14-102-12 Protective Coatings ES-14-202-14 Grouting ES-14-302-02 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 beenfabricated / manufactured, supplied and installed in accordance with:

Contract drawings and documentation; Standards and Codes specified in this Standard; Statutory Regulations; Manufacturers requirements.

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Movement of hoist and trolley shall be checked throughout their complete range in all directionsunder no-load condition.

Stage 1 Commissioning Inspection Reports General Mechanical (M101) and Hoist, Monorailand/or Monorail Jib Crane (M152) shall be used to verify equipment details.

Note: Stage 2 Commissioning, shall not commence until the Superintendent has accepted andsigned off the Stage 1 Commissioning Inspection Reports, as being successfullycompleted.

24.5.2 Stage 2 Commissioning

Monorail and hoist shall be tested in accordance with the requirements of AS1418. Results shall berecorded 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 andsigned off the Stage 2 Commissioning Test Reports, as being successfully completed.

24.5.2.1 Beam Load Testing

Unless otherwise directed by the Superintendent, beam load testing shall be carried out with:

a. Test load equivalent to SWL + 10%

b. 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 anddeformation 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 componentsshall be subject to a complete and documented annual inspection. Dependant upon theenvironmental conditions and the type of equipment being used more frequent safety checks shallbe carried out as directed by the applicable business unit.

Note: The person using lifting equipment shall inspect it for safety, before each use. Any liftingequipment found to be defective, damaged or suspect shall not be used.

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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. Extent of corrosion and condition of protective coating on monorail steelwork and endconnection bolts.

b. Condition of monorail end stops.

c. Monorail identification markings are clearly visible from ground level, or operating level ina multi level situation.

Structure

a.

Extent of corrosion and condition of protective coating on monorail support structure andconnection bolts.

b. Bolted connections are secure in areas subject to vibration.

c. Supporting structure above monorail does not have excessive deflection or the supportingcolumns are not noticeably distorted.

Hoist and Trolley

a. Mechanical

1. Extent of corrosion and condition of protective coating on trolley, end stops, wheelsand connection bolts.

2. Clearance between monorail bottom flange outside face and trolley wheel flange iswithin manufacturers limits.

3. Actual vertical and horizontal interference dimensions, between monorail andtrolley end stops are not less than those specified in Figure 4.

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-11-038-02) for requirements.

5. Wear and clearances on all movable components are within manufacturers limits.

b. Electrical

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

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25. RECORDS MANAGEMENT

25.1 AS - BUILT DRAWINGSOn completion of site modifications and installation, testing and commissioning of the monorailsystem, drawings shall be upgraded to reflect any as-built design deviations.

Drawings recording the as-built details shall be prepared/revised, numbered, approved and handedover in accordance with CSBP Engineering Standards:

ES-14-101-02 Drawing Management ES-14-101-03 Drawing Preparation ES-14-101-04 Drawing Numbering

25.2 ENGINEERING PROJECT FILES

On completion of the project all relevant hard-copy documentation, in numbered project files, shallbe archived in the designated work area.

Records in electronic format (such as drawings and JDE data) shall be stored in the appropriatedatabases and designated work area.

Refer to CSBP Guide Engineering Modifications (GM-05-050-01) for type of documents to beretained for historical purposes.

25.3

MAINTENANCE WORK ORDERSOn completion of the maintenance work order, details shall be recorded in accordance with CSBPDepartmental 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) .

Documents

ES-14-403-20