PERFORMANCE GUARANTEE TEST PROCEDURE
The specified performance parameters of various equipment’s/ system including but not
limited to the following shall be demonstrated to the full satisfaction of the Employer.
Conveyors
(a) Conveyor Profile
1. Check against lifting of Conveyor belts over concave curves at the time of start under
empty belt condition.
2. Check against wrapping/folding of belt over transition zones.
3. There should not be any roll back of cargo on moving or stopped Conveyors.
4. There shall not be build-up of cargo in chutes, spillage of cargo from
skirt/conveyor/hoods while the belt is running.
5. Smooth non-jerky running of conveyors during start-stop condition with no spillage
of cargo and centric running of conveyors without vibrations of drives and galleries.
(b) Coasting Time
Coasting down time of conveyors shall be measured and compared with design
values. Check for spillage/blockage of cargo from skirts/in chutes to be made. There
shall not be build-up of cargo in chutes after stoppage of fully loaded conveyor which
could result in spillage of cargo during next start.
(c) Belt Alignment
To check against any sway during operation under different loadings (50%, 100%)
and different conveyor criss-cross combinations.
(d) Idlers and self-aligning idlers
To check for satisfactory performance of idlers and self-aligning idlers
(e) Control/Sequential Operation
1. Performance checks for specified controls including sequential starting/stopping of
conveyors and other equipment’s as per approved control write-up.
2. Satisfactory operation of PLC and control systems including absence of spurious
trips/communication failures of PLC to be demonstrated.
3. Satisfactory operation of pull chord, belt sway, zero speed, chute blockage and other
safety / protection switches along with demonstration for detection of operated pull
cord/belt sway/chute block switch along with display in CRT with conveyor number
and operated pull cord /belt sway/chute number.
AE comment to item e (3)- Tender not asked for individual switches to be identified
in central control room. It needs each switch with separate cabling which is huge
cost difference; Currently AE offered with single wiring for all switches in each
conveyor in series, hence conveyor wise can see in control room, the particular
switch indication provided at local switch, but need to walk and locate the indication
as of now. However AE can consider additional cables and system in control panel
(no additional cost to principal) by grouping area; We propose to group area wise up
to 6 switches distance max in one group, so that the location within 120-150m is
able to locate in the main panel.
(f) Load Start
Demonstration of the ability of conveyor to start under full designed load.
(g) Vibration Level in Conveyors
Vibration limits of drive equipment’s shall be as per IS 14817 (Part-3)-2004 & ISO
10816-3: 1995/ equivalent. Observations shall be recorded in the prescribed format at
the time of testing.
Vibration of conveyor galleries at trestles, points between trestles, transfer tower
floors shall be measured, and these values shall be within allowable limits.
(h) Gear Boxes
1. Temperature rise not to exceed design values.
2. No leakages
3. No abnormal sound.
4. Satisfactory performance of hold back devices in preventing running back of
conveyor belts in case of conveyor being stopped in fully loaded (at design load)
condition to be demonstrated.
(i) Fluid Coupling.
1. No excessive rise of temperature.
2. Satisfactory and quick operation of scoop in manual/remote modes with no oil
leakages.
(j) Brakes
Satisfactory and non-jerky operation when brakes are applied to avoid hold up of
cargo in chutes.
(k) Skirt board and skirt sealing, inspection door, chute joints
Perfect sealing with no spillage/no dust from sealing areas.
OTHER EQUIPMENT
Metal Detector
1. Tests for detection of specified smallest size pieces (40 cubic mm and nonferrous &
metallic piece of 60 cubic mm as per Tender Document) of different metals including
aluminium.
2. Operation of liquid spray marker/ multiple markers.
3. Demonstration of coast count with total count of tramp metal pieces detected.
In-Line Magnetic Separators
1. Demonstration of magnet capacity to separate out specified sizes and weights (as
per the Tender Document) of magnetic pieces buried under the cargo:
MS cube of 20 mm size
Suitable size of M.S. plate
MS round bar of 50 Kg with L/D ratio of 5(min)
MS Bolt of M12, M16, minimum length equal to 5 times the size
Shovel teeth & spikes.
2. Collection of picked up pieces into tramp Iron chutes/ trolley.
3. Proper discharge of picked up metal pieces into tramp metal chute.
4. Position adjustment.
Flap/Slide Gates
1. Demonstration of remote, local and manual actuation of gates.
2. Check for stroke and operation of limit switches/ torque switches.
Travelling Trippers
1. Check for smooth to & fro travel
2. Operation of brakes and rail clamps at full load.
3. Check against dragging during start up or running (“over speed protection”).
4. Check against blockage of discharge chutes at full load.
5. Check against folding of belt in spaces between horizontal and inclined troughing
idlers at the start of Tripper.
6. Proper functioning of communication system on trippers.
Belt Weighers
1. Demonstration of specified weighing accuracy of + 0.25% between 20% and 120% of
rated capacity
2. Satisfactory operation of flow rate indicator and totaliser etc.
Vibrating feeder
1. Demonstration of capacity adjustment
2. Observation of little tendency of choking/ build-up with cargo.
3. Little transmission of vibration to building structure or floor.
Belt Scrappers
Satisfactory operation of belt scrappers shall be demonstrated as specified.
Scrapping efficiency of belt scrapper shall be minimum 95%.
Noise Levels
Noise level measurement, confirming to specified levels, to be done around the
following equipment’s/ areas:
1. Conveyor Discharge Terminal (including discharge chute, gearbox, coupling &
motor).
2. Discharge chutes on intermediate floors in possible impact zones.
3. Vibrating feeders
4. DE fans
Noise level measurement shall be done around the specified equipment location in
the following manner.
a) The measurement shall be carried out with a calibrated integrating sound
level meter meeting the requirements of IEC-651 or BS-5969 or IS:9779.
b) Sound pressure level shall be measured all around the equipment at a
distance of 1m from the vertical projected plan of the equipment as a whole
(this shall include coupling, gear box, motor etc.) at a height of 1.5 m from
floor level. Microphone positions shall be at horizontal separations of not
more than 1.5m around the equipment.
c) The measurement shall be done with slow or impulse response, as the case
may be on the A-weighting scale. The average of the A-weighted sound
pressure level measurements expressed in decibels to a reference of 0.0002
micro bar shall not exceed the guaranteed value indicated in the
specification.
d) The tests shall be carried out with the equipment’s operating at near rated
speed & load Correction for background noise will be considered In line with
IS:4758. Noise level measurement shall be recorded in the prescribed format
at the time of testing.
In addition to above, Vendor to submit the following Performance test Certificates
confirming to relevant IS Standards
i. Factory Test Certificate of Idlers
ii. Factory Test certificate of Pulleys
iii. Manufacturer test certificate of Conveyor belt.
iv. Manufacturer test certificate of Belt Weigh Scale
v. Manufacturer test certificate of Magnetic Separator
vi. Manufacturer test certificate of Metal Detector
vii. Manufacturer test certificates of Motors, Gear box and Couplings
viii. Manufacturer test certificate of Electric and Manual Hoists.
ix. Test certificate of Dust Extraction system
x. All Electrical panels, cables and CRD
xi. Manufacturer test certificates of all bought out items other than above.
NOTE:
Any one of the equipment under performance or failure to meet the performance criteria
shall be replaced or repaired to the satisfaction of principal. Alternatively max of 100% cost
of the particular part/ Equipment shall be deducted from contractor and replaced by and to
the choice of Principal.
When the capacity of conveyors are below the agreed capacity, the principal have the right
to reject the system or negotiate for the compensation to the amount for the
underperformance if not rectified within the mutually agreed time limits.
No other consequential damage claim of any kind imposed to the contractor except for the
cost of particular underperformance equipment or system.
