20.312_D25_ Rev 01 Site Installation Method Statement

Contract Name/Number- Document No. Revision - 01

SPCC ILO PERU/20.312 D25 Page 1 of 34

METHOD STATEMENT This Method Statement is not to be copied or disclosed to third parties, unless otherwise agreed in writing.

This Method Statement is the property of Schade Lagertechnik GmbH

SOUTHERN PERU COPPER CORPORATION

RANDOM WAGON UNLOADING SYSTEM

SITE INSTALLATION METHOD STATEMENT

REVISION RECORD

Revision

No.

Description Originated Checked Approved

00 First Issue for quotation purposes. DMR

Aug/2013

01

Updated in line with latest drawings.

Issued to SPCC for site planning purposes.

DMR

16Jan2014

JWH

30:Jan:2014

JWH

30:Jan:2014

INTELLECTUAL PROPERTY

The information in this document was prepared using Intellectual

Property owned by Schade Lagertechnik GmbH. This is confidential

proprietary information and remains the exclusive property of

Schade. The document is for use solely in connection with the

performance of Schades Contracts.





EXPLANATORY NOTES - READ BEFORE USE

1. The objects of this Method Statement are

- to specify the Operations necessary to perform works trial assembly, works test, site installation, site commissioning or acceptance tests, as appropriate,

- to specify where procedures are to be approved by Schade before use and where separate record documents are to be generated,

- to state the requirements for witness, inspection and document review by Schade, - to make provision for recording the satisfactory completion of requirements.

2. Listed at appropriate places within this Method Statement are the drawings and documents needed to complete

the work. Where the Issue Level has been left blank the SPCC, installer or Schade Technical Advisor, as

appropriate, is to enter the Issue Level of the drawings and documents provided by Schade.

3. Listed within the main body of the Method Statement are the Operations necessary to complete the work.

SPCC, the installer or Schade Technical Advisor, as appropriate, is to sign off and date in the "Operation

Complete" column each operation as it is completed satisfactorily.

4. The symbol X is used in the column headed "Document required" to denote a requirement for a written

procedure or a specific record. In addition, the Symbol AP is used to denote where Schade approval of a

procedure is required before implementation. SPCC, the installer or Schade Technical Advisor is to record

beneath these symbols the identity of the procedure or record document so produced.

Reference is also to be made in this column to the identity of any Technical Query or Concession, approved by

Schade, which represents a departure from specified requirements.

5. Symbols for Schade verification are shown in the column headed "Verification" according to the following

Code:

A1 - 100% inspection R1 - 100% Document Review W1 - 100% Witness of Operation

A2 - Sample inspection R2 - Sample Document Review W2 - Sample witness of Operation

SPCC or the installer, as appropriate, is to obtain the Schade Technical Advisors counter-signature beneath the

symbol as required and as work proceeds.

An Operation shown as A1 must be signed off before proceeding with the next Operation.

An Operation shown as W1 or W2 is to be performed in the presence of the Schade Technical Advisor.

6. Operations are to be performed in the sequence written unless otherwise agreed by the Schade Technical

Advisor.





CONTENTS

I. INTRODUCTION & GENERAL INSTRUCTIONS ......................................................................................................... 4

II. GENERAL LIST OF DRAWINGS & DOCUMENTS REQUIRED FOR USE WITH THIS METHOD STATEMENT .................. 5

III. METHOD STATEMENT........................................................................................................................................... 7

1. INTRODUCTION .................................................................................................................................................... 8

2. FOUNDATIONS ................................................................................................................................................... 11

3. TIPPLER & RUN-BACK STOP INSTALLATION ........................................................................................................ 13

4. DIMENSIONAL CHECK ......................................................................................................................................... 34

5. FINAL INSPECTION .............................................................................................................................................. 34

6. FINAL DOCUMENT CHECK ................................................................................................................................... 34





I. INTRODUCTION & GENERAL INSTRUCTIONS

This schedule covers the site installation of the Schade Wagon Tippler and Exit Run-Back

Stop as shown on Schade drawing 6003_02_003, General Arrangement of Wagon

Unloading System.

It is mandatory that all items have completed the manufacturing and inspection process.

It is the responsibility of the reader to ensure that all documents used during assembly and

inspections are at the latest issue level.

For a complete set of drawings refer to Schade document, 6000_00_003 - Family Tree of

Assemblies (plus associated parts lists), which is also to be used to reference Schade

drawing numbers.

Where measurement and recordings are required in this schedule they must be completed

and then returned to Schade, as a record document.

If any items (bearings, motors, power packs, cubicles etc.) have been in long term storage,

they must be checked to suppliers requirements.

All personnel working on the site must have the appropriate qualification and work

experience for the trade for which they are employed in accordance with Peruvian

legislation and local employment rules.

The Company employed to carry out the mechanical installation work should have had a

minimum of 5 years experience in erecting equipment of this type or similar.

The Site Manager employed by them should also have a similar period of experience

working on similar plant.

All site personnel should be aware of any Safety Legislation that is appropriate to working

on a Peruvian Site and be inducted on the Site Safety Procedures if appropriate.

The text in this document for the total installation should be read prior to commencement

of the work. The installation method and sequence given in the text is recommended but

not mandatory.





II. GENERAL LIST OF DRAWINGS & DOCUMENTS REQUIRED FOR USE WITH THIS METHOD STATEMENT

If they are not already shown in the right hand column, the Issue Levels of Drawings and

Documents provided are to be entered by the Installation Contractor or Schade Technical

Advisor, as appropriate.

Drawing/Document

Number

Title Rev.

6000_00_003 Family Tree of Assemblies 05

6003_02_003 GA of Wagon Unloading System 00

6035_02_007 Assembly of 14m Pivot Frame Tippler 00

6095_02_002 Assembly of Pivot Frame Tippler Structure 02

6561_02_007 End Ring Structure (Driven) 01

6562_02_007 End Ring Structure (Driven) 01

6565_02_009 Side Beam Structure 02

6186_02_002 Assembly of Tippler Ballast 00

6968_00_001 # Tippler Structure Shop Assembly Survey Drawing 00

20.312_D15 # Tippler Shop Assembly Method Statement 02

#, marked up/signed workshop copies

6130_02_003 Assembly of Tippler Fixed Blocking 00

6104_02_009 Assembly of Tippler Spill Plates and Wear Plates 00

6102_02_006 Assembly of Tippler Clamp 02

6101_02_003 Assembly of Tippler Main Pivot (Non-Locating) 00

6101_02_004 Assembly of Tippler Main Pivot (Locating) 00

6100_02_003 Assembly of Platform 01

6566_02_007 Platform Structure 01

6198_02_002 Assembly of Platform Walkways 00

6115_02_003 Assembly of Platform Support 00

6103_02_006 Assembly of Tippler Drives (Left Hand) 02

6103_02_007 Assembly of Tippler Drives (Right Hand) 02

6723_02_001 Thrust Pad 00

6105_02_003 Assembly of Tippler Cable Loop 00

6106_02_003 Assembly of Tippler Limit Switches 00

6107_02_003 Assembly of Tippler Clearance Sensors 00





6133_02_001 Assembly of Stockpile Sensors 00

6108_02_003 Assembly of Grout and Packing 00

6058_02_004 Assembly of Exit Run-Back Stop (Manual) 01

6460_00_009 Wagon Unloading System Foundation Details and Loadings 02

6974_00_001 Transport Drawing (LH End Ring) 00

6974_00_002 Transport Drawing (RH End Ring) 00

6974_00_003 Transport Drawing (Side Beam) 00

6974_00_004 Transport Drawing (Platform) 00

6974_00_005 Transport Drawing (Clamp) 00

6974_00_006 Transport Drawing (Drive Assembly LH) 00

6974_00_007 Transport Drawing (Drive Assembly RH) 00

6974_00_008 Transport Drawing (Support Roller LH) 00

6974_00_009 Transport Drawing (Support Roller RH) 00

6400_00_002 Assembly of Tippler Hydraulics 02

plus Bosch Rexroth Hagglunds drawings (see Family Tree) and

instructions

6410_00_002 Assembly of Tippler and Run-Back Stop Lubrication 01

plus Bijur Delimon drawings (see Family Tree) and instructions

6340_00_002 Assembly of Tippler and Run-Back Stop Electrics 02

plus Iconsys drawings (see Family Tree) and instructions

20.312_D26 Electrical Site Installation Method Statement 00

6495_00_001 Assembly of Dust Suppression System 00

plus Nalco Enviroflo drawings (see Family Tree) and instructions

20.312_D04 Manufacturing Specification 04

6975_00_001 Tippler Erection Sequence Diagram 00

Schade Packing List





III. METHOD STATEMENT

Ref. Description of Operation

Operation

Complete (sign and date)

SPCC/Installer

Document

Required (enter identity

where marked)

Verification (sign and date

where indicated)

SPCC/

Installer

Schade

Technical

Advisor






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

1. INTRODUCTION

1.1 All components must be checked against the

Schade packing list.

1.2 All components are to be checked for any damage caused by handling during transit.

Repair of any major steelwork damage is to

be referred to Schade design office.

Where appropriate, ensure all rotating or sliding

contact surfaces are liberally greased during

assembly.

1.3 All site work must conform to Schade

document 20.312_D04, Manufacturing

Specification.

All bolted joints are critical and their assembly

must comply with section 5 of 20.312_D04.

Refer also to Schade drawings for any specific

joints requirements.

All torque wrenches must be calibrated

immediately before use on this project.

Check the condition, size and grade of all bolts,

nuts and washers with drawing requirements

before installation.

1.4 Any damaged paint work is to be repaired in accordance with paint suppliers instructions.

The final paint coat is to be applied during

erection at appropriate stages determined by the

erection contractor in accordance with the paint

suppliers instructions.

1.5 Check that all bearings and bushes are primed

with lubricant.

During workshop assembly, temporary grease

nipples have been installed to lubricate bearings

and bushes. These are to be removed when the

Schade

packing list

Calibration

certificates

A1

A1

A1

A1

A1

when

they are

installed

A1

A1

A1

A2

A2

R1

A2

A2

W2

A1 Main

Pivots






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

centralised lubrication system is installed.

1.6 Prior to the installation of any hydraulic equipment, ensure that all components are

delivered & in their correct/un damaged

condition in accordance with the Bosch

Rexroth Hagglunds requirements, i.e. pipes

have been pickled, cleaned and ends are

capped.

1.7 Prior to the installation of any lubrication equipment, ensure that all components are

delivered & in their correct/un damaged

condition in accordance with the Bijur

Delimon requirements.

1.8 Prior to the installation of any dust

suppression equipment, ensure that all

components are delivered & in their

correct/un damaged condition in accordance

with the Nalco Enviroflo requirements.

1.9 During site installation, welding to main

structures is not allowed unless shown on a

Schade drawing and approved in writing

by Schade design office.

1.10 Any deviations to the tolerance requirements

of this method statement and Schade

drawings are to be recorded and reported to

Schade design office before proceeding.

1.11 The Tippler structure has been workshop

assembled and dimensionally inspected in

accordance with Schade drawing and

document:-

6968_00_001, Tippler Structure Shop Assembly

Survey Drawing.

20.312_D15, Tippler Shop Assembly Method

Statement

All site erection work must use the marked

up/signed workshop copies.

Schade

packing list.

Suppliers

documents

Schade

packing list.

Suppliers

documents

Schade

packing list.

Suppliers

documents

X

Marked up

drawings &

documents

Workshop

copy

Workshop

copy

A1

A1

A1

A1

R1

R1

A2

A2

A2

A1

R1

R1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

The Tippler structure has been part dismantled as

shown on the following Schade drawings:-

6974_00_001, Transport Drawing (LH End Ring)

6974_00_002, Transport Drawing (RH End Ring)

6974_00_003, Transport Drawing (Side Beam)

6974_00_004, Transport Drawing (Platform)

Prior to dismantling the Tippler structure in

the workshop, all joints have been match

marked and recorded. This match marking

must be worked to for site erection. See also

workshop photographs.

1.12 In addition to the Tippler structure, the following Schade drawings show other

workshop assemblies that have not been part

dismantled:-

6974_00_005, Transport Drawing (Clamp)

6974_00_006, Transport Drawing (Drive Assy

LH)

6974_00_007, Transport Drawing (Drive Assy

RH)

6974_00_008, Transport Drawing (Support

Roller LH)


Roller RH)

1.13 The Tippler Fixed Blocking (6130_02_003) and Spill & Wear Plates (6104_02_009) have

both been shop assembled to the Side Beam,

match marked and then fully dismantled for

transport.

1.14 Main structures do not include lifting points as the available cranage is not known to

Schade. It is the responsibility of the site

erection contractor to correctly handle the

Workshop

records

Workshop

records

R1

R1

R2

R2






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

structures taking into account the mass &

centre of gravity position. If in doubt, send

lifting proposals with sketches for Schade

design office review.

2. FOUNDATIONS

2.1 Ensure that all foundation levels and details correspond to the requirements shown on

Schade drawing:-

6460_00_009, Wagon Unloading System

Foundation Details and Loadings.

Note the civil contractor made an error with

the casting of the Tippler Main Pivot pillars

(see section D-D on above drawing) which was

accepted by Schade. Refer to SPCC records

for this error.

2.2 A complete check is to be made of all levels, dimensions and requirements shown on the

Schade drawing to ensure compliance. Any

variations are to be recorded & reported to

Schade design office before proceeding.

2.3 Foundation levels and surface conditions are critical at the following points:-

Tippler Main Pivots (x2) and Drives (x2), see

section D-D on above drawing.

Platform Supports (x2), see section E-E on above

drawing.

2.4 Check that all cast in studs are dimensionally as required and allow side movement as

shown on the above drawing. See sections K-

K, J-J and H-H.

Check that these stud groups are positioned to

within the tolerance requirements of drawing

dimensions and note 3.

2.5 At least 3x permanent datum plates are to be cast in as shown on the above drawing. Mark

all relevant centre-lines and elevation levels

Mark up copy

of drawing

6460_00_009

A1

A1

A1

A1

A2

R1

A1

A1

A1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

on the foundation datum plates. Additional

datum plates are to be fitted, if required to aid

installation.

Using these datum plates, determine the

following:-

Centreline of main railway track.

Centreline of Tippler (perpendicular to main track).

Centreline of both End Rings.

Top of concrete (TOC) level +5.321

2.6 Terminology used in this document (see Schade drawings 6460_00_009 &

6975_00_001) is:-

Non tip side of Tippler is towards building columns K12 to K17 (parallel with main

track on side of Tippler where trackside

operators work).

Tip side of Tippler is towards building columns J12 to J17 (parallel with main track

on side of Tippler where payload is

discharged).

Left hand end (LH) of Tippler is towards building columns K17 & J17 (full wagon

entry end).

Right hand end (RH) of Tippler is towards building columns K12 & J12 (empty wagon

exit end).

2.7 Where jacking screws are called for on Schade drawings to support/level components

on the foundations, an 80 x 80 x 6mm thick

plate is to be positioned centrally below them

to spread the load onto the concrete per

Schade drawing 6108_02_003.

2.8 Where grouting is shown on Schade drawing 6108_02_003, this is to be supplied by the

installation contractor.

The grout must be of suitable strength to

Grout

suppliers

instructions

A1

A1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

withstand the applied loads as given on Schade

drawing 6460_00_009, Wagon Unloading System

Foundation Details and Loadings.

3. TIPPLER & RUN-BACK STOP INSTALLATION

The Tippler erection is to be carried out in the

sequence detailed below (unless otherwise agreed

with the Schade Technical Advisor) and as shown

on Schade drawing:-

6975_00_001, Tippler Erection Sequence

Diagram.

3.1 Initial positioning of Tippler Drives and Platform Supports

Refer to the following Schade drawings:-


Diagram (step 1)

6103_02_006, Assembly of Tippler Drives (LH)

6103_02_007, Assembly of Tippler Drives (RH)

6115_02_003, Assembly of Platform Support

6974_00_006, Transport Drawing (Drive LH)

6974_00_007, Transport Drawing (Drive RH)

6688_02_001, Drive Plinth

6108_02_003, Assembly of Grout and Packing

3.1.1 Install 6688_02_001 Drive Plinths (6103_02_006 and 6103_02_007 item 1) with jacking screws

onto M30 foundation studs.

Align Plinths to the following dimensions:-

Top faces horizontal in both planes to within 1mm.

X

Record all

dimensions

R1

A1

R1

W1

W1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

Top faces level with each other to within 1mm.

Top faces 2520mm below TOC. Note this is 40mm nominal below final

level.

Longitudinal (2220mm) centre line 68772mm from centre line of Tippler.

Front face (1000mm) of top flange 1120 2mm tip side of centreline of main track.

Install packers between concrete and underside of

Drive Plinths to Schade drawing 6108_02_003.

Hand tighten M30 nuts/washers on foundation

studs.

3.1.2 Install RH workshop sub assembled drives (6974_00_007 & 6103_02_007) onto plinth and

assemble bolted joint to 20.312_D04.

3.1.3 Install LH workshop sub assembled drives

(6974_00_006 & 6103_02_006) onto plinth and

assemble bolted joint to 20.312_D04.

3.1.4 Check that all 4 pinions are free to rotate.

Note - the brakes are supplied with screws

installed which hold the brakes in the released

position and allow the motor & brake assembly to

be rotated. These screws are not to be removed

until the hydraulics are installed and

commissioned.

Tippler structure rotation is to be restrained

by chain blocks, chocks and/or tirfors etc., not

the drive brakes.

3.1.5 Sub assemble 6115_02_003 Platform Supports

(x2) to drawing.

3.1.6 Install Platform Supports with jacking screws and washers (item 6) onto M30 foundation studs.

Align Platform Supports to the following

dimensions:-

X

Drawing

X

All

dimensions

A1

A1

A1

W1

W1

W1

W1

W1

W1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

Top faces horizontal in both planes to within 1mm.


Top faces of support beams (item 1) 1270 1mm below TOC.

Longitudinal (1970mm) centre line 5500 2mm from centre line of Tippler.

Centreline of lower locating block (item 2) 755 1mm non tip side of centreline of main

track.


Platform Supports per Schade drawing

6108_02_003.


studs.

Do not weld washers (item 6) at this stage.

3.1.7 Check installation of both Drives and both Platform Supports, and record all dimensions.

3.2 Main Pivot Stools



Diagram (step 2)

6101_02_003, Assembly of Tippler Main Pivot

(Non-Locating)


(Locating)

6685_02_002, Pivot Stool


Survey Drawing



A1

A1

A1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

The installation of the Pivot Stools and Main

Pivot Bearings is crucial to the Tippler

operation.

3.2.1 Install 6685_02_002 Pivot Stools (6101_02_003 and 6101_02_004 item 1) with jacking screws

onto M30 foundation studs.

Align Pivot Stools to the following dimensions:-

Top faces horizontal in both planes to within 0.5mm.


Top faces 2700 2mm above TOC.

Longitudinal (1370mm) centre line of LH stool 7910 2mm from centre line of Tippler.

Longitudinal (1370mm) centre line of RH stool to longitudinal centre line of LH stool

per workshop drawing 6968_00_001

dimension recorded bearing housing

centres.

Transverse (450mm) centre lines 2450 2mm non tip side of centre line of main track.

Transverse centre lines within 1mm of each other.


Pivot Stools per Schade drawing 6108_02_003.


studs.

3.2.2 Check installation of both Pivot Stools and record all dimensions.

3.3 Left Hand End Ring Assembly



Diagram (step 3)


(Non-Locating)

X

All

dimensions

A1

A1

A1

W1

W1

A1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

6974_00_001, Transport Drawing (LH End Ring)

6748_02_001, Tippler Pivot Transport Bracket.

3.3.1 Position the LH End Ring sub assembly (6974_00_001) onto its Pivot Stool with the End

Ring centre line in the vertical plane.

Notes-

At some stage during this operation, the Transport Bracket (6748_02_001) will need

to be removed. Care must be taken to ensure

that the bearing seals are not damaged. Install

temporary restraints if required.

A check must be made on the rack to drive pinions meshing.

See clause 3.8.2 re final positional accuracy.

TOC down to bottom of End Ring toe slot is 578 2mm.

Secure in position with supports and guy ropes.

3.3.2 Assemble housing to stool joint and hand tighten.

3.4 Right Hand End Ring Assembly



Diagram (step 4)


(Locating)

6974_00_002, Transport Drawing (RH End Ring)

6748_02_001, Tippler Pivot Transport Bracket.

3.4.1 Position the RH End Ring sub assembly (6974_00_002) onto its Pivot Stool with the End

Ring centre line in the vertical plane.

Notes-

At some stage during this operation, the Transport Bracket (6748_02_001) will need

X

Procedure

X

Dimension

X

Procedure

A1

A1

A1

R1

W1

A1

A2

A1

R1

W1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

to be removed. Care must be taken to ensure

that the bearing seals are not damaged. Install

temporary restraints if required.

A check must be made on the rack to drive pinions meshing.

See clause 3.8.2 re final positional accuracy.

TOC down to bottom of End Ring toe slot is 578 2mm.

Secure in position with supports and guy ropes.

3.4.2 Assemble housing to stool joint and hand tighten.

3.4.3 Check alignment and dimensions between End Rings (12400mm nominal).

Check the condition of all internal and external

plate surfaces (where splice plates will locate) on

both LH and RH End Rings are to Schade

document 20.312_D04.

3.4.4 With reference to Schade drawing 6968_00_001, check that the workshop recorded end ring

centres have been achieved.

3.5 Side Beam



Diagram (step 5)

6565_02_009, Side Beam Structure

6974_00_003, Transport Drawing (Side Beam)

3.5.1 Remove the Splice Plates and review the overall Side Beam length against the End Ring inside

dimensions recorded above.

Check the condition of all internal and external

plate surfaces (where splice plates will locate) are

to Schade document 20.312_D04.

Check the condition of the splice plate surfaces to

Schade document 20.312_D04.

X

Dimension

X

Dimension

A1

A1

A1

A1

A1

A1

A1

A1

A1

A1

A2

A1

A1

A1

R1

R1

A1

A1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

3.5.2 Review workshop match marking for both joints.

Workshop match marking must be adhered to

for site assembly.

Position internal Splice Plates inside Side Beam

and secure.

3.5.3 Lift the Side Beam and position between the End Rings obtaining equal gaps (4mm max.) at both

ends. Use temporary supports as required.

3.5.4 Before making the bolted joints and with reference to Schade drawing 6968_00_001, re

check that the workshop recorded end ring

centres have been achieved.

3.6 Side Beam to End Ring Bolted Joints



Diagram (step 6)

6095_02_002, Assembly of Pivot Frame Tippler

Structure


Survey Drawing

The correct installation of these joints is

crucial to the correct operation of the Tippler.

100% contact must be achieved between all

splice plates and the structure.

3.6.1 Assemble and complete both joints in total accordance with Schade document 20.312_D04

and Schade drawing 6095_02_002.

3.7 Tippler Structure Check



Survey Drawing

Workshop

records

X

Procedure

X

Dimension

R1

A1

A1

A1

R1

R1

A1

R1

W1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor


Structure.

3.7.1 Check that Tippler structure is in total accordance with all Schade drawing and document

requirements.

Any deviations are to be reported to Schade

design office before proceeding.

3.8 Completion of Main Pivots



(Non-Locating)


(Locating)

3.8.1 Complete the assembly of the housing to stool joints.

Torque M42 bolts to SKF installation

instructions.

Do not grout pivot stools at this stage.

3.8.2 Check and record the following dimensions:-

Bearing housing centres

(158203mm)

Centre line main track to centre line LH

pivot shaft (24502mm) #1

Centre line main track to centre line RH

pivot shaft (24502mm) #1

TOC to centre line LH pivot shaft

(31102mm) #2

TOC to centre line RH pivot shaft

(31102mm) #2

Centre line LH pivot shaft to bottom of

End Ring toe slot (3687mm) #3

Centre line RH pivot shaft to bottom of

End Ring toe slot (3687mm) #3

Notes-

Schade

drawings and

workshop

records.

SKF

installation

instructions

A1

A1

A1

A2

R1

W1

A1






Operation


SPCC/Installer

Document


where marked)


where indicated)

SPCC/

Installer

Schade

Technical

Advisor

#1, and within 1mm of each other.

#2, and within 1mm of each other.

#3, and within 4mm of each other. i.e. max. 4mm twist in structure.

3.8.3 If all dimensions are correct, grout both Main

Pivots and torque nuts on foundation studs and

weld shear blocks per drawing requirements.

3.9 Clamps



Diagram (step 7)

6102_02_006, Assembly of Tippler Clamp

6974_00_005, Transport Drawing (Clamp)

3.9.1 With reference to Schade drawing 6102_02_006

section A-A, remove the Pivot Pin (Clamp Arm)

item 6 from each Clamp assembly.

Remove also the transport lifting beam

(assembled in place of the hydraulic cylinder).

3.9.2 Check that the underside of the Clamp Brackets

and mating surfaces on the Side Beam comply

with Schade document 20.312_D04 for these

bolted joints.

3.9.3 In accordance with the workshop match marking,

position the Clamp Brackets (6102_02_006 item

4) in their correct positions and assemble the

Bracket to Side Beam bolted joints in accordance

with Schade drawing 6035_02_007 and document

20.312_D04.

The correct installation of these joints is

crucial to the correct operation of the Tippler.

100% contact must be achieved at all Clamp

Brackets.

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3.9.4 Install Wear Plates (6102_02_006 items 17 to 45 inclusive), re install Pivot Pins and re install

transport lifting beams.

3.10 Fixed Blocking



Diagram (step 8)

6130_02_003, Assembly of Tippler Fixed

Blocking

3.10.1 Apply top coat of paint to all external surfaces of the Side Beam prior to fitting the Fixed

Blocking and Spill & Wear Plates.

3.10.2 In accordance with the workshop match

marking, assembly the Fixed Blocking to Side

Beam in accordance with Schade drawing

6130_02_003 and document 20.312_D04.

3.10.3 Assemble Rubber Liner (6130_02_003 item 7)

to wooden blocking in accordance with drawing

instructions.

3.11 Spill and Wear Plates



Diagram (step 9)

6104_02_009, Assembly of Tippler Spill Plates

and Wear Plates

3.11.1 In accordance with the workshop match marking, assemble the Spill Plates and Wear

Plates to Side Beam in accordance with Schade

drawing 6104_02_009 and document

20.312_D04.

3.12 Tippler out of Balance

At this stage of erection, the total mass of the

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rotating structure is 70.2 tonnes approx.

The centre of gravity position is 600mm approx.

towards the tip side, which means that the

structure would rotate anti-clockwise (when

viewed from the full wagon entry end) if not

restrained.

The angle of rotation to the balance point is 53

approx. anti-clockwise.

Under controlled conditions, rotate the Tippler to

the balance point and secure at this angle.

3.13 Alignment of Tippler Drives


6103_02_006, Assembly of Tippler Drives (LH)


3.13.1 Using the jacking screws, raise each drive to obtain the correct rack/pinion gear meshing.

Set this initially at 15mm (root gap) from pinion

outside diameter (528mm) to rack root diameter

(R5070mm). This equates to theoretical gear

centres of 5349mm.

Hand tighten Drive Plinths M30 foundation studs

and adjust packers between concrete and

underside of Drive Plinths as required.

3.13.2 Under controlled conditions, rotate the Tippler

back to the 0 angle to obtain TOC to bottom of

End Ring toe slot of 578mm.

Check meshing of pinion teeth in racks.

Do not install Base to Bracket fitted bolts at this

stage.

3.14 Platform Sub-Assembly


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6100_02_003, Assembly of Platform

6198_02_002, Assembly of Platform Walkways

6974_00_004, Transport Drawing (Platform)


Roller LH)


Roller RH)

6607_01_008, 115 lb AREMA Rail

6625_02_007, Gantrail 9 Series Rail Clip

(the weldable bases of the clips have been welded

in position during workshop assembly)

3.14.1 On levelled temporary supports adjacent to the Tippler, position the Platform Structure

(6100_02_003 item 1). Scribe lines on the top

surface for the longitudinal centre line, transverse

centre line and end ring centres (14000 3mm).

Note, the longitudinal centre line will be in line

with the main track centre line.

3.14.2 Assemble the LH and RH Support Roller

assemblies (6974_02_008 and 6974_02_009) and

the Upper Locating Blocks (6100_02_003 item

18) to the Platform Structure in accordance with

Schade drawing 6100_02_003 and document

20.312_D04.

Record the following dimensions:-

Support Roller longitudinal

centres (11000 3mm)

Structure top face to underside

of roller RH (1225mm)


of roller LH (1225mm)

Locating Block longitudinal

centres (11000 3mm)

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of locating block RH

(1070mm)


of locating block LH

(1070mm)

RH locating block to RH roller

(1510mm)

LH locating block to LH roller

(1510mm)

Structure centre line to locating

block centre RH (755mm)

Structure centre line to locating

block centre LH (755mm)

3.14.3 Produce rails to Schade drawing 6607_01_008

using Gantrail welding instructions and hardware.

3.14.4 Position Rails onto Platform Structure at 1435

2mm gauge equally spaced about the

longitudinal centre line.

3.14.5 Fasten rail ends and install clips to Schade

drawing 6100_02_003 (section E-E and F-F) and

Gantrail instructions.

3.14.6 The Platform Walkways are to be assembled in

accordance with Schade drawings 6100_02_003

& 6198_02_002, and document 20.312_D04.

Note - the platform walkways can be

assembled at any stage. To allow access into

the foundation pit area (to adjust drives and

supports or set up limit switches etc.) it will

be better to assemble the walkways at a later

stage.

3.14.7 Install the Wheel Locating Brackets

(6100_02_003 items 19) and Angles

(6100_02_003 items 20 & 21) to Schade drawing

6100_02_003 and document 20.312_D04.

3.15 Alignment of Platform Supports


Gantrail

WPS

Gantrail

instructions

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3.15.1 Using the dimensions recorded in 3.14 above; adjust the height of the Platform Supports

(6115_02_003) such that the top face of the

Platform will be at TOC level when installed.

Hand tighten Platform Support M30 foundation

studs and adjust packers as required.

3.15.2 Using the dimensions recorded in 3.14 above; adjust the Platform Supports (6115_02_003) such

that the Platform longitudinal centre line will

align with the main track centre line when

installed.

3.15.3 Using the dimensions recorded in 3.14 above; adjust the Platform Supports (6115_02_003) such

that the Platform transverse centre line will align

with the Tippler centre line when installed.

Note further/final adjustment will be carried out

at a later stage to correctly align the platform rails

with the land rails.

3.16 Platform Refer to the following Schade drawings:-


Diagram (step 10)

6100_02_003, Assembly of Platform

6035_02_007, Assembly Of 14m Pivot Frame

Tippler



Structure


section D-D, position Pivot Rollers (item 6,

6712_01_001) into the End Ring toe slot. Locate

at bottom of slot and centrally across the width.

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3.16.2 Lift the Platform sub-assembly off its temporary supports and onto the Platform Supports

6115_02_003.

3.16.3 Build Pivot Roller assemblies at both ends to

Schade drawing 6100_02_003 section D-D and

lubricate Bushes via the temporary grease

nipples.

Note Safety Hooks (6100_02_003 items 12

and13) are handed.

3.16.4 Check at both End Rings that the Pivot Rollers

are central within the 150mm thick End Ring toes

per Schade drawing 6035_02_007 section Y-Y.

Adjust the position of the Platform Supports

(6115_02_007) if necessary to achieve this.

3.16.5 With reference to Schade drawing

6095_02_002, replace Packers (item 10) with

wooden blocks that will limit Platform rotation to

110mm.

On completion of this section re install Packers.

3.16.6 Under controlled conditions, release the Tippler

restraints to allow the Tippler structure to rotate

in the anti-clockwise direction (viewed from the

full wagon entry end) until one of the End Ring

slots just contacts the Pivot Roller. Adjust the

height of the Platform at the other End Ring so

that both Pivot Rollers are contacted at the same

angle of Tippler rotation.

Repeat to confirm that both Pivot Rollers are

contacted and picked up at the same angle.

3.16.7 Under controlled conditions, release the Tippler

restraints to allow the Tippler structure to rotate

in the anti-clockwise direction (viewed from the

full wagon entry end) and pick up the Platform.

Continue rotation until both Support Rollers

(6100_02_003 item 6) are just clear of the Roller

Support Ramps (6115_02_003 item 3).

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3.16.8 Under controlled conditions, rotate the Tippler

in the opposite direction until the Upper Locating

Blocks (6100_02_003 item 18) are almost in

contact with the Lower Locating Blocks

(6115_02_003 item 2).

Adjust the positions/heights of the Lower

Locating Blocks to ensure a smooth engagement

as the Upper Locating Blocks lower.

3.16.9 Return the Tippler to its start position and

restrain against further rotation.

Notes-

The above setting up work can be carried out after completion of the electrical and

hydraulic installations.

The Upper and Lower Locating Blocks are to be set in a position dictated by the pick up

angle of the Pivot Rollers (6100_02_003 item

11) in the End Ring toe slots. The principle is

that the Upper Locating Blocks will

automatically determine the correct location

of the Lower Locating Blocks, i.e. where the

Tippler geometry needs them to be.

3.16.10 Fully tighten Platform Support M30 foundation

studs and grout in position.

Weld Washers (6115_02_003 item 6) per

drawing requirements.

3.17 Thrust Pads Refer to the following Schade drawings:-


Diagram (step 11)

6003_02_003, General Arrangement of Wagon

Unloading System

6723_02_001, Thrust Pad


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section L-L, position Thrust Pads with a 10mm

gap at each end of the Platform.

Cast in position with full strength concrete

ensuring that the 10mm gap is maintained.

3.18 Tippler Ballast



Diagram (step 12)

6186_02_002, Assembly of Tippler Ballast

3.18.1 End Ring fixing holes for the Ballast Plates have

been drilled during workshop assembly and

match marked.

Using the workshop match marking, install the

Tippler Ballast to Schade drawing 6186_02_002.

3.19 Cable Loop


6105_02_003, Assembly of Tippler Cable Loop

6003_02_003, General Arrangement of Wagon

Unloading System

3.19.1 Install Cable Loop components to above

drawings.

3.20 Tippler Limit Switches Refer to the following Schade drawing:-

6106_02_003, Assembly of Tippler Limit

Switches

3.20.1 Install Limit Switch components to above

drawing.

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3.21 Tippler Encoders

Refer to the following Schade drawing:-


3.21.1 Install Encoder components to above drawing.

3.22 Tippler Clearance Sensors


6107_02_003, Assembly of Tippler Clearance

Sensors

3.22.1 Install Clearance sensor components to above

drawing.

3.23 Stockpile Sensors


6133_02_001, Assembly of Stockpile Sensors

3.23.1 Install Stockpile sensor components to above drawing.

3.24 Tippler Hydraulics


6400_00_002, Assembly of Tippler Hydraulics

Read this drawing in conjunction with the Bosch

Rexroth Hagglunds drawings and installation

instructions.

3.24.1 Install Tippler Hydraulics in accordance with the

Bosch Rexroth Hagglunds drawings and

installation instructions.

Note- at a given stage within this installation, the

drive brake release screws are to be removed and

the brakes applied.

3.24.2 Review and verify the installation.

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3.25 Dust Suppression System


6495_00_001, Assembly of Dust Suppression

System

Read this drawing in conjunction with the Nalco

Enviroflo drawings and installation instructions.

3.25.1 Install Dust Suppression System in accordance

with the Nalco Enviroflo drawings and

installation instructions.

3.25.2 Review and verify the installation

3.26 Exit Run-Back Stop


6058_02_004, Assembly of Exit Run-Back Stop

(Manual)

6460_00_009, Wagon Unloading System

Foundation Details and Loadings

3.26.1 Workshop assembly of the Run-Back Stop has

been carried out, followed by some disassembly.

To install the Run-Back Stop in its foundation pit

below the main track rails, some further

disassembly may be required.

All components must be match marked prior to

this site disassembly.

3.26.2 Align the exit and entry main track rails with the

Tippler Platform rails and check that rail gauge is

maintained.

Check that there is a max. platform to land rail

gap of 10mm.

Check that there is no vertical or side step at the

platform to land rail gaps.

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3.26.3 Install Run-Back Stop to Schade drawing

6058_02_004.

Check the following:-

Stop (item 4) is 69mm min. above the top of both rails.

Stop can be pushed down by hand (without lever moving), representing a

wagon rolling over it.

Stop lowers when the handle is raised.

Foundation bolts (6058_02_004 item 36) are fully tightened.

3.26.4 After installation of the Run-Back Stop, re

check its operation and the platform to rail

alignment.

Do not install full strength concrete until the

Wagon Unloading System has been fully

commissioned.

3.27 Tippler & Run-Back Stop Lubrication


6410_00_002, Assembly of Tippler and Run-

Back Stop Lubrication

Read this drawing in conjunction with the Bijur

Delimon drawings and installation instructions.

3.27.1 Install Lubrication System in accordance with

the Bijur Delimon drawings and installation

instructions.

Guards may need to be manufactured (determined

during installation) to protect exposed pipes etc.


3.28 Tippler and Run-Back Stop Electrics

Refer to the following Schade drawing and

document:-

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6340_00_002, Assembly of Tippler and Run-

Back Stop Electrics

Read this drawing in conjunction with the Iconsys

drawings and installation instructions.

20.312_D26, Electrical Installation Method

Statement

3.28.1 Install Electrics in accordance with the above

drawings and document.


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4. DIMENSIONAL CHECK

In conjunction with Schade Technical Advisor,

carry out checks and record important

dimensions.

The selection of these dimensions is to be agreed

with the Schade Technical Advisor and used for

future checks of structures and mechanicals.

5. FINAL INSPECTION

Final inspection to confirm that the equipment,

including paintwork, is in its correct state and all

extraneous materials have been removed.

6. FINAL DOCUMENT CHECK

Final document check to verify that all specified

operations have been completed with the correct

results, all supporting records are available and

any reported non-conformities have been

resolved.

Record on

drawings

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