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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.
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 2 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
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.
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 3 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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 4 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
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.
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 5 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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 6 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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 7 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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 8 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
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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 9 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
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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 10 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
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
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)
6974_00_009, Transport Drawing (Support
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 11 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
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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 12 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
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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 13 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
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
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:-
6975_00_001, Tippler Erection Sequence
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 14 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
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
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
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 15 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
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
Top faces horizontal in both planes to within 1mm.
Top faces level with each other 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.
Install packers between concrete and underside of
Platform Supports per Schade drawing
6108_02_003.
Hand tighten M30 nuts/washers on foundation
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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
Diagram (step 2)
6101_02_003, Assembly of Tippler Main Pivot
(Non-Locating)
6101_02_004, Assembly of Tippler Main Pivot
(Locating)
6685_02_002, Pivot Stool
6968_00_001, Tippler Structure Shop Assembly
Survey Drawing
6108_02_003, Assembly of Grout and Packing
6108_02_003, Assembly of Grout and Packing
A1
A1
A1
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 16 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
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
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 level with each other to within 1mm.
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.
Install packers between concrete and underside of
Pivot Stools per Schade drawing 6108_02_003.
Hand tighten M30 nuts/washers on foundation
studs.
3.2.2 Check installation of both Pivot Stools and record all dimensions.
3.3 Left Hand End Ring Assembly
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
Diagram (step 3)
6101_02_003, Assembly of Tippler Main Pivot
(Non-Locating)
X
All
dimensions
A1
A1
A1
W1
W1
A1
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 17 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
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
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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
Diagram (step 4)
6101_02_004, Assembly of Tippler Main Pivot
(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
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SPCC ILO PERU/20.312 D25 Page 18 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
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
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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
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
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SPCC ILO PERU/20.312 D25 Page 19 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
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
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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
Diagram (step 6)
6095_02_002, Assembly of Pivot Frame Tippler
Structure
6968_00_001, Tippler Structure Shop Assembly
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
Refer to the following Schade drawings:-
6968_00_001, Tippler Structure Shop Assembly
Survey Drawing
Workshop
records
X
Procedure
X
Dimension
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SPCC ILO PERU/20.312 D25 Page 20 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
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
6095_02_002, Assembly of Pivot Frame Tippler
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
Refer to the following Schade drawings:-
6101_02_003, Assembly of Tippler Main Pivot
(Non-Locating)
6101_02_004, Assembly of Tippler Main Pivot
(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
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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
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
#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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
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.
Workshop
records
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SPCC ILO PERU/20.312 D25 Page 22 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
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
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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
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
Workshop
records
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records
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SPCC ILO PERU/20.312 D25 Page 23 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
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
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
Refer to the following Schade drawings:-
6103_02_006, Assembly of Tippler Drives (LH)
6103_02_007, Assembly of Tippler Drives (RH)
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
Refer to the following Schade drawings:-
X
Procedure
X
Procedure
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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
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
6100_02_003, Assembly of Platform
6198_02_002, Assembly of Platform Walkways
6974_00_004, Transport Drawing (Platform)
6974_00_008, Transport Drawing (Support
Roller LH)
6974_00_009, Transport Drawing (Support
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)
Structure top face to underside
of roller LH (1225mm)
Locating Block longitudinal
centres (11000 3mm)
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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
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
Structure top face to underside
of locating block RH
(1070mm)
Structure top face to underside
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
Refer to the following Schade drawings:-
Gantrail
WPS
Gantrail
instructions
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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
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
6115_02_003, Assembly of Platform Support
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:-
6975_00_001, Tippler Erection Sequence
Diagram (step 10)
6100_02_003, Assembly of Platform
6035_02_007, Assembly Of 14m Pivot Frame
Tippler
6115_02_003, Assembly of Platform Support
6095_02_002, Assembly of Pivot Frame Tippler
Structure
3.16.1 With reference to Schade drawing 6100_02_003
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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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
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
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).
X
Procedure
X
Procedure
X
Procedure
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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
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
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:-
6975_00_001, Tippler Erection Sequence
Diagram (step 11)
6003_02_003, General Arrangement of Wagon
Unloading System
6723_02_001, Thrust Pad
3.17.1 With reference to Schade drawing 6003_02_003
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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
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
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
Refer to the following Schade drawings:-
6975_00_001, Tippler Erection Sequence
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
Refer to the following Schade drawings:-
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.
Workshop
records
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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
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
3.21 Tippler Encoders
Refer to the following Schade drawing:-
6103_02_007, Assembly of Tippler Drives (RH)
3.21.1 Install Encoder components to above drawing.
3.22 Tippler Clearance Sensors
Refer to the following Schade drawing:-
6107_02_003, Assembly of Tippler Clearance
Sensors
3.22.1 Install Clearance sensor components to above
drawing.
3.23 Stockpile Sensors
Refer to the following Schade drawing:-
6133_02_001, Assembly of Stockpile Sensors
3.23.1 Install Stockpile sensor components to above drawing.
3.24 Tippler Hydraulics
Refer to the following Schade drawing:-
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.
X
Supplier
documents
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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
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
3.25 Dust Suppression System
Refer to the following Schade drawing:-
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
Refer to the following Schade drawings:-
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.
X
Supplier
documents
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Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 32 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
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
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
Refer to the following Schade drawing:-
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.
3.27.2 Review and verify the installation.
3.28 Tippler and Run-Back Stop Electrics
Refer to the following Schade drawing and
document:-
X
Suppliers
documents
A1
A1
R1
A1
A1
A1
A1
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 33 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
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
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.
3.28.2 Review and verify the installation.
X
Suppliers
documents
R1
A1
A1
Contract Name/Number- Document No. Revision - 01
SPCC ILO PERU/20.312 D25 Page 34 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
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
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
X
Collate all
records
A2
A1
R1
A2
A2
R2