24972-200-3PS-MFCG-00002Rev0

8/12/2019 24972-200-3PS-MFCG-00002Rev0

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TECHNICAL SPECIFICATION

24972-200-3PS- MFCG-00002

FOR

GYRATORY CRUSHER

ECCENTRIC REMOVAL CARRIAGE

Southern Peru Copper Corporation

LEACHING DUMPS PROJECT - TOQUEPALA

0 Issued for Purchase

B 25-Jul-03 Issued for Bid FG JA FG AN

A 15-Jul-03 Issued for Coordination and Approval FG JA FG ANREV DATE REASON FOR REVISION BY CHECK EGS PE CLIENT

Bechtel - ARACONSORCIO DE INGENIERIA SX LTDA.

JOB NO. 24972

TECHNICAL SPECIFICATION

24972-200-3PS- MFCG-00002

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REV.

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Tech.Specification for Gyratory Crusher Eccentric Removal Carriage

24972-200-3PS-MFCG-00002 Rev. 0

Bechtel Confidential

Copyright Bechtel Corporation 2003. All rights reserved. Contains confidential information proprietary to Bechtel not to be disclosed

to third parties without Bechtel’s prior written permission.

Page 2 of 7

TABLE OF CONTENTS

Section Description

1.0 GENERAL

2.0 CODES AND STANDARDS

3.0 OPERATING CONDITIONS

4.0 DESIGN AND CONSTRUCTION

5.0 SURFACE PREPARATION AND PAINTING

6.0 ASSEMBLY AND TESTING

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1.0 GENERAL

1.1 This specification and all attachments to the accompanying requisition cover the

furnishing of all labor, materials and services in connection with the engineering,design, fabrication, testing, and preparation for shipment of the Primary (gyratory)

Crusher Eccentric Removal Carriage for installation by others at the primary crushing

plant of the Leaching Dumps Project – Toquepala of Southern Peru Copper

Corporation in Perú.

2.0 CODES AND STANDARDS

Unless otherwise specified, the materials, design, fabrication and testing of the

Gyratory Crusher Eccentric Removal Carriage shall comply with the latest standards

issued by the following organizations:

AFBMA Anti-Friction Bearing Manufacturers Association

ABMA American Bearing Manufacturers Association

AGMA American Gear Manufacturers Association

ANSI American National Standards Institute

ASTM American Society for Testing and Materials

AWS American Welding Society

MSHA Mine Safety & Health Administration (U.S. Dept. of Labor)

NEC National Electrical Code

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

OSHA Occupational Safety & Health Administration (U.S.Dept.of Labor)

UBC Uniform Building Code

In the event of conflicting requirements between codes and/or standards, and this

specification, the more stringent shall govern.

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3.0 OPERATING CONDITIONS

3.1 The eccentric removal carriage will be installed inside the primary crusher building,

just below the crusher. The carriage shall be designed and constructed for heavy-dutyservice in a very dusty environment containing abrasive copper ore dust particles.

3.2 Project description and site conditions are described in Section 4 Site Specific

Information of the accompanying requisition.

3.3 When it becomes necessary to service the crusher eccentric, the crusher is shut down

and the surge pocket beneath it drawn down to eliminate any obstruction to carriage

movement. The crusher side door will need to be opened so that the carriage can

move along the overhead guide beams until it is positioned properly underneath the

crusher and clamped to the beams to prevent any further movement during servicing.

Carriage travel is by means of two (2) synchronized electrically driven trolleys,including motors, controlled from a single source.

The telescoping hydraulic lift table with hydraulic cylinders will lift the eccentric

removal frame from the main carriage platform up underneath the crusher to catch and

lower the drive components as they are removed. The eccentric removal frame shall

be designed to hold the crusher hydraulic assembly on its inner ring, and the eccentric

assembly on its outer ring.

The crusher hydraulic assembly will be unbolted first and lowered onto the inner ring

of the frame. The telescoping hydraulic lift table will then be lowered back down to

the carriage platform, and the carriage rolled out of the surge pocket. The hydraulicassembly will be removed from the frame in the carriage parking area, by means of the

primary crusher service crane.

The carriage will then be brought back inside the surge pocket and secured, and the

cylinder lifted again for the removal of the eccentric. When the eccentric holding bolts

are removed, the eccentric will be lowered onto the outer ring of the eccentric removal

frame. The cylinder with frame and eccentric will be lowered and the carriage moved

out in the same way as previously done for the hydraulic assembly.

3.4 Reinstallation procedure for the serviced components will be in the reverse order of

steps described above.

3.5 When not in use, the carriage will be parked outside the surge pocket, out of harm’s

way, suspended from the guide beams.

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3.6 It is anticipated that the carriage will be put into service four to six times per year for

scheduled maintenance, plus one or two times for emergency maintenance.

4.0 DESIGN AND CONSTRUCTION

4.1 The equipment shall be in accordance with the requirements of this specification and

the drawings, data sheets and other specifications attached (refer to Section 2 of the

accompanying requisition), as well as the applicable codes and standards listed in

paragraph 2.0. Standard components shall be used wherever possible. Standard

replacement parts and operating supplies shall be readily available.

4.2 The carriage structure shall be designed and built in sections or subassemblies, which

will be assembled by bolting in the field. All subassemblies and other components

must fit through an approximate 3000mm x 3000mm hatchway in the main floor of the

crusher building. The carriage components will be lowered through this hatchway bythe primary crusher service crane supplied by others.

4.3 The carriage structure shall be designed by the Seller in accordance with 24972-200-

3DR-S15L-00001, Design Criteria for Civil-Structural.

4.4 The carriage shall be designed for the removal and replacement of the eccentric and

hydraulic units from a size 60” x 110” Gyratory Crusher. The outer dimensions of the

eccentric unit (the larger of the two) are approximately 2600 mm dia. x 2200 mm high.

The weight of the eccentric is approximately 19,000 kg.

4.5 The carriage shall be designed for a net load of 25 metric tons approximately. Thecarriage shall be fabricated of standard ASTM A36 structural members. All welding

shall conform to AWS D1.1 structural welding standard.

4.6 The carriage will hang suspended from four trolleys. Each trolley shall be sized for 2

times its actual load.

4.7 Operation of all two-trolley drive units shall be electrically synchronized to provide

smooth uniform movement from a single switch. The carriage shall move only when

the push button is held down, and shall stop when the button is released. The carriage

shall be designed for two operating speeds:

Unloaded 2.5 m/min (±10%)

Loaded 1.0 m/min (±10%)

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4.8 The two (2) telescoping hydraulic cylinders shall be designed to handle an

approximately 16 metric ton load each and shall assure safe loading operation. The

platform shall be stable, and shall minimize any load oscillations during cylinders

raising and lowering.

4.9 The carriage shall include a rail clamp system as a means of securing the carriage to

prevent undesirable movement during crusher maintenance operation or in its parked

position. Locking or clamping shall be performed from the platform adjacent to the

carriage rails. Similarly, the electrical controls for the unit shall be interlocked so that

movement of the carriage, as described in paragraph 4.7 above, and movement of the

telescoping hydraulic cylinders per paragraph 4.8 above, cannot occur at the same

time.

4.10 Power supply to the carriage shall be by means of a festoon cable (20 m maximum)

terminating in a junction box at a location off the carriage and safely out of the crusher

discharge pocket. The power cable shall be supported from festoon rollers on aseparate festoon guide rail. The length of the festoon system shall be adequate for full

carriage travel without tension on the cable. The Seller shall provide all cable, rollers,

guide rails and junction box.

4.11 Seller shall provide on-board electrical distribution equipment as required (step-down

transformer for control power or any other low voltage requirement on the carriage).

4.15 Seller shall provide on-board lighting, direct upward at the work area under the crusher

and adjustable.

4.13 Seller shall provide on-board electrical receptacles for power tools.

4.14 Seller shall provide on-board control stations with pushbutton controls for carriage

travel and another for operating the telescoping hydraulic lift. The two shall not be

operable from the same station or panel.

4.15 Electrical requirements including Low Voltage Motors (below 186 kW) are given in

the Technical Specification for Electrical Components Supplied with Mechanical

Packaged Equipment, 24972-200-3PS-EKP0-00001.

4.16 Instrumentation and control requirements shall be in accordance with the General

Specification for Instruments Supplied with Packaged Equipment, 24972-200-3GS-

JQ07-00001.

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5.0 SURFACE PREPARATION AND PAINTING

5.1 All structural and miscellaneous steel surfaces for the eccentric removal carriage shall

be prepared, primed and finish painted in accordance with General Specification forShop Priming and Painting, 24972-200-3GS-NX00-00001, Class 2A.

5.2 All mechanical and electrical components, such as the trolley drives and the

telescoping hydraulic cylinders, shall be prepared, primed and finish painted in

accordance with the manufacturer’s standard procedures.

6.0 ASSEMBLY AND TESTING

6.1 The equipment must be shipped to the jobsite in subassemblies for field erectionbeneath the primary crusher. All subassemblies and components shipped loose shall

be clearly match-marked for ease of assembly.

6.2 Drives, motors, etc. may be packed separately from the actual equipment if necessary

for their protection. These components shall be clearly tagged and match-marked to

facilitate field assembly.

6.3 Seller shall provide suitable quality control inspection, and shall work with Buyer’s

Supplier Quality Representative (refer to Section 5 of accompanying requisition).

Seller shall perform all testing required, including shop test at design speed for each

piece of mechanical equipment, and load test for the carriage assembly.

6.4 All exposed machined surfaces shall be protected with corrosion-resistant compound

and covered with a hard protective shield.

Documents

24972-200-3PS-MFCG-00002Rev0