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
00
First Issue for quotation purposes.
01
Updated in line with latest drawings.

Issued to SPCC for site planning purposes.
Originated
Checked
Approved
DMR
Aug/2013
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.
Document No.
Revision - 01
D25
Page 2 of 34
METHOD STATEMENT
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
A2 - Sample inspection R2 - Sample Document Review
W1 - 100% Witness of Operation

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.
Document No.
Revision - 01
D25
Page 3 of 34
METHOD STATEMENT
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
Document No.
Revision - 01
D25
Page 4 of 34
METHOD STATEMENT
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.
Document No.
Revision - 01
D25
Page 5 of 34
METHOD STATEMENT
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 Title
Number
6000_00_003
Family Tree of Assemblies
Rev.
05
6003_02_003
GA of Wagon Unloading System
00
6035_02_007
Assembly of 14m Pivot Frame Tippler
00
6095_02_002
6561_02_007
6562_02_007
6565_02_009
6186_02_002
Assembly of Pivot Frame Tippler Structure

End Ring Structure (Driven)
End Ring Structure (Driven)
Side Beam Structure
Assembly of Tippler Ballast
02
01
01
02
00
6968_00_001 #
20.312_D15 #
Tippler Structure Shop Assembly Survey Drawing

Tippler Shop Assembly Method Statement
#, marked up/signed workshop copies
00
02
6130_02_003
6104_02_009
6102_02_006
6101_02_003
6101_02_004
Assembly of Tippler Fixed Blocking

Assembly of Tippler Spill Plates and Wear Plates
Assembly of Tippler Clamp
Assembly of Tippler Main Pivot (Non-Locating)
Assembly of Tippler Main Pivot (Locating)
00
00
02
00
00
6100_02_003
6566_02_007
6198_02_002
6115_02_003
Assembly of Platform
Platform Structure
Assembly of Platform Walkways
Assembly of Platform Support
01
01
00
00
6103_02_006
6103_02_007
Assembly of Tippler Drives (Left Hand)

Assembly of Tippler Drives (Right Hand)
02
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
Document No.
Revision - 01
D25
Page 6 of 34
METHOD STATEMENT
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
6974_00_002
6974_00_003
6974_00_004
6974_00_005
6974_00_006
6974_00_007
6974_00_008
6974_00_009
Transport Drawing (LH End Ring)

Transport Drawing (RH End Ring)
Transport Drawing (Side Beam)
Transport Drawing (Platform)
Transport Drawing (Clamp)
Transport Drawing (Drive Assembly LH)
Transport Drawing (Drive Assembly RH)
Transport Drawing (Support Roller LH)
Transport Drawing (Support Roller RH)
00
00
00
00
00
00
00
00
00
6400_00_002
Assembly of Tippler Hydraulics

plus Bosch Rexroth Hagglunds drawings (see Family Tree) and
instructions
02
6410_00_002
Assembly of Tippler and Run-Back Stop Lubrication

plus Bijur Delimon drawings (see Family Tree) and instructions
01
6340_00_002
Assembly of Tippler and Run-Back Stop Electrics

plus Iconsys drawings (see Family Tree) and instructions
02
20.312_D26
Electrical Site Installation Method Statement
00
6495_00_001
Assembly of Dust Suppression System

plus Nalco Enviroflo drawings (see Family Tree) and instructions
00
20.312_D04
Manufacturing Specification
04
6975_00_001
Tippler Erection Sequence Diagram
00
Schade Packing List
Document No.
Revision - 01
D25
Page 7 of 34
METHOD STATEMENT
III.
Ref.
METHOD STATEMENT
Description of Operation
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
(enter identity SPCC/ Schade
where marked) Installer Technical
SPCC/Installer
Advisor
Document No.
Revision - 01
D25
Page 8 of 34
METHOD STATEMENT
Ref.
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.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
Schade
packing list
A1
A2
A1
A2
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
A1
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.
A1
R1
A1
when
they are
installed
A2
A1
A2
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.
A1
W2
Check that all bearings and bushes are primed

with lubricant.
A1
A1 Main
Pivots
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
1.5
Any damaged paint work is to be repaired in

accordance with paint suppliers instructions.
During workshop assembly, temporary grease

nipples have been installed to lubricate bearings
and bushes. These are to be removed when the
Calibration
certificates
Document No.
Revision - 01
D25
Page 9 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
Schade
packing list.
Suppliers
documents
A1
A2
Schade
packing list.
Suppliers
documents
A1
A2
Schade
packing list.
Suppliers
documents
A1
A2
X
Marked up
drawings &
documents
A1
A1
Workshop
copy
R1
R1
Workshop
copy
R1
R1
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.
Document No.
Revision - 01
D25
Page 10 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
Workshop
records
R1
R2
Workshop
records
R1
R2
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
Document No.
Revision - 01
D25
Page 11 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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:-
Mark up copy
of drawing
6460_00_009
A1
A2
R1
A1
A1
Check that all cast in studs are dimensionally

as required and allow side movement as
shown on the above drawing. See sections KK, J-J and H-H.
A1
A1
Check that these stud groups are positioned to

within the tolerance requirements of drawing
dimensions and note 3.
A1
A1
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
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
Document No.
Revision - 01
D25
Page 12 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
on the foundation datum plates. Additional

datum plates are to be fitted, if required to aid
installation.
A1
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
Document No.
Revision - 01
D25
Page 13 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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:R1
6975_00_001, Tippler Erection Sequence

Diagram.
3.1
R1
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
W1
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
A1
W1
Document No.
Revision - 01
D25
Page 14 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
A1
Hand tighten M30 nuts/washers on foundation

studs.
W1
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.
W1
A1
3.1.4 Check that all 4 pinions are free to rotate.
W1
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.
X
Drawing
W1
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:-
W1
X
All
dimensions
A1
W1
Document No.
Revision - 01
D25
Page 15 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor

1mm.
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.
A1
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
6968_00_001, Tippler Structure Shop Assembly
Survey Drawing
A1
A1
Document No.
Revision - 01
D25
Page 16 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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:

0.5mm.
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.
W1
X
All
dimensions
A1
W1

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)
A1
A1
A1
Document No.
Revision - 01
D25
Page 17 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
X
Procedure
X
Dimension
Secure in position with supports and guy ropes.

3.3.2 Assemble housing to stool joint and hand tighten.
3.4
R1
W1
A1
A1
A1
A2
A1
A1
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
R1
W1
Document No.
Revision - 01
D25
Page 18 of 34
METHOD STATEMENT
Ref.
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.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
X
Dimension
A1
A1
A1
A2
3.4.2 Assemble housing to stool joint and hand tighten.
A1
A1
3.4.3 Check alignment and dimensions between End

Rings (12400mm nominal).
A1
A1
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.
A1
A1
A1
R1
3.5.1 Remove the Splice Plates and review the overall

Side Beam length against the End Ring inside
dimensions recorded above.
A1
R1
Check the condition of all internal and external

plate surfaces (where splice plates will locate) are
to Schade document 20.312_D04.
A1
A1
Check the condition of the splice plate surfaces to

Schade document 20.312_D04.
A1
A1
Secure in position with supports and guy ropes.
3.4.4 With reference to Schade drawing 6968_00_001,

check that the workshop recorded end ring
centres have been achieved.
3.5
X
Dimension
Side Beam
Diagram (step 5)
6565_02_009, Side Beam Structure
6974_00_003, Transport Drawing (Side Beam)
Document No.
Revision - 01
D25
Page 19 of 34
METHOD STATEMENT
Ref.
3.5.2 Review workshop match marking for both joints.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
Workshop
records
R1
R1
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.
X
Procedure
A1
R1
A1
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.
X
Dimension
A1
R1
A1
W1
Workshop match marking must be adhered to

for site assembly.
Position internal Splice Plates inside Side Beam
and secure.
3.6
Side Beam to End Ring Bolted Joints

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
Document No.
Revision - 01
D25
Page 20 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor

Structure.
3.7.1 Check that Tippler structure is in total accordance
with all Schade drawing and document
requirements.
Schade
drawings and
workshop
records.
A1
A2
R1
SKF
installation
instructions
A1
W1
A1
A1
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)
(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-
Document No.
Revision - 01
D25
Page 21 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
#1, and within 1mm 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.
Workshop
records
A1
A1
A1
W1
Document No.
Revision - 01
D25
Page 22 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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

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.
Workshop
records
R1
W1
Workshop
records
R1
W1
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
Document No.
Revision - 01
D25
Page 23 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
X
Procedure
R1
W1
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.
A1
A1
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
R1
W1
A1
W1
Document No.
Revision - 01
D25
Page 24 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
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).
A1
A1
A1
W1
A1
A1
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)
Document No.
Revision - 01
D25
Page 25 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor

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.
Gantrail
WPS
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
instructions
A1
A1
A1
A1
A1
W1
Document No.
Revision - 01
D25
Page 26 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor

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.
A1
W1

adjust the Platform Supports (6115_02_003) such
that the Platform longitudinal centre line will
align with the main track centre line when
installed.
A1
W1

adjust the Platform Supports (6115_02_003) such
that the Platform transverse centre line will align
with the Tippler centre line when installed.
A1
W1
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
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.
W1
Document No.
Revision - 01
D25
Page 27 of 34
METHOD STATEMENT
Ref.
3.16.2 Lift the Platform sub-assembly off its temporary

supports and onto the Platform Supports
6115_02_003.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
X
Procedure
R1
W1
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.
A1
A1
A1
R1
W1
A1
W1
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.
X
Procedure
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
Document No.
Revision - 01
D25
Page 28 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
A1
A2
A1
A1
Weld Washers (6115_02_003 item 6) per

drawing requirements.
3.17 Thrust Pads
Diagram (step 11)
6003_02_003, General Arrangement of Wagon
Unloading System
6723_02_001, Thrust Pad
Document No.
Revision - 01
D25
Page 29 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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
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.
Workshop
records
A1
W1
A1
A2
A1
A2
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.
Document No.
Revision - 01
D25
Page 30 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
A1
A2
A1
A2
A1
A2
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.
X
Supplier
documents
R1
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.
A1
A2
Document No.
Revision - 01
D25
Page 31 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
X
Supplier
documents
R1
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
A1
A2
A1
A1
Check that there is a max. platform to land rail

gap of 10mm.
A1
A1
Check that there is no vertical or side step at the

platform to land rail gaps.
A1
A1
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.
Document No.
Revision - 01
D25
Page 32 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
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.
A1
A1
A1
A1
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 RunBack Stop Lubrication
Read this drawing in conjunction with the Bijur
Delimon drawings and installation instructions.
X
Suppliers
documents
R1
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:-
A1
A1
Document No.
Revision - 01
D25
Page 33 of 34
METHOD STATEMENT
Ref.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
6340_00_002, Assembly of Tippler and RunBack Stop Electrics

Read this drawing in conjunction with the Iconsys
drawings and installation instructions.
X
Suppliers
documents
R1
20.312_D26, Electrical Installation Method

Statement
3.28.1 Install Electrics in accordance with the above
drawings and document.
A1
A1
Document No.
Revision - 01
D25
Page 34 of 34
METHOD STATEMENT
Ref.
4.
Operation
Complete
Document
Required
Verification
(sign and date

where indicated)
(sign and date)
SPCC/Installer
Advisor
DIMENSIONAL CHECK
In conjunction with Schade Technical Advisor,
carry out checks and record important
dimensions.
Record on
drawings
A2
A2
A1
A2
R1
R2
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.
X
Collate all
records

20.312 - D25 - Rev 01 Site Installation Method Statement

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Contract Name/Number-

SPCC ILO PERU/20.312

SOUTHERN PERU COPPER CORPORATION

First Issue for quotation purposes.

Updated in line with latest drawings.

The information in this document was prepared using Intellectual

SPCC ILO PERU/20.312

EXPLANATORY NOTES - READ BEFORE USE

The objects of this Method Statement are

W1 - 100% Witness of Operation

SPCC ILO PERU/20.312

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

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

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

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

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

SPCC ILO PERU/20.312

INTRODUCTION & GENERAL INSTRUCTIONS

SPCC ILO PERU/20.312

GENERAL LIST OF DRAWINGS & DOCUMENTS REQUIRED

GA of Wagon Unloading System

Assembly of 14m Pivot Frame Tippler

Assembly of Pivot Frame Tippler Structure

Tippler Structure Shop Assembly Survey Drawing

Assembly of Tippler Fixed Blocking

Assembly of Tippler Drives (Left Hand)

Assembly of Tippler Cable Loop

Assembly of Tippler Limit Switches

Assembly of Tippler Clearance Sensors

SPCC ILO PERU/20.312

Assembly of Stockpile Sensors

Assembly of Grout and Packing

Assembly of Exit Run-Back Stop (Manual)

Wagon Unloading System Foundation Details and Loadings

Transport Drawing (LH End Ring)

Assembly of Tippler Hydraulics

Assembly of Tippler and Run-Back Stop Lubrication

Assembly of Tippler and Run-Back Stop Electrics

Electrical Site Installation Method Statement

Assembly of Dust Suppression System

Tippler Erection Sequence Diagram

Schade Packing List

SPCC ILO PERU/20.312

(sign and date

SPCC ILO PERU/20.312

All components must be checked against the

All components are to be checked for any

(sign and date

Repair of any major steelwork damage is to

All site work must conform to Schade

The final paint coat is to be applied during

Check that all bearings and bushes are primed

All torque wrenches must be calibrated

Any damaged paint work is to be repaired in

During workshop assembly, temporary grease

SPCC ILO PERU/20.312

(sign and date

centralised lubrication system is installed.