Risikobeurteilung Kratzer

Product: Wagon unloading systemClient:SPCC Ilo Peru COMMENTS \* MERGEFORMAT SCHADE-No.:20.312

Operation manualWagon tipplerPivot-Frame

Client: Southern Peru Copper CorporationContractor:

SCHADE Lagertechnik GmbHTel.: +49 209 50316 0

Bruchstrae 1Fax: +49 209 50316 288

D-45883 Gelsenkircheninfo@schade-lagertechnik.de

GERMANYwww.schade-lagertechnik.de

Content:41Introduction

41.1Preface

51.2List of most important acts and regulations

62Safety instructions

62.1Safety Precautions

62.2Basic operation and intended use of the machine

62.3Organised measures

72.4Selection, qualification of personnel and basic responsibilities

72.5Safety instructions for normal operation

82.6Special work in conjunction with utilisation

92.7Electrical Safety precautions

92.8Welding, flame-cutting and grinding

92.9Hydraulic and pneumatic equipment

102.10Oil, grease and other chemical substances

102.11Prior to putting into operation

102.12Putting into operation

102.13Maintenance and repair

112.14Safety label at the machine

123Description of the machine

123.1Access limitations

123.2Plant overview, Rail level

133.3Plant overview, material dump area

143.4Parts of the wagon tippler

203.5Lubrication

203.6Dust Control System

213.7Parts of the wagon run back stop

223.8Work places for operation

223.9Work places for mechanics maintenance

233.10Personal qualification

243.11Electrical Equipment

274Function sequence

284.1Description of operations

294.2State of plant for train arrival

304.3Positioning wagons onto tippler

314.4Tipping wagons to unload

334.5Unloading the first wagon

354.6Unloading subsequent wagons

374.7Unloading the last wagon

385Technical data

385.1Environment

385.2Material handled

385.3Track data

395.4Duty

395.5System throughput

395.6Wagon specificaion

405.7Electrical data

1 Introduction1.1 PrefaceAssembly and commissioning of the machine is only allowed after intensive studies of the following operation and maintenance manual. Important instructions to use the machine in a safe, proper and economic way are included in the manual. Its attention helps to avoid dangers, to minimise repair work and lost time and to maximise the reliability and life of the machine. The valid national and general safety regulations and rules to prevent accidents have to be observed really during operation of the machine. All safety information inside this manual

READ and OBSERVE!

The manual has to be available all the time on the machine.

The type of machine guarantees at INTENDED use assembly, operation and maintenance WITHOUT personal danger.

Maintenance work such as erection, cleaning, maintenance and repair has to be done only by

SWITCHED-OFF MACHINE!

Basically the machine has to be made safe against unintentionally or not allowed commissioning and switching-on again.

Damages which result of not recognising the operation manual do not feature the guarantee force of the manufacturer.

Drawings shown in this manual are for general representation. They are not decisive for the design in each part, i.e. they are not binding.

Technical data and dimensions are not binding.

Claims cannot be deduced by this.

All rights like copyright, protection right registration or right for transmission of this manual, the attached drawings and other material or every permission, belong exclusively to

SCHADE Lagertechnik GmbHTel.: +49 209 50316 0

Bruchstrae 1Fax: +49 209 50316 288

D-45883 Gelsenkircheninfo@schade-lagertechnik.de

GERMANYwww.schade-lagertechnik.de

Definition of hazard marking in the operating instructions

DANGER: Possible consequences: Death or very severe injuries.

WARNING: Possible consequences: Injuries or heavy damages on property.

CAUTION: Possible consequences: Damages on property.

1.2 List of most important acts and regulationsBasics of design

BS 2523 Rules for the design of cranes. Part 1 (structures) and Part 2 (mechanisms)Harmonised normative references

EN ISO 12100Safety of machinery General principles for design Risk assessment and risk reduction

ISO/TR 14121-2Safety of machinery - Risk assessment - Part 2: Practical guidance and examples of methods

EN ISO 13857Safety of machinery

Safety distances to prevent hazard zones being reached by upper and lower limbs

EN 349 (ISO 13854)Safety of machinery Minimum gaps to avoid crushing of parts of the human body

EN ISO 13850Safety of machinery Emergency stop - Principles for design

EN ISO 7731Ergonomics - Danger signals for public and work areas - Auditory danger signals

EN 547 (ISO 15534)Safety of machinery - Human body measurements - Part 1: Principles for determining the dimensions required for openings for whole body access into machinery

EN ISO 13732Ergonomics of the thermal environment - Methods for the assessment of human responses to contact with surfaces

EN 626 (ISO 14123)Safety of machinery Reduction of risks to health from hazardous substances emitted by machinery

EN 953 (ISO 14120)Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards

DIN EN ISO 4413Hydraulic fluid power - General rules and safety requirements for systems and their components

EN 1037 (ISO 14118)Safety of machinery Prevention of unexpected start-up

2 Safety instructions2.1 Safety PrecautionsInside the operation and maintenance manual there is advice for instructions important for safety.

Follow exactly emphasised advice to exclude danger on body and life as impairments of the machine or other assets.

2.2 Basic operation and intended use of the machineThe machine has been built in accordance with state-of-the art standards and the recognised safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property.

The machine must only be used in technically perfect condition in accordance with its intended use and the instructions set out in the operating manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

The machine is designed exclusively for reclaiming of bulk material more mentioned in the technical specification. Using the machine for purposes other than those mentioned above is considered contrary to its intended use. The manufacturer cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. Operating the machine within the limits of its intended use also involves observing the instructions set out in the operating manual and complying with the inspection and maintenance directives.

2.3 Organised measuresThe operating instructions must always be at hand at the place of use of the machine.

In addition to the operating instructions, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and / or wearing of personal protective equipment.

The operating instructions must be supplemented by instructions covering the duties involved in supervising and notifying special organisational features, such as job organisation, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the operating instructions and in particular the chapter on safety before beginning work. Reading the instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check at least from time to time whether the personnel is carrying out the work in compliance with the operating instructions and paying attention to risks and safety factors.

For reasons of security, garments must be close-fitting. Injury may result from being caught up in the machinery or catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety without the suppliers approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied to do so.

Never make any modifications of program (software) on programmable control system.

Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the operating instructions for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are essential.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

2.4 Selection, qualification of personnel and basic responsibilitiesEmploy only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorised personnel works on or with the machine.

Define the machine operators responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

2.5 Safety instructions for normal operationAvoid any operational mode that might be prejudicial to safety.Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state.Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, sound-proofing elements and exhausters, are in place and fully functional. In the event of malfunctions, stop the machine immediately and lock it. Have any defects rectified immediately. During start-up and shut-down procedures always watch the indicators in accordance with the operating instructions. Before starting up or setting the machine in motion, make sure that no person is at risk.

2.6 Special work in conjunction with utilisationObserve the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts. These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance work and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: Locking the principle control elements and removing the ignition key and/or attaching a warning sign to the main switch.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The banksman giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Wear a safety harness when carrying out maintenance work at greater heights.

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt.

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance / repair. Never use aggressive detergents.

After cleaning, examine all lines for leaks, loose connections, chafe marks and damage. Any defects found must be rectified without delay.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.2.7 Electrical Safety precautionsUse only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs with the electrical system.

Work on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules.

The power supply to parts of machines, on which inspection, maintenance and repair work is to be carried out must be cut off.

Before starting any work, check the de-energised parts for the presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

Necessary work on live parts and elements must be carried out only in the presence of a second person who can cut off the power supply in case of danger by actuating the emergency shut-off or main power switch. Secure the working area with a red-and-white safety chain and a warning sign. Use insulated tools only.

Before starting work on high-voltage assemblies and after cutting out the power supply, the feeder cable must be grounded and components such as capacitors short-circuited with a grounding rod.

2.8 Welding, flame-cutting and grindingBefore carrying out welding, flame cutting and grinding, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

When working in a close environment, then national regulations will apply

During welding and / or flame cutting work, clients instructions for welding and flame cutting and fire protection have to be observed imperatively.

2.9 Hydraulic and pneumatic equipmentWork on hydraulic / pneumatic equipment may be carried out only by persons having special knowledge and experience in pneumatic and hydraulic systems.

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately.

Depressurise all system sections and pressure pipes (hydraulic / compressed air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic and pneumatic lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

2.10 Oil, grease and other chemical substancesWhen handling oil, grease and other chemical substances observe the product-related safety regulations.

Be careful when handling hot consumables (risk of burning or scalding).

Only SKF Bearing (or equivalent tpe) grease to be used.

2.11 Prior to putting into operationFollow the operation instructions before putting into operation.

Check the machine for visible defects.

Do not use the machine with signal lamps out of order.

All safety devices have to be in place.

No personnel to be present inside the safety guards.

2.12 Putting into operationOperate the machine according to the operation manual.

With the machine in operation do not leave unattended.

During automatic operation, the time intervals for the regular inspections of the machine will be fixed as per each operation.

2.13 Maintenance and repairFor good life and continuous duty of the machine follow the lubrication and maintenance instructions within the operation manual.

Ensure that during maintenance work and repair the main switches are switched off and are made safe against switching on.

As the machine is defect a danger sign has to be displayed and the machine has to be made safe against unauthorised switching-on.

Machine repairs are allowed only by trained and competent personnel.

During welding it is necessary to follow the welding instructions.

After maintenance and repair work all safety devices shall to be re-set.

2.14 Safety label at the machine

Safety labelMeaningPlace

W012Warning of dangerAt general places of danger

W012Warning of hazardous voltagesAt switch cabinet

W018Warning automatic-startAt drive units or moving machine parts

W008Warning of danger of falling

Fall of personsNear pit

W024Warning of the danger of crushing handsAt or near moving parts

W026Warning of the danger of crushing handsNear moving parts

W019WARNING!

Risk of crushing bodies

M002Manadatory

Read the manual before operatingAt control desk

M004Manadatory

Switch off the machineAt drive units / driven parts

P006Prohibiton

No access for unauthorized personsAt access to machine / entry of hall

3 Description of the machine3.1 Access limitationsThe facility is situated in a building on company premises surrounded by a fence with controlled access. The facility can be accessed from several points but only by company employees, sub-contractors or authorised visitors.3.2 Plant overview, Rail levelThe facility includes (a, b, c, ) and machines/assemblies supplied by SCHADE: an entry track (a), (customer supply) local control station (b) and operator control room (c) tippler entry and exit clearance sensors, flashing beacon and audible horn (e+f)

a wagon tippler (g) a wagon run back stop (h) an exit track (i), (customer supply) hydraulic power unit (k)

centralized lubrication station (L)

dust suppression container (m) entry wagon door (o)

exit wagon door (p)

vhecile doors (q)

traffic light (r), (customer supply)

3.3 Plant overview, material dump areaThe facility includes (a, b, c, ) and machines/assemblies not supplied by SCHADE: Operator control room and access (s), (customer supply) Tipped material area (t), (customer supply) Bulk material (u), (customer supply) FEL (front end loader) (v), (customer supply) Stockpile height sensor (w) FEL traffic light (x), (customer supply) FEL access door (y), (customer supply) Dust suppression (z)

Dust extraction (za), (customer supply)

3.4 Parts of the wagon tippler

(1) End ring structure

(2) Ballast

(3) Main pivot bearings

(4) Side beam

(5) Tippler clamp

(6) Wagon

(7) Platform

(8) Drive unit

(9) Platform supports

not shown

(10) Cable loop

(11) Limit switches

(12) Tippler hydraulics

(1) End ring structure

(2) Ballast

(3) Main pivot bearings

(4) Side beam

(5) Tippler clamp

(6) Wagon, not shown(7) Platform

(8) Drive unit

(9) Platform supports

not shown

(10) Cable loop

(11) Limit switches

(12) Tippler hydraulics

3.4.1 Tippler PlatformThe platform comprises a welded box section fabrication, which carries a section of the main rail track throughout its length and being of sufficient span to accommodate the wagon which has to be tipped. Walkways are fitted on both sides of the platform.

When the Tippler is at rail level (0 rotation) the platform rests on land mounted supports which ensure correct alignment of the platform rails with the land rails on the entry and exit ends.

As the Tippler starts to rotate in the tip direction, the platform is raised clear of its land mounted supports by a pivot pin/housing assembly mounted at each end of the platform and end rings respectively. As the Tippler rotates further, the platform with wagon tilts, until the wagon side makes contact with the Tippler side beam (fixed blocking). After the wagon has made contact with the side beam, the wagon, platform, side beam and end rings rotate as a single assembly.

3.4.2 Tippler End Rings, Side Beam & Main PivotsThere are two end rings, one positioned at each end of the Tippler. Each is a heavy duty welded steel structure, nominally semicircular in shape, which rotate in lubricated pedestal bearings (Main Pivots) set above and to one side of the platform. A structural toe is incorporated into each end ring which supports the platform by means of the above pivot pin/housing assembly during Tippler rotation.

The side beam is a heavy duty welded box section fabrication with internal diaphragms, bolted between the end rings with high strength bolts to form a rigid rotating structure. This assembly plus the drive racks, have been shop trial assembled and dimensionally inspected/verified against a Schade shop assembly drawing. Before dismantling for transport to site, all bolted joints arewill be match marked to ensure correct re assembly at site.

The end rings include steel plate counterweights which balance the mass of the platform and wagon during rotation, and therefore minimise the drive power requirements.

The main pivot bearing housings will be held in place by cast-in foundation studs. Once correctly aligned on site assembly, the bearing housings will be supported on full strength grout.

3.4.3 Tippler Clamp GearThere are three independent hydraulic clamp assemblies which operate during Tippler rotation to secure the wagon to the platform. Each clamp assembly comprises a pivoted clamp beam, a clamp arm and a hydraulic cylinder. The clamp beam and clamp arm are welded fabrications. All pivot points are lubricated pin/bush assemblies.

During initial Tippler rotation in the tip direction, the clamp beams lower under hydraulic control to contact the top of the full wagon, and after that contact with the wagon, the clamp assemblies, wagon and Tippler structure are rotated as a single assembly. The clamp assemblies are applied by hydraulic cylinders. The cylinders include a secondary relieving piston that ensures the compressed wagon spring forces are relieved and not transmitted into the Tippler clamps and structures.

Each cylinder includes clamps raised limit switch, clamps contacting wagon pressure switch and cylinders locked pressure switch. The cylinder stroke is sufficient to clamp wagons between 3045mm and 2554mm high.

NoteThe clamp cylinder design is based on loads generated when supporting the wagon dead load (25 tonnes) plus retained sticky Copper Concentrate of up to 10 x t tonnes (i.e. 10% of maximum wagon payload) at Tippler maximum tip angle. The recommended minimum cylinder factor of safety against buckling (3:1) is obtained with this load combination. Schade must be advised if the sticky material not discharging from the wagons will exceed 10%.

Vibrators are mounted on the clamp beams to assist in unloading any sticky retained payload. The dynamic effect of these vibrators is included in the clamp design.NoteThe use of vibrators is not guaranteed to empty wagons with sticky material that does not free flow from the wagon.

The cylinders include sealing specific for the dusty environment.

3.4.4 Tippler Wear & Spill PlatesReplaceable wear plates and spill plates are fitted to the side beam and clamps. The spill plates are positioned to guide material discharging from the ends of the wagon into the hopper. The wear plates are positioned to protect the structural steel work from the material discharge flow. Both are manufactured from wear resistant material and are bolted to the adjacent supporting structures.

3.4.5 Tippler Limit SwitchesTippler limits switches and over travel limit switches are included for both tip and return rotation.

3.4.6 Tippler Drive UnitsThe Tippler has four hydraulic drive units, two located at each end ring of the Tippler. The drives are mounted in a fabricated steel drive base and mounting frame, on which are mounted two hydraulic motor assemblies, each motor is coupled to a pinion shaft via splines. The free end of the pinion shaft is supported in a lubricated bearing/housing assembly.

The drive units are situated in the pit below the Tippler. The pinions on each of the drive units mesh with the end ring drive racks. Jacking screws are fitted to the drive base to enable correct alignment of the drive pinions and rack during installation. Once correctly aligned, the drive bases will be supported on full strength grout.

Cross line relief valves are fitted to the drive hydraulic circuit. The speed, acceleration and deceleration are controlled by means of an electronic speed control card. The system will fail safe if there is a loss of control voltage or sudden loss of fluid. The operation of the hydraulic motor brakes is initiated by normal travel switch being tripped.

The hydraulic system proposed is by BOSCH REXROTH (in line with their previous Pivot Frame Tippler installations operating in similar ambient conditions) and ensures full motor/pinion load sharing (for improved Tippler rack life) plus full overload sensing via pump setting and pressure relief valves. The system has full acceleration and deceleration control (3 second ramps), and is capable of stopping/holding/restarting the Tippler at any tip angle under full control.

Due to the operating environment, the drive motors include an additional harsh environment seal at the output pinion.

3.4.7 Tippler Hydraulic Power Unit (HPU)A land mounted hydraulic power unit is provided to drive the 4 hydraulic motors and 3 clamp cylinders. The power pack is located adjacent to the exit end ring of the Tippler, with suitably supported/clamped pipes running from it to the hydraulic motors and clamp cylinders.

The power pack will be complete and shop assembled and tested. It will include lifting lugs sized to allow lifting of the unit within a workshop and also site installation.

3.4.8 Tippler Clearance DevicesTwo sensors (one at the entry end and one at the exit end) are used to check the absence of any overlap onto the Tippler, by an adjacent wagon (or other obstruction) on the entry or exit end main tracks before the tipping cycle is initiated, whilst the Tippler is at rail level.

3.5 LubricationAll bearings and seals that require grease lubrication will be piped to one of a number of centralised automatic lubrication systems. The lubrication cycle intervals will be based on the bearing loads/speeds and in conjunction with the bearing supplier for the Main Pivot spherical roller bearings.

The principle of operation will be that new grease is pumped into to centre of the bearing or plain bush, which pushes the old grease out through the seals.

3.6 Dust Control System

The Dust Control System is water dust suppression which will include a series of spray nozzles mounted around the tipped material area, plus all the necessary valves and filters. The system will be interlocked with the Tippler such that it operates during the Tippler cycle.

3.7 Parts of the wagon run back stop

(1) Handle

(2) Cover

(3) Rail support

(4) Wheel stop

(5) Shaft

3.7.1 Exit Wagon Run Back Stop

A manual Exit Wagon Run Back Stop is installed at the exit end of the Tippler to stop an empty wagon on the main track from rolling backwards into the Tippler. The stop will be raised/lowered manually by the second operator using a trackside lever.

NoteWhen wagons travel in the normal troughput direction, the wheel stops (1) are pushed dawn by the passing wagon wheels.

Only to allow wagons to travel in the opposite direction are the wheel stops (1) lowered by use of the handle (1).

3.8 Work places for operationPush the wagon rake further on to tippler (a) locomotive driverUncouple wagons (b) railway operatorStart/stop tiping sequence (c) plant operatorIf necessary manually stop the wagon to roll back to the tippler by using the run back stop (d)

3.9 Work places for mechanics maintenance

- Tippler drive units (a)

- Main pivots (b)

- End ring structure (c)

- platform supports and platform rollers (d) - Tippler clamps (e)

- Hydraulic power unit (f)

- Lubrication system (g)

- Dust suppression (h)

3.10 Personal qualification

Depending on the activity differently qualified staff is required.

Task Qualification

Install / scrap (dismantle) Unskilled

Semi-skilled

Skilled

Supervision

Engineers

Specialist engineer

Crane driver

Operation Operator

Maintenance Operator

Unskilled

Semi-skilled

Skilled

Supervision

Repair Operator

Unskilled

Semi-skilled

Skilled

Supervision

Engineers

3.10.1 Other people

It is to be expected with foreign maintenance personnel and locomotive driver.3.11 Electrical Equipment

3.11.1 Common Control (=05 +ER)

The common control comprises the PLC equipment, arranged as follows: -

Construction

One sheet steel cubicle 800w x 1800h x 500d with 100mm plinth, selected from the Rittal TS8 range and having cabling access via base mounted gland plate. Paint colour is RAL 7035 Light Grey.

The panel contains the following items: -

Isolation and protection for the control circuits by MCBs

Power supply (20A) for the 24V DC PLC inputs and outputs

Power supply (5A) for the DeviceNet network

Safety relays for the hard wired Emergency Stop circuit

The PLC rack

Output Interface relays

Input and Output terminals

The output terminals to solenoid valves are Weidmueller, type WS1-6 and are fitted with 2 Amp 20 x 5mm cartridge fuses.

PLC

A Rockwell 1756-L71 Control Logix PLC system is included and is arranged to control the following functions: Tippler sequencing and interlocking

Starters control via DeviceNet communication

Solenoid valve control

Tippler Running

Manual/Semi-Auto Tippler sequences

Communications to the absolute encoder via Devicenet

Communications to the HMI system via Ethernet IP.

Communications to motor starters via Devicenet

The PLC system is sized for the following I/O:

642 x 32

digital inputs

642 x 32

digital outputs

81 x 8

analogue inputs (current or voltage)

61 x 6

analogue inputs (RTD)

41 x 4

analogue outputs3.11.2 Main Control Desk (=05 +OCR)The Main Control Desk is positioned in the electrical control room above the Tippler.Construction

One, floor mounted control desk, having base mounted gland plate and protected to IP54. Paint colour is RAL 7035 Light Grey.

Pos.NameStatusDescription

1HMI-Panelactivenon activePassword protected

Operation is possible when E-Stop is healthy

Operating as touch screen

2SignallampOrange

darkorange illuminated when E-Stop has pressed

3E-Stoppressed

releasedFor Emergency stop

When pressed operations are not possible

The desk has one hinged sloping surface, housing the operator controls (E-Stop pushbutton with its reset) and 15 inch touch screen HMI, type Allen Bradley Panel View Plus. The HMI is developed using FactoryTalk View Studio for Machine Edition.

The HMI screens are arranged in associated groups to assist the operation of the Tippler.

3.11.3 Local Operator Station (=20+TENLCS)

In addition to main desk there is a railway (tippler entry) local control station (LCS) comprising following controls:

E-Stop pushbutton

Pushbuttons to control train traffic lights and horn

These controls are wired directly to the PLC cubicle. Pos.NameStatusDescription

4SignallampGreendarkSignalize Ready for next wagon to the Railway Operator

5E-StopPressed

unlockedFor Emergency stop

6SignallampBlue

darkTo signalize Ready to the Locomotive driver

7ButtonHORNPressed

To signalize Ready to the Plant Operator

8Illuminated SwitchMAN

0

AUTOManual operating

Stop for shut down

Auto operating

4 Function sequenceWagons are positioned onto the Tippler platform by a means of a locomotive.

When rotation begins, the Tippler end rings permit the platform to tilt toward the side support beam until the side of the wagon body makes contact with the side beam (fixed blocking), which is a structure fitted between the end rings. As rotation continues, three hydraulically applied clamps, which are attached to the side beam, engage the top of the wagon body, holding the wagon securely to the platform. The Tippler rotates to its fully tipped angle, and after a pause to ensure complete discharge of the payload the Tippler is reversed to return the empty wagon to rail level.

Spillage into areas other than the discharge area is minimised by spill plates located on the side beam.

An encoder, driven from one of the Tippler drive modules, controls the Tippler rotational limits and limit switches provide overtravel backup.

To ensure that empty wagons on the exit end of the Tippler do not roll back onto the Tippler, a manual Wagon Run Back Stop is located against the main track rails.The exit track has a dawnhill gradient esurig that the empt wagons roll away from the Tippler.4.1 Description of operations4.1.1 Composition of wagon rakeAll wagon rakes will consist of:-

A locomotive at the rear of the wagon rake to push the wagons

An empty/dummy wagon for safety distance. This wagon will be never tip and is only used to ensure that the locomotive does not need to travel onto the wagon tippler to position the last wagon.

A number of full wagons to empty in the wagon tippler

Locomotiveempty wagon

rake of filled wagons

4.1.2 Needed Operators

The wagon unloading system will be controlled by:-

1 (or 2) railway operator(s) located on the non-tip side of the track at rail level (a).

1 plant operator located in the elevated control room at the main control desk. The control room is on the tip side of the Tippler (b).

The railway operator(s)The Railway operator has to make a manually selection of switch on local control station

A railway signalling system (by client) on the entry end of the Tippler will be installed. The system will consist of red (stop) / blue (go) traffic lights, one located near the entry end of the Tippler and the other part way along the rake away from the Tippler.

The traffic lights are controlled by both the railway operator(s) and Tippler PLC. If all conditions for positioning and tipping the wagon are satisfied, the Tippler (plant operator) will signal the lights blue. However, if the railway operator(s) are not ready for the wagons, he can signal the lights red from their local control station. The lights will remain red until both the Tippler (plant operator) and railway operator(s) are ready to start unloading wagons.

4.2 State of plant for train arrival

State of plant prior to train arrival must be as follows:

Entry railway traffic light signals red (stop) (a).

Tippler and platform are at rail level (b).

Tippler clamps are raised (c).

All wagons from the previous train have been ejected from the Tippler building (d).

Exit Run-Back Stop is raised (e).

Dust Suppression System is not operating (f).

Dust Extraction System is not operating (g).

The entry (h) and exit (i) wagon and vehicle access doors (j) may be open or closed.

The FELs access door may be open or closed (k).

The FELs traffic lights may signal red or blue (l).

On arrival, the locomotive driver stops with the lead wagon adjacent to the railway entry red (stop) traffic light and awaits instructions from the Railway Operator(s) via radio communication.

4.3 Positioning wagons onto tippler

ConditionsPositioning of wagon

not allowedallowed

aSound Horn is pressed on the HMI touch screen by the Plant Operator to sound audible alarmNoYes

bBlue signal is pressed on the LCS by the Railway OperatorNoYes

cTippler platform rail level switch is to be seenNoYes

dTippler absolute (position) encoder is indicating 0 angleNoYes

eTippler normal travel return switch is to be seenNoYes

fTippler clamp raised switches (3x) are to be seenNoYes

gEntry and exit wagon doors closed switches (by SPCC) are not seenNoYes

hExit Run-Back Stop raised switch is to be seenNoYes

4.4 Tipping wagons to unload

ConditionsTipping of wagon

not allowedallowed

aHorn button is pressed on the LCS by the Railway OperatorNoYes

bEntry railway traffic light signal redNoYes

cTippler platform rail level switch is seenNoYes

dTippler absolute (position) encoder is indicating 0 angleNoYes

eTippler normal travel return switch is seenNoYes

fTippler clamp raised switches (3x) are seenNoYes

gTippler clamp cylinder pressure sensors (3x) are seenYesNo

hStockpile height detectors (3x) are seen (indicating that there is insufficient volume for a further wagon to be unloaded)YesNo

iFEL door closed switch (by SPCC) is seenNoYes

jFEL traffic lights (by SPCC) signal redNoYes

kEntry and exit wagon doors closed switches (by SPCC) are seenNoYes

lTippler entry and exit clear ultrasonic sensors are seen (indicating an obstruction)YesNo

mExit Run-Back Stop raised switch is seenNoYes

nHydraulic system is healthy and runningNoYes

oDust suppression system is healthyNoYes

pDust extraction system (by SPCC) is healthyNoYes

qEntry and exit flashing beacons are healthyNoYes

rEntry audible alarm is healthyNoYes

If tipping of wagon is nit allowed, the HMI screen Machine Status will indicate Not Ready.If tipping of wagons are allowed, the HMI screen Machine Status will indicate Ready, allowing the Plant Operator to select Start Semi-auto Tipping Cycle.4.5 Unloading the first wagon

The railway operator(s) set the traffic lights to blue and instructs the locomotive driver (via radio) to push the rake forward and stop with the first wagon in the designated position (central within 100 mm) on the Tippler.

The railway operator(s) then release the front coupler of the second wagon (this is the nearside lever) and instructs the locomotive driver to reverse back until the second wagon is clear of the entry sensor and outside of the tippler building. The brake hose between wagon 1 and 2 will automatically uncouple.

The railway operator(s) then signals (via an audible horn) to the plant operator that the tippler can tip.

From the control room the plant operator starts the tippler. With no further input from the plant operator, the Tippler tips the wagon to unload the bulk material, pauses at the fully tipped position and then returns the wagon to rail level.

Note!Prior to all wagon tips, the PLC checks the tipped stockpile level sensors to ensure that there is enough space for another wagon payload. A further check is also made to ensure that the Front end loader is not operating in the tipped stockpile area.

The plant operator signals (via an audible horn) to the railway operator(s) that the tippler cycle for the first wagon is complete and so the second wagon can be positioned.

4.6 Unloading subsequent wagons

The railway operator(s) check that both the rear coupler of the first (tipped) wagon and the front coupler of the second (next) wagon are both closed. This is to ensure that the wagons do not automatically re couple when they contact.

The railway operator(s) set the traffic lights to blue and instructs the locomotive driver (via radio) to push the rake forward and stop with the second wagon in the designated position on the Tippler.

Part way through this travel, the closed front coupler of the second wagon hits the closed rear coupler of the first wagon and the first wagon is pushed off the tippler and rolls away down the exit track gradient.

The railway operator(s) then release the front coupler of the third wagon (this is the nearside lever) and instructs the locomotive driver to reverse back until the third wagon is clear of the entry wagon sensor and outside of the building.

The railway operator(s) then signal (via an audible horn) to the plant operator that the tippler can tip.

From the control room the plant operator starts the tippler. With no further input from the plant operator, the tippler tips the wagon to unload the bulk material, pauses at the fully tipped position and then returns the wagon to rail level.

The plant operator signals (via an audible horn) to the railway operator(s) that the tippler cycle for the second wagon is complete, and the third wagon can be positioned.

The railway operator(s) open the front coupler of the tipped wagon. This ensures that when it rolls down the exit track gradient it will automatically recouple to the prevwus wagon, or the railway operator(s) open the rear coupler of the previous wagon (positioned some way down the exit track gradient).

This procedure is repeated until the last full wagon is positioned on the Tippler.

4.7 Unloading the last wagon

With the last full wagon stopped at the designated position on the Tippler (the empty/dummy wagon in front of the locomotive is part on the Tippler), the railway operator(s) then release the front coupler of the empty/dummy wagon (this is the nearside lever) and instructs the locomotive driver to reverse back until the empty/dummy wagon is clear of the entry ultrasonic sensor and aoutside the building.

[____]= empty/dummy

The railway operator(s) then signal (via an audible horn) to the plant operator that the Tippler can tip

From the control room the plant operator starts the Tippler. With no further input from the plant operator, the Tippler tips the last wagon to unload the copper concentrate, pauses at the fully tipped position and then returns the wagon to rail level.

[____]= empty/dummy

The plant operator signals (via an audible horn) to the railway operator(s) that the Tippler cycle for the last wagon is complete, and it can be pushed off the Tippler.

The railway operator(s) check that both the rear coupler of the last (tipped) wagon and the front coupler of the empty/dummy wagon are both closed. This is to ensure that the wagons do not automatically re couple when they contact.

The railway operator(s) set the traffic lights to blue and instructs the locomotive driver (via radio) to push the empty/dummy wagon forward and stop after hitting the last wagon and pushing it off the Tippler.

CAUTION: The locomotive must not travel onto the Tippler.

The locomotive then reverses back with the empty/dummy wagon to join the bypass track that runs parallel to the Tippler. The locomotive is then able to travel forward (provided other railway signalling allows this) and collect the rake of empty wagons on the Tippler exit track

5 Technical data

5.1 Environment

Ambient temperatures:+5C to +30C (design)

Relative humidity:55% to 75% average (design)

Max. wind speed/pressure:Not applicable to Tippler design as it operates inside a building.

Rainfall:5mm yearly maximum

Barometric pressure:1.01 bar

Altitude:10m above sea level

Saline/coastal:Arid, dusty, wet (from Dust Suppression), marine and adjacent to the ILO refinery from which corrosive gases may be emitted.

Location:The Tippler is located inside a building.

Dust suppression:A Dust Suppression System is included.

Dust Extraction:Dust extraction will be installed by the client.

Atmosphere:Without a Dust Suppression System, during the Tippler cycle, the atmosphere will become dust laden with the material handled (which is highly abrasive/corrosive). All equipment shall be designed to operate in these conditions.

Solar Radiation:Not applicable as the Tippler operates within a building.

5.2 Material handled

Material:Copper Concentrate

Size:1mm maximum

Moisture:9% average (sticky)

Angle of repose:32 nominal

Aerated bulk density:1.92 t/m (material unloaded from wagons onto +3.321m level)

Packed bulk density:2.24 t/m (material compacted in the wagons)

Material abrasiveness:Highly abrasive

Material corrosiveness:Highly corrosive

5.3 Track data

Rail gauge (K):1435mm (1505mm rail centres)

Rail type:115lb AREMA rail

168mm high x 69mm head width

Exit track profile:Downhill gradient sufficient to ensure the empty wagons roll away from the Tippler as a result of being impacted by the next wagon as the locomotive positions it onto the Tippler platform.

5.4 DutyAll components are designed for heavy duty continuous operation.Working hours per day:24 hours, continuous with frequent full load Operation.

Working days per month:12 days

Design Life:30 years

Utilisation:>90%

Availability:>90%

Bearing Life L10:60,000 hours minimum

Time Cycle:3 cycles per hour150 seconds Tippler tip/pause/return time

5.5 System throughputWagons unloaded per hour:10 maximum, basis if Tippler cycle by Schade.

Cycle time:360 seconds

Tippler cycle time:70 seconds tip,

10 second pause

70 seconds return

150 seconds total.

During commissioning, the Tippler pause duration at maximum tip angle can be increased to allow more time for any sticky material to be dislodged from the wagon by the vibrators, still maintaining the 10 wagons per hour throughput.

Wagon rotation:5 (nominal) platform tilt plus 155 Tippler rotation = 160 total.

5.6 Wagon specificaionOnly wagons in arcordance with SCHADE drawing 6966_00_006 rev 0, SPCC ILO PERU Wagon Details are to be handled by the tippler.

CAUTION: Locomotives are not allowed onto the tippler for any reason5.7 Electrical data

Suppl Voltages

LV Distribution:AC 480 volts 60Hz, 3 phase + neutral, 4 wire

AC 120 volts 60Hz, 1 phase + neutral, 2 wire

Transformer neutral point solidly grounded.

Control Circuits

MCC Starter Modules:AC 120 volts 60Hz

PLC Digital I/O:DC 24 volts

PLC Analogue I/O:4-20mA

Solenoids:DC 24 volts

Motors

LV Motors:AC 480 volts 60Hz

Instrumentation

Instrument Circuits:AC 120 volts 60Hz

DC 24 volts

Maintenance Power Circuits

Single Socket:AC 120 volts 60Hz

Welding Socket:AC 480 volts 60Hz

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Return

Direction

Tip

Direction

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Tip Direction

Return Direction

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HMI =

Human

Machine

Interface

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g

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LCS =

Local

Control

Station

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HMI =

Human

Machine

Interface

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LCS =

Local

Control

Station

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Tip Direction

Return Direction

Risikobeurteilung Reclaimer

37 of 40Operation manual2014-07-043