Professional Documents
Culture Documents
TOROMOCHO PROJECT
Owner Approval:
Date:
REV
DATE
BY
CHK
08-Feb-07
WT
BL
18-Apr-08
WT
WT
23-Apr-08
WT
30-May-08
AB
18-May-09
APPROVAL
DESCRIPTION
ISSUED FOR INTERNAL REVIEW
LN
GH/LN
BL
GH/LN
RG
ML
AI
02-Jun-09
RG
ML
MD / FA
03-Jun-09
DC
FEM
AIH
15-Jun-09
RGM
MLC
MDH / FAV
Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
INDEX
PAGE
1
SCOPE............................................................................................................................3
WORK EXCLUDED.........................................................................................................5
EQUIPMENT DESCRIPTION.......................................................................................... 6
LIST OF ATTACHMENTS............................................................................................. 14
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
SCOPE
Vendor shall furnish two (2) complete and operational cone crushers, including all
necessary accessories for the Toromocho Project located in central Peru, but
specifically exclude work listed in Section 2.
Vendor shall furnish drawings, data and descriptive information in the detail and
quantity required by this specification, VDRS (Vendor Document Requirement
Schedule) Form ENG-44, Drawing and Data Requirements and Appendix M.
1.1
WORK INCLUDED
The Vendor's scope of supply shall include, but is not limited to, items in the
following list:
Item
Qty.
Equipment No.
Description
210-CR-001 / 002
1A
210-CR-001-M
210-CR-002-M
210-LU-008 / 009
2A
210-PP-040-M
210-PP-041-M
210-PP-042-M
210-PP-043-M
210-HP-003 / 004
3A
210-PP-044-M
210-HP-045-M
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Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
1.2
Item
Qty.
Lot
Lot
SPECIAL
TOOLS
LIST,
as
recommended for installation, operation,
and maintenance (including pricing).
Lot
START-UP
AND
COMMISSIONING
SPARE PARTS LIST (including pricing
and availability). Vendor shall complete
the Recommended Spare Parts List
attached with Appendix M, Installation,
Operation and Maintenance Manuals.
Lot
Lot
Lot
Equipment No.
Description
ERECTION
Competent personnel may be required to aid the construction contractor in
erecting this equipment. This personnel would be in a supervisory capacity and
would only be requested to direct work to be done and offer advice on erection
procedures for this equipment, and certify that equipment is installed in
accordance with the manufacturers recommended procedures and is in an
operable condition. All required tools, equipment and erection personnel will be
supplied by others.
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Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
1.3
ALTERNATE QUOTATIONS
Alternate quotations will be considered in the event the Bidder is not in
agreement with any portion of this specification. However, Bidder must submit a
basic quotation completely in accordance with all terms and conditions set forth
herein. Alternates will be considered only as separate items and must be
submitted in the same form called for herein.
WORK EXCLUDED
Material unloading and storage
Foundation and anchor bolts
Erection labor and materials
Electrical wiring and conduits external to crusher and auxiliary systems
Feed and discharge chutes or boxes
Piping external to the crusher and auxiliary systems
Lubricants and hydraulic fluids
Service platforms, walkways, stairs, ladders, etc.
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Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
The equipment will be installed outdoors. The plant site is located at elevations
between approximately 4540 m and 5000 m above mean sea level. Equipment shall
be de-rated, as appropriate, for continuous operation at these elevations.
The crushers shall be designed for a minimum 25 years life expectancy, based on
continuous operation (24 hours per day, 7 days per week).
The crushers will be fed with SAG Mill Screens oversize and will discharge via
recirculating conveyor back to the SAG Mill.
The vendor is strongly advised to pay special attention to the sites high altitude
(5000 m.a.s.l) effect on electrical equipment. The reduced cooling/dielectric
capabilities of the air at sites altitude adversely affect operating temperatures,
insulation, continuous current, operating voltage, spacing between components
and BIL.
EQUIPMENT DESCRIPTION
5.1
GENERAL
The equipment shall be manufacturer's standard size and heavy-duty design
suitable for the conditions specified. Crusher rotation shall be manufacturer's
standard.
Crushers shall be equipped with Vendor's recommended dust seals for
protection of moving parts against wear and abrasion.
The selected equipment suppliers shall report to the single motor
manufacturer, with the equipment required brake horsepower without derated factors.
5.2
MATERIALS OF CONSTRUCTION
Crusher main frame and bowl shall be cast steel.
The Vendor shall be responsible for the abrasion resistance of the equipment
and shall include abrasion resistant linings wherever necessary. Wear surfaces
shall be protected with replaceable wear plates or castings of high abrasion
resistance alloy.
The bevel gears and pinions shall be of cast or forged steel, with cut teeth.
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
COMPONENTS
V-belt drive (if applicable) shall be furnished by the Vendor, complete with
jackshaft, belts, guard, sheaves, and taper-lock sheave hubs as selected and
recommended by the Vendor for the specified service (see Appendix A).
If crusher drive is direct, the countershaft shall be direct-coupled to the jackshaft
by means of a flexible coupling, installed on the countershaft and suitably
protected to avoid damage to exposed parts during transit, storage and field
assembly.
5.4
5.5
LUBRICATION
The crushers shall be provided with independent, automatic, packaged
lubrication systems, complete with reservoirs, heating and air oil cooling
systems, pump(s), pump motor(s), filters, valves, instrumentation, controls and
all accessories required to insure adequate lubrication. Conduit and wiring shall
be brought to terminal blocks in a junction box for external connections to be
made by others. External piping terminals shall be mounted on a rigid frame.
5.6
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
All motors for the Toromocho Project will be bought from a single motor
manufacturer. Selected equipment suppliers will be directed to purchase
their motors from this single motor manufacturer. All motors shall be
specified to develop their power rate at 5,000 m.a.s.l. and the Toromocho
Single Motor Manufacturer (TSMM) will design the motors accordingly to
work at the site conditions.
A price list (Doc. No. 000-EL-E-002) identifying the TSMM will be provided
by Aker Solutions to all selected equipment vendors and shall be used for
establishing individual motor prices.
6.2
Instrumentation and controls furnished shall include, but not be limited to the
following:
Lube oil supply line flow indication and low flow alarm switch
Lube oil supply line pressure indicator and low pressure alarm switch.
Lube oil filters differential pressure indication and high differential
pressure alarm
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
Lube oil return line temperature indication and high temperature alarm
switch
Cooling water low flow alarm switch (if applicable)
Cooling water temperature indications (if applicable)
Hydraulic setting and clearing system controls including a control panel
complete with electric drives start/stop controls, setting controller,
remote/local select switch, and necessary hydraulic safety system.
Automatic crusher regulation control system to optimize power draw,
including a control panel complete with feed rate controls, input power
monitoring and controls, remote/local select switch and necessary
controls and/or monitoring for feed level, lube oil temperature, hydraulic
pressure and closed side setting adjustment.
6.3
All alarm sensors shall be fully adjustable over their full operating ranges.
6.4
In addition to the above and other Vendors standard system controls, the
equipment shall also be provided with the following items to allow remote control
and/or monitoring by equipment provided by others.
All controller input/output shall be isolated and shall be able to accept a
remote setpoint signal of 4-20 mA dc.
All measured variables shall be made available as isolated 4-20 mA dc
signals.
All status and alarm signals shall be made available as isolated dry
contact closures rated minimum 5 A @ 120 V ac.
All start/stop or on/off push-buttons or switches shall be wired in a
manner that will make incorporation of remote controls readily possible.
All signal circuits shall be wired to Vendor supplied terminal strips to
permit field wiring by others.
6.5
7.1
PAINTING
All shop fabricated structural steel and miscellaneous iron, exposed surfaces of
platework and shop-fabricated machinery guards shall be shop-painted in
accordance with Aker Solutions General Specification 000-GC-S-012, Painting
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Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
7.2
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Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
7.3
ASSEMBLY
All equipment shall be assembled and all critical dimensions and fits checked
and tested by the Vendor to the extent feasible.
Prior to disassembly and shipping, all components that must be disassembled
for shipment shall be permanently match marked. Vendor shall submit a record
sketch or drawing showing all match marking to Aker Solutions. Items requiring
precision alignment and location shall be provided with a minimum of two (2)
dowel pins or fitted bolts to ensure proper alignment in the field.
Sub-assemblies, preferably, shall be as large as transportation and/or erection
facilities will permit. Vendor shall review the requirements of Appendix T,
Transport Constraints to ensure compliance.
7.4
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Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
Items shall be furnished with lifting lugs, if necessary, for crane handling. Lifting
lugs shall be positioned to give maximum balance with an even weight
distribution and minimize handling hazards. Each lug shall be designed to carry
a minimum of twice the lifting load. The gross weight of the lift shall be stenciled
or painted in a conspicuous location and identified as the gross lifting weight.
Lugs shall be painted yellow. All appropriate lifting lugs shall be fitted by the
Vendor.
All components shall be marked with destination, weights, etc. as well as with
special handling instructions. Each box shall be clearly marked as to contents
and numbered as to assembly sequence. All boxes must show the purchase
order number, item numbers and equipment number(s). The Vendor shall
provide packing lists for all boxes, enclosing one list inside each box and
securely fastening one list to the outside of each box. One copy of the
Installation Manual shall be included in the box with the equipment at the time of
shipment.
7.5
TAGGING REQUIREMENTS
All instruments, whether mounted on the equipment or shipped loose, shall have
a stamped 316 stainless steel tag firmly attached by stainless steel wire. Refer
to General Specification 000-GD-I-011 for tag details.
All equipment shall have a permanent stamped 316 stainless steel nameplate
attached that contains all pertinent identification and size information.
Identification shown shall include Aker Solutions / Owner Purchase Order
Number and Equipment Number (Tag No.).
7.6
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
performed under the supervision of the Vendor. During the trial run, the
Vendors representative shall train the operating personnel of the Owner.
When the plant is in normal operating condition, and the timing is again
agreeable to both Owner and Vendor, an operating test-run shall be performed.
The length of this test run shall be 2 weeks running 24 hours per day in
production use. The performance guarantee test run will be carried out after the
operating test-run (see Section 8).
TECHNICAL PERFORMANCE GUARANTEE REQUIREMENTS
8.1
PERFORMANCE GUARANTEES
A performance guarantee test run shall be carried out under the supervision of
the Vendors personnel. The length of the test run will be 24 hours and the
Vendor shall guarantee that the equipment is capable of continuous operation in
accordance with the design values given in Section 4, and Data Sheet A,
Operating and Design Conditions.
Bidder shall specify performance guarantees when operating under the design
case detailed in Section 4, and Data Sheet A, Operating and Design
Conditions.
The description and procedure details of the performance guarantee test-run
shall be provided by the Vendor and approved by the Owner prior to carrying
out the test-run.
All instruments and measuring devices required for the test-run shall be
provided by Owner. Vendor shall provide a list of the devices for test run.
Vendor shall review equipment layout drawings and advise location of any
necessary test stations and other facilities.
Operating personnel for the performance guarantee test run will be provided by
the Owner. All other costs associated with the test run as well as the costs of
any modifications required to achieve the performance guarantee values shall
be borne by the Vendor.
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
LIST OF ATTACHMENTS
The following documents are a part of this specification:
Data Sheet A: Operating and Design Conditions
Data Sheet B: Information Required from Vendor
210-MS-M-051: Motor Specification Sheets
210-VR-M-051: Form ENG 44, Drawing and Data Requirements
Vendor Document Requirement Schedule (VDRS)
210-VQ-M-051: Vendor Quality Plan with Attachments A and B
000-OT-M-001: Appendix A, Standard Technical and Site Data
000-OT-M-002: Appendix M, Installation, Operation & Maintenance Manuals
000-GD-E-021: Appendix F, De-rating of Motors for Altitude and Temperature
000-RP-R-001 Appendix T - Transport Constraints
Aker Solutions General Specifications:
000-GC-S-012: General Specification, Painting and Protective Coatings
000-GD-E-010: Package Equipment Electrical
000-GD-I-011: Package Equipment Instrumentation
Aker Solutions Electrical Equipment Specifications:
000-TS-E-013: Medium Voltage Induction Motors
000-TS-E-014: Low Voltage Motors
Aker Solutions Drawings:
210-FS-T-001, SAG Mill Area Flow Sheet
210-FS-T-002, Pebble Crushing Area Flow Sheet
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
DATA SHEET A
OPERATING AND DESIGN CONDITIONS
Page 1 of 1
Equipment Name: Cone Crushers
Feed- Description
- Characteristics
- Operating rate, Nom. (dry basis), t/h
- Operating rate, Design, (dry basis), t/h
- Temperature, C
- Bulk density range
Packed, kg/m
Loose, kg/m
- Abrasion index
- Crushability (work index)
- Moisture, % by weight
- Specific gravity (dry solids)
- Maximum lump size, mm
- Size distribution (calculated), mm
13
Not Available
Feed from
Crushing Circuit
Mechanical availability, %
Location
Duty
80
Outdoor
Continuous
24 hr/d, 7 d/wk
Note: 1 t = 1 tonne = 1,000 kg
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
DATA SHEET B
INFORMATION REQUIRED FROM VENDOR
Page 1 of 5
Equipment No.: 210-CR-001 / 002
2/2/0
Vendor
FLSmidth-Excel
Manufacturer
FLSmidth-Excel
Model No.
XL1100
Manufacturer Location
Crusher - Type
Cone Crusher
2280 mm
1690 mm
- Drive type
13 1233
150 mm
- Eccentric throw, mm
215 305
P80 = 13 mm at 13 mm C.S.S.
1910 mm
700 mm Inner/1000 Outside
Mantle
- Material
Manganese
- Maximum thickness, mm
154 mm
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
DATA SHEET B
INFORMATION REQUIRED FROM VENDOR
Page 2 of 5
Equipment No.: 210-CR-001 / 002
Eccentric
- Diameter of outer eccentric bearing, mm
- Bearing material
700 mm
Leaded Bronze
N/A
- Lubrication description:
Main Frame
- Material
- Top diameter, mm
4060 mm
- Base dimensions, mm
3950 mm
Bowl
- Recommended bowl type (fine, medium,
coarse)
- Bowl material
SH-Medium
ASTM A148 grade 90/60
SH-Medium
- Liner material
Manganese
152 mm
Spiral Bevel
- Manufacturer
Overton
19 / 19.9 mm
AISI 4320 Forged Alloy Steel
560-722 BHN
52/19.9 mm
267 mm
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
DATA SHEET B
INFORMATION REQUIRED FROM VENDOR
Page 3 of 5
Equipment No.: 210-CR-001 / 002
T&U Labyrinth
Countershaft Box Blower
Price Engineering
20,670 kPa
16
- Motor kW / r/min
37 kW
- Description:
Submersible Gear
Automation Option
(See Quotation)
Lubrication System
- Manufacturer
Price Engineering
- Oil flow, m /h
46
204-448
- Model
- Tube material
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Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
DATA SHEET B
INFORMATION REQUIRED FROM VENDOR
Page 4 of 5
Equipment No.: 210-CR-001 / 002
- Net area, m2
LATER
15 kW / 1160 / 380-3-60
- Torque Design
- Full load torque, N-m
Later
125%
200%
LATER
Direct Drive
- Couplings - Manufacturer
HD Falk Coupling
- Size
80 R10
- Type
Wrap Flex
Jackshaft
- Diameter, mm
177.8 mm
- Length, mm
1498.6 mm
V-belt Drive
- Manufacturer
1016 mm
- Speed ratio
TBD
16 8 V
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Project C-560
Technical Specification 210-TS-M-051
Cone Crushers
Rev.3
DATA SHEET B
INFORMATION REQUIRED FROM VENDOR
Page 5 of 5
Shipping and Handling Data
- Cone crusher, kg (each unit)
153.370 kg
1043 kg (Dry)
1930 kg (Dry)
153,370 kg
162,410 kg
- Shipping volume, m x m x m
216,037 m3
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3
Enter: 0, 1, 2, 3, or 4
ITEM
Aker Solutions
Vendor
1.
2.
Certificates of Compliance
3.
Test Pieces
4.
Heat Treatment
5.
Weld Procedures
6.
Welder Qualifications
7.
8.
Radiography
Ultrasonics
10.
11.
Prototype Tests
12.
14.
Performance Test
15.
Running Test
16.
17.
Pressure/Leak Test
18.
Balancing
19.
Continuity/Megger Test
20.
M & TE Calibrations
21.
22.
Visual Inspection
23.
Drawing Dimensions
24.
Packing
25.
Tagging/Marking
26.
INSPECTOR INITIAL&
DATE ACCEPTANCE
REMARKS
ASTM E94
ASTM E165/ASTM E709
x
13.
ACCEPTANCE CRITERIA
9.
*Contact Aker Solutions prior to proceeding with items designated as Witness or Hold Points.
Aker Solutions Engineer to witness Test Numbers ______________________________
Supplier Quality Program Requirements are defined in Attachment A
Supplier Quality Surveillance Instructions are defined in Attachment B
Revision
Date
Prepared by
Approved by
Reviewed by Inspection
01-June-09
RG
ML
MD / FA
16-June-09
DC
FEM
15-June-09
RGM
MLC
MDH / FAV
Remarks