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Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
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CONTENTS
1. GENERAL........................................................................................................................... 3
2. CODES AND STANDARDS................................................................................................ 3
3. OPERATING CONDITIONS................................................................................................ 4
4. DESIGN AND CONSTRUCTION ........................................................................................ 5
5. SURFACE PREPARATION AND PAINTING .....................................................................10
6. ASSEMBLY AND TESTING...............................................................................................10
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
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1. GENERAL
This specification and all attachments hereto cover the furnishing of all labor, materials,
equipment and services in connection with the design, manufacture, testing and preparation for
shipment of a Hydraulic Rock Breaker and associated accessories for installation at Antapaccay
Crusher Station Dump Pocket.
It is the intent of this specification that this rock breaker shall be designed and supplied as
complete and operational system in accordance with the referenced specifications, drawings
and data sheets specified in Section 2 of the Material Requisition.
All equipment shall be suitable for the duty and service specified. Seller shall size all equipment,
drives and components to suit the site conditions specified in document “Technical Specification
for General Site Conditions for Antapaccay Project”, document N° 25429-220-3PS-G000-00001.
Seller shall provide foundation design requirements, including dimensioned general
arrangement drawings, dead live, operating and seismic loads for the foundations.
2. CODES AND STANDARDS
The materials, design, fabrication and testing of the Rock Breaker shall comply with the latest
issues, addenda and supplements of the applicable codes and standards issued by the
organizations listed below, as well as all applicable laws and regulations of local authorities.
ABMA American Bearing Manufacturer's Association
AGMA American Gear Manufacturer's Association
AISC American Institute of Steel Construction
AISI American Iron and Steel Institute
ANSI American National Standards Institute
ANSI B93 Hydraulic Standards for Industrial Equipment
ASCE American Society of Civil Engineers
ASME American Society of Mechanical Engineers
AWS American Welding Society
ASTM American Society for Testing Material
HI Hydraulic Institute
ISA Instrument Society of America
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
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ISO International Organization for Standardization.
JIC Joint Industry Council for National Fluid Power Association.
NFPA National Fluid Power Association
MSHA Mine Safety and Health Administration (U. S. Department of Labor)
NEC National Electrical Code
NEMA National Electrical Manufacturer's Association
OSHA Occupational Safety and Health Administration
SSPC Steel Structure Painting Council
IBC International Building Code
In case of conflict between codes and or standards, the most stringent shall apply.
3. OPERATING CONDITIONS
The Hydraulic Rock Breaker will be installed outdoors at the Crushing Station dump pocket
area, and will be operated in dusty environment. Run of Mine ore will be delivered by two 250 t
(metric) mine trucks and dumped directly into the dump pocket. The rock breaker will be used to
break the oversize and bridging rocks which are too large to enter the crusher. In addition, it will
be used for steering and positioning boulders for the crusher to digest without actual use of the
impactor.
The equipment shall also be used to break loose concave liners of a 1524×2870 mm (60”×113”)
gyratory crusher, and lift it. Extension bar tool with adequate length shall be provided for
concave removal. For liner weight refer to the Hydraulic Rock Breaker data sheets in the
Material Requisition.
Operation will be by remote control from two locations, one location will be from a portable radio
control above the gyratory crusher dump pocket and the other will be from an operator’s station
located in the Crusher Station control room.
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
.
4. DESIGN AND CONSTRUCTION
4.1 GENERAL
4.1.1 A turntable mounted hydraulic rock breaker designed to break any oversize run-of-mine
rock or maneuver rocks including lateral movement in the crusher dump pocket shall be
provided.
4.1.2 The equipment shall be the manufacturer’s extra heavy duty design, with proven service
record for the service specified and fully rated to operate at the elevation indicated in data
sheet.
4.1.3 The equipment availability shall be guaranteed at a percentage (of total time as minimum,
excluding scheduled maintenance, when is operated in accordance with Seller's operating
and maintenance instructions) as shown in the rock breaker Data Sheets.
4.1.4 The equipment and components shall be new and shall be fabricated according to the
Vendor’s standards, designed of extra heavy-duty construction, and suitable for the
specified operating conditions. Replacement parts shall be readily available.
4.1.5 The rock breaker must be able to place the hammer, or the attachment, into an assemble
stand, whose base shall be at the same elevation as the pedestal base, where the hammer
can be removed or tools safety replaced.
4.1.6 The rock breaker must be able to remove crusher liners using the hammer or a specific
attachment for that purpose.
4.1.7 Design shall comply with all requirements of “General Specification for Mechanical
Equipment”, document N° 25422-220-3PS-M000-00001.
4.1.8 The equipment and components shall be designed to withstand seismic loading without
damage in accordance with the “Technical Specification for Structural Requirements for
Mechanical Equipment”, document N° 25422-220-3PS-S000-00001.
4.1.9 The dynamic behavior of the breaker must be checked using FEM analysis (Finite Element
Analysis).
4.1.10 The bolting shall be ASTM A325 or A490.
4.1.11 All the hydraulic hoses shall be protected by a metal woven shield.
4.1.12 If the Seller finds it necessary to sublet any fabrication work, the Seller shall be required to
notify the Buyer and obtain approval in writing prior to subletting.
4.1.13 The Seller is responsible for ensuring that the equipment is constructed in accordance with
the specifications and codes referred to on the requisition and/or detail drawings. The
Buyer's review of the Seller's documents/material does not in any way relieve the Seller of
their responsibility for the accuracy of all dimensions and compliance with the applicable
codes, standards, detail drawings, specifications and all other applicable requirements
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
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4.2 MECHANICAL COMPONENTS
4.2.1 ROCK BREAKER HAMMER
4.2.1.1 The rock breaker hammer shall be capable of breaking quickly and effectively run-of-mine
rocks having dimensions indicated in the data sheet.
4.2.1.2 The hammer rated impact energy per blow shall be sufficient to meet the data sheet
conditions. The hammer shall be at least Class 7500 lb-ft, with actual impact energy 5700
J (4205 lb-ft) minimum, at 400 to 600 blows/min frequency.
4.2.1.3 The frequency of the hammer shall be adjusted by modifying the oil flow and/or the
nitrogen cushion chamber pressure. The frequency is varied in order to detach the
crusher concave liners or to break rock with different hardness.
4.2.1.4 The hammer side plates will be outfitted with lugs for material manipulation in the dump
pocket.
4.2.1.5 The hydraulic hammer shall be a complete unit, which mounts on the boom end, requires
hydraulic pressure and return quick disconnections only. Provisions shall be made to
recharge air/gas springs, permanent connection to a compressor or gas bottle is not
permitted.
4.2.1.6 The hammer shall be constructed of high strength structural steel with abrasion resistant
brackets protecting the working parts of the hammer.
4.2.1.7 The hammer shall have the ability to change the tool easily without special tools.
4.2.1.8 Tool material will have hardness and features according to ore features indicated in data
sheet.
4.2.2 ROCK BREAKER PEDESTAL AND BOOM
4.2.2.1 Pedestal shall be welded steel construction of heavy structural shapes and plate
designed to support the boom and hammer and resist overturning while material is
broken or pushed about.
4.2.2.2 The rock breaker boom shall be of extra heavy duty design to handle not only the
anticipated hammer loading, but also extreme side loading which occurs when
boulders are turned or moved to maximize utilization of the feed opening of the
crusher. The hinge and the boom shall be sized to withstand stresses and
deformations created by horizontal loads.
4.2.2.3 The rock breaker boom must be sized to reach the bottom row of concave liners with a
long reach bar tool.
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
.
4.2.2.4 The boom swing system shall be capable to swing up to a position as indicated in the
rock breaker data sheet. Hydraulic swing motors shall provide the swing movements.
4.2.2.5 The rock breaker boom shall be equipped with slewing stops to prevent damage to the
crusher control room or any other structure.
4.2.2.6 The boom shall be provided at the end with an adequate hook to lift the crusher concave
liners.
4.2.3 LUBRICATION SYSTEM
4.2.3.1 The rock breaker boom will be provided with a centralized automatic lubrication system.
4.2.3.2 The hammer shall be provided for automatic lubrication.
4.2.3.3 Bearings shall be provided with taconite seals to prevent entrance of dust particles.
4.2.4 HYDRAULIC CYLINDERS
4.2.4.1 The hydraulic cylinders installed on the boom shall be identical and interchangeable, if is
possible.
4.2.4.2 Hydraulic cylinders shall be double acting and shall have seals and wipers to protect
them from the dusty environment. Cylinders shall be clevis mounted with hardened
pins and replaceable, self-centering hardened bushing with lubrication fittings.
4.2.4.3 The hydraulic design shall include components (accumulators, relief valves.) which
shall protect the system from shocks and hydraulic over stressing. All components
shall be mounted to the pedestal.
4.2.5 HYDRAULIC UNIT
4.2.5.1 The unit shall include the following, as a minimum:
a. Hydraulic pump directly connected to the electric motor and oil cooler fan with
motor.
b. Reservoir with fill cap and pre filter, level switch, level gauge, temperature switch,
electric heater to reach the minimum operation temperature in two hours,
hygroscopic breather filter and drain. A drip pan shall be included to avoid oil
spilling on operating floor and the system shall include temperature control switch,
temperature sensing and protective element.
c. Relief valves as required.
d. Oil filters with 10-micron filters media and differential pressure indicator and high
differential pressure switch.
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
.
e. Air-oil cooler/heater with fan and motor and piping interconnections and necessary
temperature activated controls, sized in accordance to temperature described in
data sheet.
f. Complete piping between components.
g. Electric power and control circuits, control panel NEMA 4 enclosure.
h. Block valves arrangement for hydraulic control system.
i. A steel weldment base
4.2.5.2 The return oil piping shall be gravity flow type.
4.2.5.3 The hydraulic oil storage tank shall be vented to atmosphere through a 10-micron air
breather (10-micron nominal/30-microns absolute).
4.2.5.4 Heaters shall be provided to maintain the oil in the storage tank at optimum
temperature and the material shall be compatible with immersion in the hydraulic oil.
4.2.5.5 The oil storage tank shall be large enough so that the pumps do not recycle the oil more
than three times per minute, and the tank capacity shall be minimum three times the oil in
the system.
4.2.5.6 The high-pressure supply lines shall be provided with full flow filters with 10-micron filter
media (10-micron nominal/30 micron absolute) and the filters shall be provided with
differential pressure indicator and high differential pressure switch.
4.2.5.7 The low-pressure return lines shall be provided with full flow filters with 10-micron filter
media (10-micron nominal/30-micron absolute) and the filters shall be provided with
differential pressure indicator and high differential pressure switch.
4.2.5.8 The hydraulic power unit shall be skid mounted, from Vickers, Parker, Rexroth (Bosch) or
approval equal.
4.2.5.9 Hydraulic power unit shall be skid mounted and shall be located indoors. Interconnecting
piping shall be in the scope of work, quantities shall be in accordance with the lay out
drawings attached. Hoses shall be considered only for flexible connections at the boom
or hydraulic unit, accessories and fittings quantities shall be considered in 25% excess of
the best pipe route.
4.2.6 LUBRICANTS
4.2.6.1 All lubricant recommendations shall be suitable for the performance of the intended
function under the specified environmental conditions. This applies to both shop and
field lubricated items.
4.2.6.2 Seller shall recommend lubricant type, quantity and lubrication interval schedule for the
equipment.
4.2.6.3 Recommended lubrication intervals for the equipment shall be clearly shown on a chart or
drawing for maintenance purposes.
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
.
4.2.6.4 Seller recommendations will be used by the Buyer to supply all equipment lubricants and
what required for preoperational testing and commissioning of the equipment.
4.3 WELDING
4.3.1 All shop welding on the hydraulic rock breaker structure, hammer and equipments
shall be in accordance with the latest edition of the Structural Welding Code of the
American Welding Society, AWS D1.1, or approved equal standard of quality.
Manufacturer shall guarantee soundness and integrity of welds and materials used in
this equipment.
4.3.2 Magnetic particle examination will be used for spot-checking welds, or where Seller
deems appropriate. Acceptance criteria shall be per AWS D14.1, Section 10.16.
4.3.3 Welding of the rock breaker boom shall be full penetration with RT inspection as per
AWS D14.1, Section 10.9.
4.3.4 Customer inspection personnel shall perform tests as necessary prior to, during, and
after assembly and welding to ensure that materials and workmanship meet the
requirements of this specification.
4.4 ELECTRICAL
4.4.1 All electrical components shall be in accordance with “Technical Specification for
Electrical Equipment in Mechanical Packages”, document
N° 25429-220-3PS-EKP0-10001, and the specifications included in the Material
Requisition.
4.4.2 Seller shall provide with his bid anticipated maximum and average power requirements.
4.4.3 The Buyer shall bring wiring to a terminal box for ease of connection. All wires and
connections shall be clearly identified.
4.5 INSTRUMENTATION AND CONTROL
4.5.1 All instrumentation and control requirements shall be furnished in accordance with the
“Technical Specification for Instruments and Control Supplied with Packages Systems”,
document N° 25422-220-3PS-JQ07-00001.
4.5.2 The hydraulic Rock Breaker shall have two control stations; one portable radio operated
controller and one stationary control at the operators control room.
4.5.3 The hydraulic power unit controls shall include, at least, the following instruments:
a) Hydraulic power & lube pumps control.
b) A control loop for thermostatic control of the oil cooler fan motor and for the immersion
oil heater.
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. Technical Specification for Hydraulic Rock Breaker
25580-220-3PS-MFCK-00001-000
.
c) Low hydraulic oil level switch.
d) High and low hydraulic oil temperature indicators and switches.
e) Pressure switch for hydraulic oil pressure shutdown.
f) Differential pressure indicator and high differential pressure switch for suction filters.
g) Differential pressure indicator and high differential pressure switch for high-pressure filters.
4.5.4 Portable Radio Control
a) The portable radio control shall be radio controlled chest-pack type.
b) The portable radio control shall provide full positioning handling and provide access to all
Rock Breaker functions.
c) The portable radio control shall include joystick type controller, hydraulic power unit
controls, emergency stop and warning lights for all possible malfunctions.
d) The joystick controller shall be “dead man” type. The joystick shall control direction and
speed of all boom and hoist movements.
4.5.5 Stationary Control
The Stationary control shall provide the same operating capabilities as the portable unit.
5. SURFACE PREPARATION AND PAINTING
5.1 All exposed metal surface, except for machined surface, shall be prepared, primed, and
finish-painted in accordance with the manufacturer's standard procedure, previously
approved by Buyer.
5.2 Protection of machined surfaces during transit and storage shall be provided by a coat of
suitable anti-corrosive compound. All equipment shall be protected against atmospheric
exposure, both in transit and during outside storage at the jobsite.
6. ASSEMBLY AND TESTING
6.1 All equipment shall be shipped assembled to the greatest degree possible. Fasteners
and hardware required for installation, including holding down bolts, shall be shipped
with the equipment.
6.2 The Seller shall shop assemble all equipment and components, provide his own quality
control inspection and test to be carried out on the rock breaker.
6.3 The Seller shall test the complete rock breaker at jobsite. All movements shall be
checked and all critical dimensions shall be verified.
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