Crusher IOM 5400491a

SPECINT.DOC CRUSHER 10 SEPT 2001REV 1

FFE MINERALSMINERA ESCONDIDA LIMITADAPHASE IV EXPANSION PROJECT

CHILE, S.A.

60” X 113” PRIMARY CRUSHER

INSTALLATION, OPERATION,MAINTENANCE, AND SPARE PARTS

MANUAL

Prepared by

FFE Minerals USA Inc.3235 Schoenersville Road

Bethlehem, PA 18017-2103 USA(610) 264-6900

FFE Minerals Chile Ltda.Barros Errazuriz 1954, Of. 708

Providencia, Santiago, Chile(562) 341 1026

Fax (562) 341 0484


FFE MINERALSMINERA ESCONDIDA LIMITADA

PHASE IV EXPANSION PROJECTCRUSHER

OPERATING MANUAL

BASIC RULES REGARDING SAFETY IN AND AROUND A CRUSHINGPLANT ARE OUTLINED IN THIS MANUAL IN SECTION 2.0, SAFEJOB PROCEDURES.OPERATOR SAFETY—AND THE SAFETY OF OTHERS—DEPENDSUPON REASONABLE CARE AND JUDGEMENT IN THE OPERATIONOF THIS CRUSHER. A CAREFUL OPERATOR IS GOOD INSURANCEAGAINST AN ACCIDENT.MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARECAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUN-DAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON, MOSTACCIDENTS CAN BE PREVENTED BY RECOGNIZING HAZARDSAND TAKING STEPS TO AVOID THEM BEFORE AN ACCIDENT OC-CURS.REGARDLESS OF THE CARE USED IN THE DESIGN AND CON-STRUCTION OF THIS TYPE OF EQUIPMENT, THERE ARE CONDI-TIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINSTWITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY ANDEFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS IN-STRUCTION MANUAL TO HIGHLIGHT THESE CONDITIONS.

SAFETY




OPERATING MANUALTABLE OF CONTENTS

SECTION

1.0 INTRODUCTION1.1 Equipment Technical Data1.2 Process and Operating Data1.3 Ordering Parts

2.0 SAFE JOB PROCEDURES2.1 Lifting2.2 Confined Spaces2.3 Hearing Protection2.4 Hand Tools2.5 Powered Hand Tools2.6 Using Hammers and Bars in Close Quarters2.7 High-Pressure Air2.8 High-Pressure Water2.9 High-Pressure Hydraulic Systems2.10 Transfer Points and Discharge Chutes—Cleaning

and Unplugging2.11 Overhead Cranes and Rigging Practices2.12 Using a Pedestal Crane2.13 Wire Hoisting Rope2.14 Working in Bins and Hoppers2.15 Feeders and Conveyors—Working Around and

Cleaning2.16 Hydraulic Oil2.17 Safety Showers and Eyewash Stations2.18 Material Safety Data Sheets

3.0 EQUIPMENT DESIGN3.1 Equipment/Component Description and Function3.2 Alarm Fault/Cause/Remedy Chart3.3 Process Control

3.3.1 Process Variables3.4 Control Loops3.5 Interlocks

3.5.1 Crusher Software and Hardwired Interlocks





SECTION3.0 EQUIPMENT DESIGN (continued)

3.5.1.1 Crusher Software3.5.1.2 Crusher Hardwired

4.0 INSTALLATION (English and Spanish)4.1 Storage Instructions4.2 Component Installation Sequence and Instructions4.3 Gear Backlash Setting and Measurements4.4 Bolt Torque Schedule

5.0 INITIAL COMMISSIONING (English and Spanish)5.1 Safety Precautions5.2 Commissioning Plan

5.2.1 Definitions5.2.2 Commissioning Sequence Flowchart

5.3 Precommissioning Checks5.3.1 Precommissioning Instructions

5.3.1.1 Crusher AssemblyPrecommissioning Checks

5.3.1.2 Bearing Lubrication SystemPrecommissioning Checks

5.3.1.3 Hydraulic Adjustment SystemPrecommissioning Checks

5.3.2 Precommissioning Datasheets5.3.2.1 Mechanical Precommissioning

Checks5.3.2.2 Switch and Transmitter

PrecommissioningCalibration/Test Datasheet

5.3.2.3 Lubrication System Precommis-sioning Mechanical Checksheet





SECTION

5.0 INITIAL COMMISSIONING (continued) 5.3.2.4 Lubrication System Precommis-

sioning Electrical Checksheet5.3.2.5 Lubrication System Precommis-

sioning Instrument Checksheet5.3.2.6 Hydraulic Adjustment System

Precommissioning MechanicalChecksheet

5.3.2.7 Hydraulic Adjustment SystemPrecommissioning ElectricalChecksheet

5.3.2.8 Hydraulic Adjustment SystemPrecommissioning InstrumentChecksheet

5.4 No Load Commissioning Checks5.5 Initial Start-Up With Feed

6.0 OPERATIONS (English and Spanish)6.1 Operational Philosophy

6.1.1 Local Operation6.1.2 Remote Operation6.1.3 Maintenance Operation

6.2 Start-Up Procedures6.2.1 Preoperational Inspection6.2.2 Start-Up From Complete Shutdown6.2.3 Start-Up From Standby Shutdown6.2.4 Start-Up From Emergency Shutdown6.2.5 Start-Up From Power Failure

6.3 Shutdown Procedures6.3.1 Complete Shutdown6.3.2 Standby Shutdown6.3.3 Emergency Shutdown6.3.4 Power Failure

6.4 Operating Considerations





SECTION

6.0 OPERATIONS (continued)6.4.1 Ore Receiving and Crushing Routine

Inspection6.4.2 Adjusting the Crusher Open-Side Setting6.4.3 Clearing the Crusher6.4.4 Clearing a Gyratory Crusher Jammed With

Tramp Metal6.4.5 Unblocking the Crusher

7.0 MAINTENANCE7.1 Technical Specifications7.2 Component or Subsystem Operating Limits7.3 Material Specifications7.4 Paint and Coating Specifications7.5 Physical Dimensions and Weight of Components7.6 Preventive Maintenance Checksheets

7.6.1 Mechanical/Lubrication7.6.1.1 Crusher Assembly—Daily7.6.1.2 Crusher Assembly—Weekly7.6.1.3 Crusher Assembly—Monthly7.6.1.4 Crusher Assembly—Major7.6.1.5 Lube Oil System—Daily7.6.1.6 Lube Oil System—Monthly7.6.1.7 Lube Oil System—Annual7.6.1.8 Hydraulic Adjustment System—

Daily7.6.1.9 Hydraulic Adjustment System—

Monthly7.6.1.10 Hydraulic Adjustment System—

Annual7.6.1.11 Spider Bushing Lubrication

System—Daily7.6.2 Electrical





SECTION7.0 MAINTENANCE (continued)

7.6.2.1 Crusher Main Drive Motor—Weekly

7.6.2.2 Crusher Main Drive Motor—Monthly

7.6.2.3

7.6.2.4

Crusher Main Drive Motor —AnnualCrusher Lube Oil System—Weekly

7.6.2.5 Crusher Lube Oil System—Monthly

7.6.2.6 Crusher Lube Oil System—Annual

7.6.2.7 Crusher Hydraulic AdjustmentSystem—Weekly

7.6.2.8 Crusher Hydraulic AdjustmentSystem—Monthly

7.6.2.9 Crusher Hydraulic AdjustmentSystem—Annual

7.6.3 Instrumentation7.6.3.1 Crusher Assembly—Quarterly7.6.3.2 Crusher Lubrication System—

Quarterly7.6.3.3 Hydraulic Adjustment System—

Quarterly7.6.3.4 Spider Bushing Lubrication

System—Quarterly7.7 Predictive Maintenance Forecasts for Crusher

Components Subject to Wear7.8 Troubleshooting (Problem Solving)

7.8.1 Troubleshooting the Traylor TC GyratoryCrusher

7.8.2 Recommended Troubleshooting Test7.9 Component Replacement and Selected Repair Procedures 7.9.1 Disassembly of Crusher

7.9.2 Inspection of Parts for Wear and Damage





SECTION7.9.3 Rebuild the Hydraulic Cylinder Assembly7.9.4 Charge the Hydraulic Adjustment System

Accumulator7.9.5 Countershaft Assembly Component

Replacement7.9.6 Adjusting Backlash on a New Gearset7.9.7 Mantle Replacement7.9.8 Epoxy Backing Material Preparation7.9.9 Main Shaft Core Replacement7.9.10 Replacement of Contact Split Seal Rings7.9.11 Replacement of Concaves7.9.12 Lining Spider Pockets

8.0 BILLS OF MATERIAL9.0 LUBRICANT LIST10.0 AIR AND WATER REQUIREMENTS11.0 ELECTRICAL LOAD LIST12.0 FIELD INSTRUMENT LIST13.0 INPUT/OUTPUT SIGNAL LIST14.0 FFE MINERALS FUNCTIONAL SPECIFICATION

FOR ELECTRICAL CONTROL OF THE CRUSHERAND ITS AUXILIARY SYSTEMS

15.0 DRAWINGS15.1 Drawing List

16.0 GLOSSARY OF TERMS

MINERA ESCONDIDA LIMITADAPHASE IV EXPANSION PROJECT

1.0PAGE 1 OF 1

CE10.DOC CRUSHER AUG. 2001REV 0

1.0 INTRODUCTIONThe primary crusher is a crushing machine that reduces ore from the mine in prepara-tion for downstream crushing and grinding. Run-of-mine (ROM) ore is fed to thecrusher. The crusher reduces the material size and discharges the crushed ore fortransport to the downstream facilities.

The Escondida crusher size designation is 60 inches by 113 inches. This size desig-nation means the crusher measures 60 inches from the uppermost part of the top rowof concaves to the head nut on the main shaft. The crusher measures 113 inches indiameter at the widest diameter at the bottom of the lower mantle liner. The crusheris powered by a 1,000-hp motor.

The crusher technical and operating data are included in the following sections:

1.1 Equipment Technical Data

1.2 Process and Operating DataAt various places in this manual, Warnings, Cautions, Notes, and EnvironmentalAlerts are used to provide the reader with particularly important information. In thismanual, these terms have the following significance:

Information concerning safety to personnel; an injurycould result if this information is not heeded.

Information concerning possible equipment damage;equipment could be damaged if this information is notheeded.

Supplementary information not directly affecting safetyor damage to equipment.

Information concerning possible impact on the envi-ronment and actions required for prevention andproper response.


1.1PAGE 1 OF 2


1.1 EQUIPMENT TECHNICAL DATA

The following tables include the technical data for the Escondida Project crusher.

TABLE 1.1.1GENERAL CRUSHER DATA

Specification Data

Crusher size 60 inches by 113 inches

Crusher type Primary gyratory with hydraulic support

Crusher drive motor size 1,000 hp, 500 rpm

Gyrations per minute 121

TABLE 1.1.2CRUSHER SHELL DATA

Specification Data

Concave rows 4

Type installation Pinned

Number of concaves per row 16

Concaves’ material of construction Row 1 WS 7HMS 514-578 HBRow 2 WS 14EPX 444-555 HBRow 3 WS 14EPX 444-555 HBRow 4 WS 7DM 380-480 HB

Backing material Epoxy

TABLE 1.1.3CRUSHER MANTLE DATA

Specification Data

Mantle rows 3

Material of construction ASTM A-128 Gr. E-1

Backing material Epoxy


1.1PAGE 2 OF 2


TABLE 1.1.4CRUSHER LUBRICATION SYSTEM DATA

Specification Data

Lubrication pump type/rating Screw/360 Lpm (95 gpm)/690 kPa (100 psi)

Lubrication pump motor 11 kW (15 hp)/1450 rpm/460 V/3 ph/50 Hz

Lubrication reservoir capacity 3,785 L (1,000 gal)

Lubrication reservoir heaters (3) 6 kW (8 hp)/460 V/3 ph

Cooling pump type/rating Screw/360 Lpm (95 gpm)/690 kPa (100 psi)

Cooling pump motor 11 kW (15 hp)/1,450 rpm/460 V/3 ph/50 Hz

Heat exchangers Air-cooled, single pass

Heat exchanger fan motor 11 kW (15 hp)/730 rpm/460 V/3 ph/50 Hz

Eccentric 170 Lpm (45 gpm)

Countershaft 19 Lpm (5 gpm)

Flow rate per supply line

Crusher bottom 170 Lpm (45 gpm)

Lubrication oil type SSU @ 37.8ºC (100°F) = 1,500

Spider lubrication system pump/type Graco/pneumatic

Grease type Summer NLGI No. 1Winter NLGI No. 2

Dust seal grease NLGI No. 1

TABLE 1.1.5CRUSHER HYDRAULIC ADJUSTMENT SYSTEM DATA

Specification Data

Hydraulic pump type/rating Gear pump/17 Lpm (4.5 gpm)/6,900 kPa (1,000 psi)

Hydraulic pump motor 5.6 kW (7.5 hp)/1,450 rpm/460 V/3 ph/50 Hz

Hydraulic reservoir capacity 568 L (150 gal)

Hydraulic oil type SSU @ 37.8ºC (100°F) = 1,500

Hydraulic reservoir heaters (2) 1.5 kW (2 hp)/220 V/1 ph/50 Hz

Accumulator type/nominal size Bladder/10 L (5 gal)

Accumulator gas/pressure Nitrogen/2,069 kPa (300 psi)


1.2PAGE 1 OF 2


1.2 PROCESS AND OPERATING DATA

The following tables include the process and operating data for the Escondida Projectcrusher.

TABLE 1.2.1GENERAL CRUSHER DATA

Specification Data

Crusher size 60 inches by 113 inches

Crusher type Primary gyratory with hydraulic support

Crusher drive motor size 745.7 kW (1,000 hp)

Crushing circuit Open circuit

Operating schedule 365 days per year24 hours per day

Dump pocket size 600 tonnes (live)

Discharge hopper size 800 tonnes (live)

TABLE 1.2.2CRUSHER FEED DATA

Specification Data

Material Porphyry copper ore

Source Run-of-mine

Specific gravity 2.8

Moisture content 4.5

Bulk density 1.8 for volume, 2.1 for weight

Maximum feed size 1,200 mm (47 in) x 1,800 mm (71 in)

Compressive strength 50 MPa to 70 MPa

+254 mm (+10 in) 6 percent

-254 mm +127 mm(-10 in +5 in)

17 percent

-127 mm +25 mm(-5 in +1 in)

44 percent

Feed size distribution

-25 mm(-1 in)

33 percent


1.2PAGE 2 OF 2


TABLE 1.2.3CRUSHER PRODUCTION DATA

Specification Theoretical Data

20 cm (8 in) 11,260 tonnes per hour


70 cm (27.5 in) 6.970 tonnes per hour

Crusher production capacity at ROM feedmaximum size


200 mm (8 in) 94 percent passing



Product size distribution



1..3PAGE 1 OF 1

CE13.DOC CRUSHER 07 AUG. 2001REV 0

1.3 ORDERING PARTSWhen ordering parts, use the crusher serial number and part number. The crusher se-rial number is listed below. The part number is located on the Bill of Material of thesub-assembly that includes the part being ordered.

CRUSHER SERIAL NUMBER 99-31325-720


2.0PAGE 1 OF 1

SPEC20.DOC CRUSHER 07 AUG 2001REV 1

2.0 SAFE JOB PROCEDURESTo ensure employee safety, safe job procedures have been prepared for specific tasks.These tasks can be handled safely if all personnel recognize potential hazards, de-velop safe work habits, and follow the proper procedures.

The following is a list of the specific safe job procedures for the crusher area:

2.1 Lifting

2.2 Confined Spaces

2.3 Hearing Protection

2.4 Hand Tools

2.5 Powered Hand Tools

2.6 Using Hammers and Bars in Close Quarters

2.7 High-Pressure Air

2.8 High-Pressure Water

2.9 High-Pressure Hydraulic Systems

2.10 Transfer Points and Discharge Chutes—Cleaningand Unplugging

2.11 Overhead Cranes and Rigging Practices

2.12 Using a Pedestal Crane

2.13 Wire Hoisting Rope

2.14 Working in Bins and Hoppers

2.15 Feeders and Conveyors—Working Around andCleaning

2.16 Hydraulic Oil

2.17 Safety Showers and Eyewash Stations2.18 Material Safety Data Sheets

♦ Microx (Epoxy) Hardener♦ Microx (Epoxy) Resin♦ Nordbak (Epoxy)


2.1PAGE 1 OF 3

LIFTING.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.1 LIFTING

SPECIAL EQUIPMENT REQUIREDBack support

INTRODUCTIONAnyone at the facility may be involved in lifting objects. Whether lifting is an everydayjob or an occasional task, lifting improperly can cause serious injury regardless of theweight of the object or the physical condition of the person lifting the object. Alwaysfollow proper lifting procedures to reduce the risk of injury. Being physically ready to dothe job can further reduce the risk of injury. For example, doing a few basic exercisesbefore starting work can warm up the body and prepare it for strenuous work.

INSTRUCTIONS 1. Check and understand the requirements of the activity. The activity may present a

risk, particularly of back injury, if it entails one or more of the following require-ments:

• Over-frequent or over-prolonged physical effort involving, in particular, thespine.

• An insufficient bodily rest or recovery period.

• Excessive lifting, lowering or carrying distances.

• A rate of work imposed by a process that cannot be altered by the employee.

2. The employee may be at risk if not properly prepared or trained, and could be atrisk if he/she is:

• Physically unsuited to carry out the task in question.

• Is wearing unsuitable clothing, footwear, or other personal effects.

• Does not have adequate or appropriate knowledge or training.


2.1PAGE 2 OF 3


3. Check the characteristics of the load to be lifted. Lifting the load may present arisk, particularly of back injury, if the load is:

• Too heavy or large.

• Unwieldy or difficult to grasp.

• Unstable or has contents that may shift.

• Positioned in a manner requiring it to be held or manipulated at a distancefrom the trunk or with a bending or twisting of the trunk.

• Likely, because of its contours or consistency (or both), to result in injury toemployees, particularly in the event of a collision.

4. Clear the area of obstructions, litter, tripping hazards, and slipping hazards.

5. Plan ahead and prepare the area where the object is to be placed.

6. Check the characteristics of the working environment. The working environmentmay present a risk, particularly of back injury, if:

• There is not enough room, in particular vertically, to carry out the activity.

• The floor is uneven (thus presenting tripping hazards) or slippery in relation tothe employee’s footwear.

• The place of work or the working environment prevents the handling of loadsat a safe height or with good posture by the employee.

• There are variations in the level of the floor or the working surface, requiringthe load to be manipulated on different levels.

• The floor or footrest is unstable.

• The temperature, humidity, or ventilation is unsuitable.

7. Test the weight to be lifted. If it is too heavy, get help. A physical effort maypresent a risk, particularly of back injury, if it is:

• Too strenuous.

• Only achieved by a twisting movement of the trunk.

• Likely to result in a sudden movement of the load.

• Made with the body in an unstable posture.

8. Move close to the load.


2.1PAGE 3 OF 3


9. Place one foot slightly ahead of the other foot, about 25 to 30 centimeters.

10. Squat down close to the load by bending at the knees.

11. Keep the back straight.

12. Place hands under or around the load, and get a good grip with the palms to keepthe load from slipping. (Remember: the palms are stronger than the fingers.)

13. Using leg muscles, lift gradually. Do not jerk or twist.

14. Keep the load close to the body.

15. Rotate body position by shifting the feet. Do not rotate the back.

16. Set the load down gradually by bending at the knees.

17. Keep a straight back when lowering the load.

18. Be especially careful when lifting in tight spaces, and protect fingers at all times.

19. Get help for bulky or heavy loads.


2.2PAGE 1 OF 3

C-SPACES.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.2 CONFINED SPACES

SPECIAL EQUIPMENT REQUIREDOxygen gas detectorCombustible gas detectorAir line respirator with egress unit (as directed)Self-contained breathing apparatus (as directed)

INTRODUCTIONA confined space is any location so enclosed that natural ventilation may not reduce aircontaminants to levels below the threshold limit value (TLV), and where entry may resultin injury due to any of the following:

• An atmosphere that may be flammable or explosive.

• Lack of oxygen required for breathing.

• Toxic materials which, upon contact with the body or through inhalation, could resultin injury, health impairment, or death.

• General safety hazards such as steam, high-pressure gases or liquids, or other work-area hazards that could result in serious injury.

All areas that are considered to be confined spaces are marked accordingly to warn em-ployees of the potential hazards associated with entering the area.

INSTRUCTIONS 1. Employees who will enter the confined space must obtain a permit from the plant

manager’s office. The permit must be displayed in the working area at all times.

2. The supervisor who is immediately responsible for work in a confined space mustdo the following:

2.1. Inspect the area for hazards.

2.2. Test the confined space as follows:

2.2.1. Check the confined space for flammable or explosive potential.

2.2.2. Test the atmosphere for combustible gases by using a combusti-ble gas detector. No one may enter the space until the source ofthe combustible gas has been isolated and the confined space issafely free of that gas.


2.2PAGE 2 OF 3


Never enter an enclosure that is an explosion hazard.

2.2.3. Ensure that the confined space has adequate natural ventilationand/or install explosion-proof fans and ducts for air delivery. Ifthe area is still oxygen-deficient (less than 19.5 percent oxygen)after using positive ventilation, use a self-contained breathing ap-paratus or air line respirator.

Never use internal combustion engines inside enclosedspaces.

2.3. Check the confined space for toxic or corrosive materials. When toxic orcorrosive materials that could result in injury by contact or inhalation arepresent, perform the following:

2.3.1. Empty the confined space and flush it with a generous amount ofpressurized water until safe limits for the hazardous materials arereached.

2.3.2. Welding, burning, or heating in a confined space may generatetoxic fumes and gases. Everyone in such a confined space must beprotected by adequate ventilation or an air line respirator withegress unit.

2.3.3. Those entering a confined space that contains corrosive materialsmust wear eye protection and other appropriate protective equip-ment.

2.4. Check equipment to be used and general conditions of the space as fol-lows:

2.4.1. All entryways (such as gates, ducts, and piping) that may allowhazardous materials to enter the confined space must be discon-nected or locked out at valves or similar locations according tostandard lockout procedures.

2.4.2. Equipment items (such as screws or blades) in the confined spacemay be placed in motion by outside commands. Deenergize andlock out these items according to standard lockout procedures.


2.2PAGE 3 OF 3


2.4.3. For those hazards that cannot be eliminated, adequate personalprotective equipment must be provided and used.

2.4.4. Verify that alarm devices indicating the presence of gas or oxygendeficiency are in good condition.

2.4.5. Make available and ready for use appropriate emergency equip-ment, including at least two self-contained breathing units. Ensurethat all workers in the confined space have been trained to use theemergency equipment.

2.4.6. At least one person must be immediately available outside the con-fined space to provide assistance if necessary.

2.4.7. In the case of a rescue attempt, self-contained breathing units mustbe used.

2.4.8. Prepare a rescue plan in the event of an emergency. Communicatethe plan to all workers in the confined space and ensure that eve-ryone fully understands the plan.

2.4.9. All workers in confined spaces must wear a safety harnessequipped with a lifeline if deemed appropriate by management.

2.5. Determine that the area is safe and sign specific written authorization towork in the confined area.

2.6. Ensure that all employees understand entry procedures and how to use allemergency equipment.


2.3PAGE 1 OF 1

HEARING.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.3 HEARING PROTECTION

SPECIAL EQUIPMENT REQUIREDNone

INTRODUCTIONNoise is a deceptive hazard. Workers can be exposed to considerable amounts ofnoise and not be aware that they may have suffered permanent injury. Noise intensityexceeding an average of 90 decibels over an 8-hour period can cause hearing loss.This intensity exists in most industrial and processing plants. Noise also increases aworker’s fatigue and stress level. Eventually, it presents additional hazards when theworker is unable to clearly hear instructions or warning signals.

The selection and wearing of adequate hearing protection is part of the company’ssafety policy and should be taken seriously by employees.

INSTRUCTIONS 1. Know the types of hearing protection available in your area. The two basic

types of hearing protection are earplugs and ear muffs. In extreme noise-exposure areas, earplugs and ear muffs are recommended.

2. Select the hearing protection that is most comfortable and effective. Protec-tion that is uncomfortable is not likely to be worn as often as needed.

3. Always follow the manufacturer’s instructions for cleaning and storage of re-usable ear protection.

4. Be conscientious about using hearing protection anytime there is exposure tonoise.

5. Always use hearing protection in areas where it is required.


2.4PAGE 1 OF 4

HTOOLS.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.4 HAND TOOLS


INTRODUCTIONHand tools that are in poor condition or misused are a major cause of accidents in theworkplace. Proper maintenance and necessary replacement of hand tools are criticalto reducing accidents and injuries. All workers must ensure that their tools are safe touse, in good repair, adequate for the work, and free of defects.

INSTRUCTIONS 1. Workers must inspect their hand tools before use to ensure that they are in

proper working order. Damaged or defective tools must be reported to the su-pervisor and must be repaired or removed from service.

2. Personnel must inspect the tools to ensure that the tools are in proper workingcondition and meet appropriate guidelines.

3. Tools and jigs especially designed for a specific purpose should be checked bya qualified person to ensure that there are no inherent or hidden safety hazards.

4. Proper and appropriate personal protective equipment must be worn when us-ing all tools.

5. All tools must be cleaned and properly stored after use. Each tool must haveits own storage area to prevent damage. This is particularly important withpower tools.

6. Tools must not be used beyond their manufacturer’s designed capacity sincesuch use may create a personal hazard. Tools must be used solely for theirintended purpose. The designed capacity of tools must not be exceeded byunauthorized attachments.

7. Power drills, disc sanders, grinders, and both circular and chain saws (whenused in the hand-held mode) must be operated with deadman controls that re-quire constant hand pressure.

8. Circular saws and chain saws must not be equipped with devices that lockonto the operating controls.


2.4PAGE 2 OF 4


9. Face shields or goggles must be worn when operating a grinding wheel.

10. Power saws, grinders, and other power tools must have proper guards in placeat all times and must be properly grounded. Those with automatically adjust-ing guards must be inspected for proper movement.

11. Power tools must be hoisted or lowered by hand line and never by the cord orhose.

12. All fuel-powered tools must be shut down while being refueled. Smoking isprohibited during refueling operations. Other nearby sources of ignition, suchas burning and welding, also must be halted during refueling operations.

13. Chisels, screwdrivers, and pointed tools should never be carried in a pocket.They should be carried in a toolbox, cart, carrying belt, tool pouch, or in thehand with points and cutting edges away from the body.

14. Inspect and check the following common hand tools:

14.1. Screwdrivers: Ensure that handles are smooth and clean and that bitsare sharp and square. A sharp square-edged bit will not slip as easilyas a dull rounded one and requires less pressure. When workingaround electrical-current-bearing equipment, use an insulated screw-driver as a secondary precaution.

14.2. Hammers: Ensure that handles are unbroken and clean and that theface of the head is smooth and clean. Hammers are made in varioustypes and sizes, with varying degrees of hardness and different con-figurations for specific purposes. Use the correct hammer for the cor-rect purpose.

14.2.1. Common Nail Hammers: These are designed for driving un-hardened common nails, finishing nails, and nail sets by us-ing the center of the hammer face. Nail hammers are madewith a curved, straight, or ripping claw.

14.2.2. Ball-Peen Hammers: These are designed for striking chiselsand punches and for riveting, shaping, and straightening un-hardened metal.

14.2.3. Sledge Hammers: Sledge hammers are designed for generalsledging operations in striking wood, metal, concrete, orstone.


2.4PAGE 3 OF 4


14.2.4. Bricklayer’s Hammers: Bricklayer’s hammers are designedfor chipping mortar and for setting and cutting (splitting)bricks, masonry tile, and concrete blocks. They should not beused to strike metal or to drive struck tools.

14.2.5. Riveting and Setting Hammers: These are designed for driv-ing and spreading unhardened rivets on sheet metal work,forming sharp corners, closing and peening seams and lockedges, and glazing points.

Consult manufacturers for specific needs in other types of hammers.Always wear safety glasses when using a hammer. Ahammer blow should always be struck squarely. Avoidglancing blows.

14.3. Punches: Punches are designed to mark metal and other materials thatare softer than the point end, to drive and remove pins, and to alignholes. Never use a punch with a mushroomed struck face or with adull, chipped, or deformed point. Any bent, cracked, or chipped punchmust be removed from service.

14.4. Chisels: Cold chisels have a cutting edge for cutting, shaping, and re-moving metal softer than the cutting edge. Factors determining theselection of a cold chisel are the material to be cut, the size and shapeof the tool, and the depth of the cut to be made. Ball chisels held byone person and struck by another require the use of tongs or a chiselholder to guide the chisel.

14.5. Files: Ensure that tangs are protected by handles and that teeth aresharp and clean. The correct way to hold a file is to grasp the handlefirmly in one hand and use the thumb and forefinger of the other toguide the point. Push the file forward while bearing down on it. Re-lease the pressure and bring the file back to its original position. Neveruse a file without a smooth, crack-free handle. Select the proper filefor the work.

14.6. Knives: Ensure that the handle is guarded and that the blade is sharp.The cutting stroke should be away from the body. Avoid jerky mo-tions. Keep knives and other sharp hand tools separated from othertools. With the knife’s sharp edge turned away from the hand, wipethe blade with a towel or cloth. Do not substitute knives for can open-ers, screwdrivers, or ice picks.


2.4PAGE 4 OF 4


14.7. Shovels: Keep shovel edges trimmed, and check handles for splinters.When not in use, hang up shovels, stand them against walls, or keepthem in racks or boxes.

14.8. Wrenches (Spanners): Safe use of all wrenches requires that the useralways be alert and prepared for the possibility that the wrench mayslip, the fastener may suddenly turn free, or the wrench or fastener maybreak. The user must always inspect the wrench for flaws.

14.8.1. Open-End Wrenches: Open-end wrenches have strong jawsand are satisfactory for medium-duty turning.

14.8.2. Box and Socket Wrenches: These wrenches are necessary fora heavy pull. Never overload the capacity of a wrench byusing a pipe extension on the handle or by striking the handlewith a hammer. When possible, use penetrating oil to loosentight nuts.

14.8.3. Socket Wrenches: Socket wrenches should be kept clean ofdirt and grime inside the socket to ensure that the tool fits se-curely on the bolt or nut.

14.8.4. Adjustable Wrenches: Adjustable wrenches are generallyrecommended for light-duty work. Place the adjustablewrench on the nut with the open jaws facing the user;wrenches should be pulled, not pushed.

14.8.5. Pipe Wrenches: Both straight and chain pipe wrenches musthave sharp jaws and be kept clean to prevent their slipping.The handle of every wrench is designed to be long enough forthe maximum allowable safe pressure. Do not use handleextensions to gain extra turning power unless the wrench isso designed. Never use a pipe wrench on nuts or bolts.

Pliers may be used for gripping and cutting operations,but they are not a substitute for a wrench.


2.5PAGE 1 OF 2

POWRTOLS.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.5 POWERED HAND TOOLS

SPECIAL EQUIPMENT REQUIREDNoneINTRODUCTIONPowered hand tools in poor condition or misused are a major cause of accidents in theworkplace. Proper maintenance of powered hand tools is critical to reducing accidentsand injuries. Everyone must ensure that his or her tools are safe to use, in good repair,adequate for the job, and free of defects.All power tools operate at 220 V. Powered sockets are available to minimize trailingleads.INSTRUCTIONS

1. All tools must be inspected before their use to ensure that they are in properworking order. Damaged or defective tools must be repaired or removed fromservice.

2. Tools of all apprentices and tradespeople must be inspected by an authorized per-son at least twice a year to ensure that tools are in proper working condition andmeet requirements. Inspection lists must be prepared, inspections must be made,and records must be kept under the direction of the maintenance superintendent.

3. All electric power cords must be inspected before use. Do not use power toolswith frayed cords, cords with exposed wiring, power tools with cords not properlysecured to the tools, or power tools with defective electrical plugs.

4. Tools and jigs especially designed for a specific purpose should be checked by aqualified person to ensure that there are no inherent or hidden safety hazards.

5. Proper and appropriate personal protective equipment must be worn when usingall tools.

6. All tools must be cleaned and properly stored after use. Each tool must have itsown storage area to prevent damage. This is particularly important with powertools.


2.5PAGE 2 OF 2

POWRTOLS.DOC CRUSHER 1 OCT 2000REV 0

7. Tools must not be used beyond their manufacturer’s designed capacity since suchuse may create a personal hazard. Tools must be used solely for their intendedpurpose. The designed capacity of tools must not be exceeded by unauthorizedattachments.

8. Power drills, disc sanders, grinders, and both circular and chain saws must be op-erated with deadman controls that require constant power pressure.

9. Circular saws and chain saws must not be equipped with devices that lock ontothe operating controls.

10. Power saws, grinders, and other power tools must have proper guards in place atall times and must be properly grounded. Those with automatically adjustingguards must be inspected for proper movement.

11. Power tools must be hoisted or lowered by hand line and never by the electricalcord or hose.

12. Inspect the fuel system of all fuel-powered tools before use. Look for leaks andproperly fitting petrol tank caps.

13. All fuel-powered tools must be shut down while being refueled. Smoking is pro-hibited during refueling operations. Other nearby sources of ignition, such asburning and welding, also must be halted during refueling operations.

14. Power tool bits and blades should never be carried in a pocket. They should becarried in a toolbox, carrying belt, tool pouch, or in the hand with points and cut-ting edges away from the body.


2.6PAGE 1 OF 2

HAMBAR.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.6 USING HAMMERS AND BARS IN CLOSE QUARTERS

SPECIAL EQUIPMENT REQUIREDWork gloves

INTRODUCTIONHammers and bars serve many purposes throughout the plant, including:

• Unplugging chutes, bins, and transfer points that have become blocked with wetor lumpy material.

• Prying open inspection doors and covers.

• Serving as levers to lift objects for easier handling or better gripping.

Using hammers and bars can be hazardous any time, but the danger greatly increaseswhen these tools are used near other equipment, structures, or personnel. Since ham-mers and bars are often used in close or restricted quarters, extra care must be taken toprevent injury (e.g., being struck by the tools or caught in a pinch point).

INSTRUCTIONS 1. Thoroughly examine the work area. Determine how much room there is to

work, including side and overhead clearances. Clean up spills in the area,particularly oil or grease, that can cause slippery footing.

2. If the work is to be done in, on, or near power equipment, lock it out accordingto the established company lock and tag procedure.

3. Wear gloves and properly fitting safety glasses when using bars or hammers.

4. Use only bars that are in good condition; bars that are not in good conditionmust be removed from service. Bars must be straight, free of sharp snags, andhave ends that are not badly mushroomed. If necessary, bars should be sharp-ened before use.

5. Do not stand on or jerk a bar to increase the force of the leverage. Do notstraddle the bar. Keep clear of the bar’s potential path of travel.

6. Keep hands and other body parts clear of striking points when using a ham-mer.


2.6PAGE 2 OF 2

HAMBAR.DOC CRUSHER 1 OCT 2000REV 0

7. Do not hammer on any part of the bar except the end intended for that pur-pose.

8. Do not hammer on any part of another hammer or similar tool. The extremehardness of these tools can cause them to splinter, sending metal fragmentsflying at great velocity throughout the immediate vicinity.

9. Use adequate lighting in the working area.

10. Return tools to their proper storage area when the job is completed.Be careful and know personal limits! Avoid personalinjury and injury to others while working in close quar-ters.


2.7PAGE 1 OF 2

HP-AIR.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.7 HIGH-PRESSURE AIR

SPECIAL EQUIPMENT REQUIREDGoggles or face shieldEar protection

INTRODUCTIONAll employees must understand the potential hazards of working near air compres-sors, high-pressure air pipelines, and pressure vessels, as well as the necessary pre-cautions they must take when working under these conditions. Air escaping from ahigh-pressure pipeline, tank, or vessel is extremely dangerous because of its high-energy content and its ability to enlarge small leaks rapidly into major ruptures.

INSTRUCTIONS 1. Keep away from air leaks of any kind and flag the area to keep other people

away.

2. Immediately notify the shift supervisor.

3. Properly authorized, qualified personnel must test and inspect safety reliefvalves in accordance with the manufacturer’s recommendations and companypolicy. Request clarification from the shift supervisor if there are questionsregarding these valves.

4. In accordance with the company’s equipment isolation policy, close and lockout of service the upstream block valve(s) when working on high-pressurevessels or pipelines.

5. Equipment and piping subject to high pressure are normally equipped withvents, drains, emergency relief valves, and/or flushing connections that allowfor the lowering (letdown) of pressure. Before opening equipment, be certainthere is no measurable gauge pressure on the equipment.

6. Before working on pressure-related equipment (described previously), makesure all drain and vent valves are opened slowly. Be certain that no one isnear the discharge openings.

7. Confirm that air hoses are of the correct size and pressure rating for the serv-ice in which they are to be used and that connections at the ends are in properorder.


2.7PAGE 2 OF 2

HP-AIR.DOC CRUSHER 1 OCT 2000REV 0

8. Never use air hoses and lances in a playful manner. Air pipes frequently con-tain small particles of rust and metal that can discharge at high speed andcause serious injury.

9. Do not direct air streams toward people and never use high-pressure air forcleaning clothes or equipment.

Do not attempt to investigate the cause of a high-pressure air leak while the vessel or pipeline is underpressure.

Do not tamper with relief valves or place any part of thebody over them. Do not paint relief valves.


2.8PAGE 1 OF 1

HPWATER.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.8 HIGH-PRESSURE WATER

SPECIAL EQUIPMENT REQUIREDFace shield

INTRODUCTIONWorking around high-pressure water is dangerous. The force exerted by the high-pressure water stream can injure people and equipment.

INSTRUCTIONS 1. Keep away from leaks along high-pressure water lines and at high-pressure

tanks and vessels.

2. Immediately report any detected leaks to the supervisor and maintenance de-partment in order that the system can be promptly inspected and the problemquickly corrected. Switch to standby water supply equipment if possible.

3. If work is done on a high-pressure water system, lock out upstream valves andpumps according to the lockout procedures.

4. Before opening and working on equipment, ensure that the equipment doesnot contain water under pressure.

5. Leaks may develop at flanges, around outlets, at valves, etc. If these are onthe discharge piping, stand clear of the leak.

Do not attempt to find the cause of a leak while the pipe-line is under pressure. Ensure that everyone is clear ofthe discharge point of the pipeline.


2.9PAGE 1 OF 1

HPHYDSYS.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.9 HIGH-PRESSURE HYDRAULIC SYSTEMS


INTRODUCTIONHydraulic fluid under high pressure is potentially dangerous. When hydraulic fluidunder high pressure escapes the system through a leak, it exerts a force that can causeinjuries and damage equipment.

INSTRUCTIONS 1. Keep away from leaks along high-pressure hydraulic lines. If any leak is ob-

served, immediately investigate the system and correct the problem. Reportany detected leaks to the supervisor and to the maintenance department.

2. If work is to be done on a high-pressure hydraulic system, upstream supplyline valves must be closed and locked out. Hydraulic pumps must be turnedoff and locked out, provided they do not also supply other parts of the systemwhere there are no leaks and/or where interruption of hydraulic pressure couldpose a problem. Closed valves and shutdown pumps must be locked out inaccordance with the company lock-tag procedure.

3. Equipment and piping are provided with valves, vents, and drains that allowthe release of entrapped pressure. Make certain there is no pressure on thesystem (pressure gauges read zero) before opening and working on equipment.

4. Leaks may develop at hose connections, around outlets, at valves, etc. Standclear of the leak.

Do not attempt to find the cause of a leak while the sys-tem is under pressure.


2.10PAGE 1 OF 1

TPDCHT.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.10 TRANSFER POINTS AND DISCHARGE CHUTES—CLEANING AND UNPLUGGING

SPECIAL EQUIPMENT REQUIREDApproved safety harness and safety lineWork glovesKeyed lockout locks

INTRODUCTIONAccumulated material can build up or plug any ore transfer point. Do not enter achute or hopper unless attached to a safety line that is securely tied off.

When entering a chute or hopper, lock out equipment upstream and downstream usingthe company approved lockout procedure.

INSTRUCTIONS 1. Lock out (according to the lockout procedure) all feeders, conveyors, and

similar equipment ahead of and under the transfer point to be entered.Be especially careful to ensure that nuclear level detec-tors are locked out. Be familiar with the locations of allof these devices.

2. Station a person outside the transfer chute to observe and monitor workers in-side.

3. Before entering the transfer point, put on an approved safety belt that is se-curely tied off.

4. Clear away overhead hanging material before entering the chute. Never workunderneath hanging material.

5. Protect portable lighting against breakage. Position lights so that they cannotburn anyone.

6. When unplugging a transfer point, be aware of the potential for material fal-ling from any direction. Since the space at transfer points is usually very re-stricted, special precautions must be taken when using the various toolsneeded to free the blockage.


2.11PAGE 1 OF 10

CRANE.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.11 OVERHEAD CRANES AND RIGGING PRACTICESSPECIAL EQUIPMENT REQUIREDGloves (when rigging)INTRODUCTIONThe purpose of this safe job procedure is to give overhead crane operators precisesafety rules.RESPONSIBILITYOnly one operator is responsible for any given crane operation. That person is ulti-mately responsible for the entire job and must ensure that it is completed in a safefashion. The operator is responsible for making sure the daily inspection routine forthe crane has been completed. The operator must run the equipment correctly, ensurethat all personnel in the path of the load have been cleared out, and make sure the jobhas been properly concluded. The operator must designate no more than one personas the signal person and must receive signals from that person alone. The exceptionis an emergency signal, which can be given by anyone and must be acknowledged bythe operator.CRANE OPERATION 1. Efficient and safe overhead crane operation requires concentration and a rigid

application of established practices and rules of safety. Safe crane operationis the operator’s responsibility. Where an operator and a rigger or spotter areworking as a crew, the ultimate responsibility is with the operator who han-dles the controls of the crane.

2. Do not operate a bridge crane:• With an uncorrected sight or hearing disability.• Without training and authorization to operate the crane.

3. The first user of any crane each day must make a thorough inspection.3.1. Be sure to use the correct control for the crane. Try the trolley left or

right. If there is no movement, find out what is wrong; the wrong re-mote control may be in use.

3.2. Check wire rope and hooks (refer to the section on rigging below).


2.11PAGE 2 OF 10


3.3. Check the limit switches without a load on the hook. At slow speed,run each travel and hoist motor to its limit. If any limit is not working,tag out the crane and report the situation to a supervisor immediately.Check the brakes with each load. Raise the load just clear of the rest-ing position and then watch to see if it lowers itself.

4. Make sure pendants are not interfering with rope movement.

5. Pan the lift through the entire crane and load movement. If any part of the liftoperation passes into an area which does not have complete visibility from theoperator’s position, has restricted access, or may pass over a personnel accessway, an observer must be assigned and/or appropriate barriers placed beforethe lift begins.

6. To avoid swinging, place the crane directly over the load before lifting it.

7. Check that all hooks are safe and that loose materials have been removed fromthe load before starting a lift.

8. Sound the horn to give warning that there is a load to be lifted, lowered, ormoved. If people are working in the area, give them time to move away.Verify that the area is fully cleared before moving the load.

9. Operate controls smoothly and gradually to avoid swinging the load.

10. When the load is ready to be hoisted, take the slack out of all components andthen lift very slowly, watching for lateral movement (swinging) of the load.Once the load is off the ground and at a reasonable travel height, begin travelat slow speed. When lowering the load, go slowly in the latter stages.

11. Before traveling with the load, make sure that the load is high enough to clearany obstacle below. Do not carry a load over anyone or over any rotatingequipment. When traveling with a load, have a spotter precede the load towarn anyone near its path.

12. When starting or slowing down, do so gradually. For small movements, inchthe load (advance step by step).

13. To stop a swinging load, move the hook toward the load just as the load is atthe outside of its swing and begins to come back toward vertical. Move ap-proximately half the distance of the swing and then stop. The load shouldstop swinging. If the load is swinging and you are about to begin travel, waituntil the load just starts to swing in the direction of travel, then begin move-ment in that direction. No further corrections should be needed.

14. Always obey a stop signal, no matter who gives it.


2.11PAGE 3 OF 10


15. The lifting cables of the bridge crane must be kept vertical. Do not use theoverhead crane to pull sideways.

16. Never lower the hook so far that it leaves less than two complete circles ofcable in the drum. If the cable becomes unwound, make sure it is rewound inthe right direction. (If it is rewound in the wrong direction, the high-levellimit switch will not work.)

17. Use tag lines on all loads that could rotate and hit other objects. 18. Loads should have no unattached pieces on board. If loads are lifted on a

pallet, all pieces of the load should be tied down. 19. Never carry loads heavier than the overhead crane capacity. 20. Never disable or remove limit switches. 21. Never lift more than the safe working load capacity of the cables, chains, etc.

Always be aware of the break-free load when lifting fitted pieces. 22. Never leave an unattended load hanging from the overhead crane. 23. Use the standard overhead crane hand signals when operating the overhead

crane. (Refer to Figure 2.11.5.)

RIGGING PRACTICESThe size of the load is the main factor, though not the only factor, to consider whenselecting the type of equipment to be used to rig the load. The weight of the equip-ment must be included in calculations when determining the choice of rigging equip-ment. It is far better to overrig for a task than to underrig.

1. Determine the center of gravity. If the load is uniformly shaped, the center ofgravity is at the center of the shape. It may be difficult to determine the centerof gravity of oddly shaped objects, however. Ask the supervisor if there isany doubt as to the location of the center of gravity. (See Figure 2.11.1.)

2. Make sure that the hook and lift points (points of attachment) are verticallyabove the center of gravity. It is not always possible to place the lift points di-rectly above the center of gravity so it may be necessary to take additionalprecautions. However, this is not usually a problem. Support can be main-tained with additional chokers.


2.11PAGE 4 OF 10


FIGURE 2.11.1CENTER OF GRAVITY

3. Determine the hitch to be used. Often the equipment has lift points providedfor the purpose, or the problem is relatively simple. Sometimes, however, theproblem is more complex. Figure 2.11.2 shows the six hitches most oftenused.


2.11PAGE 5 OF 10


FIGURE 2.11.2HITCHES

4. Determine the loads of the hitch components. The main components of mostrigging hitches are slings. In order to determine the proper sling, several fac-tors must be taken into consideration. They are:

4.1. The Number of Slings to Be Used: If more than two slings will beused, assume that all of the load could be taken by two of the slings.

4.2. Sling Angle: This is the angle between the sling and an imaginaryplumb line from the hook. For a given load, tension in a sling is leastwhen the sling is vertical (sling angle is 0 degrees). As the sling angledeparts from vertical, the tension in the sling increases. Once the slingangle passes 60 degrees, the tension in each sling is greater than theweight of the load. Figure 2.11.3 illustrates the effects of various slingangles applied to a 1,000-kg load. Figure 2.11.4 is an example of howto calculate load.


2.11PAGE 6 OF 10


FIGURE 2.11.3EFFECT OF SLING ANGLE ON LOADS

Determine the tension by the following method:

4.2.1. Measure the vertical distance from the hook to the plane inwhich the hitch points lie.

4.2.2. Divide the length of the sling by the value measured in Step4.2.1. above.

4.2.3. Multiply the result calculated in Step 4.2.2 above by the loadthat the sling must support.


2.11PAGE 7 OF 10


FIGURE 2.11.4LOAD CALCULATION

5. Select the appropriate equipment. All slings, connectors, eyebolts, turnbuck-les, shackles, chain falls, and come-along in a leg must be able to support thetension that particular leg will carry. The capacity of the rigging equipmentshould be written or stamped legibly on the piece. If it is not, check with asupervisor.

5.1. Bends: Tension increases when slings must go around sharp cornersor bends. The tighter the radius of the bend, the more tension pro-duced. Use softeners, or corner irons, to alleviate sharp bends. In achoker hitch, the bend made by the choker increases the sling tensionby about 33 percent. A basket hitch reduces the tension (assumingthere are no sharp bends at the bottom and both legs are vertical) bydistributing the load evenly through each leg.

6. Inspect all rigging equipment for signs of wear or damage.

6.1. Wire Rope Slings: Check for:

• Kinking.

• Bird-caging or unraveling.

• Broken wires.

• Overstretching.

• Damaged eyes or eye splices.


2.11PAGE 8 OF 10


• Corrosion.

• Excessive wear (shiny or smooth spots on the rope).6.2. Chains: Check for:

• Wear (diameter less than 90 percent of new).

• Overstretching (less than 10 percent stretch is allowed).

• Cracks.

• Broken welds.6.3. Hooks, Shackles, Eyebolts, and Turnbuckles: Check for:

• Spreading of the throat (15 percent maximum allowed).

• Safety latch in place on all hooks.

• Cracking.

• Twisted shank.

• Cracking or distortion of the eye in an eyebolt.

• Damaged threads.

• Improperly substituted shackle pins (a bolt or anything other than aproper shackle pin is not allowed).

7. If eyebolts are used, shackles must be used to attach the eyebolt and the sling.Align the plane of the eyebolt with the eye of the sling to avoid twisting forcewhen the strain is taken up.

8. If there is any sling angle, use a shoulder-type eyebolt. The shoulder shouldmake complete contact with the load. An eyebolt should not be used if thesling angle exceeds 45 degrees. Use straight-shank eyebolts for vertical liftsonly.

9. Never put a hook through an eyebolt. A shackle should be used to connect thetwo.

10. Put shackle pins through the eyes of eyebolts or turnbuckles. The hook shouldrest next to the body of the shackle.

11. Shackle pins should be finger-tight, not backed off.

12. Shackles should be positioned for a direct pull, not at an angle.


2.11PAGE 9 OF 10


13. If a sling is used to make a choker, a shackle should be used rather thanchoking through the eye of the sling. The shackle pin should go through theeye of the sling.

14. Slings should not be twisted.

15. A choker should never be forced tighter than its natural fit. If the hitch mustbe tighter, use a double-wrap choker hitch or double-wrap basket hitch.

16. Do not attach more than two slings directly to a hoist hook at one time. Use alarge shackle instead.

17. Attach slings with integral hooks so that the hooks turn outwards.

18. Never double-wrap a sling around a hook, eyebolt, shackle, or anywherewhere a tight turn will result.


2.11PAGE 10 OF 10


FIGURE 2.11.5HAND SIGNALS


2.12PAGE 1 OF 3

PEDCRANE.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.12 USING A PEDESTAL CRANE


INTRODUCTIONThis safe job procedure gives pedestal crane operators precise safety rules.

INSTRUCTIONS1. Crane safety is the operator’s responsibility.

2. Efficient and safe pedestal crane operation requires concentration and a rigid ap-plication to the practices and established rules of safety.

3. Supervisors must authorize the operation of industrial equipment after the operatorhas been instructed on proper use.

4. Pedestal crane operators must not:

• Operate equipment with an uncorrected sight or hearing disability.

• Operate equipment unless trained and authorized to operate the crane.

5. Do not remove limit switches.

6. Check the pedestal crane (cables and slings) at the beginning of each use. Makesure all limit switches, brakes, and other safety mechanisms are in good workingorder. If a defect is found, report it immediately to a supervisor.

7. Never use the pedestal crane when the limit switches are defective or the cables arein poor condition.

8. Plan the lift through entire crane and load movement. If any part of the lift opera-tion passes into an area which does not have complete visibility from the opera-tor’s position, has restricted access, or may pass over a personnel access way, anobserver must be assigned and/or appropriate barriers placed before the lift begins.

9. Place the hook directly over the load before lifting it. Otherwise, the load will startto swing.

10. Before moving the load, make sure that the load is high enough to clear any obsta-cle below. (Do not carry a load over anyone.)


2.12PAGE 2 OF 3


11. When starting or slowing down the swing, do so gradually. For small movements,inch the load (advance step by step).

12. Always obey a Stop signal—no matter who gives it.

13. Operate controls smoothly and gradually to avoid swinging the load. Take up theslack in cables before lifting loads.

14. The lifting cables of the pedestal crane must be kept vertical. Do not use the ped-estal crane to pull sideways.

15. Never lower the hook so far that it leaves less than two complete circles of cable inthe drum. If the cable is unwound, make sure it is rewound in the right direction;otherwise, the High Level Limit switch will not work.

16. Verify that the area is clear before moving the load. If people are working in thearea, give them time to move away. Ensure that the area is clear before proceedingwith the lift.

17. Never lift heavy loads that could overload the pedestal crane’s capacity. Allow foradditional loading to break free fitted parts.

18. Never lift more than the safe working load capacity of the cables, chains, etc.

19. Check the brakes by moving the control to the Neutral position after a lift of someinches. If the load does not move, the brake is working properly.

20. Never leave a load hanging from the pedestal crane unattended.

21. It is an operator’s and rigger’s responsibility (if a rigger is used) to check that allhooks are safe and that all loose materials have been removed from the load beforestarting a lift.

22. Never use the pedestal crane when the switch has been tagged with a defectiveequipment note.

23. Use the standard crane hand signals when operating the pedestal crane. (Refer toFigure 2.12.1.)


2.12PAGE 3 OF 3


FIGURE 2.12.1HAND SIGNALS


2.13PAGE 1 OF 7

WIREROPE.DOC CRUSHER 1 OCT 2000REV. 0

SAFE JOB PROCEDURE

2.13 WIRE HOISTING ROPE

SPECIAL EQUIPMENT REQUIREDLeather work gloves

INTRODUCTIONWire ropes must be inspected every 3 months. The exterior of wire ropes must becleaned and regreased every 3 months. Always wear leather gloves when handlingwire ropes.

Abuse and neglect are the two chief enemies of wire rope. The rope can be abused innumerous ways, such as careless and improper reeling and unreeling, use on sheavesthat are worn or of incorrect size, improper storage, bad splicing, etc. Neglect, how-ever, means a lack of lubrication in almost every case.

Avoid adverse handling conditions such as jerking, allowing slack in the rope, accel-erating the load too rapidly, impact (from sudden stopping of the load), permittingropes to drag over obstacles, causing reverse bends, allowing wire rope to become wetby running the rope through water, exposing wire rope to fumes of acids or alkalis,allowing ropes to become overheated by friction or subjecting ropes to excessive heatof any kind, and shifting operating ropes from one job to another.

INSTRUCTIONSUnloading, Storing, Uncoiling, Unreeling, and Installation 1. When unloading, use web slings to unload steel wire ropes. The hook of a

crane or the prong of a forklift truck might damage the rope.

2. Ropes should be stored in a clean, cool, and dry place. They must be keptclear of the floor. Ropes stored outside must be protected against rain.

3. Uncoil wire rope by using an uncoiling stand or by rolling the coil along theground. Make sure the ground is clean.

4. Unreel wire rope by using an unreeling stand.

5. Never unwind wire ropes without rotating the coil or reel. Otherwise, the ropewill tend to form loops during installation or service. When pulled taut, theloops form kinks.


2.13PAGE 2 OF 7


6. During installation, the rope should travel from the top of the reel to the top ofthe drum or from the bottom of the reel to the bottom of the drum. A reversebend creates problems.

7. The first operations with a new rope should be carried out with low loads.

InspectionRope inspection books must be kept for all ropes. The result of each inspection mustbe recorded in these books, which must also contain the work certificates supplied bythe rope manufacturer.

The supervisor entrusted with the inspection must ascertain the general condition ofthe rope by inspecting its whole length. The following findings must be recorded:

• The wear of external wires.

• Rust.

• Loosening of the wire rope structure.

• Changes in shape.

• Crushed wires and strands.

• Damage to seizings.

The wire rope must be freed from grease and dirt in several places for the inspection.

During intermediate inspections, special attention must be given to the parts of therope that run over pulleys or are close to rope suspension or rope attachment points.

A maximum of five broken wires in one lay, or three wires in one strand in one lay, ispermissible.

1. Inspect the steel wire ropes regularly. Keep a record of the rope’s diameter,the lay length, broken wires, or other defects. Discard the rope in time (whileit is still safe).

2. Ropes having nodes, contractions, knots, or kinks must be rejected.

See Figure 2.13.1 for illustrations of rope defects.

LubricationTo grease a whole rope, the whole length of the rope must be removed and laid out.However, it must not be dragged along the ground because dirt and foreign materialwill adhere to it, increasing the rate of wear.


2.13PAGE 3 OF 7


If the whole length of the rope is not removed and laid out, the grease should be ap-plied by brush where the rope runs around the drum or a pulley and the strands areforced slightly apart. This allows the grease to penetrate into the rope more easily.

FIGURE 2.13.1ROPE DEFECTS


2.13PAGE 4 OF 7


FIGURE 2.13.2COMPONENTS OF A WIRE ROPE

GLOSSARY OF WIRE ROPE TERMSThe WireThe basic element of wire rope is the wire, usually round but sometimes shaped (referto Figure 2.13.2). It is cold-drawn to the desired diameter and desired physical prop-erties after special heat-treating. Most wire is made to one of two grades—ImprovedPlow Steel (IPS) or Extra Improved Plow Steel (XIP), which has about 15 percentgreater tensile strength. Both grades are carbon steel that is tough and resists wear.When the wire has a natural finish, it is called bright. Otherwise it is plated, galva-nized, or may have some other surface treatment for special applications.The CoreRope cores are usually one of three types:

1. Fiber rope core—either natural sisal fiber or man-made fiber such as polypro-pylene.

2. Wire rope core—literally an independent wire rope, which is called IWRC.

3. Strand core—a typical wire rope strand.The primary purpose of a rope core is to provide a foundation, or support, for thestrands. Approximately 7.5 percent of the rated strength of a six-strand IWRC rope isattributed to the core.


2.13PAGE 5 OF 7


The StrandsThe greatest differences between wire ropes occur in the number of strands and in thenumber and pattern of wires per strand. There are two general types: round strandsand strands that have been shaped or formed (refer to Figure 2.13.3). Strand design isa precise engineering science.

FIGURE 2.13.3STRAND TYPES

The LayThe word lay is used to describe three physical characteristics of wire rope. It is bothan engineering term and a descriptive term. Lay describes:

1. The direction strands lay in the rope—right or left. When you look along arope, strands of a Right Lay rope follow a right-turning pattern. Left Lay is op-posite. It makes no difference which direction you look (refer to Figure 2.13.4).

2. The relationship between the direction strands lay in the rope and the directionwires lay in the strands. In a Regular Lay rope, wires lay opposite the directionof the strand. In a Lang Lay rope, wires lay in the same direction as strands (re-fer to Figure 2.13.5).

3. The Lay Length, or Lay, is the length along the rope which one strand uses tomake one complete spiral around the rope core (refer to Figure 2.13.5).


2.13PAGE 6 OF 7


FIGURE 2.13.4RIGHT, LEFT, REGULAR, AND LANG LAY

FIGURE 2.13.5LAY LENGTH


2.13PAGE 7 OF 7


The SeizingsThe ends of rope that are to be cut or spliced should be seized with wire (refer to Fig-ure 2.13.6).

FIGURE 2.13.6SEIZINGS


2.14PAGE 1 OF 2

BIN-HOPP.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.14 WORKING IN BINS AND HOPPERSSPECIAL EQUIPMENT REQUIREDGoggles/face shieldApproved safety harness with a D-ring for fastening a safety lineLeather work glovesCompressed air lanceOxygen analyzer (if working inside the bin)Keyed lockout locksINTRODUCTIONMaterial can build up inside a bin and cause a flow restriction. Sometimes thisbuildup bridges over the bin and prevents material from discharging from the bottom.Other times, material builds up on the bin walls and results in only a small rat holethat severely restricts the discharge rate from the bottom of the bin.Normally, cleaning efforts are conducted from the top of the bin using an air lance.When conducting cleaning operations of this nature, no one must enter a bin unlessall overhead materials have been removed and the person entering is attached to a se-curely tied-off safety line. Another person must attend the safety line. Additionally,no one must work from above the bin using an air lance or any other tool unless thatperson is securely attached to a safety line that is securely tied off. Just as in cleaningoperations, no one must enter a bin for repair purposes without being attached to asafety line and having another person attend that line.Any belts and equipment ahead of or under the bin must be isolated and locked outaccording to the established company isolation/lockout procedure.INSTRUCTIONSCleaning and Unplugging from Outside the Bin

1. Each person working from the top of the bin must wear a safety harness. 2. Securely tie off the safety line from each safety harness to a fixed object, such

as a steel beam or column. Attach an air hose to the compressed air lance andsecure the pneumatic fitting with a safety pin to ensure that the fitting will notcome apart when compressed air is applied.

Do not use handrails to anchor/attach a safety line.


2.14PAGE 2 OF 2

BIN-HOPP.DOC CRUSHER 1 OCT 2000REV 0

3. Insert the air lance into the bin, open the air valve, and gradually work thelance into the buildup until it is dislodged.

4. Continue to work the air lance as described above until the buildup has beencompletely removed.

5. Close the upstream air valve and leave the local air valve on the lance open toallow the hose to vent to the atmosphere.

6. Remove the safety pin from the pneumatic fitting and disconnect the air lancefrom the hose.

7. Clean up all tools and hoses from the bin area before departing.

Working Inside a Bin 1. Complete a confined spaces entry permit with the supervisor of that area be-

fore accessing any bin or hopper.

2. Lock out all conveyor belts and equipment ahead of or under the bin to beentered.

3. Do not work inside a bin unless an observer has been posted outside of the binentrance.

4. Ensure that there is adequate ventilation within the bin and use an oxygenanalyzer to determine whether there is sufficient oxygen to breathe.

5. Approach the bin from its top. Remove all material from around the entranceso that no one will be struck by falling objects. Ensure that the bin is notbridged over.

6. Protect portable lighting against breakage and position it so that it cannot burnothers who are working in the bin. Protect electrical leads against sharp edgessuch as access doorways, etc.

7. Anyone entering the bin must be attached to a safety line securely tied to afixed object. Another person must attend the safety line and ensure that it iskept snug.

8. Do not enter a bin until the supervisor has granted permission to do so.

9. Communications must be maintained between the observer and those workingin the bin.


2.15PAGE 1 OF 2

FEEDCONV.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.15 FEEDERS AND CONVEYORS—WORKING AROUND ANDCLEANING

SPECIAL EQUIPMENT REQUIREDApproved respiratorWork glovesINTRODUCTIONWorking near moving feeders or conveyor belts presents potential hazards. One ofthe operator’s duties is to ensure that all walkways, tail pulleys, take-ups, etc., areclear of spills. The following instructions reduce the risk of being injured by thefeeder or conveyor while cleaning spills.INSTRUCTIONS 1. Make sure that clothing is close-fitting, that sleeves are buttoned, and that

shirttails are tucked in. 2. Clean up obstructions, litter, and tripping hazards. 3. Know the locations of the conveyor belt emergency-stop pullcords. 4. Do not clean solid conveyor decks between idlers unless the feeder or con-

veyor is locked out, in accordance with the approved company lockout proce-dure.

5. Do not use shovels inside the belt and pulley assembly or around idlers. 6. Cross over conveyors only at the crossover points provided. 7. Cross under conveyors only in designated areas where the return side is prop-

erly guarded or where there is a minimum clearance of 7 feet. Be alert to fal-ling material.

8. When shoveling, do not overextend the load by leaning. Keep back straight. 9. Do not overload shovels.

9.1. Always shovel onto a belt in the direction of travel.9.2. Do not continue to hold or grab a shovel that is caught by a conveyor.

10. Do not use hands to load chunks and boulders onto a moving belt. 11. A conveyor may start or stop automatically. Always assume that a conveyor

will start or stop at any time. Never work on or walk over the top of a con-veyor that has not been locked out.


2.15PAGE 2 OF 2

FEEDCONV.DOC CRUSHER 1 OCT 2000REV 0

12. Do not remove equipment guards unless required to do so for repair and un-less that particular piece of equipment has been locked out.

13. Ensure the control room operator knows that a worker is in the area.


2.16PAGE 1 OF 3

HYDROIL1.DOC CRUSHER 1 OCT 2000REV 0

SAFE JOB PROCEDURE

2.16 HYDRAULIC OIL

SPECIAL EQUIPMENT REQUIREDGauntlet rubber glovesSplash goggles or face shield (when eye contact may occur)Disposable overalls (to avoid contaminating regular clothing, which could result in pro-longed or repeated skin contact)Supplied-air respirator (in confined or enclosed spaces, if needed)

INTRODUCTIONHydraulic oil is a petroleum lubricating oil. It is a clear, light-yellow liquid with a mild,bland petroleum odor. When working with or near this material, avoid prolongedbreathing of its vapor, mist, and fumes, and avoid prolonged or repeated skin contact.

INSTRUCTIONS 1. If needed, use chemical-resistant gloves, splash goggles, and disposable overalls

or other impervious clothing to avoid prolonged or repeated skin or eye contact.

2. Before working with hydraulic oil, know the location of the nearest emergencyshower and eyewash station.

3. Immediately wash off affected skin, eyes, and protective clothing. Remove con-taminated clothing, and launder or dry-clean it before reuse. After contact withhydraulic oil (and especially before breaks and meals, and at the end of shifts),always cleanse skin with a waterless hand cleanser, and then wash with soap andwater.

HEALTH HAZARDSHealth studies have shown that many petroleum hydrocarbons and synthetic lubricantspose potential health risks that may vary from person to person. As a precaution, mini-mize exposure to liquids, vapors, mists, and fumes.

Prolonged or repeated skin contact with this product tends to remove skin oils, possiblyleading to irritation and dermatitis. Hydraulic oil has a low order of acute oral and der-mal toxicity, but minute amounts inhaled into the lungs may cause mild to severe pulmo-nary injury and possibly death.


2.16PAGE 2 OF 3


FIRST AID Eye or Skin ContactIf splashed into the eyes, flush with clear water for 15 minutesor until irritation subsides. If irritation persists, get medicalattention. In case of skin contact, remove any contaminatedclothing, and wash skin with soap and water. Launder or dry-clean clothing before reuse. If product is injected into or un-der the skin, or into any part of the body (regardless of the ap-pearance of the wound or its size), the person should be evalu-ated immediately by a physician as a surgical emergency.Even though initial symptoms from high-pressure injectionmay be minimal or absent, early surgical treatment within thefirst few hours may significantly reduce the ultimate extent ofinjury.

InhalationHydraulic oil has a very low vapor pressure. Vapor inhalationunder ambient conditions is normally not a problem. How-ever, if someone is overcome by vapor from the hot product,immediately remove that person from exposure and get medi-cal attention. If breathing is irregular or has stopped, start re-suscitation and administer oxygen if available. If someone isoverexposed to oil mist, remove that person from further ex-posure until excessive oil mist conditions subside.

Ingestion

If ingested, do not induce vomiting. Get medical attentionimmediately.

SPILLS Recover free product. Add sand, earth, or other suitable ab-sorbent material to the spill area. Avoid prolonged breathingof vapors and prolonged skin contact. Open all windows anddoors. Keep product out of sewers and watercourses by dik-ing or impounding. Advise proper authorities if product en-ters or may enter sewers, watercourses, or extensive land ar-eas.

HAZARDOUS CHEMICAL REACTIONSThis product is stable and will not react violently with water.However, avoid contact with strong oxidants (such as liquidchlorine, concentrated oxygen, sodium hypochlorite, calcium


2.16PAGE 3 OF 3


hypochlorite, etc.). This contact presents a serious explosionhazard.

STORAGE Keep container of hydraulic oil closed when not in use. Donot store near heat, sparks, flame, or strong oxidants.

CONTAINER DISPOSALDo not attempt to clean the containers, because the residue isdifficult to remove. Empty drums should be completelydrained and properly bunged and all other containers shouldbe crushed. Promptly dispose of all containers in accordancewith proper environmental procedures.

FIRE Use water spray, dry chemical, foam, or carbon dioxide to ex-tinguish the fire. Use water to keep fire-exposed containerscool. If a leak or spill has not ignited, use water spray to dis-perse the vapors and to provide protection for people at-tempting to stop the leak. Water spray may be used to flushspills away from exposures.

Avoid prolonged breathing of gases, vapors, fumes, or de-composition products. Use supplied-air breathing equipmentfor enclosed or confined spaces, or as otherwise needed.

SPECIAL PRECAUTIONSEmpty containers retain residue (liquid and vapor) and can bedangerous. Do not pressurize, cut, weld, braze, solder, drill,or grind such containers or expose them to heat, flame, sparks,static electricity, or other sources of ignition; they may ex-plode and cause injury or death.


2.17PAGE 1 OF 2

SHOWERS.DOC CRUSHER 1 OCT 2000REV. 0

SAFE JOB PROCEDURE

2.17 SAFETY SHOWERS AND EYEWASH STATIONSSPECIAL EQUIPMENT REQUIREDNoneINTRODUCTIONSafety showers and eyewash stations are installed in all plant areas, especially areaswhere reagents are used. Each safety shower consists of a single high-volume shower-head and a hand-operated pull lever for opening the water valve. Each eyewash stationconsists of a fountain with dual eyewash flush valves.The showers are available for employees to immediately wash off any chemicals that mayspill or splash on any part of them.INSTRUCTIONS

1. Always know the location of the nearest safety shower and eyewash station in thework area.

2. It is important for a person involved in a chemical spill to get to a shower asquickly as possible. While proceeding to the shower, try to notify other employ-ees of the emergency, and ask for their assistance.

When the eyewash and safety shower station is acti-vated, an alarm may register in the control room towarn the operator that an emergency has occurred thatrequired the use of the eyewash and safety shower sta-tion. An operator is immediately dispatched to verifywhat the emergency is, and a first aid attendant is noti-fied.

3. For a chemical splash in the eyes, the victim’s face must be placed as close aspossible to the dual eyewash valves. Turn on the water using the foot pedal or thehand-operated valve.

When using the eyewash station, hold the eyes open forat least fifteen minutes to ensure that all chemical is re-moved. Then seek medical attention.


2.17PAGE 2 OF 2

SHOWERS.DOC CRUSHER 1 OCT 2000REV. 0

4. A person splashed with a chemical must get under the shower fully clothed andmust start the shower using the pullcord with the handle. The person should re-main under the shower for fifteen minutes to ensure that all chemical is removed.Remove affected clothing only after it has been fully saturated with water andmost of the chemical has been washed out.

5. Continue to shower until all residue of the chemical has been thoroughly flushedfrom the skin.

6. Advise the team leader of the incident, and seek medical help to determine theextent of any injury.


2.18PAGE 1 OF 1

CE218.DOC CRUSHER 07AUG. 2001REV 0

2.18 MATERIAL SAFETY DATA SHEETSTo assist in storage and use of materials supplied for Crusher Installation, MaterialSafety Data Sheets (MSDS) are provided in this section.

1) MSDS Microx (Epoxy) Hardener

2) MSDS Microx (Epoxy) Resin

3) MSDS Nordbak (Epoxy Backing Material)


MSDS MICOROX HARDENER


MSDS MICOROX HARDENER (continued)










MSDS MICOROX RESIN


MSDS MICOROX RESIN (continued)










MSDS NORDBAK


MSDS NORDBAK (continued)


















3.1PAGE 1 OF 13


3.0 EQUIPMENT DESIGN3.1 EQUIPMENT/COMPONENT DESCRIPTION AND FUNCTION

INTRODUCTIONThe ultimate goal of the crushing process is to reduce the size of the ore receivedfrom the mine (known as run-of-mine or ROM ore). The crushing process is the firststep in comminution. Comminution is the process of progressively reducing ore tofiner sizes. Further reduction occurs in the downstream grinding plant.

The crusher receives ore from the mine by haul truck into a dump pocket. Thecrusher breaks down ROM material and delivers it to a surge pocket located beneaththe crusher. The crushing circuit is designed to be an open-circuit crushing system(without any screening and recycling of oversize particles). The crushed ore is with-drawn from the surge pocket for further treatment in the grinding operation. The op-erator regulates ore dumping to maintain the proper levels in the crusher bowl andsurge pocket beneath the crusher.

CRUSHERThe crusher is a 60-inch-by-113-inch unit powered by a 745.7-kW (1,000-hp) motor.This size designation means the crusher measures 1524 mm (60 in) from the upper-most part of the top row of concaves to the head nut on the main shaft. The crushermeasures 2870 mm (113 in) in diameter at the widest diameter at the bottom of thelower mantle liner. Approximately 100 percent of the feed to the crusher should besmaller than 80 percent of the radial opening size. In this case, 80 percent of the feedopening size is a measurement of 1016 mm (40 in). This size distribution reduces thepossibility of blocking the crusher openings.

The principal components of the gyratory crusher are shown in Figure 3.1. Thecrusher body consists of a cast-steel frame that includes, in its lower part, the drivingmechanism. The driving mechanism is made up of the eccentric (which provides thegyratory movement of the main shaft and mantle), the eccentric gear, and the counter-shaft assembly (which includes the pinion gear and its pinion shaft). The upper por-tion of the crusher forms a stationary crushing surface consisting of a cone-shapedchamber made up of the middle and top shell sections. The chamber is lined withwear-resistant steel pieces called concaves.

The main shaft assembly, with its mantle, is the principal moving part of the crusher.At the top of the crusher is a support system for the main shaft, referred to as the spi-der assembly. The spider assembly incorporates a machined journal that positions(restrains laterally) the upper end of the main shaft.


3.1PAGE 2 OF 13


FIGURE 3.1GYRATORY CRUSHER ARRANGEMENT

The spider is a cast-steel box section with the hub in the center and two integrally castarms. The ends of the arms are tapered and machined to fit into pockets in the topshell. Bolts secure the spider to the rim of the top shell, seating the spider in the ta-pered pocket.


3.1PAGE 3 OF 13


The shell and the main shaft are covered with cast-steel liners called concaves on theshell, and mantle liners on the main shaft. When the mantle liners wear, the mainshaft assembly is removed and replaced with another rebuilt main shaft assembly.The mantle liners on the removed main shaft can then be replaced, ready for the nextchange-out. Concave liner replacement is carried out in place, with the main shaftassembly removed. The concave liners are usually replaced as a complete set.

Note that the part of the main shaft assembly in contact with the ore is the mantle.The mantle is retained on the main shaft by a heavy head nut. This nut is self-tightening. The crushing action tends to turn the nut in the direction that tightens it.The crushing head is supported laterally at the top in the spider journal.

Plant air is used to pressurize the area above the eccentric. This area is created by anenclosure called the dust seal bonnet. The core is sealed against the dust seal bonnetby a dust seal ring located at the bottom of the core. This dust seal ring runs againstthe outer periphery of the dust seal bonnet. By pressurizing the area inside the dustseal bonnet, dust is prevented from entering the area and contaminating the lubrica-tion system and the eccentric.

A split carbon/teflon seal is installed in a groove in the main shaft above its eccentricjournal. The seal rides against the bore of the dust bonnet and contains oil splashedfrom the eccentric.

At the lower end of the crusher, the main shaft journal passes through the eccentric.This arrangement offsets the lower end of the shaft with respect to the centerline ofthe crusher. Therefore, when the eccentric is rotated by the gear train, the lower endof the main shaft gyrates (moves back and forth in a small circular path within thecrushing chamber), progressively receding from and approaching the stationary con-cave liners. The main shaft does not normally rotate when crushing. However, whenthe crusher is empty, the main shaft and crushing head rotate, driven by the oil shearfriction within the eccentric journal. Figure 3.2 illustrates the crushing action.

PRINCIPLE OF OPERATIONGYRATORY CRUSHER

In a gyratory crusher, the upper end of the main shaft is restrained laterally inthe spider. Meanwhile, the eccentric bushing that positions the lower end ofthe main shaft provides an oscillating motion to the main shaft assembly, orcrushing head. The crushing head alternately approaches and recedes fromthe outer stationary crushing surface, or concaves. As the crushing head re-cedes from the shell, ore lumps fall into the opening. As the crushing headreapproaches the shell, the ore lumps are broken.

The closest distance between the moving mantle and the concaves is calledthe closed-side setting (CSS). Similarly, the farthest distance between themantle and the concaves is called the open-side setting (OSS). The maximum


3.1PAGE 4 OF 13


size of a piece of ore discharged from the crusher is approximately equal tothe open-side setting.

The product size discharged from the crusher is changed either by raising orlowering the main shaft assembly, thereby changing the relationship (both theCSS and OSS) of the mantle to the crushing chamber. This capability is ob-tained through the use of the hydraulic adjustment system.

FIGURE 3.2GYROSCOPIC CRUSHER MOTION

The primary crusher is equipped with a circulating lubrication system for lubricatingthe eccentric drive assembly of the crusher.


3.1PAGE 5 OF 13


PRINCIPLE OF OPERATIONGYRATORY CRUSHER LUBRICATION SYSTEM

The gyratory crusher lubrication system, illustrated in Figure 3.3, supplies lu-bricating oil to the eccentric bushings and drive gears. The lubrication systemconsists of an oil reservoir, two lubrication pumps (one in operation while theother is on standby), an oil filtration system, and an air-to-oil cooling system.

The crusher components are lubricated with oil pumped into the crusher atthree points: the hydraulic adjustment piston, the countershaft bearings, andthe outer eccentric bushing. The oil entering the hydraulic adjustment pistonenters a channel formed by the two piston bushings. A port in the piston al-lows the oil to fill the piston. A port in the top of the piston allows oil to flowup and lubricate the piston wear ring, center wear ring, main shaft wear ring,eccentric wear ring, and the inner eccentric bushing. The oil from the top ofthe eccentric passes through a passage and lubricates the pinion. The oil re-turns to the sump via the lube return line.

Lube oil is fed directly above the countershaft assembly into a tapped hole inthe bottom shell. The oil flows into a tray in the countershaft housing thendrops into a sump in the housing to lubricate both Timken bearings. The oilthat lubricates the outboard bearing is discharged into a hole in the housingand returns to the lubrication sump via the lube return line. The oil that lubri-cates the inboard bearing is discharged through the bearing, then returns tothe lubrication sump via the return line.

The oil that enters the crusher at the outer eccentric bushing is transferred tothe hub of the bottom shell. The oil passes through ports machined in a chan-nel in the outer eccentric bushing passing between the bushing and eccentric,then flowing upward to the top of the eccentric and downward onto the bevelgear. After lubricating the bevel gear and pinion, the oil returns to the lubri-cation tank through the lube oil return line.

The oil reservoir is equipped with thermostatically-controlled heaters tomaintain the oil at a temperature that allows it to be easily pumped. Like-wise, the lubrication system is equipped with a circulating oil cooling systemto keep the oil from overheating. The oil cooling system is equipped with atwo cooling pumps. Two air-to-oil heat exchangers arranged in series receivethe flow from the cooling pumps. The cooling system is thermostaticallycontrolled. When the oil reaches the upper temperature limit, a cooling pumpstarts, the cooling valves close to divert the oil from the cooling pumpthrough the heat exchangers, and the cooling fans on the heat exchangersstart. When the oil has cooled to an acceptable temperature, the coolingpump and cooling fans stop and the cooling valves open again to allow the oilto drain from the heat exchangers back to the reservoir. The oil cooler returnline is equipped with a low flow switch to warn the operator if a low flowcondition exists in the cooling circuit due to a failing cooling pump, an ob-structed heat exchanger, or a leaking cooling line. The reservoir is alsoequipped with a low and a low-low oil level switch that prevents both the lu-brication pump and cooling pump from starting when there is a low level inthe oil tank, and shuts down the pumps if a low-low level is encountered.


3.1PAGE 7 OF 13


The reservoir is divided into two compartments. These two compartmentsseparate the return oil from the pump inlets to allow the separation of air fromthe oil and to prevent stratification of the oil. The sump tank is equipped withthree heaters.

The oil supply line from the lubrication pumps to the crusher is equipped witha duplex oil filter, which is a pair of oil filters connected in parallel. One fil-ter in the pair is in use while the other is on standby. The filter pair isequipped with a pressure differential switch to monitor the oil pressure differ-ential across the filter in use. Only one filter at a time is utilized. When themaximum allowable pressure differential across the filter is reached, theplugged filter is removed from service and the standby filter is put into serv-ice. The plugged filter is cleaned and made ready for service.

The three final-delivery oil lines at the crusher are each equipped with flow switchesto detect a low lubricant flow to their respective lubrication points. A low lubricantflow to any of the three delivery points sends an alarm signal to the control system,which shuts down the crusher and the lubrication system on interlock. Finally, the oilreturn line from the primary crusher to the reservoir is equipped with an oil tempera-ture switch that shuts down the crusher on interlock if the return oil temperature ishigh.

Spider Bushing Lubrication SystemThe crusher spider bushing has its own grease lubrication system. The spider lubri-cation system consists of a grease barrel equipped with a pneumatic grease pump. Atimer is used to automatically control the frequency of lubrication. The lubricationsystem can also be operated in Manual mode for filling grease lines and lubricatingnew spider bushings, but the normal mode of operation is Automatic. The spider lu-brication system is equipped with a status alarm to warn the operator of a generalsystem failure, and the crusher shuts down on interlock when a general failure occurs.Figure 3.4 shows the spider bushing lubrication system.

PRINCIPLE OF OPERATIONSPIDER BUSHING LUBRICATION SYSTEM

The air-operated grease pump, which is activated by the controller, pumpsgrease into the system. Initially in each cycle, the grease fills each injector inthe system. As pressure builds, the injectors shift, and the continued increasein pressure forces the grease that previously filled the injectors into the lubri-cation point. The last injector activates a limit switch indicating the success-ful completion of the cycle, and the pump stops.


3.1PAGE 8 OF 13


FIGURE 3.4SPIDER BUSHING LUBRICATION SYSTEM

If the pressure fails to build, due either to a lack of grease in the reservoir orto a leak in the system, the system will alarm a failure to feed condition.

The main shaft is supported at its lower end by resting on a thrust bearing. The thrustbearing is, in turn, supported on a hydraulic piston and cylinder assembly. Oil istrapped under the piston in the cylinder assembly. By varying the amount of oil, themain shaft is raised or lowered to adjust the proximity of the mantle relative to thecrushing chamber.


3.1PAGE 9 OF 13


The primary crusher is operated with an open-side setting (OSS) of 203 mm (8inches). With new concaves and new mantles the 203-mm (8-inch) OSS is attainedwhen the main shaft is raised 51 mm (2 inches) from the lowest point. The OSS re-fers to the maximum distance between the mantle and the concaves at the crusher dis-charge. It is also common to refer to the crusher closed-side setting (CSS), which isthe minimum distance between the mantle and the crusher concaves at the crusherdischarge. The OSS and the CSS are always on directly opposite sides of the crushermantle.

The crusher OSS is controlled by the hydraulic adjustment system, which varies theheight of the crusher mantle inside the crusher. Adjusting the mantle height changesthe distance between the crusher mantle and the crusher concaves, thus changing thecrusher setting and the size of the crushed product.

The hydraulic adjustment system allows a full travel range of 304 mm (12 inches) foradjustment. Raising the mantle decreases the crusher setting, and lowering the mantleincreases the crusher setting.

As the mantle and concaves wear, the OSS increases, thus increasing the size of thecrushed product. When the crushed product becomes too large, the mantle must beraised to decrease the crusher setting and reduce the size of the crushed product. Fig-ure 3.5 illustrates the components and the operation of the hydraulic adjustment.

PRINCIPLE OF OPERATIONGYRATORY CRUSHER HYDRAULIC ADJUSTMENT SYSTEM

The crusher is equipped with a hydraulic adjustment system that positions andsupports the main shaft assembly. The hydraulic adjustment system consistsof a hydraulic piston inside a cylinder at the bottom of the crusher assemblythat raises and lowers the main shaft assembly to vary the crusher setting.

The principal parts of the system include the hydraulic cylinder and piston as-sembly, the hydraulic oil supply system, and the hydraulic accumulator.

The hydraulic adjustment system performs three important functions:

• It raises or lowers the mantle as required to adjust the crusher setting orto clear the crusher.

• It absorbs shock loads with the hydraulic accumulator as the crushingload increases and decreases.

• It increases the OSS when an uncrushable object passes through thecrusher.


3.1PAGE 11 OF 13


Crusher setting: The mantle is raised or lowered in order to adjust thecrusher setting to either change the crushed product size or to clear thecrusher. As the mantle moves up, the distance between the mantle and thecrusher concaves decreases. As the mantle moves down, the distance be-tween the mantle and the crusher concaves increases. The position of themantle is monitored by a position transmitter and displayed in the controlroom. The mantle may be raised or lowered either from a local pushbuttoncontrol panel at the crusher or from controls in the primary crusher controlroom.

Before raising the mantle, the operator must first start the hydraulic adjust-ment system hydraulic pump and wait for about 20 seconds. At either the lo-cal pushbutton or control room pushbutton control, the Raise pushbutton ispressed, and the raise valve is actuated to supply oil to the hydraulic pistonvia a check valve in order to raise the mantle. When the button is released,the raise valve returns to the neutral position, and the check valve holds thepiston and mantle in position.

When lowering the mantle, the hydraulic pump is switched off. At either thelocal pushbutton or control room pushbutton control, the Lower pushbutton ispressed, and the lower valve is actuated to return oil from the hydraulic pistonback to the reservoir. When the button is released, the lower valve returns tothe neutral position, and the oil flow back to the reservoir is stopped.

Shock absorbing: During crushing, the forces on the hydraulic adjustmentsystem vary. To cushion the effects of large high-pressure spikes, the hy-draulic adjustment system is supplied with an accumulator.

The accumulator is a pressure vessel that contains a rubber bladder with com-pressed nitrogen on one side and oil from the hydraulic adjustment system onthe other side. The nitrogen is precharged in the accumulator to a pressurethat will allow the nitrogen to be compressed a given amount when the weightof the mantle pressurizes the oil on the other side of the piston. Under staticconditions, the pressure on the nitrogen side of the bladder equals the pressureon the oil side of the bladder.

The high-pressure spikes exceed the precharge pressure of the accumulatorand oil is forced into the accumulator, absorbing the effect of the high-pressure spike. When the pressure spike is reduced, oil flows from the accu-mulator back into the hydraulic adjustment piston cylinder.

Regular hydraulic oil should not be used in the hydraulic adjustment system.The oil that is used should be the same as the oil used in the crusher lubrica-tion system because if the oil leaks past the hydraulic piston seals, it will flowinto the lubrication system. There should never be any reason, however, forthe oil to leak from the lubrication system into the hydraulic adjustment sys-tem because the adjustment system is always under higher pressure due to theweight of the mantle.


3.1PAGE 12 OF 13


Occasionally, an uncrushable object may become jammed in the crusher andcause extremely high downward forces on the mantle and the hydraulic ad-justment system. This translates into an extremely high oil pressure in thehydraulic adjustment system. The hydraulic adjustment system is protectedfrom extremely high oil pressure spikes by a pressure relief valve that dumpsoil from the oil supply line back to the oil reservoir.

The height of the mantle is monitored by a position element located at the bottom ofthe adjustment piston, and the height is displayed on a local position-indicatingtransmitter and in the control room. The crusher mantle height is displayed in inchesand mm.

The mantle may need to be lowered on occasion for the purpose of clearing thecrusher after a power failure or when it becomes plugged. Therefore, the crushershould not be operated with the mantle any less than 50 mm (2 inches) from its fullydown position to ensure that the mantle has some travel for this purpose. Likewise, amaximum allowable mantle height of 280 mm (11 inches) is established to preventthe mantle from colliding with the spider assembly. The mantle height indicator isequipped with alarms to warn the operator if the mantle height has reached the mini-mum or maximum allowable height. If the mantle has reached the high level alarm,and the crushed ore size is too large, it is a clear indication that the crusher mantleand/or concaves are worn out and need to be replaced.

If the mantle position indicator shows that the mantle has dropped in position, it is adefinite indication that the relief valve has been actuated due to the wedging or pass-ing of an uncrushable object. However, the operator must not confuse the suddendrop in mantle height due to the passing of an uncrushable object with a hydraulicadjustment system oil leak.The passing of an uncrushable object will cause the mantle to drop to a lower positionand remain there. A hydraulic adjustment system oil leak will cause the mantle tocontinue to drop over time.

Crusher Discharge PocketThe crushed ore falls from the primary crusher into the crusher discharge pocket be-low the crusher. Material is withdrawn from the pocket by a conveyor or apronfeeder.


3.1PAGE 13 OF 13


The level of the crushed ore in the discharge pocket is maintained between a high andlow level. These limits are designed to protect the primary crusher and the crusherdischarge conveyor. The level in the discharge pocket is continuously monitored anddisplayed in the control room. The operator must control the truck-dumping rate tomaintain the level in the discharge pocket between the high and low limits. If a high-high condition is encountered in the discharge pocket, the crusher will shut down oninterlock to prevent the level in the discharge pocket from rising up to the bottom ofthe crusher and causing crusher damage.


3.3PAGE 1 OF 1


3.3 PROCESS CONTROL

For the primary crusher to operate as it was designed, certain variables within thecrushing process must be carefully controlled by the operator. These variables in-clude such process parameters as pressure and ore feed rate. Where applicable, Sec-tion 3.3.1 contains a table of the target ranges for each of the important process vari-ables in that section. A description of how the operator should control the variablesunder both manual and automatic conditions is contained in the Control Loops sec-tion.

Each of the variables to be controlled has been divided into separate control loops(control loops are defined in Section 3.4). Each control loop consists of a written de-scription, a block diagram, and a loop diagram. When reading the written descrip-tion, refer to both the block and loop diagrams. The written description is dividedinto the following parts:

• The purpose of controlling the variable.

• The method used to control the variable automatically.

• The method used by the operator to control the variable manually.

• In the case of control valves, the type of valve and whether the valve fails closedor open upon a loss of power.

The productive capacity of the gyratory crusher depends largely on how closely theoperator controls these variables.


3.3.1PAGE 1 OF 1


3.3.1 PROCESS VARIABLESProcess System Process Variable Target

RangeControl Method Impact on Process

Crushing Primary run-of-mine (ROM) feed

100 per-cent lessthan 1200mm (47inches)

Mine has a procedure forcontrolling drilling andblasting to provide desiredfeed size.

Ore larger than the targetmay bridge the crusher, re-sulting in reduced through-put, excessive downtime,and potential safety hazardsto personnel and equipment.Ore that is finer than opti-mum can choke the crusherand reduce throughput.

Crushing Crusher through-put

7,500tonnes perhour

Mine blasting proceduresmust be done correctly forproper feed size distribu-tion. Ensure that thecrusher open-side setting iscorrect.

Improper size distribution,too low a truck dumpingrate, and an impropercrusher setting reduce thecrusher’s throughput.

Crusher Crushed productsize

80 percentless than152 mm(6 inches)

Adjust the crusher open-side setting as the crushermantle and concaves wear.Replace the mantle andconcaves when they areworn.

Too small a crusher productsize may result in a lowcrusher throughput and highcrusher power consumptionand concave wear.

Crusher Discharge pocketlevel

Betweenthe high-and low-levelalarms

Ensure that trucks dump ata rate that is fast enough toprevent the low level alarmfrom being activated.Dumping rate can be easilyslowed down when the highlevel is reached.

Too low a level is an indi-cation of low productionrates. Too high a level candamage the crusher.


3.4PAGE 1 OF 1


3.4 CONTROL LOOPS

There are no crusher control loops.


3.5PAGE 1 OF 5

COMM35.DOC CRUSHER 1 OCT 2000REV 0

3.5 INTERLOCKS

To operate a plant effectively and safely, certain equipment cannot be started unlessother equipment is already operating. Likewise, there are pieces of equipment that,when they stop running, automatically shut down other equipment. Any arrangementwhere the operation of one part or mechanism brings about or prevents the operationof another is generally known as an interlock. Motors are commonly interlocked, butother pieces of equipment, such as timers and solenoid valves, can be interlocked aswell.There are two types of interlocks: 1. Permissive

A permissive is a condition that must be satisfied before an item of equipmentcan be started. If Equipment A cannot start unless Equipment B is runningand Switch C is closed, Equipment A has two permissives: Equipment B run-ning and Switch C closed.

For example, consider a pump that cannot be started unless a gland seal waterpressure switch is closed. When the pressure switch senses that the pressure ishigh enough, the pressure switch closes, allowing the operator to start thepump. If the pressure switch does not sense that the pressure is high enough,the pressure switch does not close, and the operator cannot start the pump.This condition is known as a permissive.


3.5PAGE 2 OF 5


Permissives are noted on the interlock tables that follow with an “X” in thePermissive column. The condition required to satisfy each permissive isshown directly to the left of the Permissive column.

A permissive is denoted on an interlock diagram as an input to a numbereddiamond, which corresponds to a number on the interlock table. An item ofequipment can have many permissives, each of which is shown as a separateinput arrow. Each input arrow is designated with a letter that corresponds tothe letter in the Condition column on the interlock table. The output arrowfrom the diamond goes to the equipment for which the permissives must besatisfied for it to start. Each diamond generally has only one output arrow.

2. Interlock

An interlock represents the automatic shutdown or start-up of equipmentbased on conditions associated with other equipment or instruments. If Equip-ment A automatically shuts down when Equipment B stops, Equipment A isinterlocked to Equipment B. Occasionally, an interlock will automaticallystart an item of equipment when its condition is satisfied. Equipment A mightautomatically start when Equipment B starts. In this case Equipment A is alsointerlocked to Equipment B.


3.5PAGE 3 OF 5


For example, if a conveyor drive is interlocked to a plugged chute detector,the conveyor drive will automatically shut down (known as a trip) if the de-tector senses a plugged chute.

Interlocks are noted on the attached interlock tables with an “X” in the Inter-lock column. The condition required to satisfy each interlock is shown di-rectly to the left of the Permissive column.

In the same way as previously described for permissives, an interlock is de-noted on the interlock diagram as an input to a numbered diamond that corre-sponds to a number on the interlock table. An item of equipment can havemany interlocks, each of which is shown as a separate input arrow. Each ofthe input arrows is designated with a letter that corresponds to the letter in theCondition column on the interlock table. The output arrow from the diamondgoes to the equipment for which the interlock must be satisfied for it to keepoperating (or to the equipment which will automatically start). Each diamondgenerally has only one output arrow. In cases where the interlock provides astart signal instead of a stop (or trip) signal, the input arrow is so labeled onthe interlock diagram.

From the following interlock tables, it is clear that a condition can apply toboth a permissive and an interlock; in fact, this situation is very common. Insuch a case, the condition must be satisfied for the equipment to start, and itmust be maintained for the equipment to continue to run.


3.5PAGE 4 OF 5


In another type of interlock, solenoid valves are interlocked to a motor starteror switch so that they automatically open when the motor starts and automati-cally close when the motor shuts off. For example, a gland seal water sole-noid valve is interlocked to automatically open when a pump motor starts andclose when the motor stops.

Valve-related interlocks are denoted on the interlock diagram as follows: aninput to a numbered interlock diamond represents a signal that causes a valveto open or close; the output signal indicates which valve will be affected.


3.5PAGE 5 OF 5

SPEC35.DOC CRUSHER 1 OCT 2000REV 0

CRUSHER INTERLOCKS3.5.1 Crusher Software and Hardwired Interlocks

3.5.1.1 Crusher Software

3.5.1.2 Crusher Hardwired


3.5.1.1PAGE 1 OF 4


3.5.1 CRUSHER SOFTWARE AND HARDWIRED INTERLOCKS3.5.1.1 INTERLOCKS—CRUSHER SOFTWARE

Equipment Interlock Condition Permis-sive

Inter-lock

Primary Crusher Motor210-CR-001A

A. Primary crusher cannot start or run if lubricantflow is less than 132 Lpm (34.9 gpm) to the ec-centric bushing (FAL-7029), if the lubricant flowis less than 13 Lpm (3.4 gpm) to the countershaft(FAL-7030), or if lubricant flow is less than 132Lpm (34.9 gpm) to the hydraulic adjustmentbottom (FAL-7026).

X X

B. Primary crusher cannot start or run if the lubri-cating oil return temperature exceeds 63°C(TAH-7027).

X X

C. Primary crusher cannot start or run unless theselected lubricating oil pump (210-CR-001-2Aor -2B) is running.

X X

D. Primary crusher cannot start unless the selectedlubrication system cooling pump (210-CR-001-2C or -2D) is ready.

X -

E. Primary crusher cannot start or run unless thespider lubrication system is operating (XA-7043).

X X

F. Primary crusher shuts down if there is low airpressure in the crusher dust seal air line (PSL).

- X

G. Primary crusher cannot start if the crusher mantleheight is less than 10 mm (ZAL-7005) or if it isgreater than 290 mm (ZAH-7005).

X -

H. Primary crusher cannot start or run if eithercountershaft bearing temperature (TAHH-7002or -7003) is greater than 82°C (180ºF).

X X

I. Primary crusher cannot start or run if there is ahigh-high level in the crusher discharge pocket(LSHH).

- X

J. Primary crusher cannot start unless the hydraulicadjustment system pump (210-CR-001-1A or-1B) is ready.

X -

K. Primary crusher cannot run if the motor current ishigh-high (IAHH-7001).

- X


3.5.1.1PAGE 2 OF 4



Inter-lock

Primary Crusher LubricationOil Cooling Pumps210-CR-001-2C or -2D

A. The selected primary crusher lubrication oilcooling pump starts when the oil temperaturereaches 46°C (115ºF) and stops when the oiltemperature reaches 40.5°C (105ºF) (TIC-7021).

- X

B. Selected oil cooling pump cannot start if there isa low level in the lubrication system oil tank(LAL-7021).

X -

C. Selected oil cooling pump cannot start or run ifthere is a low-low level in the lubrication systemoil tank (LALL-7021).

X X

Primary Oil Cooling SystemMotorized ValvesHV-7025 and -7033

A. The valves open when the oil temperaturereaches 46°C (115ºF) and close when the oiltemperature reaches 40.5°C (105ºF) (TIC-7021).

- X

Primary Oil Cooling SystemCooling Fans210-CR-001-3A and -3B

A. The fans start when the oil temperature reaches46°C (115ºF) and stop when the oil temperaturereaches 40.5°C (105ºF) (TIC-7021).

- X

B. Both fans start automatically when the ambienttemperature is 10ºC (50ºF) or above.

- X

Primary Oil Cooling SystemCooling Fan 210-CR-001-3B

A. The fan cannot start or run if the ambient tem-perature is below 10ºC (50ºF).

X X

Primary Crusher LubricationOil Reservoir HeatingElements201-CR-001-2E, -2F, and -2G

A. Primary crusher lubrication oil tank thermostatstarts the oil heaters when the oil temperature isbelow 35°C (95ºF) and stops the oil heaters whenthe oil temperature is above 38°C (100ºF)(TIC-7021).

- X

A. Selected lubrication oil supply pump cannot startif there is a low level in the lubrication system oiltank (LAL-7021).

X -Primary Crusher LubricationSystem Oil Pumps210-CR-001-2A and -2B

B. Selected lubrication oil supply pump cannot startor run if there is a low-low level in the lubricationsystem oil tank (LALL-7021).

X X


3.5.1.1PAGE 3 OF 4



Inter-lock

Primary Crusher HydraulicAdjustment System Oil Pumps210-CR-001-1A and -1B

A. Selected hydraulic adjustment oil pump cannotstart if there is a low level in the hydraulic ad-justment system oil tank (LAL-7011).

X -

B. Selected hydraulic adjustment oil pump cannotstart or run if there is a low-low oil level in thehydraulic adjustment system oil tank (LALL-7011).

X X

Primary Crusher HydraulicAdjustment Oil ReservoirHeating Elements210-CR-001-1C and -1D

A. Primary crusher hydraulic adjustment system oiltank thermostat starts the oil heating elementswhen the oil temperature is below 35°C (95ºF)and stops the oil heating elements when the oiltemperature is above 38°C (100ºF) (TIC-7011).

- X


3.5.1.2PAGE 1 OF 2


3.5.1.2 INTERLOCKS—CRUSHER HARDWIREDEquipment Interlock Condition Permis-

siveInter-lock

Primary Crusher Motor210-CR-001A

A. Crusher motor cannot start if the inboard or out-board motor bearing temperature is high (TAH-7001A or -B).

X -

B. Crusher motor cannot start or run if the inboardor outboard motor bearing temperature is high-high (TAHH-7001A or -B).

X X

C. Crusher motor cannot start if any stator windingtemperature is high (TAH-7001C through -H).

X -

D. Crusher motor cannot start or run if any statorwinding temperature is high-high (TAHH-7001Cthrough -H).

X X


4.1PAGE 1 OF 3


4.0 INSTALLATION4.1 STORAGE INSTRUCTIONS

INTRODUCTIONThis section instructs the operator in how to properly care for the crusher and itscomponents between the time it is received on the site, through installation, and to theprecommissioning stage.

PROCEDURE 1. Check for damage in shipment.

Considerable care is taken in the manufacture of thiscrusher. It is thoroughly inspected and prepared forshipment before being placed in the hands of the carri-ers. Despite this effort, it is possible for machinery tobe damaged during shipment.

1.1. Receive and inventory the shipment against the packing list suppliedby FFE Minerals USA, Inc.

1.2. A clear and accurate notation is to be made on the carrier’s deliveryreceipt at the time of delivery if any shortages and/or damages arevisible at the time of receipt. Keep a copy of this delivery receipt inyour files in case of a possible future claim. Promptly contact the car-rier and/or insurance company to perform a physical inspection of thegoods. Exercise due caution not to move the goods in question, nor todestroy any of the packing materials used, prior to the actual inspec-tion. Doing so may jeopardize any possible future claim. Keep a copyof the carrier’s and/or insurance company’s inspection report in yourfiles in case of a possible future claim.

1.3. Any concealed damage discovered at a later date that was not evidentat the time of receipt must be promptly reported to the carrier and/orinsurance company as well. If possible, any concealed damage mustbe reported within 15 days after receipt of the goods.

The terms of sale between the Buyer and Seller will determine the ac-tual party responsible to file the claim with the carrier for anyloss/damage sustained during shipment.


4.1PAGE 2 OF 3


Indoor StorageIt is recommended that during the initial installation ofthe crusher a building or shipping container dedicatedfor the indoor storage of parts be provided.

2. All protective materials such as waterproof paper, wood, and rust preventivecoatings must be repaired or replaced if these items have been damaged dur-ing shipment. Refer to Section 7.0, Maintenance: Paint and Coating Specifi-cations, for the correct coatings that are applied to specific surfaces.

2.1. While in storage, the equipment must be inspected every two months.At this time, rust must be removed and paint or rust preventive coat-ings replaced as required.

2.2. The following items are to be stored indoors at a temperature not lessthan 5°C (40°F) unless noted otherwise by the manufacturer:

• Countershaftassembly.

• Countershaftextension assembly.

• Eccentric assembly.

• Electric motors.

• Bronze bushings andwear plates.

• Main shaft wearingring.

• Main shaft contactseal.

• Lubrication systemassembly.

• Hydraulic systemassembly.

• Spider lubricationsystem assembly.

• Air/oil coolers.

• Control panels.

• Instruments.

• Gears.

• Couplings.

• Dust bonnet.

• Gaskets.

• Seals.

• Epoxy.

• Head nut.

• All bolts, nuts,washers, dowel pins,shims, pipe valves,and miscellaneoushardware.


4.1PAGE 3 OF 3


Outdoor Storage 3. The remaining crusher components consist of major fabricated and machined

parts. These items are painted and the machined surfaces are coated withChek-rust #1, Tectyl 891, or an approved equivalent product.

3.1. All parts are to be inspected upon arrival at the site. Surfaces damagedduring shipment are to be repaired by removing rust and repainting orrecoating with rust preventive as required. Thereafter, the parts shouldbe inspected at frequent intervals to remove rust and repair protectivecoatings as required.

Special attention should be given to machined surfaces,such as:

• Main shaft bearing surfaces.

• Shell flanges, pilots, and bolt holes.

• Spider bore and spider pocket fit surfaces.

• Mantle bore.

• Core bore and outside diameter.

• Soleplates.

• Bottom shell bores and flanges.

• Bottom plate surfaces.

Rust formation on these surfaces may cause irreparabledamage.

3.2. These components may be stored outside; however, where possible itis suggested they be protected from the elements. All items storedoutside must be placed on appropriate pads and blocking to preventthese components from sinking into the mud. These pads and blockingshould be inspected at frequent intervals and necessary corrective ac-tion must be undertaken to prevent damage to stored components.


4.2PAGE 1 OF 40

CE42A.DOC CRUSHER 7 AUG 2001REV 1

4.2 COMPONENT INSTALLATION SEQUENCE ANDINSTRUCTIONS

INTRODUCTIONThe purpose of this section is to assist the installation contractor with the installationsequence and procedures of the crusher.

Read this section before performing any installation,operation, or maintenance procedures.All equipment must be operated and maintained in ac-cordance with all applicable governmental safety andhealth laws, regulations, and generally recognized in-dustrial standards.

Note to the Installation Contractor(s)Normal installation operations include the correction ofmisfits by straightening, shimming, chipping, cutting,or grinding for proper fit of elements. Misfits whichcannot be corrected by the foregoing means or whichrequire major changes in equipment configuration areto be reported immediately to FFE Minerals USA, Inc.,for correction of misfits or to approve the most efficientand economic method of correction to be implemented.

The installation of the crusher is to be made in accordance with the drawings pro-vided. They define the physical arrangements, pertinent dimensions, interconnec-tions, loads, and other characteristics, data, and information needed for the erectionand installation of all components supplied.

While there is a general, overall sequence of installation which will be followed, thereare many details for which the sequence will be determined by conditions existing atthe site. There may be other conditions for which this sequence can be an overviewof the installation procedures, and it presents important detail on individual assem-blies, components, and various other facets of installation. These details may be help-ful in determining and employing the sequences and techniques used at this site.

An Erection Record Book must be procured and made available to compile all prog-ress made, problems encountered, and measurements obtained during the differentinstallation phases of each crusher. This information is valuable for comparing con-ditions during the installation and later during production, and for helping identifycauses of potential problems for easier and lasting solutions.


4.2PAGE 2 OF 40


The crusher is shipped in major subassemblies whose final assembly must be com-pleted on site. The installation of these subassemblies, and those assembled on site,must be installed in accordance with the drawings provided in this manual, and theinstallation data referenced in this section of the manual. These documents containinformation specific to this crusher. They define the physical arrangements, pertinentdimensions, loads, and other characteristics, data, and information needed in theerection and installation of all components supplied. Carefully observe match mark-ing of mating components during installation.

PROCEDUREReceiving and Inspection

1. All shipments must be inspected immediately upon receipt for shortages anddamage. If any are found, they should be called to the attention of the localfreight agent or the carrier that delivered the shipments. To avoid future con-troversy over loss or damage claims, make certain that the agent or carrier rep-resentative makes appropriate notations on the freight bill. Advise the FFEMinerals USA, Inc. Traffic Manager of the problem immediately, and inwriting.

Warranty Considerations

Any field modification to components can and willnullify the warranty, unless authorized by FFE Miner-als USA, Inc.

Preinstallation Considerations

1. The crusher includes precision bearings, gears, and machined surfaces andparts which must be protected from adverse ambient conditions. Althoughcomponents are adequately protected for shipment, the protective materialshave a relatively limited life and should not be depended upon for extensiveperiods. The protective coatings on the more sensitive items such as bearings,bushings, and gears must be inspected immediately upon receipt and renewedif necessary.

Foundation/Structure

Note:

Installation shall be performed in accordance to crusher station manufacturerand instructions below:

The crusher is to be erected upon a foundation structure which must be designed tosupport the weight of the equipment and to withstand the loads occurring during


4.2PAGE 3 OF 40


operation. The foundation’s/structure detailed design is dependent upon the nature ofthe geological substructure on which it rests at the site and is the responsibility of thepurchaser. Normally, the purchaser is also responsible for designing an adequate rockbox, discharge chamber, and any other surrounding structure required at the crusherstation.The foundation/structure should include an opening in its side through which the ec-centric and hydraulic adjustment assemblies are moved when they are being installedand removed. Provisions for removable rails on which to roll a cart for handlingthese assemblies under the crusher should be included.• Make certain that allowance is made for shims, grout, the crusher base, and

mounting hardware when setting the bolts.• Provisions must also be made for supporting items such as drive units, the hy-

draulic pumping unit, the lubrication pump unit, and the sump tank.Considerations Before Installing the Bottom ShellWhen an eccentric cart is provided, as is the case with this crusher, the bottom shell isinstalled directly on shims resting on the foundation.One method is to place the hydraulic assembly in the discharge bin directly below thecrusher, and then place the bottom plate, eccentric wear ring, and the eccentric on topof the hydraulic assembly. These assemblies can be lowered into position with suffi-cient hoisting equipment. Be aware that a lifting device must be placed below thebottom plate so that it can be lowered and hoisted. Also be aware that the eccentric isan unbalanced part and it will be necessary to balance the load when lowering andhoisting.Also, when assembling the crusher without an eccentric cart, it is wise to place thelower bottom shell hub liners beneath the crusher before placing the bottom shell intoposition. This should be done as it may be difficult to pass the liners through thebottom shell once it is set in place on top of the foundation.Installing the CrusherThe following procedures and sequence are commonly used to install the crusher.The sequence may be modified to suit the availability of equipment and conditionsthat exist at the site at the time of the installation.During installation, handle the components carefully to avoid damaging the machinedsurfaces. Inspect each component carefully at the time of assembly and remove anyburrs or upsets that may have been introduced during shipment and handling.The shell for this crusher is provided in three sections: the bottom shell, middle shell,and the top shell. The bottom shell section is installed first.

1. Install the bottom shell on the foundation/structure.


4.2PAGE 4 OF 40


1.1. Thoroughly clean the top surface of the foundation/structure and thebottom surface of the bottom shell to remove all dirt, grease, oil, andpaint.

1.2. Place steel shims 50 mm x 50 mm x 50 mm (grout thickness) in sizeon the foundation at both sides of each foundation bolt.

Use only steel shims. Brass shims are not acceptablefor this installation.

1.3. Check that the shim stacks are nearly level. Add shims as required.1.4. Lower the bottom shell into position, making sure it is in alignment

with the foundation bolts.1.5. Place a precision machinist’s level on top of the mating flange for the

middle shell section.1.6. Level the bottom shell with wedges and shims to 0.048 mm per meter

(0.001 inch per foot).1.7. Tighten the nuts on the foundation bolts evenly in a cross pattern.1.8. Verify the level of the bottom shell section.

2. Grout the bottom shell.2.1. Use a nonshrink grout suitable for use on heavy operating equipment.

The loads indicated on the foundation drawing are used to select thecorrect grout.

2.2. Apply the grout according to the grout manufacturer’s directions.2.3. After the grout has become sufficiently strong, according to the grout

manufacturer’s recommendations, install the:• Install studs and guide pins in the bottom shell. Refer to Figure

4.2.1.• Install 8 studs with long thread in the tapped holes marked “A”.• Install 3 guide pins in tapped holes marked “B”.• Install 24 studs with short threads in the remaining tapped holes.• Gear case shields.• Upper hub liners.• Outer bottom shell liners.• Countershaft liners.• Rib shields.


4.2PAGE 5 OF 40


These items are shipped separately from the bottom shell.Do not install the lower hub liners at this time as thismay interfere with tightening the hydraulic assemblyfasteners.

3. Prepare the outer eccentric bushing and dust seal bonnet for installation.3.1. Carefully clean the top, the bore, and the lower portion of the bottom

shell hub including the countershaft chamber.3.2. Coat these areas with oil, not grease, as grease will contaminate the lu-

brication filter.3.3. Make sure the lube oil drain is clean. This is a channel cast in the

bottom shell. With the use of a mirror and flashlight it can be easilyinspected.

3.4. Inspect the bore holes in the hub for the outer eccentric bushing lubri-cation feed, and the dust bonnet air feed, making sure that they areclear of foreign material.

3.5. Examine the arrangement of drilled and tapped holes in the outer ec-centric bushing flange and the crusher shell. One hole is spaced un-evenly to orient the bushing in the crusher shell. Identify and markthis hole in each piece before proceeding.

3.6. Insert a threaded guide rod in two holes of the bottom shell hub to as-sure alignment of the bushing during installation. The guide rods mustbe of sufficient length to permit the rod to guide the bushing its entirelength during installation.

3.7. Carefully clean the outer eccentric bushing, and remove any upsets onthe surfaces. To facilitate the installation of the bushing, cool thebushing with either dry ice or liquid nitrogen.3.7.1. Using dry ice:

3.7.1.1. Stand the bushing vertically on timbers.3.7.1.2. Pack the interior (bore) completely with dry ice

and cover the bushing with an insulating blanketor a tarpaulin.


4.2PAGE 7 OF 40


3.7.1.3. The cooling period may take three or more hours.Use heavy, well-insulated gloves when handling dry ice.Handling dry ice without adequate protection could re-sult in severe burns.

3.7.2. Using liquid nitrogen:3.7.2.1. Fabricate a tank of mild steel of sufficient height

and diameter to accommodate the bushing.3.7.2.2. Place the bushing into the tank.3.7.2.3. Fill the tank with liquid nitrogen until the lower

1/4 of the bushing is submerged.3.7.2.4. Cover the tank and bushing with an insulating

blanket or tarpaulin.3.7.2.5. Let the bushing stand in the liquid nitrogen until it

has cooled. This may take more than one hour.Liquid nitrogen is a cryogenic liquid. Only trained per-sonnel should be allowed to handle this liquid. Do nothandle with unprotected hands. Use well-insulatedgloves.

3.8. Clean and remove any upsets from the bonnet.3.9. Locate the bonnet gasket and fasteners.

4. Install the outer eccentric bushing and the dust bonnet.4.1. Rig and, with a crane, lower the bushing onto the guide rods, taking

care of bushing alignment with respect to the drilled and tapped holes.4.2. Begin insertion of the bushing into the hub of the bottom shell. If the

bushing begins to jam or tilt in the hub, raise it slightly and realign.Once the bushing begins to lower into the hub, do not stop; continuewith installation until the bushing is fully seated.

4.3. When the bushing has fully seated, the bonnet with gaskets is installed.4.4. Measure the outside diameter of the bonnet and fabricate a cover for it.

Make it sturdy as it will be used as a work platform during later as-sembly, and to prevent dirt and debris from falling into the eccentric.

5. Install the eccentric and bottom plate assemblies.5.1. Clean the bottom chamber for the bevel gear, and the mating surface

for the bottom plate on the bottom shell.


4.2PAGE 8 OF 40


5.2. The bottom plate has three flat bottom drill holes to orient the bottomplate to the bottom shell. Place the eccentric cart on the rails with thepainted “IN” arrow pointing toward the crusher.

5.3. Clean and oil the bottom plate, and place it on the eccentric cart withthe three index pins of the eccentric cart in the three flat bottom drilledholes in the bottom plate.

If an eccentric cart is not available, another method ofraising the assembly is needed. One method is to fabri-cate a lifting frame in the shape of an “H”. With theeccentric assembly placed on the “H” frame, cables arepassed through the bottom shell between the hub andthe outer wall of the crusher and fastened to the “H”.The assembly is raised into place. Care must be exer-cised as the eccentric is an unbalanced load.

5.4. Center the eccentric wearing ring on the bottom plate after thoroughcleaning, removal of any upsets, and oiling of both surfaces.

5.5. After thoroughly cleaning the eccentric, place it onto the bottomplate/eccentric wearing ring.

5.6. Next place all gaskets, both initial assembly and gear backlash adjust-ment, onto the bottom plate. Refer to FFE Minerals USA, Inc. Draw-ing No. 720-94-2-0704, Bottom Plate Assembly, on the followingpage. Also refer to Bill of Material No. 720-94-2-0704-00, M/L Bot-tom Plate Assembly in Section 4.3, Bills of Material.

The above bill of material specifies the number of ini-tial assembly and gear adjustment gaskets that are to beinstalled. It is advisable to install all the gaskets listed,as it is easier to remove them than install them for thegear set backlash adjustment after installation of thegear set.

5.7. Seal the joints of the gaskets with a silicone-type sealant.5.8. Remove the fabricated cover over the bonnet for ease in observing the

raising of the eccentric assembly into position.5.9. Oil the outer surface of the eccentric and oil the bevel gear.5.10. Raise the bottom plate and the eccentric assembly into position.5.11. Install nuts on the long threaded studs and torque these nuts to the val-

ues specified in Section 4.5, Bolt Torque Schedule.


4.2PAGE 10 OF 40


5.12. The hydraulic cylinder assembly is shipped assembled. Orient the as-sembly for proper hole alignment with the bottom plate.

5.13. The bottom of the hydraulic cylinder assembly has a protruding tab toorient the hydraulic cylinder assembly to the bottom shell. Place theeccentric cart on the rails with the painted “IN” arrow pointing towardthe crusher. Place the hydraulic cylinder assembly with the protrudingtab in the notch of the support ring of the eccentric cart.

5.14. Clean and inspect the mating surface, and remove any upsets.5.15. Inspect the piston center for obstructions. This is the oil port for the

crusher bottom lubrication.5.16. Place the cleaned and oiled piston wearing ring and the center wearing

ring on the piston, and move the assembly under the bottom shell.5.17. Refer to FFE Minerals USA, Inc. Bill of Material No. 720-99-1-0904-

01, Hydraulic Assembly, in Section 4.3, Bills of Material, for the gas-kets or O-rings that are installed with the assembly. Place these itemsin position on the assembly.

5.18. The assembly is hoisted into position most easily by using an overheadcrane. Align it with the guide pins while hoisting or jacking it into po-sition.

5.19. Install and torque the nuts on all the studs to the values in the Erectionand Maintenance datasheets.

If an eccentric cart in not available, four equal-lengthcables are passed through the crusher and fastened tothe hydraulic assembly, and the assembly is hoistedinto position.

5.20. Reinstall the cover over the bonnet to prevent debris from falling intothe interior of the crusher.

6. Install the countershaft assembly.6.1. The countershaft assembly is shipped completely assembled. Clean

and oil it, and remove any upsets on machined surfaces.6.2. Refer to Bill of Material 720-99-1-1204-01, Countershaft Assembly, in

Section 4.3, Bills of Material, for the number of gaskets recommendedfor installation with the countershaft assembly. Place the gaskets andinsert it into the bottom shell. Take particular care in engaging thepinion with the bevel gear so that neither is damaged.


4.2PAGE 11 OF 40


6.3. Bolt the assembly to the bottom shell. Two tapped holes are providedto assist in removal by jacking the assembly.

6.4. Measure and record the vertical position of the gear as shown on Fig-ure 4.2.2 after the gearset backlash is correct. Record this position inthe comments column on a copy of the datasheet shown in Figure7.9.6.3, Gearset Backlash Data, and use subsequent measurements toindicate wear of the support surfaces of the bottom plate, eccentricwearing ring, and eccentric.

7. Set gearset backlash.7.1. Refer to Section 4.4, Gear Backlash Setting and Measurements, for

pertinent information relative to this procedure.7.2. When measuring backlash, remove all clearance between the eccentric

and outer eccentric bushing by jacking the eccentric toward the pinionso that the teeth of the gears are in their closest relationship. Thisplacement of the eccentric will provide the measurement of the mini-mum backlash.

7.3. To obtain this placement of the eccentric with the main shaft assemblyin the crusher, place a hydraulic jack between the mantle and concavesat the lowest possible point on the concaves and jack the main shaftassembly and eccentric toward the pinion.

7.4. Release jack pressure before measuring the backlash.7.5. Backlash is measured using the procedure shown in Figure 7.9.6.2.

Place a dial indicator in contact with a bar wedged in a slot of thecountershaft nut.

7.6. Refer to Section 4.4, Gear Backlash Setting and Measurements. Rec-ord the pinion gear pitch radius at the center of the tooth face in Col-umn A on a copy of the datasheet in Figure 7.9.6.3 in Section 7.9,Component Replacement and Selected Repair Procedures: AdjustingBacklash on a New Gearset.

7.7. Measure the distance “R” from the centerline of the pinion shaft to thepoint where the dial indicator plunger touches the bar in the counter-shaft nut. Record this measurement in Column B on the datasheet.

7.8. Rotate the countershaft counterclockwise until the pinion contacts thegear.

7.9. Set the dial indicator to “0”.7.10. Rotate the countershaft clockwise until the pinion again contacts the

gear. Record the dial indicator reading in Column C on the datasheet.


4.2PAGE 12 OF 40


7.11. Calculate the backlash.7.11.1. Divide the pinion pitch radius (Column A) by the distance

between the countershaft centerline and the dial indicator(Column B).

7.11.2. Multiply the result of the division by the dial indicator read-ing (Column C).

7.11.3. Record the result of this multiplication in Column D. This isthe backlash of the gearset.

7.12. Compare the backlash calculated in Column D with the requiredbacklash shown in Section 4.4, Gear Backlash Setting and Measure-ments. Adjust the backlash as required, and check again.

7.13. When the correct backlash has been set, complete the datasheet by re-cording comments, the date, and the names of the technicians thatmade the measurements, calculations, and backlash adjustments.

7.14. Send a copy of Figure 7.9.6.3, Gearset Backlash Data, to FFE Miner-als USA, Inc.

7.15. Changing the backlash is accomplished by removing or adding gasketsbetween the bottom plate and the bottom shell. Minor changes can bemade by removing or adding gaskets between the countershaft assem-bly and the bottom shell. Refer to Section 4.4, Gear Backlash Settingand Measurements, for the amount of movement caused by additionand subtraction of gaskets.

7.16. To remove gaskets from between the bottom plate and the bottomshell:7.16.1. Support the hydraulic cylinder assembly with the eccentric

cart, remove the nuts holding the hydraulic assembly in posi-tion, and lower the eccentric cart and the hydraulic assemblyapproximately 57 mm (2-1/4 inches).

7.16.2. Place four 50-mm (2-inch)-thick blocks between the hydrau-lic cylinder assembly and the bottom plate and raise the hy-draulic cylinder assembly until the blocks contact the bottomplate.

7.16.3. Loosen the eight nuts holding the bottom plate to the bottomshell and lower the hydraulic cylinder assembly and the bot-tom plate together until the bottom plate is supported by theeight nuts.


4.2PAGE 14 OF 40

CE42B.DOC CRUSHER 7 AUG 2001REV 1

7.16.4. Continue to support the hydraulic cylinder assembly with theeccentric cart. Remove the required thickness and number ofgaskets from between the bottom plate and bottom shell.

7.16.5. Reassemble the bottom plate and the hydraulic cylinder as-sembly.

7.16.6. Check the backlash again and record the measurements, finalcalculation results, and the number of gaskets at the bottomplate and the countershaft on the gearset backlash datasheet.

8. Install the main shaft position indicator.

8.1. Use the position indicator manufacturer’s instructions to install andcalibrate this device.

9. Weld in concave ring segments.

9.1. The concave ring segments support the lower row of the concave dur-ing installation. The segments consisting of four arcs are placed into arecess of the bottom shell and are welded to form a continuous ring.Note that the ends of each segment are chamfered for fillet welding.

9.2. Grind welds so that the welding beads do not protrude above the sur-face of the ring. The rings are made from mild steel.

10. Install the middle shell.

10.1. Clean the mating flanges and inspect for upsets and oil.

10.2. Check the specifications and the latest revision of FFE Minerals USA,Inc. Drawing No. 3.500102, Middle Shell, for weight, center of gravity(C.G.), and handling requirements to determine if special orientationof the shell is required. The drawing follows.

10.3. Lower the shell into position, carefully aligning the holes of the boltswith the bottom shell, and install the bolts.

10.4. Torque the nuts evenly until the flanges are in full, tight contact. Referto Section 4.5, Bolt Torque Schedule, for the correct torque values.

The fit between the shells is a taper fit. Tighten thenuts evenly to prevent cocking of the shells.


4.2PAGE 15 OF 40


11. Install the top shell.

11.1. Clean the mating flanges for the middle shell and inspect them for up-sets and oil. Be sure to orient it so the spider will be at the correct po-sition for the feed arrangement.

11.2. Lower the top shell into position, carefully aligning the holes of thebolts, and then install the bolts.

11.3. Torque the nuts evenly until the flanges are in full, tight contact. Referto the Section 4.5, Bolt Torque Schedule, for the correct torque values.

12. Installation of manganese concaves.

After a row of concaves has been installed, an epoxybacking material is poured between the row of con-caves and the crusher shell.

12.1. Prepare the surfaces of the lower concaves and the portion of the mid-dle shell they cover as directed by the instructions of the epoxy back-ing material manufacturer.

As a result of operation, the face of each concave isworked and expands. Space is allowed between theconcaves for this expansion. When positioning them,equalize the space between all concaves in each rowand between rows.

12.2. To determine the space to be left between each row, place a top shellwearing plate on the top shell and stack one concave from each row upthe side of the shell as shown in Figure 4.2.3. Notice that the concavesfor the top row have hooks that must fit into the machined recess in thetop shell.

12.3. Set the lower concaves in place on the concave ring segments usingthe lower key concave to complete the set. Verify that all pads are incontact with the shell. Use steel shims if necessary.

12.4. Position the key concave, if provided, under one of the spider arms soits location is known when the time comes to remove the concave.Equalize the spaces between all of the concaves. Seal the joints andpour backing material between the shell and the concaves in accor-dance with the information provided by the backing material manu-facturer.


4.2PAGE 18 OF 40


12.5. Most backing material is poured in the field, using the following basicprocedures that must be supplemented on site to include additionaldetail and to adjust for local conditions.

12.6. Gaps and joints must be sealed to prevent leakage during pouring.12.7. Complete mixing of the two-part compound is very necessary. Be sure

to mix thoroughly to the bottom of the container. The mixture can setvery fast in the container. As soon as the two parts are mixed, it mustbe used.

12.8. Repeat the procedure for each row of concaves, also filling the spacesbetween rows with backing material. Stagger all vertical joints asshown in Figure 4.2.4.

12.9. Locate the key concave, if provided, in the second row 180 degreesaway from the one in the lower row, then continue alternating the lo-cation of key concaves in each successive row in this same manner.

13. Installation of alloy concaves.13.1. Alloy concaves are installed in the very same fashion as the manga-

nese concaves, except that they do not contain a key in each row andthe concaves are provided with a tapered pin for each concave that ishammered into a hole formed at the top of two adjacent concaves.

• Alloy concaves do not work harden nor expand sothere is no need to scarf the joints.

• Follow manufacturer’s instructions.13.2. Trim off any excess pin above the top surface of the concaves. Refer

to FFE Minerals USA, Inc. Drawing No. 2.501039, Concave Assem-bly, on the following page, for the arrangement of the concaves.

14. Lining spider pockets:14.1. Clean the spider pockets and the mating ends of the spider arms. Place

shims on the machined ledge at the open side of each pocket to keepthe spider elevated slightly, so that subsequently there will be room todraw the spider down and set it firmly in its taper fit. Refer to Figure4.2.5. Use shim thickness of 1 inch (25 mm).


4.2PAGE 21 OF 40


14.2. Block the spider bolt holes with wooden plugs or a board and fill thebottom of the pocket with clay, plaster of Paris, or other sealing mix-ture until it is flush with the top of the shims.

14.3. Coat the machined tapers at the ends of the spider with a thin film ofoil, then place the spider in the top shell, as shown in Figure 4.2.5.

14.4. Use a feeler gauge between the machined ledge on the top shell andthe lip under the spider to determine when the spider is centered.

14.5. Measure at two or more points on each side.14.6. Cover any gap through which backing material could escape.14.7. Prepare and pour epoxy backing material in accordance with instruc-

tions provided for the concaves and the manufacturer of the backingmaterial.

14.8. Mark an end of the spider and its corresponding pocket of the topshell. This will ensure the proper mating of the spider ends to the cor-rect to the top shell spider pocket in the future.

14.9. After the backing material hardens, remove the shims, plugs, sealingmaterial, and spider.

15. Main shaft assembly:15.1. The main shaft, core, mantle, head nut, dust seal ring, and dust seal

ring retainer are usually factory assembled. If they have not been pre-assembled, use the assembly procedure included in Section 7.9, Com-ponent Replacement and Selected Repair Procedures: MainshaftAssembly Component Replacement.

15.2. Two split rings made of graphite and teflon must be installed on themain shaft. Install the split rings in the groove provided and as shownin FFE Minerals USA, Inc. Drawing No. 1.500457, Main Shaft As-sembly (113” Dia. Head), on the following pages.

15.2.1. Coat the inside surfaces of the main shaft groove with grease.

15.2.2. Position the upper seal ring over the lower journal area of theshaft (1,066.8 mm [42.0 inches] in diameter) with the sealdowel pin hole facing down.

15.2.3. Slide the seal up to the lower flange of the groove. Move theseal off-center as far as possible in the direction of the split.Start one end of the seal split into the groove and feed theseal into the groove with a threading motion.


4.2PAGE 23 OF 40


15.2.4. With the upper seal installed in the groove, pack the area be-hind the seals with grease. This is done to help keep the sealscentered for assembly of the main shaft into the crusher.

15.2.5. Position the lower seal ring over the lower journal with theseal dowel pin holes facing up.

15.2.6. Install this seal in the same manner as the upper seal.

15.2.7. The two seals should have the dowel pin holes facing eachother when properly installed. Line up the dowel pin hole atthe split line of the upper seal with the dowel pin hole at 90degrees from the split line of the lower seal.

15.2.8. Install the wood dowel pin in the holes in the upper andlower seals.

15.3. Clean and oil the main shaft assembly eccentric journal.

15.4. Remove the cover over the bonnet.

15.5. Lift the main shaft assembly only by the lifting device on top of the as-sembly.

15.6. Carefully lower the eccentric journal of the main shaft into the bonnetuntil it enters the eccentric.

15.7. Carefully align the contact seal to enter the bonnet and lower the mainshaft assembly further until the seal ring is just inside the bonnet.

15.8. Carefully align the dust seal ring so that it will clear the bonnet on theoutside.

15.9. Continue to lower the main shaft assembly until it has made contactwith the center wearing ring.

15.10. Install the two lubrication fittings on the bottom of the dust seal ringretainer and pump in EP-2 grease lubricant.

15.11. Remove the two pieces of angle iron welded between the inner andouter head nuts.

16. Install the spider lubrication hose and bushing.16.1. Clean the bushing bore and machined bore for the spider hose clamp.

Remove any upsets.16.2. Install the spider hose, clamp, and gasket into the spider. Make sure

that the bolts are tight.


4.2PAGE 25 OF 40


16.3. Clean the bushing and remove any upsets in it.16.4. If a straight bore spider bushing is provided, cool the bushing with dry

ice or liquid nitrogen and install it in the spider bore. The procedure issimilar to the one used for the outer eccentric bushing.

16.5. If a tapered bore spider is provided, a spider bushing installation ringand bolts are provided to assist in installing the bushing. Place thissteel ring on top of the spider bushing flange and draw the bushinginto the spider bore with the bolts until the bushing flange is firmlyseated on the spider. Check the hole register while drawing the bush-ing into place. Use a star tightening pattern on the bolts while drawingthe bushing into place.

16.6. If the bushing is difficult to draw into place with the bolts, it may becooled with dry ice or liquid nitrogen. The procedure is similar to theone used for the outer eccentric bushing.

16.7. After the bushing is firmly in place, remove the installation ring ifused.

16.8. Install and tighten all fasteners for the bushing in a star pattern to thespecified torque.

17. Install the spider shields.Some spider shields have spider bolt access holesthrough the bottom of the spider shield. These through-holes allow the installation of the spider bolts after thespider shields are installed.

17.1. Inspect the shields. If the shields have cast holes for the spider bolts,the shields can be installed without first installing the bolts. If not,then the bolts must be installed first.

17.2. Install the bolts, nuts, and washers into the shields and spider arms andtighten the nuts securely. To ensure that the nuts do not loosen, theycan be tack-welded onto the bolts.

17.3. Epoxy backing material is placed behind the spider shields and thespider.

17.4. Install the bolts, nuts, and washers into the shields and spider arms andtighten the nuts securely. To ensure that the nuts do not loosen, theycan be tack-welded onto the bolts.

17.5. Seal the gaps between the edge of the shields and bolt holes in the spi-der arms.


4.2PAGE 26 OF 40


17.6. Prepare and pour epoxy backing material between the shields and spi-der arms in accordance with instructions provided for the concaves andthe manufacturer of the backing material.

18. Install the spider.18.1. Grease the machined surfaces at the ends of the spider and the interior

of the bushing.18.2. Place the spider seal retainer and the seal onto the bottom of the spider

journal of the main shaft. For most applications, the lip of the sealshould point downward towards the head nut. Refer to Figure 4.2.6.This allows some grease to leak by and purge dust and stone chipsaway from the seal. It also tends to wipe the main shaft clean as theshaft is raised. There are a few applications where petroleum productsare detrimental to downstream processes. In this case the lip of theseal should point upward to keep the grease in the bearing.

18.3. The seal is a split seal, and can be installed as such, but it can also beglued together to form one continual ring. Refer to Figure 4.2.6 for theorientation of the seal.

18.4. The spider is lowered into position using care as the journal of themain shaft enters the bushing and the ends enter the pockets. Do not letit bind in the pockets. Make sure that the spider grease hose enters inthe correct hole in the top shell.

18.5. Install the spider bolts and tighten the bolts gradually and alternately.When all nuts are tight, sledge them.

18.6. The procedure to tighten the torque nuts is as follows:18.6.1. Place the washers and nuts on the bolts. Thread the nuts onto

the bolts by hand until firmly in place.18.6.2. Tighten the torsion bolts on each of the nuts with a torque

wrench to 50 percent of the recommended torque. Tightenthe bolts in a star pattern. Refer to Section 4.5, Bolt TorqueSchedule, for the recommended bolt torque.

18.6.3. Go back to the first spider bolt and tighten the torsion bolts oneach of the nuts in the identical pattern with a torque wrenchto 75 percent of the recommended torque.


4.2PAGE 28 OF 40

CE42C.DOC CRUSHER 7 AUG 2001REV 1

18.6.4. Go back to the first spider bolt and tighten the torsion bolts oneach of the nuts in the identical pattern with a torque wrenchto 100 percent of the recommended torque.

Do not overtighten the tension bolts. A torque wrenchmust be used and the bolts tightened as recommended.

19. Install the top shell wearing plates.19.1. Place the top shell wearing plates in position on the top shell and bolt

them into place. 20. Install the spider cap.

20.1. If the spider lubrication pump is in operation at this time, operate thepump until grease appears between the spider bushing and the mainshaft spider journal.

20.2. The cap does not have any fasteners and is simply set into place. 21. Install the bottom shell liners.

21.1. With a crane, hoist the bottom shell liners into position by running along cable through the crusher.

21.2. Hoist each liner into position and fasten each liner with the fastenersprovided.

21.3. Tack weld the head of each fastener to the liner disc. 22. Connect the hydraulic adjustment system.

22.1. Interconnections and instruction for the hydraulic adjustment systemare shown in FFE Minerals USA, Inc. Drawing No. 1.503575, Hy-draulic System Schematic, on the following page.

22.2. Mount the accumulator in a vertical position on the foundation walland secure it in place with a bracket.

22.3. Locate the relief valve close to the crusher in an accessible place, asfinal adjustments are made to its setting when the crusher is operatingunder load. The initial setting is 2,760 kPa (400 psi). Refer to Section5.5, Initial Start-Up With Feed, for the procedure for adjusting thevalve setting for operation with a normal full crushing load.

During installation, be particularly careful in keepingpipes, fittings, and hoses free of all forms of dirt,grease, and foreign matter that could enter the system.Inspect each piece carefully, clean it as necessary, andblow and flush it clear at the time of connection.


4.2PAGE 30 OF 40


22.4. Make provisions for heating all lines that will be exposed to tempera-tures lower than those specified on the hydraulic system schematic.

22.5. Make appropriate electrical connections to the components of the sys-tem. Interconnect the heaters and thermostat and/or RTD’s with theelectrical service so that the oil can be maintained at operating tem-perature at all times, including weekends and other shutdown periods.

Do not activate the sump tank heater or pump until thesystem has been filled with oil.

22.6. Charge the accumulator.

22.6.1. Charge the accumulator to 21 kg/cm2 (300 psi) with dry ni-trogen in accordance with the manufacturer’s instructions.Use the charging hose and pressure gauge supplied as part ofthe crusher. A cylinder containing 2,265 liters (80 cubic feet)of nitrogen pressurized to 155 kg/cm2 (2,200 psi) is required.

22.7. Fill the hydraulic system.

22.7.1. After flushing the system, verify that the plug is in thereservoir.

22.7.2. Pour in the amount of oil required to fill the reservoir. Closethe cover immediately after filling has been completed toprevent contaminants from entering the system.

22.7.3. The correct oil to be used has the following specification:1500 SSU at 38°C (100°F) EP oil.

Do not activate the heater or pump(s) until the reservoirhas been filled with oil. Be sure appropriate valves arefully open before starting the pump.

23. Install the lubrication system.

23.1 Interconnections and instructions for the lubrication system areshown on FFE Minerals USA, Inc. Drawing No. 1.503574,Lubrication System Schematic, on the following page.


4.2PAGE 32 OF 40


23.1. The sump tank includes a removable screen basket through which thereturn oil passes and serves as a monitoring point. Locate the sumptank where the screen basket can be accessed easily, quickly, andregularly. Depending on the installation, the system may use air orwater to cool the oil. This system uses air to cool the oil with twocoolers in series.

23.2. During installation, be particularly careful in keeping pipes, fittings,and hoses free of all forms of dirt, grease, and foreign matter whichcould enter the system. Inspect each piece carefully, clean it as neces-sary, and blow and flush it clear at the time of connection. Make pro-visions for heating all lines which will be exposed to ambient tem-perature lower than specified on the lubrication system schematicdrawing.

23.3. Make appropriate electrical connections to the components of the sys-tem. Interconnect the heaters and thermostat with the electrical serviceso that the oil can be maintained at operating temperature at all times,including weekends and other shutdown periods.

Do not activate the sump tank heater or pump until thesystem has been filled with oil.

24. Install the spider bushing lubrication equipment.

24.1. Lubricant to the spider for the spider bushing is delivered from a barrelpump which can be located for convenience near the bottom shell ofthe crusher. Refer to the manufacturer’s instructions for details of in-stallation for this system.

24.2. Make provisions to heat the lubrication container used with the pumpand the interconnecting line between the pump and the spider if theywill be subjected to ambient temperatures lower than specified on FFEMinerals USA, Inc. Drawing No. 2.501028, Spider Lube SystemSchematic (see following page).

24.3. Interconnect the controller so that, normally, lubricant will be pumpedto the spider only when the crusher is in operation.


4.2PAGE 34 OF 40


24.4. At the same time, provide for running the spider lubrication equipmentindependently for special functions such as filling the lines. The con-troller also includes terminals for connecting an alarm which will beactivated if lubricant is not pumped in accordance with the programtimer.

24.5. The controller controls the interval at which lubricant is pumped to thebushing and monitors the system performance. The controller can beset to deliver a constant stream of lubricant when the bushing area isbeing filled initially or after the bushing area has been cleaned out.For normal operation, set the controller to deliver twenty counts of lu-bricant every five minutes. Refer to the manufacturer’s literature forprogramming details. Operating conditions of a specific installationmay dictate a different cycle, but the system should operate at leasttwenty counts of lubricant every fifteen minutes.

24.6. When the pump is operational, remove the spider cap and operate thepump until lubricant appears.

25. Install the drive units.

25.1. The drive units consist of a countershaft extension, two couplings, anda 1,000-hp electric motor. Prepare to install the motor by checkingFFE Minerals USA, Inc. Drawing No. 1.503563, Foundation Clear-ance Requirements, with the motor manufacturer’s installation in-structions (see following page). Correct any differences or deviations.

25.2. Refer to FFE Minerals USA, Inc. Drawing No. 2.501050, CountershaftExtension Assembly. Install the coupling rigid hub on the motor. Thecountershaft is provided with the rigid hub installed. The drawingfollows.

25.3. Locate and inspect the countershaft extension. This unit is providedwith the flexible hub assemblies installed.

25.4. Install the motor on its foundation.

25.5. Level and align the motor output shaft with the crusher countershaft.Make sure gaps between the coupling hubs are maintained accordingto the countershaft assembly drawing.


4.2PAGE 37 OF 40


25.6. Install the countershaft extension assembly and set runout on the hubsto the coupling manufacturer’s specification. Realign as required. Re-cord results and readings.

25.7. Jog the motor to verify rotation. If it is not rotating in the correctdirection, reconnect it.

Do not run the crusher in the reverse direction. Themain shaft and head nut threads have been designed forrotation in the specified direction only.

26. Connect pressurizing air.

26.1. Connect a compressed air line to the air inlet connection on the side ofthe bottom shell. The air precludes the entrance of dust at the dustseal. It must be filtered and regulated. Provide 566 to 850 Lpm (20 to30 cfm) at 0.035 to 0.070 kg/cm2 (½ to 1 psi). If the optional blowerwas purchased from FFE Minerals USA, Inc., it will furnish the neces-sary air for the dust seal.

27. Electrical installation, interlocks, and alarms.

27.1. Electrical drawings and schematics are not normally supplied with thecrusher nor are switches, pushbuttons, and the other electrical suppliesand materials unless specified.

27.2. The lubrication and hydraulic schematic diagram and the followingadditional information will aid in designing a suitable electrical in-stallation.

27.3. Manufacturer’s instructions are supplied for the spider bushing lubri-cation monitor and for the drive speed monitor. Incorporate an alarmto be activated by the spider bushing lubrication monitor and an alarmand shutdown circuit to be activated by the speed monitor.

27.4. For the lubrication system, provide switching which will permit theoperator to select, start, and stop the pump. When two pumps are sup-plied, only one pump is run at a time; the second is a backup unit.

27.5. Referring to Figure 4.2.7, connect the flow switches which have beenprovided to activate an alarm and cause a shutdown if there is not anadequate flow of oil to the crusher.

27.6. Connect the temperature switch provided for the return line so that italso will activate the alarm and cause a shutdown if the oil temperaturehigh set point is reached.


4.2PAGE 39 OF 40


27.7. Install a time delay relay in the shutdown circuit to permit the materialin the crusher to empty out before the shutdown occurs. The durationof the time delay depends on the crusher size and the size of the trucksfeeding the crusher, but should not exceed two minutes.

27.8. Install a material level indicator in the crusher discharge chamber toactivate an alarm if material reaches a point that it may back up in thechamber. It is not necessary for it to cause a shutdown, but feed to thecrusher should be stopped until the chamber level drops.

27.9. It is desirable to incorporate a timer which will begin timing when thelubrication pump is started and which will prevent the crusher drivemotor from being started until oil circulates through the crusher andbegins to flow back to the sump. The length of the time delay dependson the size of the crusher and the location of the pumping unit with re-spect to it.

27.10. Crusher hydraulic adjustment systems can have a pumping unit whichhas either one or two pumps. For those having two pumps, provideswitching which will permit the operator to select, start, and stop thepump he wants to use. Only one pump is run at a time; the other is abackup unit.

27.11. The two solenoid valves, “A” and “B” are used in raising and loweringthe crusher’s main shaft. When the solenoids are deenergized, the oilflows from the pump through the filter and back to the tank. Connectthe solenoid on valve “A” through a pushbutton for raising the shaft.Energizing this solenoid will open “A” and allow oil from the pump toflow to the crusher.

27.12. Connect the solenoid on valve “B” through a pushbutton to lower theshaft. Energizing this solenoid will open valve “B” and allow the oilfrom the crusher to flow to the tank.

27.13. Set the alarms for the main shaft position indicator. Set the low posi-tion alarm to sound when the position of the main shaft is less than 51mm (2 inches) above the at rest (no hydraulic pressure) position. Setthe high-position alarm to sound when the main shaft head nut is lessthan 25.4 mm (1.0 inch) from contacting the spider.


4.2PAGE 40 OF 40


28. Provide interconnection protection.

28.1. Provisions must be made to protect all piping and wiring located underthe crusher’s discharge. This is the responsibility of the installer.Frame work, plating, etc. are not supplied by FFE Minerals USA Inc.

29. Conduct a post-installation inspection.

29.1. Before the crusher is started, check the entire installation thoroughly.Include the following points:

29.1.1. All temporary installation aids, debris, tools, etc. have beenremoved from the interior of the crusher and surroundingarea.

29.1.2. The lubrication system and the hydraulic adjustment systemhave been prepared for operation; their pumps rotate in thespecified direction.

29.1.3. The spider bushing lubrication equipment has been flushed,the spider bushing lubricated, the controller programmed, andthe spider cap installed.

29.1.4. All components requiring it have been lubricated.

29.1.5. The drive has been properly aligned.

29.1.6. The mantle position indicator has been calibrated in accor-dance with its manufacturer’s instructions.


4.3PAGE 1 OF 1


4.3 GEAR BACKLASH SETTING AND MEASUREMENTS

This section contains the gear set backlash settings and measurements.

Description Measurements Comments

Required transverse backlash at center oftooth face.

Minimum:1.86 mm (0.073 inch)

Maximum:2.12 mm (0.083 inch)

None.

Pinion pitch radius at center of toothface.

273.85 mm (10.782inches)

Measure backlash at this radius.

Change in transverse backlash for insertion and removal of gasket

0.787 mm (0.031 inch) at countershaft 0.15 mm (0.006 inch) With 15 percent compressionallowance of gasket material.


0.787 mm (0.031 inch) at bottom plate 0.53 mm (0.021 inch) With 15 percent compressionallowance of gasket material.


Countershaft assembly end play

Bearing end play Minimum: 0.03 mm(0.001 inch)

Maximum: 0.13 mm(0.005 inch)

Timken tapered roller bearings:Cone—EE295102Cup—295193


4.4PAGE 1 OF 1


4.4 BOLT TORQUE SCHEDULE

This section contains the bolt/nut torque schedule for assembly of the crusher. Alltorques are for lubricated threads.

Description Item Number Major Diameter ofBolt

Torque

Spider torque nut bolts 1-2-27 24mm (0.945 in) 519 Nm (382 ft-lbs)

Spider bushing bolts 1-2-3 38 mm (1.473 in) 1,750 Nm (1,291 ft-lbs)

Top shell wearing platenuts

1-3-13 42 mm (1.653 in) 1,505 Nm (1,110 ft-lbs)

Shell bolt nuts 1-3-15 100 mm (3.937 in) 37,513 Nm (27,664 ft-lbs)

Dust seal retainer bolts 1-10-19 30 mm (1.181 in) 1,013 Nm (747 ft-lbs)

Inner eccentric bushingbolts

1-8-7, 1-8-8 24 mm (0.945 in) 519 Nm (382 ft-lbs)

Countershaft housingbolts

1-12-19 48 mm (1.889 in) 4,149 Nm (3,059 ft-lbs)

Bottom plate to bottomshell nuts

1-5-16 56 mm (2.205 in) 6,313 Nm (4,656 ft-lbs)

Hydraulic bottom tobottom shell nuts

1-5-16 56 mm (2.205 in) 6,313 Nm (4,656 ft-lbs)

Bottom cover tohydraulic bottom nuts

1-9-20 56 mm (2.205 in) 6,313 Nm (4,656 ft-lbs)

Bottom shell outer wallliner nuts

1-6-44 24 mm (0.945 in) 519 Nm (382 ft-lbs)

Bottom shell rib shield 1-6-46 36 mm (1.417 in) 1,750 Nm (1,291 ft-lbs)

Dust bonnet to bottomshell bolts

1-5-5 36 mm (1.417 in) 1,750 Nm (1,291 ft-lbs)

Spider shield nuts 1-2-20, 1-2-21 76 mm (2.992 in) 8,920 Nm (6,578 ft-lbs)

Spider arm shield nuts N/A

Gearcase shield nuts 1-6-45 42 mm (1.653 in) 1,505 Nm (1,110 ft-lbs)


4.1PAGINA 1 DE 5

CE41-S.DOC CRUSHER NOV. 2001REV 0

4.0 INSTALACION4.1 INSTRUCCIONES DE ALMACENAMIENTO

INTRODUCCIONEsta sección instruye al operador acerca de cómo cuidar del chancador y suscomponentes desde que es recibido en el lugar de la obra hasta su instalación y laetapa de pre-puesta en servicio.

PROCEDMIENTO 1. Comprobar si se produjo alguna avería durante el embarque.

La fabricación de este chancador demanda un cuidadoconsiderable. Antes de ser entregado al transportista esinspeccionado cuidadosamente a la vez que espreparado para embarque. No obstante este esfuerzo,existe el riesgo que este equipo sufra daño durante eltraslado.

1.1. El embarque es recibido e inventariado contra la lista de empaqueentregada por FFE Minerals USA, Inc.

1.2. En la eventualidad que a la recepción del equipo se observe mermasy/o averías visibles, se dejará de ello constancia clara y exacta en laguía de despacho. Se recomienda dejar una copia de esta guía deentrega en sus archivos por si pudieran presentarse reclamos en elfuturo. Se deberá contactar oportunamente al transportista y/o lacompañía de seguros para que efectúe una inspección física de lamercancía. Se deberá tener especial cuidado de no cambiar de lugar lamercancía en cuestión ni destruir ningún material de empaque antes dela correspondiente inspección; hacerlo podría poner en riesgo elderecho a reclamo. Deberá guardar una copia del informe de lainspección del transportista y/o de la compañía de seguros en susarchivos, como prueba en caso de un posible reclamo.

1.3. Cualquier avería oculta a la inspección preliminar, descubierta enfecha posterior, deberá ser informada al transportista inmediatamente,como también a la compañía de seguro. De ser posible, cualquieravería oculta a la inspección visual inicial, deberá ser informada dentrode los 15 días siguientes a la fecha de recepción de la mercancía.


4.1PAGINA 2 DE 5


Los términos de venta acordados entre el Cliente y el Vendedordeterminarán cual de las partes notificará del reclamo al transportistapor cualquier merma o avería ocurrida durante el traslado.

Almacenamiento bajo techoSe recomienda que, durante el inicio de la instalacióndel chancador, se cuente con un edificio o uncontenedor para el almacenamiento de las partes bajotecho.

2. Todos los materiales de protección tales como papel a prueba de agua yrecubrimiento para prevenir la oxidación, deben ser reparados o reemplazadossi han sufrido daño durante el traslado. Remitirse a la Sección 7.0,Mantenimiento: Especificaciones de Pintura y Recubrimiento, para que seautilizado el recubrimiento adecuado para las superficies específicas. 2.1. Mientras el equipo se encuentra almacenado, deberá ser inspeccionado

cada dos meses. En cada ocasión se deberá eliminar el óxido, y lapintura o recubrimiento protector deberán ser reemplazados de sernecesario.

2.2. Los siguientes ítemes deberán ser almacenados bajo techo, atemperatura no menor que 5°C (40°F), a menos que el fabricanteindique otra.

• Conjunto del contraeje

• Conjunto de extensión delcontraeje

• Conjunto de la excéntrica

• Motores eléctricos

• Bujes de bronce y placas dedesgaste

• Anillo de desgaste del ejeprincipal

• Sello de contacto del ejeprincipal

• Conjunto del sistema delubricación

• Conjunto delsistema hidráulico

• Conjunto delsistema delubricación tipoaraña

• Enfriadores de aire/aceite

• Paneles de Control

• Instrumentos

• Engranajes

• Acoplamientos


4.1PAGINA 3 DE 5


• Casquete contra polvo

• Empaquetaduras

• Sellos

• Sellante epóxico

• Tuerca principal

• Todos los pernos, tuercas,golillas, clavijas, lainasválvulas de tuberías yelementos de ferretería engeneral.


4.1PAGINA 4 DE 5


Almacenamiento a la intemperie 3. Los restantes componentes del chancador corresponden a las partes mayores y

mecanizadas. Estos ítemes están pintados y las superficies mecanizadas debenestar cubiertas con una capa de Chek rust #1, Tectyl 891, u otro productosimilar, debidamente aprobado.

3.1. Todas las partes deberán ser inspeccionadas a su llegada al lugar de laobra. Las superficies dañadas durante el traslado deberán ser reparadasremoviendo el óxido y repintando o recubriendo con el materialanticorrosivo necesario. De ahí en adelante las partes deberán serinspeccionadas con frecuencia regular para remover el óxido yproteger con material anticorrosivo.

Especial atención se deberá brindar a las superficiesmecanizadas que se menciona a continuación:

• Las superficies de los descansos de los ejesprincipales.

• Los flanches del cuerpo, los pilotos, y lasperforaciones para pernos.

• Las superficies de ajuste interiores y concavidadesde la araña.

• Superficie interior lisa del manto.

• Superficie lisa interior y diámetro exterior delnúcleo.

• Las placas base.

• Partes lisas del cuerpo inferior y flanches.

• Las superficies de las placas del fondo.

La formación de óxido sobre estas superficies podríacausar daño irreparable.

3.2. Estos componentes pueden ser almacenados a la intemperie, sinembargo, en lo posible, se deberá elegir un lugar que permitamantenerlos protegidos de los efectos climáticos. Todos los ítemesalmacenados a la intemperie deberán ser depositados sobre basasadecuadas para evitar que se hundan en barro. Estos elementos deapoyo deberán ser inspeccionados frecuentemente y se deberá tomar


4.1PAGINA 5 DE 5


las medidas correctivas necesarias, si corresponde, para prevenir dañoa los componentes almacenados


4.2PAGINA 1 DE 53

CE42A-S.DOC CRUSHER NOV. 2001REV 1

4.2 SECUENCIA E INSTRUCCIONES PARA LA INSTALACIONDE LOS COMPONENTES

INTRODUCCIONEl propósito de esta sección es brindar asistencia al contratista a cargo de lainstalación con la secuencia y procedimientos para la instalación del chancador.

Lea esta sección antes de efectuar cualquier trabajo deinstalación, operación o mantenimiento.Todos los equipos deben ser operados y mantenidos deacuerdo con los sistemas de seguridad gubernamentalesy leyes de salubridad, regulaciones y estándaresindustriales reconocidos.

Recomendaciones para el ContratistaLas operaciones normales de montaje incluyen lacorrección de desajustes menores mediante moderadasrectificaciones, aplicación de láminas de ajuste, cortes oesmerilado para el adecuado ajuste de los elementos. Losdesajustes que no puedan ser corregidos mediante losprocedimientos mencionados o que requieran mayorescambios en la configuración de los equipos, deberán serinmediatamente informados a FFE Minerals USA, Inc.,para que efectúe sea la corrección del desajuste o paraindicar la aplicación del método más eficiente yeconómico de corrección

La instalación del chancador se deberá efectuar de acuerdo con los planossuministrados. Ellos definen la disposición física, las dimensiones pertinentes, lasinterconexiones, cargas y otras características, datos e información necesaria para elmontaje e instalación de todos los componentes suministrados.En tanto haya una secuencia a seguir para la instalación, habrán muchos detalles queharán necesario modificar dicha secuencia de acuerdo a las condiciones que presente ellugar de la faena. Pueden existir otras condiciones que podrían convertir esta secuenciaen una visión general de los procedimientos de instalación que puedan presentarimportantes detalles en conjuntos individuales, componentes y varias otras facetas deinstalación. Estos detalles pueden ser de ayuda para determinar y utilizar las secuenciasy técnicas apropiadas para esta faena.Deberá haber un Cuaderno de Obras, siempre disponible para registrar todos losavances de la obra, los problemas encontrados y también para registrar las dimensiones


4.2PAGINA 2 DE 53


obtenidas durante las diversas fases de instalación de cada chancador. Esta valiosainformación permitirá comparar diversos aspe durante la instalación de cada chancadory las que se presenten posteriormente durante la operación de ellos; servirá ademáspara identificar orígenes potenciales de problemas, lo que ayudará para llegar asoluciones más fáciles y definitivas.

El chancador es embarcado en subconjuntos mayores cuya unión final deberá sercompletada en el lugar de la obra. La instalación de estos subconjuntos, y todosaquellos ensamblados en el lugar de la obra, serán de acuerdo con los planosproporcionados en este manual, y a los datos de instalación indicados en esta seccióndel manual. Estos documentos contienen información específica para este chancador.Ellos definen la disposición física, las dimensiones pertinentes, las cargas y otrascaracterísticas, datos e información necesaria para el montaje y la instalación de todoslos componentes suministrados. Observe cuidadosamente las marcas de montaje delos componentes durante su instalación.

PROCEDIMIENTORecepción e Inspección

1. Todos los embarques deberán ser inspeccionados inmediatamente al momentode ser recibidos para verificar mermas y averías. En caso de evidencia decualquiera de éstas, se deberá informar de ello al agente embarcador local o altransportista que efectuó el flete. Para evitar futuras controversias acercareclamos por pérdidas o averías, asegúrese que el representante del agente odel transportista haga las anotaciones correspondientes en la guía dedespacho. Informe inmediatamente acerca del problema, por escrito, alGerente de Tráfico de FFE Minerals USA.

Condiciones de Garantía

Cualquier modificación a los componentes en terreno, amenos que haya sido autorizada por FFE Mineral USA,Inc., podrá y anulará la garantía

Recomendaciones para la Pre-Instalación

1. El chancador incluye descansos de precisión, engranajes y superficiesmecanizadas y partes que deben ser protegidas de las condiciones climáticasadversas. Aún cuando los componentes han sido protegidos adecuadamentepara el embarque, se debe tener presente que la vida de los materiales deprotección es relativamente limitada y que no se podrá contar con ellos porperíodos prolongados. Los recubrimientos protectores de los ítemes másdelicados, tales como descansos, bujes y engranajes, deben ser inspeccionadosinmediatamente al momento de su recepción y renovarlos de ser necesario.


4.2PAGINA 3 DE 53


Fundaciones/Estructura

Nota:

La instalación del chancador se deberá efectuar de acuerdo con el tipo de plantarecomendado por el fabricante y siguiendo las instrucciones que se entrega acontinuación:

El chancador se deberá montar sobre una fundación lo suficientemente resistente parasoportar el peso del equipo y las cargas que éste recibirá durante su operación. Elmencionado diseño de la fundación dependerá de las características geológicas delterreno en el que será construida, y será de responsabilidad del cliente. Normalmente,el cliente es también responsable del diseño una adecuada caja de piedra, una cámarade descarga, y cualquier otra estructura necesaria en las inmediaciones de la planta dechancado.

La fundación/estructura deberá tener una abertura en el costado para permitir elmovimiento de la excéntrica y los conjuntos de ajuste hidráulico al ser instalados odesmontados. Se debe considerar la instalación provisoria de rieles, necesarios parainstalar un carro para movilizar estos conjuntos que serán instalados bajo elchancador.• Cerciórese que se ha considerado el espacio suficiente para instalar lainas, el

grout, la base del chancador y los elementos y accesorios de montaje necesariospara los pernos de anclaje.

• También se tendrá presente el espacio requerido para elementos tales como elaccionamiento, la fuente de energía hidráulica, la bomba de lubricación, y eltanque de acumulación.

Aspectos a ser considerados antes de instalar la Parte Inferior del CuerpoCuando se cuenta con un carro de desplazamiento excéntrico, como es el caso delchancador, la parte inferior del cuerpo es instalada directamente sobre lainasapoyadas sobre la fundación.Un método es ubicar el sistema hidráulico en la tolva de descarga, directamentedebajo del chancador para después instalar la placa inferior, el anillo de desgasteexcéntrico y la excéntrica sobre la parte superior del sistema hidráulico. Acontinuación, estos elementos son bajados a su posición definitiva con los equipos deelevación adecuados. Se deberá tener presente que un equipo de elevación deberáser ubicado bajo la placa inferior a fin de poder bajar y subir ésta. Además, se deberátener presente que la excéntrica es un elemento que no está equilibrado, debiéndosepor lo tanto, equilibrar la carga en la faena de bajarla o subirla.


4.2PAGINA 4 DE 53


Por otra parte, al efectuar el montaje del chancador sin el apoyo de un carroexcéntrico, es recomendable instalar el revestimiento de la campana de la parteinferior del fondo del cuerpo, ubicado debajo del chancador, antes colocar la parteinferior de éste en su posición definitiva. Se deberá hacer de este modo, ya que serádifícil pasar las partes del revestimiento a través del fondo del cuerpo una vez queesté ubicado en su lugar definitivo sobre la fundación.Instalación del ChancadorLos siguientes procedimientos y su secuencia son utilizados habitualmente parainstalar chancadores. La secuencia puede ser modificada para adaptarse a ladisponibilidad de equipo y condiciones existentes en el lugar de la obra al momentode la instalación.Durante la instalación se deberá manipular en forma cuidadosa todos loscomponentes para evitar daños en las superficies mecanizadas. Cada componente seráinspeccionado acuciosamente en el momento de su instalación, y se eliminará todarebaba o material extraño que pudiera haberse introducido en ellos durante eltransporte y manipulación.El cuerpo de este chancador es suministrado en tres secciones: la sección inferior, lasección central y la sección superior del cuerpo. La sección inferior del cuerpo deberáser instalada en primer lugar.

1. Instalación de la sección inferior del cuerpo sobre la fundación.1.1. Limpiar cuidadosamente la fundación y la zona de contacto con ella de

la sección inferior del cuerpo a fin de eliminar remover todo materialextraño, grasa, aceite y restos de pintura.

1.2. Colocar lainas de acero de 50 x 50 x 50 mm (del espesor del grout)sobre la fundación a ambos lados de cada perno de la fundación.

Use solamente lainas de acero. Para esta instalación nose acepta lainas de bronce.

1.3. Verificar que los conjuntos de lainas están aproximadamente al mismonivel. Agregue las lainas necesarias para lograrlo.

1.4. Bajar la parte inferior del cuerpo a su posición definitiva,asegurándose que se encuentra alineada con los pernos de montaje enla fundación.

1.5. Colocar un nivel de precisión sobre el flanche de unión con la seccióncentral del cuerpo.

1.6. Nivelar la sección inferior del cuerpo con cuñas y lainas hasta lograrun valor 0.048 mm por metro (0.001 pulgada por pie).


4.2PAGINA 5 DE 53


1.7. Apretar las tuercas de los pernos de la fundación siguiendo unasecuencia en forma de cruz.

1.8. Verificar que la sección inferior del cuerpo quedó perfectamentenivelada.

2. Groutear la parte inferior del cuerpo.2.1. Usar grout no contráctil concebido para la instalación de equipos

pesados. Las cargas indicadas en los planos de la fundación serviráncomo pauta para seleccionar el grout correcto.

2.2. Aplicar el grout siguiendo las recomendaciones del fabricante.2.3. Una vez que el grout ha adquirido una consistencia suficientemente

fuerte, siguiendo las recomendaciones del fabricante, instalar:• Pernos tipo espárrago y pasadores guía en la parte inferior del

cuerpo. Remitirse a la Figura 4.2.1.• 8 pernos tipo espárrago de rosca larga en las perforaciones

roscadas marcadas con la letra “A”.• 3 pasadores guía en las perforaciones roscadas marcadas con la

letra “B”.• 24 pernos tipo espárrago con rosca corta en las restantes

perforaciones roscadas.• Las protecciones de la caja de engranajes.• Los revestimientos de la campana de la sección superior.• Los revestimientos de la sección inferior externa del cuerpo.• Los revestimientos de los contraejes.• Las protecciones de los pilares.Estos ítemes son despachados separados de la sección inferior delcuerpo.

No instalar los revestimientos de la campana de lasección inferior en esta etapa ya que dicha faena podríainterferir con el apriete de los elementos de fijación delsistema hidráulico.

3. Preparar los bujes excéntricos externos y el casquete contra polvo para suinstalación.3.1. Limpiar cuidadosamente la parte superior, interior y la sección inferior

de la campana de la sección inferior del cuerpo, incluyendo la cámaradel contraeje.


4.2PAGINA 6 DE 53


3.2. Cubrir estas áreas con aceite; por ningún motivo usar grasa, pues éstaobstruirá el filtro de lubricación.

3.3. Asegúrese que el drenaje de aceite lubricante no está obstruido. Estedrenaje es un canal incorporado al cuerpo inferior de fundición ypuede ser fácilmente inspeccionado con la ayuda de un espejo y de unalinterna. .

3.4. Inspeccionar las perforaciones para el aceite lubricante en la masa y lallegada de aire al casquete contra polvo para asegurarse que estánlibres de material extraño.

3.5. Examinar la disposición de las perforaciones lisas y las roscadas en elflanche del buje excéntrico externo y del cuerpo del chancador. Unaperforación está separada en forma asimétrica para permitir laorientación del buje en el cuerpo del chancador. Se identificará ymarcará esta perforación en cada pieza antes de continuar con lostrabajos.

3.6. Introducir como guía una varilla roscada en dos perforaciones de lacampana del fondo del cuerpo para asegurar la alineación correcta delbuje durante la instalación. Estas guías roscadas deberán tener lalongitud suficiente para poder guiar al buje en toda su longituddurante la instalación.

3.7. Limpiar cuidadosamente el buje excéntrico externo y eliminarcualquier engrosamiento de las superficies. Para facilitar la instalacióndel buje, enfriar éste ya sea con hielo seco o nitrógeno líquido.3.7.1. Si se utilizare hielo seco:

3.7.1.1. Poner el buje en posición vertical sobre una piezasde madera adecuadas.

3.7.1.2. Rellenar completamente su interior con hielo secoy cubrir el buje con una manta aislante o con unalona.


4.2PAGINA 8 DE 53


3.7.1.3. El proceso de enfriamiento toma tres o más horas.Al manipular hielo seco se deberá usar guantes dematerial aislante. La manipulación de hielo seco sinprotección adecuada podría causar severasquemaduras.

3.7.2. Si se utilizare nitrógeno líquido:3.7.2.1. Fabricar un estanque de acero dulce de suficiente

altura y diámetro para acomodar el buje.3.7.2.2. Colocar el buje dentro del estanque3.7.2.3. Llenar el estanque con nitrógeno líquido hasta que

¼ de la parte inferior del buje quede sumergido.3.7.2.4. Cubrir el estanque con una manta aislante o con

lona.3.7.2.5. Mantener el buje en el nitrógeno líquido hasta que

se haya enfriado. Esto puede tomar más de unahora.

El nitrógeno líquido es un líquido criogénico. Solamentepersonal debidamente entrenado estará autorizado paramanipular este líquido. No trabaje con las manos sinprotección. Utilice guantes aislantes.

3.8. Limpiar y eliminar cualquier protuberancia del casquete.3.9. Colocar la empaquetadura del casquete contra polvo y los elementos

de fijación. 4. Instalar el buje excéntrico externo y casquete contra polvo.

4.1. Aparejar el buje y depositarlo sobre las varillas guía mediante unagrúa, asegurándose que quede alineado con respecto a lasperforaciones de interior liso y las perforaciones roscadas.

4.2. Comenzar la instalación del buje en la masa de la zona inferior delcuerpo. Si el buje se atascara o inclinara la campana, levantarloligeramente y realinearlo. Una vez que el buje comienza a deslizarsedentro de la campana, no interrumpir la faena y continuar con lahasta que el buje está completamente asentado.

4.3. Terminada la instalación del buje, se instalará el casquete contra polvocon sus empaquetaduras.


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4.4. Medir el diámetro externo el casquete contra polvo y fabricarle unacubierta. Esta deberá ser firme, ya que será utilizada como plataformade trabajo durante el montaje final, y para prevenir la entrada debasura y desechos dentro de la excéntrica.

5. Instalar la excéntrica y los conjuntos de placas de la parte inferior.5.1. Limpiar la cámara de la parte inferior por el engranaje cónico, y la

superficie de ajuste de la placa inferior de la sección inferior delcuerpo.

5.2. La placa inferior tiene tres perforaciones de interior liso para orientarla placa inferior de la sección inferior del cuerpo. Colocar el carroexcéntrico sobre los rieles con la flecha “IN” apuntando hacia elchancador.

5.3. Limpiar y aceitar la placa inferior y colocarla sobre el carro excéntricocon las tres clavijas de división del carro excéntrico en las tresperforaciones lisas de fondo plano en la placa inferior.

Si no se cuenta con un carro excéntrico, se deberáutilizar otro método para elevar los conjuntos. Unmétodo es fabricar una estructura de elevación enforma de “H”. Con el conjunto de la excéntricacolocado sobre la estructura en forma de “H”, sedeberán pasar los cables a través de la parte inferior delcuerpo entre la campana y la pared exterior delchancador para fijarlos a la estructura “H”. De estamanera, el sistema es elevado hasta su lugar definitivo.Al ejecutar este procedimiento se deberá tener muchocuidado ya que la excéntrica es una cargadesequilibrada.

5.4. Centrar el anillo de desgaste excéntrico sobre la placa inferior, previacompleta limpieza, removiendo cualquier engrosamiento y aceitandoambas superficies.

5.5. Una vez que se ha limpiado completamente la excéntrica, colocarlasobre la placa inferior/anillo de desgaste excéntrico.

5.6. El próximo paso será instalar las empaquetaduras, el ensamblaje inicialy el ajuste del contra golpe del engranaje sobre la placa inferior.Remitirse al plano No. 720-94-2-0704 de FFE Minerals USA, Inc.,Ensamblaje de la Placa Inferior, que se incluye más adelante.Remitirse también a la Lista de Materiales No. 720-94-2-0704-00,


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M/L Ensamblaje de la Placa Inferior en la Sección 4.3, Listas deMateriales.

5.7. Sellar las uniones de las empaquetaduras con sellante tipo silicona.5.8. Retirar la protección del casquete contra polvo para facilitar la

observación de la elevación de la excéntrica a su posición definitiva.5.9. Aceitar la superficie externa de la excéntrica y también el engranaje

cónico.5.10. Elevar la placa inferior y el ensamblaje de la excéntrica hasta su

posición definitiva.5.11. Instalar tuercas en los pernos tipo espárrago roscados y apretarlas a los

valores especificados en la Sección 4.5, Programa de Apriete dePernos.


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5.12. El conjunto del cilindro hidráulico es embarcado ensamblado. Orientarel conjunto para alinear las perforaciones con la placa inferior.

5.13. La parte inferior del conjunto del cilindro hidráulico tiene una lengüetasobresaliente para orientar el conjunto del cilindro hidráulico hacia laparte inferior del cuerpo. Colocar el carro excéntrico sobre los rielesmarcados con la flecha “IN” apuntando hacia el chancador. Ubicar elconjunto del cilindro hidráulico con la lengüeta sobresaliente en laranura del anillo de soporte del carro excéntrico.

5.14. Limpiar e inspeccionar la superficie de ajuste y eliminar todoengrosamiento.

5.15. Inspeccionar el centro del pistón para verificar posibles obstrucciones.Este es el conducto del aceite para la lubricación de la sección inferiordel chancador.

5.16. Colocar el anillo de desgaste del pistón, limpio y aceitado y el anillode desgaste central en el pistón, y situar el conjunto debajo de la parteinferior del cuerpo.

5.17. Remitirse a la Lista de Materiales No. 720-99-1-0904-01, SistemaHidráulico, en la Sección 4.3, Listas de Materiales, de FFE MineralsU.S.A, Inc., para mayor información acerca de las empaquetaduras oLlantas que deben ser instaladas con el sistema. Colocar estos ítemesen su posición definitiva sobre el conjunto.

5.18. El sistema se debe elevar hasta su posición definitiva de manera másfácil, utilizando una grúa para trabajo en altura. Alinearlo mediante lospasadores durante el proceso de elevación o al alzarlo hasta suposición definitiva.

5.19. Instalar y apretar las tuercas en los pernos tipo espárrago a los valoresespecificados en las hojas de datos de Montaje y Mantenimiento.

Si no se cuenta con una carro so, se deberá utilizarcuatro cable del mismo largo, los que se deberán pasara través del chancador y fijados al sistema hidráulicopara elevar el conjunto hasta su posición definitiva.

5.20. Reinstalar la cubierta sobre el casquete contra polvo para evitar laentrada de desechos al interior del chancador.


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6. Instalación del conjunto del contraeje.6.1. El conjunto de contraeje es embarcado completamente ensamblado.

Limpiarlo y aceitarlo, y eliminar cualquier engrosamiento desde lassuperficies mecanizadas.

6.2. Remitirse a la Lista de Materiales No. 720-99-1-1204-01, Ensamblajedel Contraeje, en la Sección 4.3, Listas de Materiales, para obtenermayor información acerca del número de empaquetadurasrecomendado para la instalación del conjunto del contraeje. Instalar lasempaquetaduras e insertarlas en la parte inferior del cuerpo. Serecomienda especial cuidado al ensamblar el piñón con el engranajeangular para que ninguno resulte dañado.

6.3. Apernar el ensamblaje al fondo del cuerpo. Se cuenta con dosperforaciones roscadas como apoyo para trasladar el conjuntomediante gata hidráulica.

6.4. Medir y registrar la posición vertical del engranaje como se muestra enla Figura 4.2.2 una vez que el contragolpe del tren de engranaje está enla posición correcta. Registrar estar posición en la columna decomentarios en una copia de la hoja de datos que se muestra en laFigura 7.9.6.3, Datos del Contragolpe del Tren de Engranaje, y utilicelas siguientes mediciones para indicar del desgaste de las superficiesde soporte de la placa inferior, del anillo de desgaste excéntrico y de laexcéntrica.

7. Fijación del contragolpe del tren de engranaje.7.1. Remitirse a la Sección 4.4, Fijación y Mediciones del Contragolpe del

Engranaje, para obtener la información pertinente en relación a esteprocedimiento.

7.2. Al efectuar la medición del contragolpe, eliminar toda separación entrela excéntrica y el buje excéntrico externo elevando con gata hidráulicala excéntrica hacia el piñón, a fin de que los dientes de los engranajesestén en su más estrecha relación.

7.3. Para obtener esta ubicación de la excéntrica con el conjunto ejeprincipal en el chancador, colocar una gata hidráulica entre el manto ylas cóncavas en el punto más bajo posible de estas últimas y levantar elconjunto del eje principal y la excéntrica hacia el piñón.

7.4. Soltar presión de la gata hidráulica antes de medir el contragolpe delengranaje.


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7.5. El contragolpe se mide utilizando el procedimiento que se muestra enla Figura 7.9.6.2. Colocar un reloj comparador en contacto con unbarra acuñada en una ranura de la tuerca del contraeje.

7.6. Remitirse a la Sección 4.4, Fijación y Mediciones del Contragolpe delEngranaje. Registrar el radio del paso del engranaje del piñón alcentro de la cara del diente en la Columna A, en una copia de la hojade datos que se incluye en la Figura 7.9.6.3, en la Sección 7.9,Reemplazo de Componentes y Selección de Procedimientos deReparación: Ajuste del Contragolpe del Engranaje sobre un NuevoTren de Engranaje.

7.7. Medir la distancia “R” desde el eje central del eje del piñón hacia elpunto donde el émbolo del reloj comparador toca la barra en la tuercadel contraeje. Registrar esta medición en la Columna B de la hoja dedatos.

7.8. Rotar el contraeje en sentido contra horario hasta que el piñón contacteel engranaje.

7.9. Fijar el reloj comparador en “0”.7.10. Rotar el contraeje en el sentido horario hasta que el piñón haga

contacto otra vez con el engranaje. Registrar la lectura del relojcomparador en la Columna C de la hoja de datos.

7.11. Calcular el contragolpe del engranaje.7.11.1. Dividir el radio del paso del piñón (Columna A) por la

distancia entre el eje central del contraeje y la lectura del relojcomparador (Columna B).

7.11.2. Multiplicar el resultado de la división por la lectura del relojcomparador (Columna C).

7.11.3. Registrar el resultado de esta multiplicación en la Columna D.Este es el contragolpe del contragolpe del engranaje.

7.12. Comparar el contragolpe del engranaje calculado en la Columna D conel contragolpe que se muestra en la Sección 4.4, Fijación delContragolpe del Engranaje y Mediciones. Ajustar el contragolpesegún necesidad y revisar de nuevo.

7.13. Cuando el contragolpe correcto del engranaje ha sido fijado, completarla hoja de datos mediante el registro de comentarios, la fecha. y losnombres de los técnicos que efectuaron las mediciones, cálculos yajustes del contragolpe de los engranajes.

7.14. Enviar una copia de Figura 7.9.6.3, Datos del Contragolpe del Tren deEngranajes a FFE Minerals USA; Inc.


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7.15. El cambio del contragolpe del engranaje se obtiene retirando oagregando empaquetaduras entre la placa inferior y la sección inferiordel cuerpo. Los cambios menores se pueden hacer retirando oagregando empaquetaduras entre el sistema del contraeje y la seccióninferior del cuerpo. Remitirse a la Sección 4.4, Fijación y Medicionesdel Contragolpe del Engranaje, para obtener información acerca delmovimiento causado al agregar o retirar empaquetaduras.

7.16. Para retirar empaquetaduras de entre la placa inferior y el fondo delcuerpo:7.16.1. Soportar el conjunto del cilindro hidráulico con el carro

excéntrico, retirar las tuercas que sostienen el sistemahidráulico en su posición, y bajar el carro excéntrico y elconjunto hidráulico aproximadamente 57 mm (2-1/4pulgadas).

7.16.2. Colocar cuatro bloques de 50 mm (2 pulgadas) de espesorentre el conjunto del cilindro hidráulico y la placa inferior ysubir el conjunto del cilindro hidráulico hasta que los bloqueshagan contacto con la placa inferior.

7.16.3. Aflojar las ocho tuercas que mantienen unida la placa inferiora la sección inferior del cuerpo y bajar el conjunto delcilindro hidráulico y la placa inferior juntos hasta que la placainferior sea soportada por las ocho tuercas.

.


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CE42B-S.DOC CRUSHER NOV. 2001REV 1

7.16.4. Continuar apoyando el conjunto del cilindro hidráulico con elcarro excéntrico. Retirar juntas de la unión entre la placainferior y la sección para llegar al espesor requerido.

7.16.5. Ensamblar nuevamente la placa inferior y el conjunto delcilindro hidráulico. Revisar nuevamente el contragolpe de losengranajes y registrar las mediciones, los resultados de loscálculos finales y el número de juntas en la placa inferior y enel contraeje, en la hoja de datos del contragolpe en el tren deengranajes.

8. Instalación del indicador de posición del eje principal.

8.1. Seguir las instrucciones del fabricante del indicador de posición parainstalar y calibrar este dispositivo.

9. Soldadura en los segmentos del anillo cóncavo.

9.1. Los segmentos del anillo cóncavo soportan las hileras inferiores de lasección cóncava durante la instalación. Los segmentos consisten encuatro arcos que son colocados en su alojamiento en la sección inferiordel cuerpo y que son posteriormente soldados para formar un anillocontínuo. Observe que los extremos de cada segmento son biseladosantes de aplicar los cordones de soldadura.

9.2. Esmerilar las soldaduras a fin de que sus bordes no sobresalgan de lasuperficie del anillo. Estos anillos son fabricados de acero dulce.

10. Instalación de la sección central del cuerpo.

10.1. Limpiar los flanches de ajuste y buscar protuberancias y presencia deaceite, los que deberán ser eliminados.

10.2. Chequear la última revisión del Plano No. 3.500102 con lasespecificaciones, Sección Central del Cuerpo, de FFE Minerals USA,Inc., para conocer el peso, la ubicación del centro de gravedad (C.G.) ylas necesidades para manipulación a fin de determinar si deberá darseuna orientación especial a este cuerpo. El plano se incluye másadelante.

10.3. Bajar el cuerpo a su posición definitiva alineando cuidadosamente lasperforaciones para los pernos con las de la sección inferior del cuerpo,e instalar los pernos.

10.4. Apretar las tuercas uniformemente hasta que los flanches hagan plenocontacto entre sí. Remitirse a la Sección 4.5, Programa de Apriete de


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los Pernos, para conocer los valores del torche a aplicar a los pernospara su apriete.

.

La superficie de unión entre los cuerpos es de formacónica. Apretar las tuercas uniformemente, paraprevenir el descuadre de los cuerpos.


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11. Instalación de la sección superior del cuerpo.

11.1. Limpiar los flanches de unión con la sección central del cuerpo einspeccionarlos para verificar la presencia de protuberancias y aceite,los que deberán ser eliminados. Asegúrese de orientarlos de modo quela araña quede en la posición correcta para instalar el sistema laalimentación.

11.2. Bajar la sección superior del cuerpo a su posición definitiva alineandocuidadosamente las perforaciones de los pernos, e instalar estosúltimos.

11.3. Apretar las tuercas uniformemente hasta que los flanches hagan plenocontacto. Remitirse a la Sección 4.5, Programa de Apriete de losPernos, para conocer los valores del torche a aplicar a los pernos parasu apriete.

12. Instalación de las cóncavas de manganeso.

Una vez instalada una hilera de cóncavas, se verterámaterial epóxico entre dicha hilera de piezas cóncavasy el cuerpo del chancador.

12.1 Preparar las superficies de las cóncavas inferiores y la zona del cuerpocentral que ellas cubren de acuerdo a las instrucciones del fabricantedel material epóxico.

Como resultado de la operación del chancador, la carade cada cóncava trabaja y se expande. Deberá haberespacio suficiente entre las cóncavas para permitir estaexpansión. Al instalar las cóncavas, las separacionesentre ellas en cada hilera y entre hileras deberán seriguales.

12.2 Para determinar el espacio que deberá dejarse entre cada hilera, secolocará una placa de desgaste en el extremo superior y se apilaráncóncavas hacia arriba tal como se indica en la figura 4.2.3. Observeque las cóncavas para la hilera del extremo superior poseen ganchosque deberán ser ajustado en los alojamientos mecanizados del cuerposuperior.

12.3 Instalar las cóncavas inferiores en su lugar en el anillo usando lacóncava de cierre para completarlo. Verificar que todos los elementosestén en pleno contacto con el cuerpo. Colocar lainas de acero si fuesenecesario.


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12.4 Colocar la cóncava guía, en caso de haber sido suministrada, bajo unolos brazos de la araña de modo que su ubicación sea conocida cuandollegue el momento de reemplazar las cóncavas. Asegurarse que losespacios entre las cóncavas sean todos iguales. Sellar las uniones yverter material de relleno entre el cuerpo y las cóncavas de acuerdo alas instrucciones proporcionadas por el fabricante del material derelleno.


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12.5 La mayor parte del material de relleno es vertida en terreno, siguiendolos procedimientos básicos que se detallará los que deberán sercomplementados en el lugar de la obra considerando los detallesnecesarios para adaptarse a las condiciones locales.

12.6 Las separaciones y uniones deberán ser selladas para prevenirfiltraciones del material de relleno cuando éste es vertido.

12.7 Es indispensable revolver los dos componentes lo suficientemente paraobtener una mezcla homogénea. Asegurarse de revolver la mezclahasta el fondo del recipiente. La mezcla fragua rápidamente dentro delrecipiente, por lo tanto, ella deberá ser aplicada apenas lista.

12.8 Repetir el procedimiento para cada hilera de cóncavas, tambiénrellenando los espacios entre las hileras con el material de relleno.Alternar todas las uniones verticales como indicado en la Figura 4.2.4.

12.9 Colocar cóncava guía, en caso de haber sido suministrada, en lasegunda hilera y a 180 grados de la cóncava guía de la hilera inferior.Para las hileras sucesivas de cóncavas, se instalará la cóncava guíaubicándola tal como descrito.

13. Instalación de las cóncavas de aleación.

13.1 Las cóncavas de aleación son instaladas de la misma forma como loson las cóncavas de manganeso. Sin embargo, en el caso de lascóncavas de aleación no existe una cóncava guía en cada hilera. Cadacóncava posee una espiga cónica que es ajustada a golpes de martillodentro de una perforación en la zona superior de dos cóncavasadyacentes.

• Las cóncavas de aleación no se endurecen ni seexpanden durante la operación del chancador, porconsiguiente no es necesario, rebajar las uniones.

• Siga las instrucciones del fabricante.13.2 Recorte cualquier porción de la clavija que sobresalga de la superficie

superior de las cóncavas. Remitirse al Plano No. 2.501039 EnsamblajeCóncavo, de FFE Minerals USA, Inc., que se incluye más adelante,para informarse sobre cómo son distribuidas las cóncavas.

14. Cavidades de la araña del revestimiento.14.1 Limpiar las cavidades para la araña y los extremos de acoplamiento de

los brazos de la araña que serán colocados dentro de ellas. Colocarlainas sobre el borde mecanizado al lado de cavidad a fin de mantener


4.2PAGINA 24 DE 53


la araña ligeramente sobre su ubicación final. Ello, para que haya elespacio suficiente para bajar la araña hasta su posición definitiva yasentarla firmemente dentro de sus asientos. Remitirse a la Figura4.2.5. Utilizar lainas de 1 pulgada (25 mm) de espesor.


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14.2 Obturar las perforaciones para los pernos de la araña con tarugos demadera, y rellenar el fondo de las cavidades con arcilla, yeso mate uotro material sellante hasta que queden a ras con la superficie superiorde las lainas.

14.3 Cubrir las partes cónicas mecanizadas en los extremos de la araña en laparte superior del cuerpo con una delgada capa de aceite, tal comoseñalado en la Figura 4.25.

14.4 Utilice un feeler gauge para determinar la separación entre lasuperficie mecanizada del cuerpo superior y la superficiecorrespondiente en la parte inferior de la araña. Con ello podráverificarse que la araña está centrada.

14.5 Efectúe esta medición en dos o más puntos en cada costado.14.6 Cubrir cualquier separación a través de la cual podría escurrir el

material de relleno.14.7 Preparar y verter material epóxico de relleno de acuerdo a las

instrucciones proporcionadas para las cóncavas y por el fabricante delmaterial de relleno.

14.8 Marcar un extremo de la araña y su correspondiente cavidad de la partesuperior del cuerpo. Esto asegurará, la ubicación correcta de la arañasobre el cuerpo superior para el futuro.

14.9 Una vez que fraguado el material de relleno, retirar las lainas, lostarugos, el material sellante y la araña.

15. Conjunto del eje principal:

15.1 El eje principal, la pieza central, el manto, la tuerca, el anillo deprotección contra el polvo, y el anillo de fijación del anillo proteccióncontra el polvo, son normalmente, entregados por el fabricante yaensamblados. Si ello no fuere el caso, siga los procedimientos deensamblaje detallados en la Sección 7.9, Reemplazo de Componentes yProcedimientos de Reparación Específicos: Reemplazo deComponentes del Conjunto del Eje Principal.

15.2 Dos anillos partidos fabricados de grafito y Teflon deben ser instaladosen le eje principal. Instalar estos anillos partidos en la ranura destinadaa tal efecto indicada en el No. 1.500457 Conjunto del Eje Principal(113” Diámetro del Dabezal), de FFE Minerals USA, Inc., que seincluye más adelante.

15.2.1. Cubrir con grasa la superficie interior de la ranura en el ejeprincipal.


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15.2.2. Colocar el sello superior en la zona del descanso inferiordel eje (1.066,8 mm (42,0 pulgada) de diámetro) con laperforación para la clavija hacia abajo.

15.2.3. Deslizar el sello hasta el flanche inferior de la ranura.Desplazar el sello alejándolo del centro tan lejos como seaposible en dirección hacia la hendidura. Insertar un extremodel sello dentro de la ranura y, con movimientos de rotación,completar su introducción en la ranura.


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15.2.4. Con el sello superior ya instalado en la ranura, rellenar congrasa el área limitada por los sellos. Esto se realiza paramantener los sellos centrados en la instalación del ejeprincipal dentro del chancador.

15.2.5. Colocar el anillo de sello inferior sobre el muñón inferior conlas perforaciones para la clavija apuntando hacia arriba.

15.2.6. Instalar este sello del mismo modo como lo fue el sellosuperior.

15.2.7. Si los dos sellos fueron correctamente instalados, lasperforaciones para las clavijas se enfrentarán. Alinear laperforación para la clavija del sello superior de modo quequede girada en 90 grados respecto a la del sello inferior.

15.2.8. Instalar los pasadores de madera en las perforaciones de lossellos superior e inferior.

15.3 Limpiar y aplica aceite muñón excéntrico del conjunto del ejeprincipal.

15.4 Retirar la protección del casquete para polvo.

15.5 El conjunto del eje principal solamente deberá ser izado mediante eldispositivo dispuesto en el extremo superior del conjunto para talefecto.

15.6 Bajar cuidadosamente el muñón excéntrico del eje principal dentro dela cubierta hasta que quede alojado en la excéntrica.

15.7 Alinear cuidadosamente el sello de contacto para introducirlo en lacubierta y, posteriormente, bajar el conjunto del eje principal hasta queel anillo de sello esté por completo dentro de la cubierta.

15.8 Alinear cuidadosamente el anillo de sello contra polvo de modo que nointerfiera con el casquete.

15.9 Continúe bajando el conjunto del eje principal hasta que entre encontacto con el anillo de desgaste central.

15.10 Instalar dos graseras en la parte inferior del anillo de sello contra polvoy rellenar con grasa lubricante EP-2.

15.11 Retirar las dos piezas de fierro ángulo soldadas en las tuercas interior yexterior.

16. Instalar la manguera y sus accesorios en la araña de lubricación .


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16.1. Limpiar cuidadosamente las perforaciones y zonas mecanizadas pararecibir la abrazadera de la manguera de la araña. Eliminar todoelemento extraño.

16.2. Instalar la manguera de la araña, la abrazadera, y la empaquetadura.Asegurarse que los pernos quedan con el apriete correcto.


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16.3. Limpiar el buje y eliminar cualquier elementos extraño.16.4. Si es suministado un buje de tipo recto, enfriar este buje con hielo seco

o nitrógeno líquido e instalarlo en la perforación destinada para ello enla araña. El procedimiento es similar al seguido para la instalación delbuje excéntrico externo.

16.5. Si se cuenta con una araña con perforaciones roscadas, se deberáproporcionar un anillo y los pernos para facilitar la instalación debuje. Colocar este anillo de acero en la parte superior del flanche delbuje de la araña y asiente el buje dentro de la perforación de la arañacon los pernos hasta que el flanche del buje quede firmementeasentado sobre la araña. Revisar el registro de la perforación mientrasse efectúa esta operación. Siga la secuencia en forma de cruz para darel apriete de los pernos mientras es buje es desplazado hacia su lugar.

16.6. Si el desplazamiento del buje hasta su lugar fuera dificultoso, estepodrá ser enfriado con hielo seco o con nitrógeno líquido. Elprocedimiento es similar al seguido para instalar el buje excéntricoexterno.

16.7. Con el buje firmemente asentado en su lugar, retirar el anillo deinstalación, en caso de habérsele utilizado.

16.8. Instalar y apretar todos los pernos de fijación del buje, siguiendo unasecuencia de apriete en forma de estrella, y aplicando a los pernos eltorque especificados.

17. Instalación de los blindajes.Algunos blindajes de la araña tienen perforaciones parainstalar los pernos de la araña, a través de la zonainferior de dicho blindaje. Estas perforaciones pasadaspermiten la colocación de los pernos de la araña con losblindajes de la araña ya instalados. .

17.1. Inspección de los blindajes. Si los blindajes tuvieren perforacionesfundidas para los pernos de la araña, ellos pueden ser instalados sinhaber instalado previamente los pernos. En caso contrario, deberácolocarse primero los pernos.

17.2. Instalar los pernos, tuercas y golillas dentro de los blindajes y de losbrazos de la araña y apretar firmemente las tuercas. Para asegurarseque las tuercas no se soltarán, aplique un “pinchazo” de soldadura enla tuerca y el perno correspondiente.


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17.3. Aplicar material epóxico en el espacio entre los blindajes de la araña yla araña.

17.4. Instalar los pernos, tuercas y golillas dentro de los blindajes y de losbrazos de la araña y apretar firmemente las tuercas. Para asegurarseque las tuercas no se soltarán, aplique un “pinchazo” de soldadura enla tuerca y el perno correspondiente.

17.5. Sellar el espacio entre el borde de los blindajes y las perforacionespara los pernos en los brazos de la araña.

17.6. Preparar y verter el material de relleno epóxico entre los blindajes ylos brazos de la araña, de acuerdo a las instrucciones para las cóncavaslas del fabricante de material de relleno.

18. Instalación de la araña.18.1. Cubrir con grasa las superficies mecanizadas en los extremos de la

araña y el interior del buje.18.2. Colocar el anillo de fijación del sello de la araña y el sello mismo en la

parte inferior del muñón en el eje principal de la araña. En la mayoríade los casos, el labio del sello debiera apuntar hacia abajo, en direcciónhacia la tuerca del eje. Remitirse a la Figura 4.2.6. Esto permite ciertafuga de grasa y eliminar el polvo y partículas de mineral de la zona delsello. También permite limpiar el eje principal cuando éste eslevantado. En algunos casos los productos en base a petróleo resultanperjudiciales para los procesos siguientes. En tales casos, el labio delsello debiera apuntar hacia arriba para mantener la grasa en eldescanso.

18.3. El sello es un sello partido y puede ser instalado como tal; sin embargotambién se puede aplicar adhesivo a sus partes para así obtener unanillo contínuo. Remitirse a la Figura 4.2.6 para la información acercade la orientación del sello.

18.4. La araña es cuidadosamente bajada hasta su posición definitiva,mientras el muñón del eje principal entra en el buje y los extremosentran en las cavidades correspondientes. No permitir que se trabedentro de las cavidades. Asegurarse que la manguera de grasa de laaraña entra en la perforación destinada a tal fin en la parte superior delcuerpo.

18.5. Instalar los pernos de la araña y apretarlos gradual y alternativamente.Cuando todas las tuercas están apretadas, golpearlas con un combo.

18.6. El procedimiento para apretar las tuercas es el siguiente:


4.2PAGINA 35 DE 53


18.6.1. Colocar las golillas y las tuercas en los pernos. Atornillar amano las tuercas en los pernos hasta que estén firmes en sulugar.

18.6.2. Apretar los pernos de torsión en cada una de las tuercas conuna llave de torche al 50 por ciento del torque recomendado.Apretar los pernos siguiendo una secuencia en forma deestrella. Remitirse a la Sección 4.5, Programa de Apriete delos Pernos, para obtener la información acerca de los valoresde los torches recomendados.

18.6.3. Regresar al primer perno de la araña y apretar los pernos detorsión en cada una de las tuercas idéntica secuencia con unallave de torche ajustada al 75 por ciento del torcherecomendado.


4.2PAGINA 37 DE 53

CE42C-S.DOC CRUSHER NOV. 2001REV 1

18.6.4. Regresar al primer perno de la araña y apretar los pernos detorsión en cada tuerca de idéntica forma, ahora con una llavede torche ajustada al 100 por ciento del torche recomendado.

No sobreapriete los pernos. Se reitera que deberáutilizarse una llave de torche para dar a los pernos elapriete recomendado.

19. Instalación de las placas de desgaste en la parte superior del cuerpo.19.1. Instalar las placas de desgaste en su lugar en la parte superior del

cuerpo y apernarlas. 20. Instalación de la cubierta de la araña.

20.1. Si la bomba de lubricación de la araña está operativa en esta etapa,accionar la bomba hasta que la grasa reviente entre el buje de la arañay el muñón de la araña del eje principal.

20.2. La cubierta no tiene elementos de fijación, simplemente se coloca ensu lugar.

21. Instalación de los revestimientos de la parte inferior del cuerpo.21.1. Con la ayuda de una grúa, izar los revestimientos de la parte inferior

del cuerpo hasta su posición definitiva pasando un cable de longitudadecuada a través del chancador.

21.2. Izar cada pieza de revestimiento hasta su posición definitiva y fijarlacon los elementos de fijación suministrados.

21.3. Soldar (“pinchazo”) cada elemento de fijación al disco delrevestimiento.

22. Conexión del sistema de ajuste hidráulico.22.1. Las interconexiones e instrucciones para el sistema de ajuste

hidráulico se muestran en el Plano No. 1.503575 Esquema del SistemaHidráulico, de FFE Minerals USA, Inc., que se incluye más adelante.

22.2. Montar el acumulador en posición vertical apoyado en el costado de lafundación y asegurarlo en su lugar con una consola.

22.3. Instalar la válvula de alivio en un lugar de fácil acceso y cercano alchancador, pues los últimos ajustes se efectúan cuando el chancadorestá funcionando con carga. El ajuste inicial es a 2760 kPa (400 psi).Remitirse a la Sección 5.5, Puesta en Marcha Inicial conAlimentación, sobre el procedimiento de ajuste de la válvula paraoperación del chancador a plena carga.


4.2PAGINA 38 DE 53


Durante la instalación, se recomienda especial cuidadoen mantener las tuberías, fittings y mangueras libres detodo tipo de suciedad, grasa y material extraño quepudieran entrar al sistema. Inspeccionar cada piezaacuciosamente, limpiarla de ser necesario, y almomento de conectarla, soplarla o hacerle un flushing.


4.2PAGINA 40 DE 53


22.4. Asegurarse de tener un sistema para calefaccionar todos los circuitosque estarán expuestos a temperaturas menores que las especificadasen el esquema del circuito hidráulico.

22.5. Hacer las adecuadas conexiones eléctricas para los componentes delsistema. Conectar los calefactores y termostato y/o DTR’s al sistemaeléctrico de modo que el aceite pueda ser mantenido constantemente asu temperatura de operación, incluyendo los fines de semana yperíodos en que los equipos se encuentran fuera de servicio.

No se deberá conectar el calefactor del tanque deacumulación o la bomba sin previamente haberlollenado con la cantidad correcta de aceite.

22.6. Cargar el acumulador.

22.6.1. Cargar el acumulador hasta una presión de 21 kg/cm2 (300psi) con gas nitrógeno seco de acuerdo con las instruccionesdel fabricante. Utilizar la manguera para carga y elmanómetro incluidos en el chancador como parte delsuministro. Se necesita un cilindro con 2.265 litros (80 piescúbicos) de nitrógeno a una presión de 155 kg/cm2 (2.200psi).

22.7. Llenado del sistema hidráulico.

22.7.1. Una vez sometido el sistema a flushing, verificar que el tapónen la descarga del estanque de acumulación haya sidonuevamente colocado.

22.7.2. Verter la cantidad de aceite necesaria para llenar el estanque.Cerrar la boca de llenado apenas terminada esta operaciónpara evitar la entrada de algún contaminante al sistema,inmediatamente después que haya sido llenado.

22.7.3. El aceite a ser utilizado para este efecto debe tener lasiguiente especificación: 1500 SSU a 38°C(100°F) EP.

No se debe conectar el calefactor ni las bombas sinhaber llenado previamente el estanque con aceite.Asegurarse que las válvulas correspondientes esténcompletamente abiertas antes de iniciar el bombeo.

23. Instalación del sistema de lubricación.


4.2PAGINA 41 DE 53


23.1 Las conexiones e instrucciones para el sistema de lubricación se muestran enel plano No. 1.503574, Esquema del Sistema de Lubricación, de FFE MineralsUSA, Inc. incluido en la siguiente página.


4.2PAGINA 43 DE 53


23.1 El estanque de acumulación posee un tamiz desmontable a través delcual fluye el aceite de retorno y que sirve como punto de monitoreo.Instalar el estanque de acumulación en un lugar que permita un accesofácil y de cierta frecuencia a dicho tamiz. Según las características dela instalación, el medio para refrigerar el aceite será aire o agua. Eneste sistema se utiliza aire para enfriar el aceite mediante dosenfriadores en serie.

23.2 Durante la instalación, se recomienda especial cuidado en mantener lastuberías, fittings y mangueras libres de todo tipo de suciedad, grasa ymaterial extraño que pudieran entrar al sistema. Inspeccionar cadapieza acuciosamente, limpiarla de ser necesario, y al momento deconectarla, soplarla o hacerle un flushing. Instalar un sistema paracalefaccionar todos los circuitos que estarán expuestos a temperaturasmenores que las especificadas en el esquema del circuito hidráulico

23.3 Hacer las adecuadas conexiones eléctricas para los componentes delsistema. Conectar los calefactores y termostato al sistema eléctrico demodo que el aceite pueda ser mantenido constantemente a sutemperatura de operación, incluyendo los fines de semana y períodosen que los equipos se encuentran fuera de servicio.

No se deberá conectar el calefactor del tanque deacumulación o la bomba sin previamente haberlollenado con la cantidad correcta de aceite.

24. Instalación del sistema de lubricación de la araña.

24.1. El lubricante para el buje de la araña es suministrado por una bombaque puede ser montada en un lugar adecuado, sercano al cuerpoinferior del chancador para facilitar el acceso a ella. Remitirse a lasinstrucciones del fabricante para mayores detalles sobre cómo instalareste sistema.

24.2. Instalar un sistema para calefaccionar el tanque de aceite usado con labomba y el circuito entre la bomba y la araña si todos estos elementospudieran estar sometidos a temperaturas ambiente inferiores a lasespecificadas en el plano No. 2.501028, Esquema del Sistema deLubricación de la Araña, de FFE Minerals USA, Inc que se incluyemás adelante.


4.2PAGINA 44 DE 53


24.3. Conectar un sistema de control que asegure que el aceite lubricante seabombeado hacia la araña solamente cuando el chancador se encuentreen operación.


4.2PAGINA 46 DE 53


24.4. Junto con ello se deberá instalar un sistema de lubricaciónindependiente que cumplirá ciertas funciones específicas, tales comoel llenado del circuito de aceite. El sistema de control está además,provisto de terminales para la conexión de una alarma que seráactivada si el lubricante no es bombeado de acuerdo al programaajustado en el timer.

24.5. El sistema de control define los períodos en los que el aceite lubricantees bombeado hacia el buje, y además monitorea el funcionamiento delsistema. El sistema de control puede ser ajustado de modo de tener unflujo constante de aceite lubricante cuando el área del buje llenada alinicio de la operación o cuando el área a sido sometida a una limpieza.En condiciones de operación normal, se ajustará el sistema de controlde modo de entregar veinte descargas de aceite lubricante cada cincominutos. Para mayores detalles acerca de la programación, remitirse ala información proporcionada por el fabricante. Las condiciones deoperación de una instalación específica pueden, eventualmente, hacernecesario un ciclo distinto; sin embargo el sistema debiera asegurar unmínimo de, veinte descargas de aceite lubricante cada quince minutos.

24.6. Una vez lista la bomba para su funcionamiento, retirar la cubierta de laaraña y hacer funcionar la bomba hasta que aparezca el lubricante.

25. Instalación de los sistemas motrices .

25.1. Los sistemas motrices consisten de la extensión del contraeje, dosacoplamientos y un motor eléctrico de 1.000 hp. Para instalar el motorse deberá revisar el Plano No. 1.503563 Requerimientos de Fundación,de FFE Minerals USA, Inc., que contiene las instrucciones deinstalación del fabricante, que se incluye más adelante. Se corregirátoda diferencia o variación.

25.2. Remitirse al Plano No. 2.501050 Ensamblaje de la Extensión delContraeje de FFE Minerals USA, Inc. Instalar la maza rígida delacoplamiento en el muñón del eje del motor. El contraeje es a su vez,suministrado con la maza ya instalada. El plano se incluye másadelante.

25.3. Colocar e inspeccionar la extensión del contraeje. Esta unidad essuministrada con los elementos flexibles ya instalados.

25.4. Instalar el motor en su fundación.

25.5. Nivelar y alinear el eje del motor con el contraeje del chancador.Asegurarse que las distancias entre las mazas del acoplamiento.


4.2PAGINA 49 DE 53


25.6. Instalar el conjunto de la extensión del contraeje y verificar que laexcentricidad está dentro de las especificaciones del fabricante delacoplamiento. Alinear de nuevo si fuere necesario. Registrar losresultados y las lecturas.

25.7. Dar un “pique” corto al motor para verificar que gira en el sentidocorrecto. Si ello no fuera el caso, efectuar la reconexión en la caja deconexiones del motor.

Por ningún motivo, el chancador deberá girar en elsentido contrario al especificado por el fabricante. Eleje principal y la rosca de la tuerca solamente permiten,debido a su diseño, la rotación del chancador en elsentido especificado.

26. Conexión del aire para presurizar.

26.1. Conectar una línea de aire comprimido a la entrada de aire al costadode la parte inferior del cuerpo. Este aire impide la entrada de polvo enla zona del sello contra polvo y debe ser previamente filtrado yregulado. El caudal será de 566 a 850 Litros / minuto (20 a 30 cfm) a0.035 a 0.070 kg/cm2 (1/2 a 1 psi). Si el soplador opcional fueadquirido a FFE Minerals U.S.A, este equipo suministrará el airenecesario para el sello contra polvo.

27. Instalación eléctrica, enclavamientos y alarmas.

27.1. Los planos y esquemas eléctricos no son habitualmente suministradosjuntos con el chancador, como tampoco los interruptores, botoneras yotros materiales eléctricos, a menos que haya sido especificado. .

27.2. El esquema de lubricación y el esquema hidráulico y la siguienteinformación adicional serán de utilidad para el diseño de la instalacióneléctrica apropiada.

27.3. Para el monitor de la lubricación del buje de la araña y para el monitorde velocidad del sistema de accionamiento se suministraninstrucciones del fabricante. Se deberá incorporar una alarma que seráactivada por el sistema de monitoreo de la lubricación del buje de laaraña y una alarma y un circuito de puesta fuera de servicio que seránactivados por el sistema de monitoreo de velocidad.

27.4. Para el sistema de lubricación, se provee un partidor que permitirá aloperador seleccionar, poner en servicio y detener la bomba. Cuando se


4.2PAGINA 50 DE 53


ha suministrado dos bombas, solamente una se encuentra en servicio,la segunda bomba es una unidad de respaldo.

27.5. En la Figura 4.2.7 muestra cómo se debe conectar los interruptores deflujo que han sido suministrados para activar la alarma y poner elequipo fuera de servicio si el flujo de aceite no es el adecuado para elchancador.

27.6. Conectar el interruptor de temperatura suministrado para el circuito deretorno, de modo que éste activará la alarma y pondrá el equipo fuerade servicio si la temperatura del aceite alcanzara el valor máximoajustado.


4.2PAGINA 52 DE 53


27.7. Instalar un relé de tiempo en el circuito de puesta en servicio para queel material aún dentro del chancador alcance a ser descargado antes deque el chancador quede fuera de servicio. El tiempo ajustadodependerá del tamaño del chancador y de la capacidad de los camionesque lo alimentan. Sin embargo, este tiempo no deberá exceder dosminutos.

27.8. Instalar un indicador del nivel de mineral en la cámara de descarga delchancador para activar una alarma si el mineral alcanza una altura talque bloquee la cámara. Esta situación no hace necesaria una puestafuera de servicio; sin embargo se deberá interrumpir la alimentación alchancador para permitir que el nivel en la cámara disminuya.

27.9. Es recomendable incorporar un timer que será activado con la partidade la bomba de lubricación y que impedirá arrancar el motor deaccionamiento antes que el aceite lubricante circule a través delchancador y comience el flujo de retorno hacia el estanque deacumulación. El ajuste de este relé de tiempo dependerá del tamañodel chancador y de la ubicación de la unidad de bombeo con respecto aéste.

27.10. Los sistemas de ajuste hidráulico del chancador pueden tener unaunidad de bombeo con una o con dos bombas. Para las unidades queposeen dos bombas se suministrará un partidor que permitirá aloperador seleccionar, arrancar y detener la bomba deseada. Solamenteuna bomba se mantiene en operación, la otra bomba es una unidad derespaldo.

27.11. Las dos válvulas de solenoide, “A” y ”B”, se utilizan para elevar ybajar el eje principal del chancador. Cuando estas válvulas estándesenergizadas, el aceite proveniente de la bomba fluye a través delfiltro para retornar posteriormente al estanque. Para subir el eje, seconectará el solenoide de la válvula “A” a un pulsador. Al energizareste solenoide se abrirá la válvula “A” permitiendo al aceite fluir desdela bomba hacia el chancador.

27.12. Para bajar el eje, se conectará el solenoide de la válvula “B” a unpulsador. Al energizar este solenoide se abrirá la válvula “B”,permitiendo al aceite fluir desde el chancador hacia el estanque.

27.13. Setear las alarmas para el indicador de la posición del eje principal.Setear la alarma sonora de la posición inferior para una posición deleje principal a menos de 51 mm (2 pulgadas) sobre la posición de


4.2PAGINA 53 DE 53


reposo (sin presión hidráulica). Fijar la alarma de posición alta paraque suene cuando la tuerca del eje principal esté a menos de 25.4 mm(1.0 pulgada) de hacer contacto con la araña.

28. Conectar el enclavamiento de protección.

28.1. Se protegerán todas las cañerías de instalaciones eléctricas que seencuentran bajo la descarga del chancador, lo que es responsabilidadexclusiva del personal de montaje. Los perfiles, planchas, etc.necesarios para este efecto, no son suministrados por FFE MineralsUSA, Inc..

29. Realización de una inspección con el equipo ya instalado.

29.1. Antes de poner en marcha el chancador, inspeccionar por completotoda la instalación, considerando los siguientes aspectos:

29.1.1. Todos los elementos provisorios, material de desecho,herramientas, etc., deberán ser retirados desde el interior delchancador y del área circundante.

29.1.2. El sistema de lubricación y el sistema de ajuste hidráulicodeberán estar listos para su operación, y se verificará que lasbombas giran en el sentido correcto.

29.1.3. El equipo de lubricación del buje de la araña deberá habersido sometido a flushing, el buje de la araña deberá estarlubricado, el controlador programado y la cubierta de laaraña, instalada.

29.1.4. Todos los componentes que requieran de lubricación deberánestar lubricados.

29.1.5. El sistema motriz deberá estar correctamente alineado.

29.1.6. El indicador de la posición del manto deberá haber sidoajustado de acuerdo con las instrucciones del fabricante.


4.3PAGE 1 OF 1


4.3 GEAR BACKLASH SETTING AND MEASUREMENTS

This section contains the gear set backlash settings and measurements.

Description Measurements Comments

Required transverse backlash at center oftooth face.

Minimum:1.86 mm (0.073 inch)

Maximum:2.12 mm (0.083 inch)

None.

Pinion pitch radius at center of toothface.

273.85 mm (10.782inches)

Measure backlash at this radius.

Change in transverse backlash for insertion and removal of gasket





Countershaft assembly end play

Bearing end play Minimum: 0.03 mm(0.001 inch)

Maximum: 0.13 mm(0.005 inch)

Timken tapered roller bearings:Cone—EE295102Cup—295193


4.4PAGE 1 OF 1


4.4 BOLT TORQUE SCHEDULE

This section contains the bolt/nut torque schedule for assembly of the crusher. Alltorques are for lubricated threads.

Description Item Number Major Diameter ofBolt

Torque

Spider torque nut bolts 1-2-27 24mm (0.945 in) 519 Nm (382 ft-lbs)

Spider bushing bolts 1-2-3 38 mm (1.473 in) 1,750 Nm (1,291 ft-lbs)

Top shell wearing platenuts

1-3-13 42 mm (1.653 in) 1,505 Nm (1,110 ft-lbs)

Shell bolt nuts 1-3-15 100 mm (3.937 in) 37,513 Nm (27,664 ft-lbs)

Dust seal retainer bolts 1-10-19 30 mm (1.181 in) 1,013 Nm (747 ft-lbs)

Inner eccentric bushingbolts

1-8-7, 1-8-8 24 mm (0.945 in) 519 Nm (382 ft-lbs)

Countershaft housingbolts

1-12-19 48 mm (1.889 in) 4,149 Nm (3,059 ft-lbs)

Bottom plate to bottomshell nuts

1-5-16 56 mm (2.205 in) 6,313 Nm (4,656 ft-lbs)

Hydraulic bottom tobottom shell nuts

1-5-16 56 mm (2.205 in) 6,313 Nm (4,656 ft-lbs)

Bottom cover tohydraulic bottom nuts

1-9-20 56 mm (2.205 in) 6,313 Nm (4,656 ft-lbs)

Bottom shell outer wallliner nuts

1-6-44 24 mm (0.945 in) 519 Nm (382 ft-lbs)

Bottom shell rib shield 1-6-46 36 mm (1.417 in) 1,750 Nm (1,291 ft-lbs)

Dust bonnet to bottomshell bolts

1-5-5 36 mm (1.417 in) 1,750 Nm (1,291 ft-lbs)

Spider shield nuts 1-2-20, 1-2-21 76 mm (2.992 in) 8,920 Nm (6,578 ft-lbs)

Spider arm shield nuts N/A

Gearcase shield nuts 1-6-45 42 mm (1.653 in) 1,505 Nm (1,110 ft-lbs)


5.0PAGE 1 OF 1

CEXXXX.DOC CRUSHER AUG. 2001REV 0

5.0 INITIAL COMMISSIONINGThe purpose of initial commissioning is to ensure that all the crusher systems and as-sociated equipment have been constructed according to their design. Commissioningincludes preoperational testing and initial run-in and operation of the crusher withoutfeed. Commissioning begins in accordance with the overall project schedule andcommences during the construction phase.

Preoperational testing activities include:

• Cleaning and flushing of equipment.

• Testing of controls and instrumentation.

• Preliminary system run-in performance tests and inspections.

• Installation of temporary facilities required to perform the tests and run-in.

• Scheduling and coordination of participating vendors and their associated activi-ties.

• Establishing and enforcing safe operating practices.


5.1PAGE 1 OF 3


5.1 SAFETY PRECAUTIONS

The purpose of following safety precautions is to ensure and reinforce the recognitionand practice of safe work habits during the commissioning procedure. Establishedsafe work practices tend to relax when the construction activity nears its end andcommissioning begins. To avoid accidents and possible personal injury during thisperiod of the project, these precautions must be recognized.

The following safety precautions are not intended to cover the management aspects ofsafety. These precautions discuss where specific hazards may exist that are generallyassociated with commissioning heavy rotating equipment. All personnel safety mat-ters and adherence to local safety laws and regulations remain the responsibility ofthe owner and their contractors.

The safety of operation and maintenance personnel must be assured at all timesthrough the use of appropriate safety practices. In particular, maintenance should notbe performed close to rotating parts on a crusher in service. Once the crusher is shutdown for inspection, maintenance, and repair purposes, it should be locked out in ac-cordance with an appropriate fail safe system to prevent the accidental starting of theequipment. The planning of operation and maintenance procedures and the trainingof personnel must include the definition and communication of procedures designedto accomplish this. Refer to Section 2.0, Safe Job Procedures.

The following safety precautions are included in this section:

• Lockout and tagging.

• Overhead work activity.

• High-pressure hydraulics.

• Scaffolds.

• Starting the crusher.Personnel shall not work on or in the crusher or thecrusher systems while the crusher is in operation orwhile the crusher drive motor is energized. Failure toheed this warning may result in serious injury or death.

LOCKOUT AND TAGGINGLockout and tagging provides a means of effectively demobilizing and/or de-energizing equipment that may, upon movement or start-up, injure personnel per-forming inspections, tests, maintenance, repairs, or necessary operations. Accidentalor unintentional movement or start-up may also cause equipment damage.


5.1PAGE 2 OF 3


When equipment and systems are involved in a powered test procedure, the lock maybe removed from its power source, usually its motor control center (MCC). A tagmust be attached to the main and control power sources and local control panel(s) in-dicating that the equipment and/or system are being tested. This prevents unexpectedcutoff of power and a change of operating modes.

When the test is interrupted, the lockout lock must be placed on the primary powersource at the appropriate MCC with the tag in place.

When the test is completed, the lockout lock and tags must be removed and the sys-tem/equipment controls placed in the Off mode in preparation for the preoperationalinspection.

OVERHEAD WORK ACTIVITYWhen testing, maintenance, and repair work takes place above equipment and per-sonnel access ways, special precautions must be exercised to protect the personneldirectly involved in the work, and the personnel and equipment below.

All personnel working in elevated areas must wear and properly connect an approvedsafety harness, regardless of the time they intend to stay in the work area.

The area directly below the elevated work area must be marked to prevent entry bypersonnel. A high-visibility color (bright yellow or orange) tape is typically placedaround the floor level below the overhead activity. Signs are also used, in addition tothe tape, to warn all personnel below that there is work activity above the marked-offarea.

Overhead crane operators must be made aware that overhead work is in progress toprevent accidental crane hook and load entry into the elevated work area.

When cranes are used in elevated work areas, space is usually limited, and a sus-pended load must be rigged as precisely as possible above its center of gravity. Ashifting load can easily sweep personnel and equipment from elevated work plat-forms.

When welding, cutting, and using chemicals such as acid or solvents in an elevatedwork area, the marked-off area below must be clear of combustible and flammablematerials to prevent personal injury, fire, and explosion. Combustible materials in-clude wood cribbing and packing materials, paint, solvent, and liquid fuels. Fire-fighting equipment and materials, as well as absorbing materials, must be readilyavailable.


5.1PAGE 3 OF 3


HIGH-PRESSURE HYDRAULIC LEAKSHigh-pressure hydraulic leaks are usually very dangerous and can cause severe injury.In addition to the instructions given in Section 2.0, Safe Job Procedures: High-Pressure Hydraulic Systems, special cautions must be exercised when working withand on hydraulic systems, particularly when looking for and fixing leaks.

When leaks, particularly thin streams, are known to exist in a system, they are de-tected with a strong light or a dry, bare wood stick. Bare or gloved hands are neverused to locate a hydraulic leak. When the source of a leak is found, the system is shutdown for repairs. Repairs are never attempted on an operating system at design pres-sure. If a fitting leak is detected, the system is shut down, locked out and tagged, andthe leaking fitting removed and inspected for damage, defect, or cross-threading.

Attempting to tighten a fitting that is leaking may cause the fitting to unthread orbreak, exposing the mechanic or operator to high-pressure, hot hydraulic fluid. Thin,high-pressure hydraulic fluid streams can easily breach leather gloves and skin, andsever fingers and hands.

SCAFFOLDSScaffolds are temporary, elevated work platforms. When possible, only preformedmetal structural scaffold components should be assembled for this purpose. All thesafety fasteners should be used in their assembly. The platforms used to work fromthe scaffolds must be substantial and stable. They should cover the entire work areaof the scaffold structure.

Care must be taken to not overload the scaffold structure with too many people,heavy equipment, and equipment components. All scaffolds must be secured to sta-tionary structures to prevent tipping over.

STARTING THE CRUSHERPrior to starting the crusher for repositioning the main shaft, inspection, or testing, athorough inspection must be made of the immediate area. This is done to make surethat there is no potential for personal injury or equipment damage as a result of mov-ing the crusher main shaft and mantle.

The areas that must be visually inspected include the exterior of the crusher shell, theeccentric cart, and the interior of the crusher. The MCC, hydraulic lift power skid,and the lube skid and spider lube system should also be observed to make sure theyare operable and present no hazards to personnel or equipment in the area.


5.2PAGE 1 OF 1

CEXXXX.DOC CRUSHER AUG. 2001REV 0

5.2 COMMISSIONING PLAN

The following items are included in the commissioning plan:

5.2.1 Definitions

5.2.2 Commissioning Sequence Flowchart


5.2.1PAGE 1 OF 1


5.2.1 DEFINITIONS

The following definitions are general in nature and describe the work delineation ofthe participants in the commissioning plan.

ENGINEERING, PROCUREMENT, CONSTRUCTION MANAGEMENT(EPCM) CONTRACTORThe EPCM Contractor is appointed by the Owner and functions at the direction of theOwner. The EPCM Contractor is responsible for ensuring the proper installation ofplant equipment by the Contractors, including proper documentation and completionof preoperational testing and cleanup.

CONTRACTOREach appropriate Contractor is responsible for the installation of plant equipment perthe EPCM Contractor’s, the Vendors’, and/or the Manufacturer’s drawings, specifi-cations, and documentation manual(s).

MANUFACTURERThe Manufacturer is the provider of equipment and system packages. The Manufac-turer is responsible to the EPCM Contractor for the design, specification adherence,and suitable documentation of the equipment and systems provided.

VENDORThe Vendor is the provider of components, systems, and sub-systems that are usuallydesigned and manufactured by other parties. The Vendor may all also provide sup-port services. The Vendor’s primary responsibility is to ensure that the components,systems, and services provided meet or exceed the specifications and documentedperformance expectations of the EPCM Contractor and the Manufacturer.

OWNERThe Owner is the person or party that has the legal right of possession of the plant andall the equipment and facilities the plant includes. The Owner provides the EPCMContractor with direction and resources to conduct the construction and commission-ing of the plant.


5.2.2PAGE 1 OF 2


5.2.2 COMMISSIONING SEQUENCE FLOWCHART

EPCM Contractor Final Stages ofConstruction

Schedules with CompletionMilestones for Equipment

Responsibility Forms/Reports

Prepare Preoperational andFunctional Test Guidelines

Manufacturer

Identify Test Packages;Prepare Procedures and

Database

Written Guidelines for EachEquipment Type

Manufacturer

Bar Chart of Each PackagePrepare Preliminary TestSchedule

Manufacturer with Ownerand EPCM Contractor

Content of Each Package:• Equipment List• Instrument List• C&IDs (Marked Up)• Test Description• Test Datasheets• Test Certificate• Procedure

Test Certificates and Data-sheets

Prepare Detailed TestSchedule

EPCM Contractor,Manufacturer, and Vendors

EPCM Contractor

Final Installation and VendorApprovals

Conduct Preoperational Test

Punchlist

All Equipment in PackageSuccessfully Tested

Conduct Package FunctionalTest

Printout of Equipment WithMilestone Dates

Vendor End of Service Formand Daily Summaries

Printout of Deficiencies andResponsibilities

Punchlist

EPCM Contractor, Manufac-turer, and Owner Witness

EPCM Contractor andManufacturer


Test Certificates andDatasheets

Printout of Deficiencies andResponsibilities


Activity


5.2.2PAGE 2 OF 2


Responsibility Activity Forms/Reports

Package Successfully Testedas a System

Turnover Package:• Turnover Letter• Exceptions List• Test Datasheets• Test Certificates• Vendor Data• Other Required

Information

EPCM Contractor and Owner Crusher Package Turnoverto Owner and Signoff;

Hang Green Tags

Monitor Operation of CrusherPackage as Feed is

Introduced

Resolve Performance Issues

EPCM Contractor, Owner,and Manufacturer

EPCM Contractor,Manufacturer, Vendors

Monitor Operation of CrusherPackage No-Load Run

Resolve Performance Issues

EPCM Contractor, Owner,and Manufacturer

EPCM Contractor,Manufacturer, Vendors


5.3PAGE 1 OF 1


5.3 PRECOMMISSIONING CHECKS

The purpose of this section is to provide the procedures and documentation withwhich to conduct the precommissioning checks on the crusher and its auxiliaryequipment and systems. The tasks involved in the precommissioning checks arehands-on activities including:

• Cleaning.

• Paint touch-up.

• Removal of shipping materials and fasteners.

• Lubrication.

• Motor, pump rotation verification.

• Motor coupling alignment.

• Instrument testing and calibration.

• Electrical insulation testing (meggering).

• Electrical high potential testing (hi-potting).

• Other checks and tests.The procedures for these activities are provided in Section 5.3, PrecommissioningChecks: Precommissioning Instructions.

All observations, corrections, tests, and measurements are documented on the da-tasheets provided in Section 5.3, Precommissioning Checks: Precommissioning Da-tasheets.


5.3.1PAGE 1 OF 1


5.3.1 PRECOMMISSIONING INSTRUCTIONS

The following precommissioning datasheets are included in this section:

5.3.1.1 Crusher Assembly Precommissioning Checks

5.3.1.2 Bearing Lubrication System Precommissioning Checks

5.3.1.3 Hydraulic Adjustment System Precommissioning Checks


5.3.1.1PAGE 1 OF 2


5.3.1.1 CRUSHER ASSEMBLY PRECOMMISSIONING CHECKS

SPECIAL EQUIPMENT REQUIREDConstruction documents

INTRODUCTIONThe purpose of this procedure is to prepare the crusher assembly, including the shelland its attachments, for the no-load and initial start-up.

PROCEDUREMechanical/Lubrication

1. Ensure the crusher drive system is locked out and tagged in accordance withestablished procedures.

2. Inspect the interior of the crusher for missing and loose liners, bolts and nuts.Check the following:

• Spider arms and cap.

• Concaves.

• Mantle.

• Bottom shell interior and exterior.

• Countershaft assembly. 3. Remove all temporary installation aids, debris, and construction materials

from inside the crusher.

4. Check the exterior of the crusher shell for missing and loose flange bolts andnuts. Tighten or install as required.

5. Check that there is grease at the upper spider bushing. If there is none, flushthe spider lubrication system, reconnect it and operate spider lube system tillbushing is full of grease, and then prepare it for operation.

6. Check that all components requiring lubricants have been lubricated.

7. Check that the countershaft extension assembly has been securely attached tothe crusher and its motor, and is in correct alignment.

8. Ensure that the mantle position indicator is in place, wired, and has been cali-brated according to the manufacturer’s instructions.

9. Recheck all piping and wiring under the crusher to make sure that all are pro-tected from damage.


5.3.1.1PAGE 2 OF 2


10. Bleed the air from the hydraulic adjustment system and inspect the hydrauliclines for leakage.

11. Raise the crusher main shaft 50 mm (2 inches) using the hydraulic adjustmentsystem.

12. When the lubricating oil is at operating temperature, start the oil pump andallow the oil to circulate through the crusher until a full flow can be seen re-turning to the sump tank.

13. Check the volume of oil flow to the eccentric and countershaft bearings.

14. To prevent the main shaft from rotating too rapidly during the breaking-in pe-riod, insert two tires of ample size into the crushing chamber.

15. Complete a mechanical preoperation checksheet (refer to Section 5.3, Pre-commissioning Checks: Precommissioning Datasheets—Mechanical Pre-Commissioning Checks).

Electrical/Instrument 16. Verify that all instruments, sensors, alarms, timers, and interlocks are at the

settings specified in Section 7.2, Component or Subsystem Operating Limits,before starting the crusher.

17. Check the operation of the alarms on the lubrication oil inlet and outlet lines.

18. Complete an electrical preoperation checksheet (refer to Section 5.3, Pre-commissioning Checks: Precommissioning Datasheets—Switch and Trans-mitter Precommissioning Calibration/Test Datasheet).


5.3.1.2PAGE 1 OF 1


5.3.1.2 BEARING LUBRICATION SYSTEM PRECOMMISSIONINGCHECKS

SPECIAL EQUIPMENT REQUIREDLaser alignment set, or precision dial indicator toolsHigh impedance VOM4- to 20-mA, 24V DC external power supplyINTRODUCTIONThe purpose of this procedure is to prepare the crusher lubrication system for the no-load and initial start-up of the crusher. This is accomplished by checking the me-chanical and electrical components and the instruments in the system.PROCEDUREMechanical/Lubrication

1. Check the physical and functional condition of the crusher lubrication systemand its mechanical components.1.1. Use the mechanical precommissioning checksheet (refer to Section

5.3, Precommissioning Checks: Precommissioning Datasheets—Lu-brication System Precommissioning Mechanical Checksheet) as aguide for the lubrication system components that are to be checked andto record observations and measurements.

Electrical 1. Check the physical and functional condition of the lubrication system’s elec-

trical components.1.1. Use the electrical precommissioning checksheet (refer to Section 5.3,

Precommissioning Checks: Precommissioning Datasheets—Lubrica-tion System Precommissioning Electrical Checksheet) as a guide forthe lubrication system components that are to be checked and to recordobservations and measurements.

Instruments 1. Check the physical and functional condition of the lubrication system’s in-

struments.1.1. Use the instrument precommissioning checksheet (refer to Section 5.3,

Precommissioning Checks: Lubrication System Precommissioning In-strument Checksheet) as a guide for the lubrication system instrumentsthat are to be checked and to record observations and measurements.


5.3.1.3PAGE 1 OF 1


5.3.1.3 HYDRAULIC ADJUSTMENT SYSTEM PRECOMMISSIONINGCHECKS

SPECIAL EQUIPMENT REQUIREDLaser alignment set, or precision dial indicator toolsHigh impedance VOM4- to 20-ma, 24V DC external power supplyINTRODUCTIONThe purpose of this procedure is to prepare the hydraulic adjustment system for theno-load and initial start-up of the crusher. This is accomplished by checking the me-chanical and electrical components and the instruments of the system.PROCEDUREMechanical/Lubrication

1. Check the physical and functional condition of the hydraulic adjustment sys-tem and its components.1.1. Use the mechanical precommissioning checksheet (refer to Section

5.3, Precommissioning Checks: Precommissioning Datasheets—Hy-draulic Adjustment System Precommissioning Mechanical Checksheet)as a guide for the hydraulic adjustment system components that are tobe checked and to record observations and measurements.

Electrical 1. Check the physical and functional condition of the hydraulic adjustment sys-

tem’s electrical components.1.1. Use the electrical precommissioning checksheet (refer to Section 5.3,

Precommissioning Checks: Precommissioning Datasheets—HydraulicAdjustment System Precommissioning Electrical Checksheet) as aguide for the hydraulic adjustment system components that are to bechecked and to record observations and measurements.

Instrument 1. Check the physical and functional condition of the hydraulic adjustment sys-

tem’s instruments.1.1. Use the instrument precommissioning checksheet (refer to Section 5.3,

Precommissioning Checks: Precommissioning Datasheets—HydraulicAdjustment System Precommissioning Instrument Checksheet) as aguide for the hydraulic adjustment system instruments that are to bechecked and to record observations and measurements.


5.3.2PAGE 1 OF 1


5.3.2 PRECOMMISSIONING DATASHEETS

The following precommissioning datasheets are included in this section:

5.3.2.1 Mechanical Precommissioning Checks

5.3.2.2 Switch and Transmitter Precommissioning Calibration/TestDatasheet

5.3.2.3 Lubrication System Precommissioning MechanicalChecksheet

5.3.2.4 Lubrication System Precommissioning Electrical Checksheet

5.3.2.5 Lubrication System Precommissioning InstrumentChecksheet

5.3.2.6 Hydraulic Adjustment System PrecommissioningMechanical Checksheet

5.3.2.7 Hydraulic Adjustment System Precommissioning ElectricalChecksheet

5.3.2.8 Hydraulic Adjustment System Precommissioning InstrumentChecksheet


5.3.2.1PAGE 1 OF 1


MECHANICAL PRECOMMISSIONING CHECKSSHEET OF

Client: Equipment:

Project: Equipment No.:

Project No.: Motor No.:

DIRECT DRIVE DETAILS

COUPLING TYPE(S)

COUPLING SIZE(S)

COUPLING ELEMENT(S)

ALIGNMENT (TIR)

OTHER

LUBRICATION DETAILS

MECHANISM LUBE TYPE LEVEL

COOLING SYSTEM/GLAND WATER:

PRESSURE GAUGES READING:

RPM: mm/min: L(gal)/min: GUARDS:

REMARKS:

CALIBRATED/TESTED BY Signed/Date


5.3.2.2PAGE 1 OF 1


SWITCH AND TRANSMITTER PRECOMMISSIONINGCALIBRATION/TEST DATASHEET

SHEET OF

Certificate No.

Instrument Description

Instrument Tag Number

Manufacturer

Model No.

Accuracy of Instrument

Max. Range

Calibrated Range

Date of Calibration

Ambient Temperature

Date of Next Calibration

Test Equipment Used:

Certificate No.

Description

Manufacturer

Model No.

Serial No.

Accuracy of Test Equip.

Description of Test and Method Ref:

Note:

Test Results Simulated Process Value Expected mAOutput

Actual mA Out-put

% Error ofExpected

DCS Act. Value % Value 0C mA mA %

4

8

12

16

20

Tested By:_____________________ Witnessed By:_____________________Signed:________________________ Signed:__________________________


5.3.2.3PAGE 1 OF 2


5.3.2.3 LUBRICATION SYSTEM PRECOMMISSIONINGMECHANICAL CHECKSHEET

Components,Sub-Assemblies

Check Procedures Observations,Measurements

Crusher lube oilsupply and return

Lube Hoses and Piping—Clean and inspect thelubrication supply and return hoses and pipe fit-tings for damage and leakage. Replace defectivehose and fittings. These components are criticalfor correct and continuous operation of thecrusher.

Drain Valve—Make sure the main supply linedrain valve is closed.

Block Valves—Make sure the supply blockvalves are open.

Air Vent—Check that the return line air vent isinstalled securely and properly supported.

Lube oil system (skid) Filters/Strainers—Clean/replace the main pumpfilter element. Make sure the drain valves areclosed. Check and clean the lube oil reservoirreturn and vent filters. Open and clean all “Y”strainers.

Seals and Gaskets—Inspect all seals and gasketsfor leakage. Replace as required.

Close and Clean Reservoir—After mechanical,electrical, and instrument PM inspections andrepairs, close all access panels on the reservoir,clean its exterior, and prepare it for operation.

Coolers—Check that all the shipping materialshave been removed. Make sure all mountingbolts are in place and secure, and that the coolingsurfaces are clear of debris. Also make sure thefan blade is in good operating condition.

Main and Standby Oil Pump Alignment—Check the motor-pump alignment of the main oilpumps. Refer to the pump manufacturer’s speci-fication. Realign as required. Record results andreadings.


5.3.2.3PAGE 2 OF 2




Lube oil system (skid)(continued)

Drive Couplings—Inspect all the pump drivecouplings. Replace damaged and missing flexi-ble elements as required.

Clean and Cover Pumps—Clean the pumps andmotor coupling cover. Secure the coupling cov-ers.


5.3.2.4PAGE 1 OF 4


5.3.2.4 LUBRICATION SYSTEM PRECOMMISSIONINGELECTRICAL CHECKSHEET



Lube oil system skid,pump motors

Power Terminals—With the pump motors iso-lated from their power and control circuits, checkthe power connections to the correct motor termi-nals.

Junction Box Seal—Inspect the junction boxcover seals for signs of leakage and damage.Replace as required. Vacuum-clean the junctionbox interiors.

Local Controls—Inspect local control panel fordamaged or missing buttons, switches, and indi-cators. Repair or replace as required.

Conduit and Cable—Inspect power cable andconduit for physical damage. Repair or replaceas required.

Stator Resistance—At the MCC, megger thestator at 500 VDC, and record the measurements.

Fan—Remove the fan cover, inspect the fan forcracks, and clean the blades. Inspect the outboardbearing housing for leaks and signs of excessiveheat. Replace the cover.

Release for Tests—Clean motor housing sur-faces to assist cooling. Remove locks at MCCaccording to established procedure when all thepreceding checks and tests have been completed,and release the unit for running checks.

Check Rotation—When all other checks havebeen completed, start and run the system, onemotor and pump set at a time. Check the rotationof each and record direction looking from motorto fan.


5.3.2.4PAGE 2 OF 4




Lube oil system skid,pump motors(continued)

Motor Current Draw—When the lubricationsystem is operating normally, go to the MCC andmeasure and record the total current draw and thecurrent in each phase. Compare the phase cur-rents. Each should be at least 93 percent of thegreatest current reading. Low phase currentmeasurements indicate a motor phase unbalanceand may require motor replacement.

Cooler fan motors Power Terminals—With the fan motors isolatedfrom their power and control circuits, check thepower terminals for tightness. Disconnect andclean loose terminals, and reconnect securely.

Junction Box Seal—Inspect the junction boxcover seals for signs of leakage and damage.Replace as required. Vacuum-clean the junctionbox interiors, and replace the covers.


Conduit and Cable—Inspect power cable andconduit for signs of excessive heat and physicaldamage. Repair or replace as required.


Check Rotation—When all other checks havebeen completed, start and run the fans. Check therotation of each and record direction lookingfrom motor to pump.

Motor Current Draw—With the lubricationsystem operating normally, remove the junctionbox covers for the fan motors and measure andrecord the total current draw and the current ineach phase. Compare the phase currents. Eachshould be at least 93 percent of the greatest cur-rent reading. Low phase current measurementsindicate a motor phase unbalance and may re-quire motor replacement.


5.3.2.4PAGE 3 OF 4




Motor operated valves Power Terminals—With a valve motor isolatedfrom its power and control circuits, check thepower connections to the correct motor terminals.




Limit Switches—With an external power supply,check the continuity and function of the limitswitches.


Check Rotation—When all other checks havebeen completed, start and run the system, onevalve at a time. Check the rotation of each andrecord direction looking from motor to valvebody.

Motor Current Draw—With the lubricationsystem operating normally, remove the junctionbox covers for the motors and measure and recordthe total current draw and the current in eachphase. Compare the phase currents. Each shouldbe at least 93 percent of the greatest currentreading. Low phase current measurements indi-cate a motor phase unbalance and may requiremotor replacement.

Lube oil heaters Power Terminals—With a valve motor isolatedfrom its power and control circuits, check thepower connections to the correct heater terminals.


5.3.2.4PAGE 4 OF 4




Lube oil heaters(continued)



Check Continuity and Resistance—Check eachheater for continuity. With an external powersource, check the resistance of each heating ele-ment. Record the results. Replace the junctionbox covers.

Release for Tests—Remove locks at MCC ac-cording to established procedure when all thepreceding checks and tests have been completed,and release the unit for running checks.


5.3.2.5PAGE 1 OF 6


5.3.2.5 LUBRICATION SYSTEM PRECOMMISSIONINGINSTRUMENT CHECKSHEET



TI-7027, -7021,-7025,-7035, -7031,-7032, -7034—Temperature Indicator(gauge)

Inspect the instrument for physical damage andsigns of excessive heat. Repair or replace as re-quired.

Check the date on the calibration sticker.

Inspect the instrument for physical damage andsigns of leakage. Replace as required.

TE/TT-7021, -7027—Temperature Element/Transmitter Clean the display glass and the exterior of the

enclosure.

Remove the junction box cover and check theseal for signs of dust and moisture entry. Repairor replace the seal as required.

Inspect wiring terminals for tightness. Discon-nect loose terminals, clean contact surfaces untilbright, and reconnect the terminals.

Inspect wiring for damage, abrasion and exposedconductors. Repair or replace damaged wiring.

With an independent DC power supply, checkspan (4-20 mA) and zero settings. Compare withambient temperature at the sensing element. Setzero as required.


Inspect the instrument for signs of leakage andheat damage. Repair or replace as required.

Clean the glass and enclosure.

LG-7021—LevelGauge

Check and reconcile with visual observation ofreservoir level.

LIT-7021—LevelIndicating Transmitter


Clean the display glass and the exterior of theenclosure.


5.3.2.5PAGE 2 OF 6




LIT-7021—LevelIndicating Transmitter(continued)


Inspect wiring terminals for signs of excessiveheat. Disconnect loose terminals, clean contactsurfaces until bright, and reconnect the terminals.


With an independent DC power supply, checkspan (4-20 mA) and zero settings. Set zero asrequired.


PSV-7022A, -7022B,-7022C, -7022D—Pressure Relief Valve

Check normal set point:

• PSV-7022A: 1,035 kPa, increasing.

• PSV-7022B: 1,035 kPa, increasing.

• PSV-7022C: 1,035 kPa, increasing.

• PSV-7022D: 1,035 kPa, increasing.

No adjustments should be necessary.

Check valve body and bonnet for damage andleaks. Replace as required. Do not attempt fieldrepairs.

Check for certification tag. Clean valve exterior.

Ensure valve mounting is secure.

Inspect the instrument housing for signs of physi-cal damage. Replace unit as required.

Check the condition of the position label. Re-place as required.

HS-7025, -7033—Hand Selector Switch

Remove the junction box cover and check theseal for signs of dust and moisture entry. Repairor replace as required.


5.3.2.5PAGE 3 OF 6




HS-7025, -7033—Hand Selector Switch(continued)

Inspect wiring terminals for signs of excessiveheat and tightness. Remove loose terminals,clean until bright, and reconnect.

Inspect wiring for damage and abrasion. Repairor replace damaged wiring.

Manually operate the switch to check the firm-ness of the detents. Check positions for continu-ity and stability.

Replace the junction box cover. Inspect conduitfor signs of damage and corrosion. Repair orreplace as required.

Inspect the gauge for signs of leakage and dam-age. Repair or replace as required.


PI-7023A, -7023B,-7023C, -7023D,-7025, -7031, -7032,-7034—PressureIndicator Check the date on the calibration sticker.


PDIT-7024—PressureDifferential IndicatingTransmitter Clean the display glass and the exterior of the

enclosure.




With an independent DC power supply, checkspan (4-20 mA) and zero settings. Compare withambient pressure differential at the sensing loca-tions. Set zero as required.

Check the date on the calibration sticker. Re-place the instrument if the calibration date is inexcess of one year old.


5.3.2.5PAGE 4 OF 6




ZSO-7033—PositionSwitch Open

Inspect the instrument head for signs of physicaldamage and excessive heat. Replace the unit asrequired.

Inspect the cable connector and cable for damage.Replace as required.

Apply appropriate input voltage and ensure thatswitch opens. Reconcile with position of valve.

Inspect the power/signal cable for signs of physi-cal damage and missing or cracked insulation.Replace or repair as required.


Inspect wiring terminals for tightness. Removeloose terminals, clean contact surfaces untilbright, and reconnect.



ZSC-7033—PositionSwitch Closed



Apply appropriate input voltage and ensure thatswitch closes. Reconcile with position of valve.



Inspect wiring terminals for tightness. Removeloose terminals, clean until contact surfaces arebright, and reconnect.


5.3.2.5PAGE 5 OF 6




ZSC-7033—PositionSwitch Closed(continued)






TE, TIT-7022—Ambient Temp. Sen-sor/Transmitter









FIT-7028—LubeCooler Oil Return LineFlow IndicatingTransmitter



5.3.2.5PAGE 6 OF 6





FIT-7028—LubeCooler Oil Return LineFlow IndicatingTransmitter (contin-ued) Check the date on the calibration sticker.

Inspect the instrument bezel for signs of physicaldamage and excessive heat. Replace unit as re-quired.




HIS-CR012A,-CR012B, -CR012C,-CR012D;HS2-CR012A,-CR012B, -CR012C,-CR012D—HandSwitch Pushbutton



5.3.2.6PAGE 1 OF 1


5.3.2.6 HYDRAULIC ADJUSTMENT SYSTEM PRECOMMISSIONINGMECHANICAL CHECKSHEET



Crusher hydraulicsupply and return

Lube Hoses and Piping—Clean and inspect thehydraulic supply and return hoses and pipe fit-tings for damage and leakage. Replace defectivehose and fittings. These components are criticalfor correct and continuous operation of thecrusher.

Accumulator—Check that the accumulator isinstalled and is not damaged. Make sure the ac-cumulator is charged with nitrogen.

Hydraulic system skid Filters—Clean/replace the main pump supplyand the return filter elements. Check and cleanthe lube oil reservoir vent filters.


Reservoir Magnets—Check the condition of thereservoir magnets. Record observations, clean,and replace.


4-Way Diverter Valves—Check the installationand condition of the valves. Ensure that theLower valve is normally closed, and the Raisevalve is normally open.

Pump Alignment—Check motor-pump align-ment of the hydraulic oil pumps. Refer to thepump manufacturer’s specification. Realign asrequired. Record results and readings.



5.3.2.7PAGE 1 OF 3


5.3.2.7 HYDRAULIC ADJUSTMENT SYSTEM PRECOMMISSIONINGELECTRICAL CHECKSHEET



Hydraulic system skid,pump motors



Local Controls—Inspect the local control panelfor damaged or missing buttons, switches, andindicators. Repair or replace as required.


Stator Resistance—Remove the junction boxcover, disconnect the power leads, megger thestator at 500 VDC, and record the measurements.Reconnect the power leads.



Check Rotation—When all other checks havebeen completed, start and run the system, onemotor and pump set at a time. Check the rotationof each and record direction looking from motorto pump.


5.3.2.7PAGE 2 OF 3




Hydraulic system skid,pump motors(continued)

Motor Current Draw—When the hydraulicsystem is operating normally, remove the junc-tion box covers for the motors and measure andrecord the total current draw and the current ineach phase. Compare the phase currents. Eachshould be at least 93 percent of the greatest cur-rent reading. Low phase current measurementsindicate a motor phase unbalance and may re-quire motor replacement.





Hydraulic oil heaters Power Terminals—With a heater isolated fromits power and control circuits, check the powerconnections to the correct heater terminals.




5.3.2.7PAGE 3 OF 3




Hydraulic oil heaters(continued)




5.3.2.8PAGE 1 OF 4


5.3.2.8 HYDRAULIC ADJUSTMENT SYSTEM PRECOMMISSIONINGINSTRUMENT CHECKSHEET




PI-7013A, 7013B,-7015—PressureIndicator







HS1-CR011A,-CR011B;HS2-CR011A,-CR011B—HandSwitch, Pushbutton


Inspect the instrument housing for signs of physi-cal damage and excessive heat. Replace unit asrequired.




HS-7014A, -7014B—Hand Switch



5.3.2.8PAGE 2 OF 4




PSV-7012A, -7012B—Pressure ReliefValve


• PSV-7012: 6,895 kPa, increasing.

No adjustments should be necessary. Do notcrack with lever.






enclosure.


Inspect wiring terminals for signs of excessiveheat. Disconnect loose terminals, clean contactsurfaces until bright, and reconnect the terminals


With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient pressure differential at the sensing loca-tions. Set zero as required.







5.3.2.8PAGE 3 OF 4







With an independent DC power supply, checkspan (4-20 ma) and zero settings. Set zero asrequired.



TE/TT-7011—Temperature Element/Transmitter Clean the display glass and the exterior of the

enclosure.




With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient temperature at the sensing element. Setzero as required.



5.3.2.8PAGE 4 OF 4




TI-7011—Tempera-ture Indicator (gauge)




Inspect the instrument for signs of leakage. Re-pair or replace as required.




Inspect power and signal terminals for signs ofexcessive heat and tightness. Disconnect looseterminals, clean contact surfaces until bright, andreconnect the terminals.

Inspect wiring for signs of abrasion, damagedinsulation, and exposed conductor. Repair orreplace as required.

HV-7014A—SolenoidValve



5.4PAGE 1 OF 3


5.4 NO LOAD COMMISSIONING CHECKS


INTRODUCTIONThere are several phases in placing a new crusher into operation. There is an initialrunning-in period when the crusher is operated under no-load conditions for an eight-hour period. This is followed by a one-hour operating period with a partial feed load.Upon satisfactory completion of this operation, the crusher is prepared for normal,full-load service by operating at 50 percent feed load for six to eight hours. Aftersatisfactory operation at this feed rate, the load is gradually increased to 100 percentof design feed load over a period of 40 hours.

PROCEDURE 1. Conduct each of the precommissioning check procedures discussed in Section

5.3, Precommissioning Checks. The following conditions should exist at thistime:

• The crusher main shaft has been raised 50 mm (2 inches) with the hydrau-lic adjustment system.

• The lubricating oil is at operating temperature, an oil pump has beenstarted, and oil is circulating through the crusher. Oil flow has been veri-fied by the observation of a full flow of oil to the sump tank (reservoir) onthe lube skid.

• The correct volume of oil is flowing to the eccentric and countershaft andhas been verified.

• The spider lubrication system is operational.

• The countershaft extension is secure and its coupling covers are in place.

• The motor lockout locks have been removed at the motor control center(MCC).

2. Ensure all safety interlocks have been tested and are functional prior to start-ing the crusher and its auxiliary equipment.

When the crusher is first started, it must contain no ore.The purpose of the running-in test is to allow thecrusher to bed-in and run in the bearings and gears tocheck their operation closely.


5.4PAGE 2 OF 3


3. Insert two grader-size tires into the crushing chamber with steel cables. Placethem 180 degrees apart.

The normal motion of the main shaft is gyratory (thebottom end of the shaft moves in a circle while the topis stationary). Is some cases, due to the viscosity of theoil between the shaft and the eccentric, there is a ten-dency for the idle running main shaft to rotate or spin inaddition to gyrating. The spinning is not beneficialduring the running-in period. The grader tires are in-serted into the crusher to provide just enough friction tokeep the shaft from spinning. They will move fromtheir original positions as the crusher is running.

4. Start the crusher from the local control panel or from the distributed controlsystem (DCS).

5. With the crusher in operation, look for oil leakage from the oil inlet and returnpipe lines.

6. Check for oil leakage through the countershaft seal. Leakage here indicatesexcessive oil flow to the countershaft bearing. If leakage occurs, close thevalve in this line a little to reduce the flow, but observe the flow indicator toensure that the flow is not stopped completely. Approximately no less than 11Lpm (3 gpm) is required.

7. Check the countershaft bearing temperature. No discomfort should be feltwhen a bare hand is placed on the countershaft housing. Confirm suspectedexcessive temperatures through the DCS and with a portable thermal detector.If the temperature is high, the indication is that there is insufficient oil flow tothe bearings or too little roller clearance. Refer to Section 7.9, ComponentReplacement and Selected Repair Procedures: Countershaft Assembly Com-ponent Replacement.

8. Ensure that the oil cooling system is operating properly. Check that the tem-perature and pressure gauges operating on the pumping unit are steady andoperating correctly.

9. Ensure that the spider bushing lubrication system is functioning properly.

10. Test the hydraulic support and adjustment systems.

11. At 15-minute intervals record the motor power draw and the temperature ofthe oil to the crusher and returning to the reservoir on the lube skid. Continuerecording these readings until the oil temperature remains constant for onehour.


5.4PAGE 3 OF 3


12. Observe the drive motor winding and bearing temperatures with the motormonitoring device or through the DCS.

13. At the end of the eight-hour running-in period, stop the crusher and the lubesystem.

14. Remove the return screen from the lube oil skid reservoir. Inspect its contentsand record observations, and clean the screen with solvent. Install the screenand secure it.

It is normal to find a small amount of foreign materialin the screen basket due to the bedding-in process anddislodged particles not removed by flushing.

15. Remove the tires from the crushing chamber.

16. Ensure that the shell bolts, spider bolts, and foundation bolts are tight.

17. Ensure that the crusher drive motor foundation bolts are tight.

18. Prepare the crusher for initial start-up with feed.


5.5PAGE 1 OF 2


5.5 INITIAL START-UP WITH FEEDSPECIAL EQUIPMENT REQUIREDNoneINTRODUCTIONThe purpose of the initial start-up with feed is to run the crusher for 1 hour with afeed load of 50 percent of crusher capacity, inspect the crusher, and then graduallyincrease the feed rate over a 48-hour period.The crusher is run for 1 hour with a 50 percent feed load. (It is important to ensurethat the feed material is dry and does not contain fines or lumps larger than two-thirdsof the feed opening.) The feed is stopped and the crusher is cleared (crushed out) andstopped. The crusher is inspected and, if all is satisfactory, started again at a feed rateof 50 percent of capacity. The crusher is run for eight hours at a 50 percent feed rate.If the crusher is within operating and design specifications, the crusher is run for 40hours while gradually increasing feed rate to full design capacity.PROCEDURE

1. Perform the preoperational inspection. (Refer to Section 6.2, Start-Up Proce-dures: Preoperational Inspection.)

2. Alert other operators to the impending start-up. 3. When the lubricating oil, hydraulic adjustment, and spider lube systems have

been started, check their operations.3.1. Check that the lubricating oil is at operating temperature. An oil pump

has started and the oil is circulating through the crusher. Oil flow isverified by observation of a full flow of oil to the sump tank (reser-voir) on the lube skid.

3.2. Ensure that the correct volume of oil is flowing to the eccentric andcountershaft.

3.3. Ensure that the spider lube system is operational. 4. Check that the drive motor is ready for operation.

4.1. Ensure that the countershaft extension is secure and its coupling coversare in place.

4.2. Ensure that the motor lockout locks have been removed at the motorcontrol center (MCC).

5. The crusher is started and a 50 percent feed rate is established.5.1. Look for oil leakage from the oil inlet and return pipelines.


5.5PAGE 2 OF 2


5.2. Check for oil leakage through the countershaft seal. If leakage occurs,close the valve in this line a little to reduce the flow, but observe theflow indicator to ensure that the flow is not stopped completely. Ap-proximately no less than 11 Lpm (3 gpm) is required.

5.3. Ensure the oil cooling system is operating properly. Check that thetemperature and pressure gauges are operating on the pumping unitand are steady.

5.4. Check the countershaft bearing temperature.5.5. Ensure that the spider bushing lubrication system is functioning prop-

erly.5.6. Ensure that the hydraulic adjustment system is operating properly.5.7. Observe the drive motor winding and bearing temperatures with the

motor monitoring device and through the distributed control system(DCS).

6. After eight hours of successful partial load operation, the feed is stopped andthe crusher crushed out and stopped. The auxiliary systems remain in opera-tion if they were operating properly.

7. Check the crusher shell bolts, spider bolts, and foundation bolts to make sureall are tight. Tighten loose nuts and bolts as required.

8. Check the drive motor foundation bolts to make sure all are tight. Tightenloose nuts and bolts as required.

9. When all checks, inspections, and adjustments have been completed, thecrusher is started and feed introduced at a 50 percent rate. During the fol-lowing 40 hours, the feed rate is gradually increased to 100 percent of designcapacity.

10. Set the adjustment system relief valve while the crusher is operating under anormal full crushing load. Adjust the relief valve until the normal load causesit to open and allows the main shaft to descend, then set it higher so that it willhold under the normal load peaks. Several adjustments may be necessary toattain a satisfactory setting.

The purpose of the relief valve is to protect the crusherfrom uncrushable objects. If an object gets caught inthe crusher, the valve opens and the main shaft de-scends.

11. During the following 40 hours, repeat all checks and inspections made duringthe previous eight hours of operation.

12. Record all observations and measurements.


5.0PÁGINA 1 DE 1

CE50-S.DOC CRUSHER NOV.. 2001REV 0

5.0 PUESTA EN SERVICIO INICIALEl propósito de la puesta en servicio inicial es asegurar que todos los sistemas delchancador y equipos asociados, han sido construidos de acuerdo a su diseño. Lapuesta en servicio incluye pruebas pre-operacionales y funcionamiento inicial yoperación del chancador sin alimentación. La puesta en servicio se inicia de acuerdocon el total del programa del proyecto y comienza durante la fase de construcción.

Las actividades de pruebas pre-operacionales incluyen:

• Limpieza y flushing de los equipos.

• Pruebas de controles e instrumentación.

• Pruebas e inspecciones preliminares de desempeño del equipo durante elfuncionamiento inicial.

• Construcción de instalaciones temporales para efectuar las pruebas y el rodaje.

• Programación y coordinación de proveedores participantes y sus actividadesasociadas.

• Establecimiento y fortalecimiento de prácticas de operación seguras.


5.1PÁGINA 1 DE 4


5.1 MEDIDAS DE SEGURIDAD

El propósito de tomar medidas de seguridad es asegurar y reforzar el reconocimientoy la práctica de hábitos de trabajo seguro durante el procedimiento de puesta enservicio. Las prácticas de seguridad laboral establecidas tienden a relajarse cuando lasactividades de construcción se acercan a su término y comienza la puesta en servicio.Con el fin de evitar accidentes y posibles lesiones al personal durante este período delproyecto, se debe estar consciente de estas medidas.Las siguientes medidas de seguridad no pretenden cubrir aspectos direccionales deseguridad. El objetivo de estas medidas es prevenir riesgos específicos, generalmenteasociados con la puesta en servicio de equipos giratorios pesados. Todos los aspectosrelacionados con la seguridad del personal y, por añadidura, las leyes y regulacionesde seguridad son de responsabilidad del cliente y sus contratistas.

La seguridad del personal de operaciones y mantenimiento debe ser garantizada todoel tiempo a través de la observación de las prácticas de seguridad. En particular, elmantenimiento no se debería efectuar muy cerca de partes girando de un chancadoren operación. Solamente cuando el chancador ha sido detenido para fines deinspección, mantenimiento y reparaciones, se deberá cortar la corriente eléctricacomo medida seguridad para prevenir la partida accidental del equipo. Losprocedimientos de planificación de la operación y mantenimiento y el entrenamientodel personal deben incluir la definición y comunicación de procedimientos diseñadospara cumplir ésto. Remitirse a la Sección 2.0, Procedimientos de Trabajo Seguro.

Las siguientes precauciones de seguridad están incluidas en esta sección:

• Bloqueo del equipo e instalación de tarjetas de advertencia.

• Trabajo en altura.

• Altas presiones hidráulicas.

• Andamios.

• Puesta en marcha del chancador.El personal no deberá trabajar sobre o dentro delchancador o en los sistemas del chancador cuando estáen operación o mientras el motor de accionamiento estáactivado. Cualquier negligencia en atender estaadvertencia puede causar serios daños o la muerte.

BLOQUEO E INSTALACION DE TARJETAS DE ADVERTENCIA.El bloqueo del equipo e instalación de tarjetas de advertencia permiten la efectivainmovilización y/o desactivación del mismo, lo cual constituye un medio eficaz para


5.1PÁGINA 2 DE 4


evitar una repentina partida del equipo lo que podría causar lesiones al personal acargo de la inspección, pruebas, mantenimiento, reparaciones u operacionesnecesarias. Cualquier movimiento involuntario o accidental o la puesta en marcha delequipo podrían también, causarle daño.Al momento de efectuar una prueba de potencia al equipo y sus sistemas, serecomienda desconectar el mecanismo activador de la fuente de poder o retirar sucentro de control del motor (CCM). Se deberá poner una tarjeta en el control principaly en el control de la fuente de poder y en el (los) panel(es) de control, indicando queel equipo y/o el sistema están siendo sometidos a pruebas. Esto evitará un inesperadocorte de corriente o un cambio de los modos operativos.Cuando la prueba es interrumpida, se debe colocar el seguro del sistema de bloqueoen la fuente de poder primario en el correspondiente centro de control del motor conla tarjeta de advertencia en su lugar.Cuando la prueba ha finalizado, se deben retirar el seguro del sistema de bloqueo ylas tarjetas de advertencia y los controles del sistema/equipo serán colocados en elmodo fuera de servicio (Off), en preparación para la inspección preoperacional.

TRABAJOS EN ALTURAAl efectuar actividades de pruebas, mantenimiento y reparaciones en altura y sobrelas vías de acceso del personal, se deberá tomar precauciones especiales paraproteger al personal directamente involucrado en el trabajo, y al personal y equipobajo ellos.Todo el personal que efectúe trabajos en áreas elevadas deberá usar correctamentearneses de seguridad aprobados, sin importar el tiempo que deban permanecer en elárea de trabajo.La zona directamente debajo de la de trabajo deberá ser marcada para prevenir laentrada de personal. Una tarjeta de color fácilmente visible (amarillo o naranjabrillante) se ubica normalmente al nivel del suelo debajo de la zona de trabajo enaltura. Adicionalmente, se utiliza señalización para advertir a todo el personal delnivel del suelo que hay una actividad sobre el área marcada como restringida.Los operadores de grúas de altura deberán ser informados acerca del progreso deltrabajo en altura para prevenir el enganche accidental y el depósito de carga dentrodel área de trabajo en altura.Cuando se está usando grúas en áreas de trabajo de altura, el espacio es normalmentelimitado, y una carga suspendida deberá ser inmovilizada de la manera más seguraposible sobre su centro de gravedad. Una carga en movimiento puede fácilmentearrastrar al personal y equipo de plataformas de trabajo en altura.


5.1PÁGINA 3 DE 4


Mientras se efectúan trabajos de soldadura, haciendo cortes, y se está utilizandomateriales químicos como ácidos o solventes en altura, el área inmediatamentedebajo, marcada como restringida, deberá estar libre de materiales combustibles einflamables para prevenir lesiones al personal por fuego o explosiones. Los materialescombustibles incluyen encofrados de madera y materiales de empaque, pintura,solventes y combustibles. Equipos y materiales contra incendio, como tambiénmateriales absorbentes, deben estar a mano.FILTRACIONES HIDRAULICAS DE ALTA PRESIONLas filtraciones hidráulicas de alta presión son normalmente muy peligrosas y puedencausar severos daños. Adicionalmente a las instrucciones entregadas en la Sección2.0, Procedimientos para un Trabajo Seguro: Sistemas Hidráulicos de Alta Presión,se debe tener especial cuidado mientras se trabaja con sistemas hidráulicos,especialmente durante la búsqueda y reparación de filtraciones.

Ante la sospecha de filtraciones en el sistema y si éstas son muy finas, se detectanmediante una fuerte luz o una pieza de madera seca. Jamás se debe usar las manos, yasea con guantes o sin ellos, para localizar una filtración hidráulica. Cada vez que sedescubre una filtración, el sistema debe ser puesto fuera de servicio para efectuar lasreparaciones. Jamás se debe intentar una reparación con el sistema en operación a lapresión de diseño. Si se detecta una filtración en un fitting, el sistema debe ser puestofuera de servicio, bloqueado, y se deberá instalar tarjetas indicativas, para luegoretirar el fitting que está filtrando e inspeccionarlo para confirmar si está dañado,defectuoso o mal atornillado.

Al tratar de apretar un fitting que está filtrando podría ocurrir que éste se soltara oquebrara, exponiendo al mecánico u operador a flujo hidráulico caliente de altapresión. Delgados chorros de flujo hidráulico de alta presión pueden fácilmentedesgarrar guantes de cuero y la piel, y causar daño severo en dedos y manos.

ANDAMIOSLos andamios son plataformas temporales de trabajo en altura. En lo posible, paraeste propósito se deberá ensamblar solamente andamios de estructura metálica.Todos los fijadores de seguridad deberán ser utilizados en su ensamblaje. Lasplataformas utilizadas para trabajar desde los andamios deben ser de grandesproporciones y estables. Deberán cubrir toda la zona de trabajo de la estructura delandamio.

Se deberá tener mucho cuidado de no sobrecargar la estructura del andamio condemasiadas personas, equipo pesado y componentes de los equipos. Todos losandamios deben ser asegurados a estructuras fijas para prevenir su volcamiento.


5.1PÁGINA 4 DE 4


PUESTA EN MARCHA DEL CHANCADORAntes de poner en marcha el chancador para reposicionar el eje principal, parainspección o para pruebas, se deberá efectuar una inspección acuciosa del áreacircundante. Esto se debe hacer para cerciorarse de que no hay riesgo de lesión para elpersonal o de daño para el equipo derivados del movimiento del eje principal y delmanto del chancador.

Las áreas que deben ser inspeccionadas visualmente incluyen el exterior del cuerpodel chancador, el carro excéntrico y el interior del chancador. El centro de control delmotor (CCM), el soporte de poder de elevación hidráulica, y el soporte de lubricacióny el sistema de lubricación de la araña también deberán ser observados paracerciorarse que están operativos y que no presentan riesgos para el personal y para elequipo en esa área.


5.2PÁGINA 1 DE 1


5.2 PLAN DE PUESTA EN SERVICIO

El plan de puesta en servicio incluye los siguientes ítemes:

5.2.1 Definiciones

5.2.2 Gráfico de Secuencia de Puesta en Servicio.


5.2.1PÁGINA 1 DE 1


5.2.1 DEFINICIONES

Las siguientes definiciones son generales en naturaleza y describen la delineación deltrabajo de quienes participan en el plan de puesta en servicio.

INGENIERIA, ADQUISICIONES, GERENCIA DE CONSTRUCCION (IAGC)DEL CONTRATISTAEl equipo IAGC del contratista es designado por el Cliente y sus funciones sonrealizadas bajo su dirección. El IAGC del contratista es responsable por elaseguramiento de la correcta instalación del equipo de la planta por los Contratistas,incluyendo la documentación pertinente y la ejecución de las pruebas pre-operacionales y la limpieza.

CONTRATISTACada Contratista es responsable de la instalación del equipo de la planta por el IAGCdel Contratista, del Vendedor y/o, según los planos, especificaciones y manuales deinstrucciones del Fabricante.

FABRICANTEEl Fabricante es el proveedor del equipo y sistemas. El Fabricante es responsable anteel IAGC del Contratista por el diseño, especificaciones y documentación pertinentedel equipo y sistemas suministrados.

VENDEDOREl Vendedor es el proveedor de los componentes, sistemas y sub-sistemas quenormalmente son diseñados y fabricados por otros. El Vendedor puede tambiénproveer todos los servicios de soporte. La responsabilidad primaria del Vendedor esasegurarse que los componentes, sistemas y servicios proporcionados satisfagan oexcedan las especificaciones y expectativas de desempeño especificadas del IAGCdel Contratista y del Fabricante.

CLIENTEEl Cliente es la persona o parte que tiene el derecho legal de posesión de la planta ytodos los equipos e instalaciones que ésta incluye. El Cliente entrega al IAGC delContratista la dirección y los recursos para conducir construcción y la puesta enservicio de la planta.


5.2.2PÁGINA 1 DE 2


5.2.2 CRONOGRAMA DE SECUENCIA DE LA PUESTA ENSERVICIO

IAGC del Contratista Etapas Finales deConstrucción

Programas de Completaciónde Hitos por Equipo

Responsabilidad Formularios/Informes

Preparación de Pautas paraPruebas Preoperacionales y

Funcionales

Fabricante

Indentificación de losPaquetes de Pruebas;

Preparación de Procedi-mientos y Base de Datos

Pautas Escritas para cadaEquipo

Fabricante

Gráfico de Barras por cadaPaquete

Preparar Programa dePruebas PreliminaresFabricante con Cliente e

IAGC del Contratista

Contenido de cada Paquete:• Lista de Equipos• Lista de Instrumentos• C&IDs (Destacado)• Descripción de Pruebas• Hojas de Datos de Pruebas• Certificados de Pruebas• Procedimiento

Certificados de Pruebas yHojas de Datos

Preparar Programa detalladode Pruebas

IAGC del Contratista,Fabricante, y Vendedores

IAGC del Contratista

Instalación Final y Apro-bación del Vendedor

Conducción de PruebasPreoperacionales

Listas Clave

Todos los Equipos de cadaPaquete exitosamente Pro-

bados

Conducción Paquete dePruebas de Funcionamiento

Publicación de Equipos conFechas de Hitos

Formulario de Término delServicio del Vendedor

y Resumen Diario

Publicación de Deficiencias yResponsabilidades

Listas Clave

IAGC del Contratista, Fabri-cante y Representante del

Cliente

IAGC del Contratista y delFabricante


Certificados de Pruebas yHojas de Datos

Publicación de Deficencias yResponsabilidades


Actividad


5.2.2PÁGINA 2 DE 2


Responsibilidades Actividades Formularios/Informes

Paquete de Pruebas Exito-sas como un Sistema

Paquete Traspasos• Carta de Traspaso• Lista de Excepciones• Hoja de Datos de Pruebas• Certificados de Pruebas• Datos del Vendedor• Otra Información

Requerida

Paquete de Traspaso delChancador al Cliente yAnuncio fin Programa;

Cuelgue Tarjetas Verdes

Paquete de Monitoreo deOpeación Chancador sin

Carga

Solución Problemas Fun-cionamiento

IAGC del Contratista yCliente

IAGC del Contratista, Clientey Fabricante

Paquete de Monitoreo Oper-ación Chancador a medida

que es alimentado

IAGC del Contratista,Cliente y Fabricante

Solución ProblemasFncionamiento

IAGC Contratista, Fabricantey Vendedores

IAGC del Contratista,Fabricante, Vendedores


5.3PÁGINA 1 DE 1


5.3 CONTROLES DE PRE-PUESTA EN SERVICIO

El propósito de esta sección es dar a conocer los procedimientos y documentaciónnecesarios para conducir los controles previos a la puesta en servicio del chancador yde sus equipos y sistemas auxiliares. Las tareas involucradas en los controles de pre-puesta en servicio son actividades de traspaso que incluyen:

• Limpieza.

• Retoque de pintura.

• Retiro de los materiales de embalaje y fijadores.

• Lubricación.

• Verificación de rotación del motor, bombas.

• Alineamiento de los ensamblajes del motor.

• Pruebas y calibración de instrumentos.

• Pruebas de aislamiento eléctrico (megohmio).

• Pruebas de potencial de alto voltaje. (alta potencia).

• Otras revisiones y pruebas.Los procedimientos para estas actividades se entregan en la Sección 5.3, Revisionesprevias a la Puesta en Servicio: Instrucciones para la Pre-puesta en Servicio.

Todas las observaciones, correcciones, pruebas y mediciones se encuentrandocumentadas en las hojas de datos incluidas en la Sección 5.3. Controles de Pre-puesta en Servicio: Hojas de Datos de Pre-puesta en Servicio.


5.3.1PÁGINA 1 DE 1


5.3.1 INSTRUCCIONES PARA LA PRE- PUESTA EN SERVICIO

En esta sección se incluyen las siguientes hojas de datos de pre-puesta en servicio:

5.3.1.1 Revisiones de Pre-Puesta en Servicio del Conjunto delChancador

5.3.1.2 Revisiones de Pre-Puesta en Servicio del Sistema deLubricación de los Descansos

5.3.1.3 Revisiones de Pre-Puesta en Servicio del Sistema de AjusteHidráulico


5.3.1.1PÁGINA 1 DE 2


5.3.1.1 CONTROLES DE PRE-PUESTA EN SERVICIO DELCONJUNTO DEL CHANCADOR

EQUIPO ESPECIAL REQUERIDODocumentos de Construcción

INTRODUCCIONEl propósito de este procedimiento es preparar el conjunto del chancador, incluyendoel cuerpo sus aditamentos, para la puesta en marcha inicial sin carga.

PROCEDIMIENTOMecánico/Lubricación

1. Asegúrese que el sistema de accionamiento del chancador está asegurado ycon las correspondientes tarjetas de advertencia según los procedimientosestablecidos.

2. Inspeccionar el interior del chancador para verificar que no haya piezas derevestimiento, pernos ni tuercas sueltos. Chequear lo siguiente:

• Brazos y cubierta de la araña.

• Cóncavas.

• Manto.

• Interior y exterior de la sección inferior del cuerpo.

• Conjunto del contraeje. 3. Retirar todos los elementos provisorios, desechos y materiales de construcción

desde el interior del chancador.

4. Chequear el exterior del cuerpo del chancador para verificar que no falten nihayan quedado pernos de flanches ni tuercas sueltos. Apretar o instalar sifuera el caso.

5. Confirmar que el buje superior de la araña tenga grasa. De no ser así, someterel sistema de lubricación de la araña a flushing, reconectarlo y hacerlofuncionar hasta que el buje esté lleno de grasa, y recién entonces, prepárelopara operación.

6. Chequear que todos los componentes que requieran lubricante hayan sidolubricados.

7. Chequear que el conjunto de extensión del contraeje haya sido acoplado demanera segura al chancador y su motor, y que esté correctamente alineado.




8. Asegúrese que el indicador de posición del manto esté en su lugar, cableado yque haya sido calibrado de acuerdo a las instrucciones del fabricante.

9. Revisar de nuevo las tuberías y el cableado debajo del chancador paracerciorarse que todos están debidamente protegidos.

10. Sangrar el aire desde el sistema de ajuste hidráulico e inspeccionar loscircuitos hidráulicos para verificar que no haya fugas.

11. Levantar 50 mm (2 pulgadas) el eje principal del chancador, utilizando unsistema de ajuste hidráulico.

12. Cuando el aceite lubricante está a temperatura de operación, poner en marchala bomba y permitir al aceite circular a través del chancador hasta que un flujoen toda su magnitud pueda ser visto retornando al tanque de acumulación.

13. Chequear el volumen del flujo de aceite a la excéntrica y a los descansos delcontraeje.

14. Para impedir una rotación demasiado rápida del eje principal durante elperíodo de interrupción, insertar dos llantas de gran tamaño dentro de lacámara del chancador.

15. Completar una hoja de control preoperacional mecánico (remitirse a laSección 5.3, Revisiones de Pre-Puesta en Servicio: Hojas de Datos de Pre-Puesta en Servicio – Controles de Prepuesta en Servicio Mecánico).

Electrico/Instrumental 16. Verificar que todos los instrumentos, sensores, alarmas, medidores de tiempo,

y sistemas de trabado están en los puntos de fijación especificados en laSección 7.2, Límites de Operación de Componentes o Subsistemas, antes deponer en marcha en chancador.

17. Chequear el funcionamiento de las alarmas en los circuitos de entrada ysalida del aceite lubricante.

18. Completar una hoja de control preoperacional eléctrico (remitirse a la Sección5.3. Revisiones de Pre-Puesta en Servicio: Hojas de Datos de Pre-Puesta enServicio – Hojas de Datos de Calibración/Pruebas de Pre-Puesta en Serviciode Interruptores y Transmisores.




5.3.1.2 CONTROLES DE PRE-PUESTA EN SERVICIO DEL SISTEMADE LUBRICACION DE LOS DESCANSOS

EQUIPO ESPECIAL REQUERIDOUn set de alineamiento laser o un reloj comparador de precisiónUn VOM de alta impedanciaUna fuente de poder externa de 4 a 20 mA, 24 V DCINTRODUCCIONLa finalidad de este procedimiento es preparar el sistema de lubricación delchancador para la puesta e marcha inicial sin carga del chancador. Esto se efectúarevisando los componentes mecánicos y eléctricos y los instrumentos del sistema.PROCEDIMIENTOMeánico/Lubricación

1. Revisar las condiciones física y de funcionamiento del sistema de lubricacióndel chanchador y sus componentes mecánicos.

1.1. Utilice las hojas de control de pre-puesta en servicio del sistemamecánico (remítase a la Sección 5.3, Revisiones de Pre-puesta enServicio: Hojas de Datos de Pre-puesta en Servicio – Hojas deControl Mecánico de Pre-Puesta en Servicio del Sistema deLubricación) como guía para la revisión y para registrar lasobservaciones y mediciones del funcionamiento de los componentesdel sistema de lubricación.

Eléctrico1. Revisar la condición física y funcional de los componentes eléctricos del

sistema de lubricación.

1.2. Utilice las hojas de control de pre-puesta en servicio del sistemaeléctrico (remítase a la Sección 5.3, Revisiones de Pre-puesta enServicio: Hojas de Datos de Pre-puesta en Servicio – Hojas deControl Eléctrico de Pre-Puesta en Servicio del Sistema deLubricación) como guía para la revisión y para registrar lasobservaciones y mediciones del funcionamiento de los componentesdel sistema de lubricación.

Instrumentos 1. Revisar la condición física y funcional de los instrumentos del sistema de

lubricación.




1.1. Utilice las hojas de control de la pre-puesta en servicio de losinstrumentos (remítase a la Sección 5.3, Revisiones de Pre-puesta enServicio: Hojas de Control de Instrumentos para la Pre-Puesta enServicio del Sistema de Lubricación) como guía para la revisión y pararegistrar las observaciones y mediciones del funcionamiento de losinstrumentos del sistema de lubricación.




5.3.1.3 CONTROLES DE PRE-PUESTA EN SERVICIO DEL SISTEMADE AJUSTE HIDRAULICO

EQUIPO ESPECIAL REQUERIDOUn set de alineamiento laser o un reloj comparador de precisiónUn VOM de alta impedanciaUna fuente de poder externa de 4 a 20 mA, 24 V DCINTRODUCCIONEl propósito de este procedimiento es preparar el sistema de ajuste hidráulico para lapuesta en marcha sin carga e inicial del chancador. Esto se efectúa revisando loscomponentes mecánicos y eléctricos y los instrumentos del sistema.PROCEDIMIENTOMecánico/Lubricación

1. Revisar las condiciones física y de funcionamiento del sistema de ajustehidráulico y sus componentes.1.1. Utilice las hojas de control de pre-puesta en servicio del sistema

mecánico (remítase a la Sección 5.3, Revisiones de Pre-puesta enServicio: Hojas de Datos de Pre-puesta en Servicio – Hojas deControl Mecánico de Pre-puesta en Servicio del Sistema de AjusteHidráulico), como guía para la revisión y para registrar lasobservaciones y mediciones del funcionamiento de los componentesdel sistema de ajuste hidráulico.

Eléctrico 1. Revisar las condiciones física y de funcionamiento de los componentes

eléctricos del sistema de ajuste hidráulico.1.1. Utilice las hojas de control de pre-puesta en servicio del sistema

eléctrico (remítase a la Sección 5.3, Revisiones de Pre-puesta enServicio: Hojas de Datos de Pre-puesta en Servicio – Hojas deControl Eléctrico de Pre-puesta en Servicio del Sistema de AjusteHidráulico), como guía para la revisión y para registrar lasobservaciones y mediciones del funcionamiento de los componentesdel sistema de ajuste hidráulico.

Instrumentos 1. Revisar las condiciones física y de funcionamiento de los instrumentos del

sistema de ajuste hidráulico



CE 5313-S.DOC CRUSHER NOV. 2001REV 0

1.1. Utilice las hojas de control de pre-puesta en servicio de losinstrumentos (remítase a la Sección 5.3, Revisiones de Pre-puesta enServicio: Hojas de Datos de Pre-puesta en Servicio – Hojas deControl de Instrumentos de Pre-puesta en Servicio del Sistema deAjuste Hidráulico), como guía para la revisión y para registrar lasobservaciones y mediciones del funcionamiento de los instrumentosdel sistema de ajuste hidráulico.


5.3.2PÁGINA 1 DE 1


5.3.2 HOJAS DE DATOS DE PRE-PUESTA EN SERVICIO

En esta sección se incluyen las siguientes hojas de datos de pre-puesta en servicio:

5.3.2.1 Controles de Pre-puesta en Servicio de Equipos Mecánicos

5.3.2.2 Hojas de Datos de Calibación7Pryebas para Pre-Puesta enServicio de Interruptor y Transmisor

5.3.2.3 Hojas de Revisión Mecánica para Pre-puesta en Servicio delSistema de Lubricación

5.3.2.4 Hojas de Revisión Eléctrica para Pre-puesta en Servicio delSistema de Lubricación

5.3.2.5 Hojas de Revisión de Instrumentos para Pre-puesta enServicio del Sistema de Lubricación

5.3.2.6 Hojas de Revisión Mecánica para Pre-puesta en Servicio delsistema de Ajuste Hidráulico

5.3.2.7 Hojas de Revisión Eléctrica para Pre-puesta en Servicio delsistema de Ajuste Hidráulico

5.3.2.8 Hojas de Revisión de Instrumentos para Pre-puesta enServicio del sistema de Ajuste Hidráulico




CONTROLES DE PRE-PUESTA EN SEVICIO DE EQUIPOS MECANICOSHOJA DE

Cliente: Equipo:

Proyecto: Equipo No.:

Proyecto No.: Motor No.:

DETALLES DEL ACCIONAMIENTO DIRECTO

TIPO ACOPLAMIENTO(S)

TAMAÑO ACOPLAMIENTO(S)

ELEMENTOS DE ACOMPLAMIENTO

ALINEAMIENTO (TIR)

OTROS

DETALLES DE LUBRICACION

MECANISMO TIPO DE LUBRICNTE NIVEL

SISTEMA DE REFRIGERACION/ AGUA

LECTURA DE PRESION CON MANOMETRO:

RPM: mm/min: L(gal)/min: PROTECCIONES:

COMENTARIOS:

CALIBRADO/PROBADO POR Firma/Fecha




HOJA DE DATOS DE CALIBRACION/PRUEBASDE PRE-PUESTA EN SERVICIO DE INTERRUPTOS Y TRANSMISOR

HOJA DE

Certificado No.

Descripción del Instrumento

Número de Tarjeta del Instrumento

Fabricante

Modelo No.

Precisión del Instrumento

Rango Máximo

Rango Calibrado

Fecha de Calibración

Temperatura Ambiente

Fecha de la Próxima Calibración

Prueba del Equipo usado:

Certificado No.

Descripción

Fabricante

Modelo No.

Serie No.

Precisión del Equipo Probado

Descripción de la Prueba y Método Ref:

Nota:

Resultados de laPrueba

Valor de Proceso Simulado Salida

Esperada mA

Salida

Actual mA

% Error deExpectación

Valor Actual delDCS

% Valor 0C mA mA %

4

8

12

16

20

Probado por_____________________ Presenciado por:_____________________Firmado: _______________________ Firmado: __________________________


5.3.2.3PAGE 1 OF 2


5.3.2.3 LUBRICATION SYSTEM PRECOMMISSIONINGMECHANICAL CHECKSHEET



Crusher lube oilsupply and return

Lube Hoses and Piping—Clean and inspect thelubrication supply and return hoses and pipe fit-tings for damage and leakage. Replace defectivehose and fittings. These components are criticalfor correct and continuous operation of thecrusher.

Drain Valve—Make sure the main supply linedrain valve is closed.

Block Valves—Make sure the supply blockvalves are open.

Air Vent—Check that the return line air vent isinstalled securely and properly supported.

Lube oil system (skid) Filters/Strainers—Clean/replace the main pumpfilter element. Make sure the drain valves areclosed. Check and clean the lube oil reservoirreturn and vent filters. Open and clean all “Y”strainers.



Coolers—Check that all the shipping materialshave been removed. Make sure all mountingbolts are in place and secure, and that the coolingsurfaces are clear of debris. Also make sure thefan blade is in good operating condition.

Main and Standby Oil Pump Alignment—Check the motor-pump alignment of the main oilpumps. Refer to the pump manufacturer’s speci-fication. Realign as required. Record results andreadings.


5.3.2.3PAGE 2 OF 2




Lube oil system (skid)(continued)

Drive Couplings—Inspect all the pump drivecouplings. Replace damaged and missing flexi-ble elements as required.



5.3.2.4PAGE 1 OF 4


5.3.2.4 LUBRICATION SYSTEM PRECOMMISSIONINGELECTRICAL CHECKSHEET



Lube oil system skid,pump motors





Stator Resistance—At the MCC, megger thestator at 500 VDC, and record the measurements.



Check Rotation—When all other checks havebeen completed, start and run the system, onemotor and pump set at a time. Check the rotationof each and record direction looking from motorto fan.


5.3.2.4PAGE 2 OF 4




Lube oil system skid,pump motors(continued)

Motor Current Draw—When the lubricationsystem is operating normally, go to the MCC andmeasure and record the total current draw and thecurrent in each phase. Compare the phase cur-rents. Each should be at least 93 percent of thegreatest current reading. Low phase currentmeasurements indicate a motor phase unbalanceand may require motor replacement.

Cooler fan motors Power Terminals—With the fan motors isolatedfrom their power and control circuits, check thepower terminals for tightness. Disconnect andclean loose terminals, and reconnect securely.





Check Rotation—When all other checks havebeen completed, start and run the fans. Check therotation of each and record direction lookingfrom motor to pump.

Motor Current Draw—With the lubricationsystem operating normally, remove the junctionbox covers for the fan motors and measure andrecord the total current draw and the current ineach phase. Compare the phase currents. Eachshould be at least 93 percent of the greatest cur-rent reading. Low phase current measurementsindicate a motor phase unbalance and may re-quire motor replacement.


5.3.2.4PAGE 3 OF 4




Motor operated valves Power Terminals—With a valve motor isolatedfrom its power and control circuits, check thepower connections to the correct motor terminals.






Check Rotation—When all other checks havebeen completed, start and run the system, onevalve at a time. Check the rotation of each andrecord direction looking from motor to valvebody.


Lube oil heaters Power Terminals—With a valve motor isolatedfrom its power and control circuits, check thepower connections to the correct heater terminals.


5.3.2.4PAGE 4 OF 4




Lube oil heaters(continued)






5.3.2.5PAGE 1 OF 6


5.3.2.5 LUBRICATION SYSTEM PRECOMMISSIONINGINSTRUMENT CHECKSHEET



TI-7027, -7021,-7025,-7035, -7031,-7032, -7034—Temperature Indicator(gauge)




TE/TT-7021, -7027—Temperature Element/Transmitter Clean the display glass and the exterior of the

enclosure.






Inspect the instrument for signs of leakage andheat damage. Repair or replace as required.








5.3.2.5PAGE 2 OF 6










PSV-7022A, -7022B,-7022C, -7022D—Pressure Relief Valve






No adjustments should be necessary.




Inspect the instrument housing for signs of physi-cal damage. Replace unit as required.


HS-7025, -7033—Hand Selector Switch



5.3.2.5PAGE 3 OF 6




HS-7025, -7033—Hand Selector Switch(continued)







PI-7023A, -7023B,-7023C, -7023D,-7025, -7031, -7032,-7034—PressureIndicator Check the date on the calibration sticker.



enclosure.




With an independent DC power supply, checkspan (4-20 mA) and zero settings. Compare withambient pressure differential at the sensing loca-tions. Set zero as required.



5.3.2.5PAGE 4 OF 6




ZSO-7033—PositionSwitch Open



Apply appropriate input voltage and ensure thatswitch opens. Reconcile with position of valve.



Inspect wiring terminals for tightness. Removeloose terminals, clean contact surfaces untilbright, and reconnect.



ZSC-7033—PositionSwitch Closed



Apply appropriate input voltage and ensure thatswitch closes. Reconcile with position of valve.



Inspect wiring terminals for tightness. Removeloose terminals, clean until contact surfaces arebright, and reconnect.


5.3.2.5PAGE 5 OF 6










TE, TIT-7022—Ambient Temp. Sen-sor/Transmitter









FIT-7028—LubeCooler Oil Return LineFlow IndicatingTransmitter



5.3.2.5PAGE 6 OF 6





FIT-7028—LubeCooler Oil Return LineFlow IndicatingTransmitter (contin-ued) Check the date on the calibration sticker.





HIS-CR012A,-CR012B, -CR012C,-CR012D;HS2-CR012A,-CR012B, -CR012C,-CR012D—HandSwitch Pushbutton



5.3.2.6PAGE 1 OF 1


5.3.2.6 HYDRAULIC ADJUSTMENT SYSTEM PRECOMMISSIONINGMECHANICAL CHECKSHEET



Crusher hydraulicsupply and return

Lube Hoses and Piping—Clean and inspect thehydraulic supply and return hoses and pipe fit-tings for damage and leakage. Replace defectivehose and fittings. These components are criticalfor correct and continuous operation of thecrusher.

Accumulator—Check that the accumulator isinstalled and is not damaged. Make sure the ac-cumulator is charged with nitrogen.

Hydraulic system skid Filters—Clean/replace the main pump supplyand the return filter elements. Check and cleanthe lube oil reservoir vent filters.


Reservoir Magnets—Check the condition of thereservoir magnets. Record observations, clean,and replace.


4-Way Diverter Valves—Check the installationand condition of the valves. Ensure that theLower valve is normally closed, and the Raisevalve is normally open.

Pump Alignment—Check motor-pump align-ment of the hydraulic oil pumps. Refer to thepump manufacturer’s specification. Realign asrequired. Record results and readings.



5.3.2.7PAGE 1 OF 3


5.3.2.7 HYDRAULIC ADJUSTMENT SYSTEM PRECOMMISSIONINGELECTRICAL CHECKSHEET



Hydraulic system skid,pump motors



Local Controls—Inspect the local control panelfor damaged or missing buttons, switches, andindicators. Repair or replace as required.


Stator Resistance—Remove the junction boxcover, disconnect the power leads, megger thestator at 500 VDC, and record the measurements.Reconnect the power leads.





5.3.2.7PAGE 2 OF 3




Hydraulic system skid,pump motors(continued)

Motor Current Draw—When the hydraulicsystem is operating normally, remove the junc-tion box covers for the motors and measure andrecord the total current draw and the current ineach phase. Compare the phase currents. Eachshould be at least 93 percent of the greatest cur-rent reading. Low phase current measurementsindicate a motor phase unbalance and may re-quire motor replacement.





Hydraulic oil heaters Power Terminals—With a heater isolated fromits power and control circuits, check the powerconnections to the correct heater terminals.




5.3.2.7PAGE 3 OF 3




Hydraulic oil heaters(continued)




5.3.2.8PAGE 1 OF 4


5.3.2.8 HYDRAULIC ADJUSTMENT SYSTEM PRECOMMISSIONINGINSTRUMENT CHECKSHEET











HS1-CR011A,-CR011B;HS2-CR011A,-CR011B—HandSwitch, Pushbutton


Inspect the instrument housing for signs of physi-cal damage and excessive heat. Replace unit asrequired.







5.3.2.8PAGE 2 OF 4




PSV-7012A, -7012B—Pressure ReliefValve









enclosure.


Inspect wiring terminals for signs of excessiveheat. Disconnect loose terminals, clean contactsurfaces until bright, and reconnect the terminals


With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient pressure differential at the sensing loca-tions. Set zero as required.







5.3.2.8PAGE 3 OF 4







With an independent DC power supply, checkspan (4-20 ma) and zero settings. Set zero asrequired.



TE/TT-7011—Temperature Element/Transmitter Clean the display glass and the exterior of the

enclosure.




With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient temperature at the sensing element. Setzero as required.



5.3.2.8PAGE 4 OF 4




TI-7011—Tempera-ture Indicator (gauge)




Inspect the instrument for signs of leakage. Re-pair or replace as required.




Inspect power and signal terminals for signs ofexcessive heat and tightness. Disconnect looseterminals, clean contact surfaces until bright, andreconnect the terminals.

Inspect wiring for signs of abrasion, damagedinsulation, and exposed conductor. Repair orreplace as required.

HV-7014A—SolenoidValve



5.4PÁGINA 1 DE 3


5.4 CONTROLES DE PUESTA EN SERVICIO SIN CARGA

EQUIPO ESPECIAL REQUERIDONinguno

INTRODUCCIONPara poner un chancador nuevo en operación se debe completar varias fases. Existeun período de “rodaje” inicial, en que el chancador es operado sin carga durante ochohoras. Esta fase es seguida por un período de operación de una hora con carga dealimentación reducida. Una vez cumplida satisfactoriamente esta etapa, el chancadores preparado para servicio normal a plena carga, operando con carga por alimentacióndel 50 por ciento durante seis a ocho horas. Cumplida una operación satisfactoria aeste rango de alimentación, la carga es aumentada gradualmente hasta llegar al 100por ciento de alimentación según diseño, por un período superior a 40 horas.

PROCEDIMIENTO 1. Se deberá seguir los procedimientos de control de pre-puesta en servicio

mencionados en la Sección 5.3, Controles de Pre-puesta en Servicio. En estaetapa se deberá observar las siguientes condiciones:

• El eje principal del chancador ha sido elevado 50 mm (2 pulgadas)mediante el sistema de ajuste hidráulico.

• El aceite lubricante está a su la temperatura normal de operación, unabomba de aceite está funcionando normalmente, y el flujo de aceite através del chancador ha sido establecido. Se ha verificado el correcto flujode aceite hacia el estanque de acumulación sobre su estructura soportanteha sido verificado.

• El caudal de aceite que fluye hacia la excéntrica y hacia el contraeje es elcorrecto.

• La extensión del contraeje es segura y sus cubiertas de acoplamiento estánen su lugar.

• En la sala de control central del motor (CCM) los seguros de bloqueo delsistema de arranque del motor han sido retirados.

2. Antes de poner en marcha el chancador y sus equipos auxiliares, asegúreseque todos los bloqueos de seguridad han sido probados y están funcionandocorrectamente.


5.4PÁGINA 2 DE 3


Cuando el chancador es puesto en marcha por primeravez, no deberá contener mineral. La finalidad delperíodo de rodaje es permitir al chancador asentarse yverificar el correcto funcionamiento de los descansos yde los engranajes.

3. Colgar dos neumáticos de gran tamaño con cables de acero, dentro de lacámara del chancador. Instalarlos a una distancia de 180 grados.

El movimiento normal del eje principal es giratorio (elextremo inferior del eje se mueve en círculo mientras elextremo superior está fijo). En algunos casos, el ejeprincipal tiende a patinar por efecto de la viscosidad delaceite entre el eje y la excéntrica. Esto no esbeneficioso en la etapa de asentamiento. La finalidad deinsertar los dos neumáticos dentro del chancador esproducir suficiente fricción para evitar que el eje patine.Ellos cambiarán su posición a medida que el chancadoresté funcionando.

4. Poner en marcha en chancador desde el panel de control local o desde elsistema de control de distribución (SCD)

5. Con el chancador en operación, verificar que no haya filtraciones en la bocade entrada del aceite ni en los circuitos de retorno.

6. Verificar que no haya filtraciones a través del sello del contraeje. Unafiltración en este lugar indica excesivo flujo de aceite hacia el descanso delcontraeje. De confirmarse la existencia de una filtración, se deberá cerrarparcialmente la válvula en este circuito para reducir el flujo, pero observe elindicador de flujo para asegurarse que éste no haya sido interrumpidocompletamente. Se requiere aproximadamente 11 Lpm (3gpm).

7. Chequear la temperatura del descanso del contraeje. Esta será consideradanormal cuando permita poner la mano sin protección en el alojamiento delcontraeje. El nivel de temperatura se podrá confirmar a través del SCD ytambién mediante un detector de temperatura portátil. Si la temperatura esalta, significa que el flujo de aceite hacia los descansos es insuficiente o que eljuego en los descansos es muy en menor que el requerido. Remítase a laSección 7.9, Reemplazo de Componentes y Procedimientos de ReparacionesSeleccionados: Reemplazo de Componentes del Juego del Contraeje.


5.4PÁGINA 3 DE 3


8. Verificar que el sistema de refrigeración del aceite esté funcionandoadecuadamente. Confirmar que los indicadores de presión y temperatura en launidad de bombeo están estables y funcionando correctamente.

9. Confirmar que el sistema de lubricación del buje de la araña esté funcionandocorrectamente.

10. Probar los sistemas de ajuste y soporte hidráulico.

11. Registrar cada 15 minutos, los requerimientos de fuerza del motor y latemperatura del flujo de aceite hacia el chancador y de retorno hacia el tanquede acumulación sobre el soporte. Continuar registrando estas lecturas hastaque la temperatura del aceite sea estable por una hora.

12. Observar el inducido del motor de accionamiento y las temperaturas de losdescansos con el dispositivo de monitoreo del motor o a través SCD.

13. Una vez cumplido el período de ocho horas de asentamiento, detener elchancador y el sistema de lubricación.

14. Retirar el cedazo de retorno del aceite lubricante del tanque de acumulación.Inspeccionar su contenido y registrar las observaciones, y limpiar el cedazocon solvente. Instalar el cedazo, cuidando que quede bien firme.

Es normal encontrar cierta cantidad de material extrañoen la rejilla del cedazo debido al proceso deasentamiento y a partículas sueltas no eliminadas por elflushing.

15. Retirar los neumáticos de la cámara del chancador.

16. Verificar que los pernos del cuerpo, los de la araña y los de la fundación esténapretados.

17. Cerciorarse que los pernos de la fundación del sistema motriz del chancadorestén apretados.

18. Preparar el chancador para la puesta en marcha inicial con alimentación.


5.5PÁGINA 1 DE 3


5.5 PUESTA EN MARCHA INICIAL CON ALIMENTACIONEQUIPO ESPECIAL REQUERIDONingunoINTRODUCCIONEl propósito de la puesta en marcha inicial con alimentación es hacer funcionar elchancador durante una hora con carga por alimentación del 50 por ciento de lacapacidad del chancador, inspeccionar el chancador, y gradualmente aumentar elrango de alimentación hasta completar 48 horas de funcionamiento.El chancador se hace funcionar durante 1 hora al 50 por ciento de carga poralimentación. (Es importante verificar que el material esté seco y que no contengafinos o terrones de mayor tamaño que el equivalente a los dos tercios de la aberturapara alimentación). Al completarse la hora de funcionamiento, la alimentación essuspendida, el chancador es vaciado y puesto fuera de servicio. El chancador deberáser inspeccionado y, si el resultado de la inspección es satisfactorio, se debe echar aandar a un rango de alimentación del 50 por ciento de su capacidad. El chancador sehará funcionar durante 8 horas a un rango de alimentación del 50 por ciento. Si surendimiento está dentro de las especificaciones de operación y diseño, se deberá hacerfuncionar durante 40 horas incrementando gradualmente el rango de alimentaciónhasta llegar a la plena capacidad de diseño.PROCEDIMIENTO

1. Efectuar la inspección preoperacional. (Remitirse a la Sección 6.2,Procedimientos para la Puesta en Marcha: Inspección Preoperacional).

2. Alertar a otros operadores sobre la inminente puesta en marcha. 3. Cuando el circuito de aceite lubricante, el ajuste hidráulico y los sistemas de

lubricación de la araña hayan sido puestos en operación, se deberá chequearsu funcionamiento.3.1. Confirmar que el aceite lubricante esté a la temperatura de operación.

Se ha puesto a funcionar una bomba y el aceite está circulando a travésdel chancador. El flujo de aceite ha sido verificado observando unflujo de aceite adecuado en dirección el tanque de acumulación sobresoporte tipo patín.

3.2. Cerciorarse que esté fluyendo el volumen correcto de aceite hacia laexcéntrica y el contraeje.

3.3. Cerciorarse que el sistema de lubricación de la araña esté operando. 4. Confirmar que el motor principal esté listo para operar.


5.5PÁGINA 2 DE 3


4.1. Verificar que la extensión del contraeje sea segura y que sus cubiertasde acoplamiento estén en su lugar.

4.2. Verificar que los seguros de los sistemas de bloqueo del motor hansido cambiados al centro de control del motor (CCM)

5. El chancador es puesto en marcha y un 50 por ciento del rango dealimentación es establecido.5.1. Verificar que no haya filtración de aceite en la boca de entrada ni en

los circuitos de retorno.5.2. Verificar que no haya filtración de aceite a través del sello del

contraeje. De confirmarse la existencia de una filtración, se deberácerrar parcialmente la válvula en este circuito para reducir el flujo,pero observando el indicador de flujo para asegurarse que éste no hayasido interrumpido completamente. Se requiere aproximadamente 11Lpm (3gpm).

5.3. Cerciorarse que el sistema de refrigeración del aceite esté operandoadecuadamente. Confirmar que los indicadores de presión ytemperatura en la unidad de bombeo están estables.

5.4. Chequear la temperatura del descanso del contraeje.5.5. Cerciorarse que el sistema de lubricación del buje de la araña esté

funcionando correctamente.5.6. Cerciorarse que el sistema de ajuste hidráulico esté operado

correctamente.5.7. Observar el inducido del motor de accionamiento y las temperaturas de

los descansos con el dispositivo de monitoreo del motor y a través delsistema de control de distribución (SCD).

6. Cumplidas ocho horas de operación con carga parcial exitosa, se debesuspender la alimentación y el chancador deberá ser vaciado y puesto fuera deservicio. Los sistemas auxiliares permanecerán en operación si estánfuncionando correctamente.

7. Verificar que los pernos del cuerpo, los de la araña y los de la fundación esténapretados. Apretar las tuercas y los pernos sueltos si fuera el caso.

8. Chequear los pernos de la fundación del motor para cerciorarse que esténapretados. Apretar las tuercas y los pernos sueltos si fuera el caso.

9. Una vez completados los chequeos, inspecciones y ajustes, el chancador espuesto en marcha, alimentado a un rango de 50 por ciento. Durante lassiguientes 40 horas, el rango de alimentación deberá ser aumentadogradualmente hasta llegar al 100 por ciento de la capacidad de diseño.


5.5PÁGINA 3 DE 3


10. Fijar la válvula de alivio del sistema de ajuste mientras el chancador estáoperando bajo plena carga de trituración normal. Ajustar la válvula de aliviohasta que la carga normal provoque su apertura y permitiendo que el ejeprincipal se desplace hacia abajo; a continuación, ajústela a un valorligeramente mayor de modo que quede los peacks normales de carga quedencompensados. Algunos ajustes pueden ser necesarios para obtener un ajustesatisfactorio.

El propósito de la válvula de alivio es proteger alchancador contra objetos imposibles de triturar. Si unobjeto queda aprisionado en el chancador, la válvula seabre y el eje principal desciende.

11. Durante las siguientes 40 horas se repetirá todos los chequeos e inspeccionesefectuados durante las ocho horas iniciales de prueba.

12. Registrar todas las observaciones y mediciones.


6.1PAGE 1 OF 1


6.0 OPERATIONS6.1 OPERATIONAL PHILOSOPHY

Section 6.1 contains information pertaining to the operational philosophy for the pri-mary crusher. This section has been divided into the following subsections:

6.1.1 Local Operation

6.1.2 Remote Operation

6.1.3 Maintenance Operation


6.1.1PAGE 1 OF 1


6.1.1 LOCAL OPERATION

Normally the primary crusher is started, stopped, and operated from the control con-sole located in the control room. It is also possible to start and stop the primarycrusher from the field control panels. Field stations typically have Start and Stoppushbuttons.

The primary crusher lubrication system, spider lubrication system, and hydraulic ad-justment system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes.

Although the operation of the primary crusher is accomplished almost entirely fromthe control console, the field operator can assist the control room operator with fieldobservations of ore product size as well as a variety of observations of the mechanicaloperation of the equipment.


6.1.2PAGE 1 OF 1


6.1.2 REMOTE OPERATION

The primary crusher is operated from the control console located in the control roomor field control stations if so equipped. The control console is used for starting andstopping equipment as well as for monitoring the process.


6.1.3PAGE 1 OF 1

CE60.DOC CRUSHER 1 OCT 2000REV 0

6.1.3 MAINTENANCE OPERATION

There are no special procedures involved in operating the crusher during maintenanceperiods. All controls and interlocks must be satisfied before operating the crusher.During start-and-stop procedures, the crusher motor must not be overheated by re-peated starts. A limited number of starts per hour are allowed.


6.2PAGE 1 OF 2


6.2 START-UP PROCEDURESSection 6.2 contains procedures for preoperational inspections and for starting theprimary crusher equipment from different states of readiness. These procedures havebeen divided into the following subsections:

6.2.1 Preoperational Inspection6.2.2 Start-Up From Complete Shutdown6.2.3 Start-Up From Standby Shutdown6.2.4 Start-Up From Emergency Shutdown6.2.5 Start-Up From Power Failure

A preoperational inspection of all major and auxiliary equipment is required when-ever any portion of the primary crusher is started up from a complete shutdown.The primary crusher and primary crusher discharge conveyor require the followingutilities in order to start up and be operated:• Electrical power.• Water.• Plant air.In addition to the start-up procedures specified on the following pages, portions of theprimary crusher may be started after one or more equipment items have been downfor maintenance. In this case, perform the appropriate preoperational inspection foreach equipment item worked on.When the preoperational inspection is complete, the primary crusher equipment canbe restarted according to the appropriate start-up procedure, depending on the natureof the maintenance that was performed. Any personnel working in the area near theprimary crusher equipment being started must be warned of the impending start-up.The primary crusher equipment must not be started until the downstream circuits areprepared to accept feed. Primary crusher service and utility equipment must be run-ning before starting the process equipment.The general starting sequence is:• Primary crusher lubrication systems.• Primary crusher hydraulic system.• Primary crusher spider lubrication system.• Downstream equipment.• Primary crusher drive motor.


6.2PAGE 2 OF 2


Start-up from a standby shutdown involves essentially the same steps as from a com-plete shutdown, except that services and ancillary equipment may already be running.

Whenever equipment is to be started, the operator must ensure that the equipment isready and no personnel working in the area are too close to the equipment. Motorcontrol is normally performed by the operator from the central control room.

With the exception of the compressed air system and the spider lubrication system, allstart-up functions are controlled from the control console in the primary crusher con-trol room. The compressed air system and the spider lubrication system are startedfrom local control panels.

Ensure that an observer who is in communication with the control room is postedwhere he or she can see each major piece of equipment being started.


6.2.1PAGE 1 OF 5


6.2.1 PREOPERATIONAL INSPECTION


INTRODUCTIONOperators must inspect the primary crushing area visually before start-up from acomplete shutdown. This inspection determines whether activities, such as mainte-nance tasks, must be performed before the start-up begins. Included in the inspectionare checks for:

• Incomplete or omitted repairs.

• Tools, slings, and ladders that have not been cleared away after maintenance.

• Locks left on equipment, and stop buttons that have not been reset.

• General safety hazards, such as obstructions in walkways or stairways, slipperyfloors, or tripping hazards.

PROCEDURE 1. If the primary crusher was down for maintenance or any other activities that

required the primary crusher discharge pocket to be completely emptied, fineore material must be transported to the primary crusher and dumped into theprimary crusher.

This material helps prevent damage to the dischargeconveyor by forming a bed on the conveyor.

2. Throughout the primary crushing area, check aisles and walkways aroundequipment for debris, maintenance materials, and other tripping or slippinghazards. Clean up as required.

3. Ensure that all electrical disconnects for the primary crusher and all ancillaryequipment are closed (switched on). All lockout devices should be removedexcept for equipment undergoing maintenance.

4. Visually inspect the primary crusher dump pocket for foreign debris.

5. Visually inspect the primary crusher chamber.

5.1. Ensure there are no loose or missing liners.

5.2. Check the spider assembly for worn, damaged, or missing wear plates.


6.2.1PAGE 2 OF 5


5.3. Examine the bottom of the lower lip of the mantle for formation of alip. Examine the corresponding concaves for a pocket.

A lip or pocket may form after processing a large ton-nage of material. This lip can lead to excessive powerrequirements and may cause the hydraulic system reliefvalve to actuate. Maintenance should be notified totrim the lip at the next shutdown. If a pocket is present,replacement of the concaves may be necessary.

6. Ensure that the primary crusher compressed air system is running. Start ifnecessary.

7. Visually inspect the primary crusher.

7.1. Check the primary crusher motor and drive shaft assembly for signs ofvisible damage.

7.2. Ensure that all safety guards are in place and securely fastened. En-sure that all safety and warning signs are clearly visible.

7.3. Check for loose or missing mounting bolts and fixing screws.

7.4. Check primary crusher motor shaft seals for signs of lubricant leaks.

7.5. Check the primary crusher motor cooling fan and motor for signs ofvisible damage. Check for loose or missing mounting bolts and fixingscrews, and check for signs of lubricant leaks.

7.6. Check for loose or missing primary crusher shell bolts.

Loose shell bolts will be more apparent when the pri-mary crusher is in operation, but look for signs of nutmovement evidenced by fretting under the nuts and/orwashers.

8. Ensure that compressed air is available at the primary crusher dust seal, andensure that the air supply isolation valves are open.

9. Visually inspect the spider lubrication system.

9.1. Check the spider lubrication system components for signs of visibledamage.

9.2. Check the grease pump and grease line for signs of leaks and otherdamage.

9.3. Check the grease level in the drum by tapping on the side of the drum.


6.2.1PAGE 3 OF 5


DO NOT open the drum to check the grease level.Opening the drum may allow contaminants to enter thegrease.

9.4. Ensure there is power available at the spider lubrication system localcontrol panel, and turn on the spider lubrication system.

9.5. Ensure there is compressed air available to the spider lubrication sys-tem.

10. Visually inspect the primary crusher lubrication system.Components of the lubrication system could start with-out warning from a remote command. DO NOT reachbehind or remove safety guards during the preopera-tional inspection.

10.1. Ensure that the power is on at the lubrication unit.

10.2. Check the lubrication oil level.

10.3. Energize the lubrication oil heaters. Feel the oil reservoir to ensurethat the oil heaters are functioning (the oil reservoir surface should bewarm).

The lubrication oil temperature must be within thethermostat-controlled temperature range of 36° to 38°C(97º to 100ºF) before the lubrication pump is started.The oil heaters can raise the oil temperature approxi-mately 6°C (43ºF) per hour. Therefore, if the lubrica-tion system was deenergized, ensure the lubricationunit is energized several hours prior to a planned pri-mary crusher start-up.


10.5. Check pumps, fans, motors, and all other system components for looseor missing mounting bolts and fixing screws, and check for any visibledamage.

10.6. Check the oil reservoir, oil coolers, all supply and return piping, andall valves for signs of oil leaks.

10.7. Select which lubrication pump will be used, and ensure that the inletand outlet isolation valves are open.


6.2.1PAGE 4 OF 5


10.8. Open the inlet and outlet valves for the backup pump. This allowsrapid changeover if necessary.

10.9. Ensure the inlet and outlet isolation valves on the selected duplex oilfilter are open.

10.10. Ensure the inlet and outlet valves for the standby duplex oil filter areclosed.

10.11. Ensure the vent and drain line valves for each duplex filter are closed.

10.12. Select the cooling circuit pump to be used, and ensure that the inletand outlet isolation valves are open.

10.13. Open the inlet and outlet valves for the standby cooling circuit pump.This allows rapid changeover if necessary.

10.14. Open the inlet and outlet valves for each oil cooler. Close the bypassvalve around the first cooler.

This arrangement aligns the oil coolers for series flow.

10.15. Inspect the oil cooler radiators and remove any debris that may haveaccumulated on the radiators.

10.16. Ensure the three lubrication oil supply valves to the primary crusherare open.

11. Visually inspect the primary crusher hydraulic adjustment system.Components of the hydraulic adjustment system couldstart without warning from a remote command. DO NOTreach behind or remove safety guards during the preop-erational inspection.

11.1. Ensure that power is available at the hydraulic adjustment system.

11.2. Check the hydraulic adjustment system oil level.

11.3. Energize the hydraulic oil heaters. Feel the oil reservoir to ensure thatthe oil heaters are functioning (tank surface should be warm).


11.5. Check oil pumps, motors, and all other system components for looseor missing mounting bolts and fixing screws, and check for any visibledamage.


6.2.1PAGE 5 OF 5


11.6. Check the oil reservoir, accumulator, raise and lower valves, and allsupply and return piping for signs of oil leaks.

11.7. Ensure that the selected hydraulic oil pump inlet and outlet isolationvalves are open.

11.8. Open the inlet and outlet valves for the standby hydraulic oil pump.This allows rapid changeover if necessary.

11.9. Ensure that the oil filter inlet and outlet isolation valves are open.


6.2.2PAGE 1 OF 1


6.2.2 START-UP FROM COMPLETE SHUTDOWN

A preoperational inspection of all major and auxiliary equipment is required when-ever any portion of the primary crusher is started up from a complete shutdown.

1. Action: Perform the preoperational inspection. (Refer to Sec-tion 6.2, Start-Up Procedures: Preoperational Inspec-tion.)

2. Action: Select a primary crusher lubrication pump and start thepump.

The primary crusher lubrication system should be oper-ated for about 10 minutes prior to starting the primarycrusher. Therefore, this task should be performed first.

3. Action: Ensure that the compressed air system is operating andair is available to the crusher bonnet seal.

4. Action: Start the primary crusher spider lubrication system.

5. Action: Prior to starting the primary crusher, ensure that themantle height is correct and within current operatinglimits.

The mantle height should be at least 50 mm (2 inches)above the fully down position. This allows room tomove the mantle both up and down.

6. Action: Initiate the start of the primary crusher discharge con-veyor.

7. Action: Initiate the start of primary crusher.

Observation: An alarm will sound, a beacon light will flash for 10seconds, and then the primary crusher will start.


6.2.3PAGE 1 OF 1


6.2.3 START-UP FROM STANDBY SHUTDOWN

The start-up actions required for a start-up from a standby shutdown are essentiallythe same as those required for a start-up from a complete shutdown. However, duringa start-up from a standby shutdown, the auxiliary crushing equipment (lubricationsystems and hydraulic system) is operating. The start-up assumes that the primarycrusher was shut down in a controlled manner.

1. Action: Ensure that the compressed air system is operating andair is available to the crusher bonnet seal.

2. Action: Ensure that the primary crusher spider lubrication sys-tem is operating.

3. Action: Prior to starting the primary crusher, ensure that themantle height is correct and within current operatinglimits.

The mantle height should be at least 50 mm (2 inches)above the fully down position. This allows room tomove the mantle both up and down.

4. Action: Initiate the start of the primary crusher discharge con-veyor.

5. Action: Determine the time elapsed since the last primarycrusher start.

Excessive restarts in a short period of time can damagethe crusher motor.

6. Action: If the elapsed time is sufficient, initiate the start of pri-mary crusher.

Observation: An alarm will sound, a beacon light will flash for 10seconds, and then the primary crusher will start.


6.2.4PAGE 1 OF 1


6.2.4 START-UP FROM EMERGENCY SHUTDOWNThe procedures for starting up from an emergency shutdown differ from those aftercontrolled shutdowns. In an emergency shutdown, the primary crusher shuts downunder load and retains all the ore that was inside when it shut down.The primary crusher lubrication systems and hydraulic system continue to run unlessall or part of the system was involved in the emergency.

1. Action: If actual personal injury caused the shutdown, reportthe incident to the supervisor. Proceed with the start-upwhen authorization is received from supervision.Ensure that all personnel are accounted for before re-starting any equipment.

2. Action: If an equipment fault caused the shutdown, visually in-spect the equipment that caused the shutdown and en-sure that the cause has been cleared.

3. Action: If a process upset condition caused the shutdown, pro-ceed with the start-up when the upset condition is cor-rected and when authorization is received from supervi-sion.

4. Action: Restart the hydraulic and lubrication systems if neces-sary.

5. Action: If ore remains in the crusher, it may be necessary toclear the crusher before starting the crusher (refer toSection 6.4, Operating Considerations: Clearing theCrusher, for additional information).

Lowering the mantle reduces the load on the motorduring the subsequent start-up. Failure to do so canresult in failure of the crusher motor.

6. Action: When authorized by the supervisor, proceed with thecrusher start-up following the procedures in Section6.2, Start-Up Procedures: Start-Up From StandbyShutdown.


6.2.5PAGE 1 OF 1


6.2.5 START-UP FROM POWER FAILURE

This procedure is based on the assumption that the primary crushing system was op-erating normally when the power failure occurred, and that the crusher dischargeconveyor was loaded. After the cause of the power failure has been determined andthe condition corrected, the start-up is essentially the same as that from a com-plete/standby shutdown.

1. Action: Ensure that the cause of the power failure has been cor-rected.

2. Action: Ensure that there is no resulting damage to equipment. 3. Action: Ensure that all motor disconnects have been reset. 4. Action: If the crusher was not loaded when the power failure

occurred, start the primary crushing system as if it werea standby shutdown (refer to Section 6.2, Start-Up Pro-cedures: Start-Up From Standby Shutdown).

Lowering the mantle reduces the load on the motorduring the subsequent start-up. Failure to do so canresult in failure of the crusher motor.

5. Action: If the crusher was loaded at the time the power failureoccurred, the crusher must be cleared to restart (refer toSection 6.4, Operating Considerations: Clearing theCrusher). Once the crusher has been cleared, start theprimary crushing system as if it was a complete shut-down (refer to Section 6.2, Start-Up Procedures: Start-Up From Complete Shutdown).


6.3PAGE 1 OF 1


6.3 SHUTDOWN PROCEDURES

There are two primary objectives of the shutdown procedure: to secure equipment sodamage is prevented and to make start-up efficient and timely. After a completeshutdown, equipment should be inspected thoroughly and a list of maintenance andrepair items prepared. After an emergency shutdown, a visual inspection of theequipment is required before start-up.

Section 6.3 contains procedures for shutting down the crushing equipment. Theseprocedures have been divided into the following subsections:

6.3.1 Complete Shutdown

6.3.2 Standby Shutdown

6.3.3 Emergency Shutdown

6.3.4 Power FailureWith the exception of the compressed air system, all shutdown functions are con-trolled from the control console in the crusher control room. The compressed airsystem must be shut down at the local control panel.


6.3.1PAGE 1 OF 1


6.3.1 COMPLETE SHUTDOWNA complete shutdown is generally defined as a shutdown that will last for more than24 hours or a shutdown of such a duration that the crusher lubrication oil and hydrau-lic systems are shut down.The crusher lubrication system and hydraulic system shutdowns are included at theend of this procedure. Always check with the supervisor to verify that a lubricationsystem equipment shutdown is necessary before shutting down the crusher lubricationcomponents and auxiliary systems.

1. Action: Notify the mine that the crusher is shutting down andno more ore may be dumped into the crusher.

2. Action: Allow the crusher to operate until all material in thedump pocket and crusher has been crushed and passedinto the crusher discharge pocket.

3. Action: If any rocks remain that are bridging the crusher open-ing, or that are plugging the crusher chamber, they mustbe broken with the rock breaker. If the blockage cannotbe broken up, it must be removed (refer to Section 6.4,Operating Considerations: Unblocking the Crusher).

4. Action: Shut down the primary crusher drive motor. 5. Action: If the shutdown will be for an extended period of time

(more than 2 hours), shut down the auxiliary equip-ment.Unless it is necessary to remove power from the lubri-cation system and the hydraulic adjustment system, en-sure that the system power supply remains energizedand that the electric reservoir heaters continue to oper-ate. This will ensure a timely start-up later on.5.1. Shut down the spider lubrication system.5.2. Shut down the hydraulic adjustment system hy-

draulic pump.5.3. Shut down the lubrication system oil pump.5.4. Shut down the lubrication oil cooler circulation

pump.5.5. Close the air supply isolation valves to the

crusher dust bonnet seal.


6.3.2PAGE 1 OF 1


6.3.2 STANDBY SHUTDOWN

A standby shutdown occurs when the crusher is expected to remain shut down for lessthan 2 hours. Generally, the lubrication systems and hydraulic system are not shutdown.

1. Action: Notify the mine that the crusher is shutting down andno more ore may be dumped into the crusher.

2. Action: Allow the crusher to operate until all material in thedump pocket and crusher has been crushed and passedinto the crusher surge pocket.

3. Action: If any rocks remain that are bridging the crusher open-ing, or that are plugging the crusher chamber, they mustbe broken with the rock breaker. If the blockage cannotbe broken up, it must be removed (refer to Section 6.4,Operating Considerations: Unblocking the Crusher).

4. Action: Shut down the primary crusher drive motor.

Do not shut down the crusher lubrication systems orhydraulic system unless instructed to do so by the su-pervisor.

5. Action: Stop the spider lubrication system.


6.3.3PAGE 1 OF 1


6.3.3 EMERGENCY SHUTDOWN

An emergency shutdown can be caused or initiated by a major equipment malfunc-tion, by a personnel safety situation, or by certain protective interlock conditions de-signed to prevent equipment damage. An emergency shutdown may be initiated bypersonnel to prevent, for example, damage to the crusher discharge conveyor.

If the crusher discharge conveyor shuts down due to an emergency condition, and itwill remain down for a prolonged period of time, the primary crusher should bemanually shut down. However, it should not be shut down before its present load hasbeen crushed. If the whole crushing system will be down for more than two hours,the auxiliary equipment should also be shut down.

The following procedure is based on the assumption that when the emergency oc-curred, the primary crushing system was operating normally. After the cause of theemergency shutdown has been determined and the condition corrected, the primarycrushing system may be started up according to Section 6.2, Start-Up Procedures:Start-Up From Emergency Shutdown.

1. Action: Notify the mine that no dumping is allowed.

2. Action: Set any dump pockets signals to No Dumping mode.

3. Action: Shut down any equipment as required to isolate theemergency.

4. Action: Determine the cause of the emergency shutdown andcorrect the condition. Determine whether any personnelhave been injured as a result of the emergency.Ensure that all personnel are accounted for before re-starting any equipment.

5. Action: Notify supervision of the emergency shutdown.

6. Action: If the primary crushing system will be down for morethan two hours, shut down the auxiliary equipment.


6.3.4PAGE 1 OF 1


6.3.4 POWER FAILURE

When a power failure occurs, the primary crusher may be loaded. In the event of apower failure, all process equipment stops without further action on the part of theoperator.

In the event of a power outage, all process equipment trips and/or shuts down.


6.4PAGE 1 OF 1


6.4 OPERATING CONSIDERATIONS

Operators must perform certain tasks related to crusher equipment and operations.The operator tasks for the primary crusher area are listed below.

6.4.1 Ore Receiving and Crushing Routine Inspection

6.4.2 Adjusting the Crusher Open-Side Setting

6.4.3 Clearing the Crusher

6.4.4 Clearing a Gyratory Crusher Jammed With Tramp Metal6.4.5 Unblocking the Crusher


6.4.1PAGE 1 OF 3


6.4.1 ORE RECEIVING AND CRUSHING ROUTINE INSPECTION


INTRODUCTIONIt is the responsibility of the operator to monitor the operation of the primary crushingsystem to ensure that the ore is crushed and stockpiled in a safe and efficient manner.The operator must correct any deficiencies noted or notify the supervisor if the repairsare beyond the scope of the operator.

The following procedures list the routine inspection requirements of the operatorwhile the unit is in operation. This inspection should be carried out several timesduring the course of each shift.

PROCEDURE 1. Ensure that all personnel working in and around the area are using their per-

sonal protective equipment and that they are obeying all safety rules andregulations.

2. Throughout the primary crushing area, check aisles and walkways aroundequipment for debris, maintenance materials, and other tripping or slippinghazards. Clean up as required.

3. When trucks are dumping, observe the loads being dumped to identify anyforeign material or tramp metal that could jam or damage the crusher.

4. Ensure that the primary crushing compressed air system is running. Listen tosystem operation for unusual sounds that may indicate mechanical problems.Check the air lines, air receiver, and air dryer for leaks and other damage.

5. Visually inspect the primary crusher.The primary crusher motor could start without warningfrom a remote command. DO NOT reach behind or re-move safety guards during the inspection.

5.1. When in operation, listen to the crusher motor operation for unusualsounds and vibrations that could indicate mechanical problems.

5.2. Check for signs of leaking crusher motor seals and leaking crushercountershaft seals.



6.4.1PAGE 2 OF 3


5.4. Check for loose or missing crusher shell bolts.

Loose shell bolts will be more apparent when thecrusher is in operation.

6. Visually inspect the spider lubrication system.

6.1. Check the spider lubrication system components for signs of visibledamage.

6.2. Check the grease pump and grease line for signs of leaks and otherdamage.

6.3. Ensure sufficient grease is remaining in the barrel. Prepare for achange out if necessary.

7. Visually inspect the primary crusher lubrication system.Components of the lubrication system could start with-out warning from a remote command. DO NOT reachbehind or remove safety guards during the inspection.


7.2. When in operation, listen to the system operation for unusual soundsand vibrations that could indicate mechanical problems.

7.3. Check the oil reservoir, oil coolers, all supply and return piping, andall valves for signs of oil leaks.

7.4. Check the lubrication oil level.

7.5. Examine the oil coolers. Remove any accumulated debris from the ra-diators.

7.6. Listen to the radiator fans for any abnormal noise.

8. Visually inspect the primary crusher hydraulic adjustment system.Components of the hydraulic adjustment system couldstart without warning from a remote command. DO NOTreach behind or remove safety guards during the in-spection.



6.4.1PAGE 3 OF 3


8.2. When in operation, listen to the system operation for unusual soundsand vibrations that could indicate mechanical problems.

8.3. Check the oil reservoir, accumulator, raise and lower valves, and allsupply and return piping for signs of oil leaks.

8.4. Check the hydraulic adjustment system oil level.

9. Visually inspect the crusher discharge product.

9.1. Evaluate the size of the material and determine whether an adjustmentof the mantle is necessary. If an adjustment is necessary refer to Sec-tion 6.4, Operating Considerations: Adjusting the Crusher Open-SideSetting, for additional information.


6.4.2PAGE 1 OF 4


6.4.2 ADJUSTING THE CRUSHER OPEN-SIDE SETTINGSPECIAL EQUIPMENT REQUIREDA lead or foil ball approximately 200 mm (7.9 inches) in diameterRuler or tape measureSafety harness and safety lineRopeINTRODUCTIONThe operator is responsible for setting and adjusting the primary crusher open-sidesetting (OSS) to maintain an opening that produces a crushed ore product in which 80percent is less than 152 mm (6 inches). The closed-side setting is measured; how-ever, the emphasis is placed on setting the open-side. This is because of the near-vertical orientation of the crushing chamber of a gyratory crusher. This orientationallows some ROM to pass through the open side of the crusher without beingcrushed. The open side, therefore, represents the approximate top size of the crusherproduct.The OSS should be checked weekly, whenever there is reason to suspect that the set-ting has changed, or after major crusher maintenance work that may have affected thesetting. The OSS is impossible to measure while the crusher is operating, but theclosed-side setting (CSS), or gap, is easily measured. The crusher throw is defined asthe offset distance of the eccentric journal of the crusher. Knowing the throw and theclosed-side crusher gap, the open-side setting can easily be calculated by the equa-tion:

CSS + THROW = OSSThe Escondida crusher values, with unworn mantles and concaves, for each variableare as follows:

Open-side setting 203 mm (8 inches)Closed-side setting 159 mm (6.3 inches)Throw 44 mm (1.7 inches)

The closed-side setting is measured by passing a soft malleable metal, such as a leador foil ball, through the crusher. The ball is only slightly larger than the crusher open-side setting, and it is attached to a rope or wire so that it may be easily retrieved afterit has passed through the crusher. The ball is slowly lowered through the crusher and,as the ball passes through the crusher, the crusher compresses it to a thickness equalto the CSS. After the ball is retrieved, the operator can measure the ball to determinethe closed-side setting, and then perform the above calculation to determine the OSS.


6.4.2PAGE 2 OF 4


The primary crusher is adjusted by raising or lowering the mantle with the hydraulicadjustment system. Lowering the mantle increases the OSS; raising the mantle de-creases the OSS. The crusher gap is checked and set while the crusher is operatingand the crusher chamber is empty.

With new crusher concaves and mantle, a 2.5-cm (1-inch) upward movement of the mantle gives an OSSreduction of approximately 6 mm (1/4 inch). After thecrushing surfaces have become worn, the height atwhich the desired gap is achieved increases. However,the ratio of shaft movement to setting reduction willremain fairly constant. This can be used to determineliner wear and when the liners need to be replaced.

PROCEDURE 1. Ensure that the crusher is running empty.

Ensure that the operator performing the CSS measure-ment is equipped with a safety harness and that theharness is securely attached to a fixed object. The CSSmeasurement requires the operator to stand at the edgeof the crusher dump pocket above the running crusher.

2. Tie a lead or foil ball to a rope and lower it through the running crusher.

3. Retrieve the ball and measure the smallest dimension. This dimension is theclosed-side setting (CSS).

4. Calculate the crusher open-side setting (OSS), and determine how much, ifany, the mantle height needs to be adjusted.

5. If the OSS is not within the target range setting, the mantle must be raised orlowered to attain the desired OSS. The mantle height may be adjusted usingthe local hydraulic adjustment system controls or using the controls in thecontrol room. The following steps describe how to adjust the crusher mantleheight.

The crusher mantle height is displayed in mm orinches.

5.1. Approximate how far the mantle must be raised or lowered to attainthe desired crusher setting, and use the calibration curve to determinethe percent mantle movement.


6.4.2PAGE 3 OF 4


A 2.5-cm (1-inch) increase in mantle height is ap-proximately equal to a reduction of the OSS of 6 mm(1/4 inch). Conversely, a 2.5-cm (1-inch) decrease inmantle height is approximately equal to an increase ofthe OSS of 6 mm (1/4 inch).

5.2. Note the present percent mantle height on the mantle height indicator.

5.3. If the mantle must be raised, start the hydraulic adjustment systemmotor. Allow the motor to run for a couple of minutes to ensure theadjustment system is filled with oil.

5.4. If the mantle needs to be raised, depress the Raise pushbutton. Watchthe mantle height on the mantle height indicator, and release the push-button when the mantle height has increased the desired amount.

5.5. If the mantle needs to be lowered, depress the Lower pushbutton.Watch the mantle height on the mantle height indicator, and release thepushbutton when the mantle height has decreased the desired amount.

If the mantle needs to be lowered, the motor does nothave to be started.

5.6. Measure the crusher CSS again, and calculate the OSS.

5.7. If the OSS is not within the target range setting, adjust the crushermantle height again.

5.8. If the OSS is within the target range setting, turn off the hydraulic ad-justment system motor.

During normal operations, it may not be practical topass an object into the crusher.

6. Examine the material discharging from the crusher on the discharge conveyor.

6.1. Note the top size of the material. If a significant percentage of thematerial is sized greater than the desired top size, then the crusher OSSneeds to be reduced.

Some material is always sized greater than the top size.This is due to the orientation of the material duringcrushing. Proper orientation of the large axis of somematerial allows the material to pass through the crusherwithout being crushed adequately.


6.4.2PAGE 4 OF 4


6.2. If very little of the material approaches the desired top size, the OSSneeds to be increased.

Excessive size reduction is often accompanied by anincrease in the crusher power requirements.


6.4.3PAGE 1 OF 2


6.4.3 CLEARING THE CRUSHER

SPECIAL EQUIPMENT REQUIREDBarricadesExcavatorSpecial abrasion-resistant rope and lifting slingsRigging gearBody harnessPry barsHooksPrimary crusher service cranePrimary crusher hydraulic rock breaker

INTRODUCTIONDuring the course of normal crushing operations, there may be occasion (such as atemporary power failure, or an interlock trip condition) when the crusher stops withore in the dump pocket and crushing chamber. When this occurs, the following pro-cedure should be followed to restart the crusher.

PROCEDURE 1. Depress the hydraulic adjustment system mantle Lower pushbutton until the

mantle has dropped approximately 20 to 25 mm (.79 to .98 inches), as shownon the mantle position indicator.

2. Energize the crusher motor.

3. As soon as the crusher motor starts, release the Lower pushbutton and allowthe crusher to clear itself.

4. Start the hydraulic adjustment system and allow it to run for about 20 seconds.

5. Depress the hydraulic adjustment system Raise pushbutton to bring the mantleback to its normal position.

All crusher mantle adjustments should only be madewith the crusher stopped or running empty.


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6. If the crusher cannot be cleared in this manner, lower the mantle a little moreand try again.

If successive attempts to lower the mantle and start thecrusher fail, the crusher may be overloaded or theremay be an uncrushable object such as a shovel tooth ordrill bit which is larger than the open-side settingwedged in the crusher. It may be necessary to clear allmaterial from the crushing chamber to determine whythe crusher cannot be started. Refer to Section 6.4, Op-erating Considerations: Clearing a Gyratory CrusherJammed With Tramp Metal, for additional information.

7. The crusher may be cleared by using an excavator to reach down into thecrushing chamber to clear the material. Attempts to start the crusher may bemade as more and more material is cleared.

Ensure that sufficient time is allowed between attemptsto avoid overheating and damaging the crusher motor.

8. As the excavator is clearing the crushing chamber, a single large rock that ispreventing the crusher from starting may be uncovered, or a piece of trampmetal wedged between the mantle and the concaves may ultimately be uncov-ered.

8.1. If a large rock is uncovered, an attempt should first be made to breakthe rock with the rock breaker. If this is unsuccessful, the rock mustbe removed from the crushing chamber with the service crane (refer toSection 6.4, Operating Considerations: Unblocking the Crusher).

8.2. If the crusher has been jammed with tramp metal, it will be necessaryto remove the object with a thermal torch or an oxy-acetylene torch(refer to Section 6.4, Operating Considerations: Clearing a GyratoryCrusher Jammed With Tramp Metal).


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6.4.4 CLEARING A GYRATORY CRUSHER JAMMED WITHTRAMP METAL

SPECIAL EQUIPMENT REQUIREDLockout locksApproved respiratorWork glovesSafety harnessWork cageHeat-resistant protective clothingFace shieldShaded welding gogglesThermal cutting torchOxy-acetylene cutting torch with extensionsOxygenAcetyleneRubber safety bootsFlashlight or suitable light source

INTRODUCTIONClearing tramp metal from a gyratory crusher is a major problem that usually requiresmany hours of downtime to resolve. Accordingly, every effort must be made to pre-vent uncrushable objects from entering the crusher. The normal remedy is to clearsuch jams with a thermal cutting torch or an oxygen-acetylene cutting torch.

Each circumstance must be evaluated by the supervisor to determine the best and saf-est course of action. Using a thermal cutting torch is considered a safe method to re-move tramp iron. Oxygen-acetylene cutting torches with extra-long gas-mixingchambers (also called butts) are also used to cut metals. Cutting and burning metals,such as tramp iron, is generally slower with oxygen-acetylene torches.

The thermal cutting torch is a self-contained tool consisting of a combination of spe-cial metal alloy wires inside a long steel pipe. Sections are available in standardlengths (usually about 10 feet long), and two or more lengths may be coupled to-gether to reach into the crusher cavity. The torch generates heat to temperatures ex-ceeding 2,475°C (4,487ºF) when the alloys combine with pressurized oxygen forcedthrough the pipe. The intense, concentrated heat generated by the torch melts thetramp iron with such speed that there is usually no structural damage to the sur-rounding materials. The procedure is specific for a thermal cutting torch. The tech-niques described are applicable to an oxy-acetylene cutting torch.


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PROCEDURE 1. Clear the crusher of ore. Refer to Section 6.4, Operating Considerations:

Clearing the Crusher, for additional information.

2. Notify the supervisor that tramp metal has jammed the crusher. Clearing ajammed primary crusher is a major undertaking that requires special actionunder the direction of qualified personnel.

3. Erect barricades to block access to the dump pocket area.

4. Post signs on the barricades that say, “No Dumping—Workers in Crusher”.

5. Lock out the primary crusher and the rock breaker according to lockout pro-cedure.

Always work from the top of the crusher and never en-ter the crushing cavity. Preferably, the cutting torchoperator should work from a suspended cage.

6. The torch operator should either stand in a cage, lowered into a position aboveand to the side of the tramp iron, or stand on a temporarily constructed steelplatform erected for clearing the crusher. A thermal cutting torch pipe can beeasily lengthened and bent to reach the tramp iron without placing a person inthe crusher.

Do not attempt to dislodge or loosen the tramp materialwith a sledge hammer, pry bar, or long pipe. Seriouspersonal injury could result.Anyone working near the top of the crusher must wearan approved safety harness with a line securely fas-tened to a fixed object.The tramp metal may be under stress. Relieving thestress by heating may cause the tramp metal to beforcibly ejected. Place the work platform in a protectedposition.

7. Connect the cutting torch to an oxygen supply, and set the oxygen pressure topermit a small amount of oxygen to flow through the cutting torch.

8. Ignite the cutting torch while carefully following the manufacturer’s operatinginstructions.


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When working with torch cutting equipment, use heat-resistant protective clothing and gloves, shaded weld-ing goggles, hardhat, and face shield.

9. Open the oxygen-regulating valve completely. The cutting torch should nowburn vigorously.

When doing any torch cutting around a crusher, wear arespirator. The noxious fumes produced during the cut-ting process can be harmful if breathed continuously inconcentrated form. Avoid inhaling fumes. Provide ade-quate ventilation.Do not permit anyone to watch (i.e., to be in a line ofsight of) the operation. It is possible for material re-leased from the crusher to fly out with great force andvelocity.

10. After the tramp iron has been located, lower the cutting torch into the crushingcavity and proceed to “wash” the tramp metal away. Start at the top of thetramp iron and wash the molten metal downward. It is very important that themolten metal run out freely and not form a puddle on the tramp iron. Slightlyrotate the cutting portion of the torch to accelerate the washing operation andto keep the tramp iron from rewelding to itself.

Do not touch the tramp iron or put any pressure on itwith the torch. Always maintain a short gap when cut-ting metals. Always keep the torch moving in order toprevent it from being fused to the metal being burned.

11. During the cutting operation, protect the discharge feeder from sparks, moltenslag, and metal by maintaining ore in the crusher surge hopper or otherwiseblocking material from reaching the discharge belt feeder. It is possible formolten slag to drop out of the crusher onto the belt feeder.

12. When using a thermal cutting torch, work quickly because the burning time ofa 10-foot-long thermal cutting torch is only 3 to 5 minutes. Never start with atorch less than 10 feet long because the torch is consumed during burning.

The pipe portion of a thermal cutting torch is similar toa conventional welding electrode in that the entirelength of pipe is self-consuming (it “disappears” duringuse).


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Do not use a thermal cutting torch when the pipe lengthis shorter than 1.5 m (5 feet). Either thread or push onan additional 3-m (10-foot) length. The cutting torchesare designed for quick attachment of additional lengths.

12.1. Save the thermal torch remains and remove them from the crusher.

13. When the tramp metal is removed, inspect the crusher and discharge conveyorfor damage.

14. Remove the lockouts and barricades and restart the crusher.


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6.4.5 UNBLOCKING THE CRUSHER

SPECIAL EQUIPMENT REQUIREDSpecial abrasion-resistant rope and strapsRigging gearTemporary lightingLadderBarsHooksPrimary crusher craneRock breaker

INTRODUCTIONThe crusher operator is responsible for removing pieces of ore blocking the normalflow of ore into the crusher cavity. For tramp iron jammed in the crusher, refer toSection 6.4, Operating Considerations: Clearing a Gyratory Crusher Jammed WithTramp Metal. If the operator must descend into the dump pocket at any time, thefollowing procedure is to be used.

PROCEDUREResort to physical removal of oversized rocks onlywhen the rock breaker or backhoe cannot break or ma-nipulate the rock so it falls into the crusher, or when therock breaker is out of service.

1. When ore is obstructing the crusher, turn the dump light to the No Dumpingposition in order to indicate no more dumping is allowed.

2. If the obstruction is hanging up with space between the piece and the crusheror ore below it, use the rock breaker to dislodge or break the piece withoutstopping the crusher.

Keep the crusher running so that—when the ore is dis-lodged and falls into the crusher cavity—the ore iscrushed, and normal crushing can continue.

3. Gather the necessary tools, and ask for help from a second operator.


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4. If the obstruction is an oversized piece of ore, allow the crusher to operate un-til all the ore other than the oversize has been crushed.4.1. Erect barricades to block access to the dump pocket area, and close the

access doors.4.2. Post signs on the barricades that say, “No Dumping—Workers in

Crusher”.4.3. Use the rock breaker to rake down the dump pocket.4.4. Shut down the crusher.4.5. Lock out the crusher according to the lockout procedure.

5. The operator descends into the dump pocket by ladder to secure a hoisting lineon the rock.

Be particularly careful; do not dislodge other rocks thatmight fall and injure the person working in the dumppocket.

5.1. Securely tie off two ropes to the top of the ladder.5.2. Lower the ladder down to where the operator will be able to access the

rock.5.3. Securely tie off the two ropes holding the ladder to a fixed point on the

surface.5.4. The operator must be on a rope belay when descending into the dump

pocket. The belay line must be a nonslip knot where it is tied to theoperator. The other end of the belay must be securely tied off to afixed point on the surface.

5.5. The second operator must man the belay, and only let out enough linefor the operator descending the ladder to move freely. Excess slackline must be avoided. Use a friction wrap around the belaying opera-tor’s waist.

The operator descending the ladder and the operatormanning the belay must always have direct line of sightwith each other.The man in the dump pocket must be on belay at alltimes.The operator descending the ladder must not attempt tocarry anything. All tools are lowered from the surfaceonce the operator is in position in the dump pocket.


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6. Once the operator has reached the bottom of the ladder and has accessed therock, the tools required for removing the rock can be lowered into the dumppocket.

7. Once a sling or ropes have been attached to the rock, the operator in the dumppocket leaves before the rock is removed.

8. Using the crane, remove the rock, and place it in an area of the dump pocketwhere it can be broken using the rock breaker. The rock can also be placed onthe surface, where a loader can remove it to another location in order to bebroken.

9. When the task is complete, remove the lockouts, remove the barriers, and re-start the crushing operations. Notify affected personnel.


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6.0 OPERATCIONES6.1 FILOSOFIA OPERACIONAL

La sección 6.1 contiene información correspondiente a la filosofía operacional para elchancador primario. Esta sección ha sido dividida en las siguientes subsecciones:

6.1.1 Operación Local

6.1.2 Operación Remota

6.1.3 Operación de Mantenimiento


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6.1.1 OPERACION LOCAL

Normalmente, el chancador primario se hace funcionar, se detiene y se opera desde laconsola ubicada en la sala de control. También es posible poner en operación ydetener el chancador primario desde los paneles de control en terreno. Las estacionesde terreno normalmente tienen botones de contacto Start y Stop.El los sistemas de lubricación del chancador y de la araña, y el sistema de ajustehidráulico también pueden ser echados a andar desde la consola de control en la salade control. Estas unidades también tienen paneles de control locales utilizadosnormalmente para fines de mantenimiento.

A pesar de que la operación del chancador primario se efectúa casi completamentedesde la consola de control, el operador de terreno puede asistir al operador de la salade control con observaciones en terreno acerca del tamaño del mineral como tambiéncon una variedad de observaciones acerca de la operación mecánica del equipo.


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6.1.2 OPERACION REMOTA

El chancador primario es operado desde la consola de control ubicada en la sala decontrol o desde las estaciones de control en terreno, si están debidamente equipadas.La consola de control es usada para poner en operación y detener el equipo, comotambién para monitorear el proceso.


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6.1.3 OPERACION DE MANTENIMIENTO

No hay procedimientos especiales involucrados en la operación del chancador durantelos períodos de mantenimiento. Todos los controles y sistemas de bloqueo debenoperar satisfactoriamente antes de operar el chancador. Durante los procedimientos departida y parada, el motor del chancador no debe ser sobrecalentado debido partidasrepetidas. Se permite solamente un número limitado de partidas por hora.


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6.2 PROCEDIMIENTO DE PUESTA EN MARCHALa Sección 6.2 contiene procedimientos para inspecciones preoperacionales y paraponer en operación el chancador primario a partir de diferentes estados de lecturas.Estos procedimientos han sido divididos en las siguientes subsecciones:

6.2.1 Inspección Preoperacional6.2.2 Puesta en Marcha a Partir de una Parada de Planta

Completa6.2.3 Puesta en Marcha a Partir de Parada de Planta Standby6.2.4 Puesta en Marcha a Partir de una Parada de Planta de

Emergencia6.2.5 Puesta en Marcha a Partir de Falla Eléctrica

Una inspección preoperacional de todos los equipos mayores y auxiliares es necesariacada vez que cualquier parte del chancador primario es echada a andar a partir de unaparada de planta completa.El chancador primario y la cinta transportadora en la descarga del chancadorrequieren los siguientes suministros para su puesta en marcha y ser operados:• Energía eléctrica.• Agua.• Aire comprimido.Adicionalmente a los procedimientos de puesta en marcha especificados en lassiguientes páginas, diferentes partes del chancador primario pueden ser echadas aandar después que uno o más equipos han sido puestos fuera de servicio paramantenimiento. En este caso, se deberá efectuar la inspección preoperacionalcorrespondiente por cada equipo sometido a mantenimiento.Cuando la inspección preoperacional está completa, el equipo del chancador primariopuede ser puesto en operación según el procedimiento correcto de puesta en marcha,dependiendo de la naturaleza del mantenimiento que se le efectuó. Cualquier personaque esté trabajando en el área próxima al equipo del chancador primario a ser puestoen operación, debe ser advertida acerca de la inminente puesta en marcha.El equipo del chancador primario no debe ser puesto en operación hasta que loscircuitos siguientes (aguas abajo) estén listos para recibir carga. Los serviciosaccesorios del chancador primario deben estar funcionando como también aseguradoel adecuado suministro eléctrico, de agua, y de aire comprimido antes de poner enoperación los equipos de proceso.


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La secuencia general de partida es:• Sistemas de lubricación del chancador primario.• Sistema hidráulico del chancador primario.• Sistema de lubricación de la araña del chancador primario.• Equipo aguas abajo.• Motor de accionamiento del chancador primario.

La puesta en marcha a partir de una parada de planta standby contemplaesencialmente los mismos pasos que a partir de una parada de planta completa,excepto que los servicios y los equipos auxiliares están ya funcionando.

Cada vez que un equipo debe ser puesto en operación, el operador debe asegurarseque el equipo esté listo y que no haya personal trabajando en el área más próxima alequipo. El control del motor es normalmente efectuado por el operador desde la salade control central.

Con la excepción del sistema de aire comprimido y el sistema de lubricación de laaraña, todas las funciones de puesta en marcha son controladas desde la consola decontrol en la sala de control del chancador primario. El sistema de aire comprimido yel de lubricación de la araña son puestos en operación desde los paneles de controllocales.

Asegurarse que un observador, en comunicación con la sala de control, esté ubicadoen un lugar que le permita ver cada pieza mayor del equipo que está siendo puesto enoperación.


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6.2.1 INSPECCION PREOPERACIONAL


INTRODUCTIONLos operadores deben inspeccionar visualmente el área del chancador primario antesde ponerlo en marcha a partir de una parada de planta completa. Esta inspeccióndetermina si actividades tales como tareas de mantenimiento, deben ser efectuadasantes de la puesta en marcha. Esta inspección deberá incluir los siguientes chequeos:

• Reparaciones incompletas u omitidas.

• Herramientas, eslingas y escalas que no hayan sido retiradas después deefectuados los trabajos de mantenimiento.

• Seguros que hayan permanecido en los equipos, y botones de parada que no hayansido reseteados.

• Riesgos de accidente generales, tales como obstrucciones en pasarelas o escaleras,pisos resbalosos o riesgos de tropezar.

PROCEDIMIENTO 1. Si el chancador primario fue detenido para efectuar trabajos de mantenimiento

o cualesquiera otras actividades que demandara la necesidad de vaciarcompletamente la cavidad de descarga del chancador primario, se deberácargar con mineral fino.

Este material ayuda a prevenir daño en la cintatransportadora en la descarga mediante la formación deun lecho en la cinta transportadora.

2. Revisar toda el área alrededor del chancador, como pasillos y pasarelasalrededor de los equipos para verificar que no haya escombros, materiales demantenimiento y otros con los que se pudiera tropezar o resbalar. Limpiar elárea completamente.

3. Cerciorarse que todos los equipos eléctricos del chancador esténdesconectados y que todos los equipos auxiliares estén energizados (switchedon). Todos los dispositivos de bloqueo deberán ser retirados, excepto losequipos que serán sometidos a mantenimiento.


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4. Inspeccionar visualmente el compartimento de descarga del chancador paraverificar que no haya material de desecho en él.

5. Inspeccionar visualmente la cámara del chancador.

5.1. Verificar que no haya piezas de revestimiento sueltas o que falten.

5.2. Chequear el conjunto de la araña para verificar desgaste, daño o quefalten placas de desgaste.

5.3. Examinar el fondo del borde inferior del manto para verificar que sehaya formado un reborde. Examinar las correspondientes cóncavaspara verificar que no se haya formado un bolsillo.

Un reborde o bolsillo se pueden formar después delprocesamiento de una gran cantidad de material. Estereborde puede conducir a un excesivo requerimiento deenergía y puede causar la activación de la válvula dealivio del sistema hidráulico. El departamento demantenimiento debería ser notificado al respecto paraque este reborde sea recortado en la próxima parada deplanta. Si se ha formado un bolsillo, se deberíanreemplazar las cóncavas.

6. Asegurarse que el sistema de aire comprimido del chancador primario estéfuncionando. Echarlo a andar de ser necesario.

7. Inspeccionar visualmente el chancador primario.

7.1. Inspeccionar visualmente el motor del chancador primario y elconjunto del eje motor para verificar signos de daño visible

7.2. Cerciorarse que las protecciones de seguridad estén en su lugar y bienseguras. Cerciorarse que todas las señales de advertencia y seguridadsean claramente visibles.

7.3. Chequear que estén instalados todos los pernos de montaje y lostornillos de fijación.

7.4. Chequear los sellos del eje motor del chancador primario para verificarque no presentan filtraciones.

7.5. Chequear el ventilador del motor del chancador y el motor en busca designos de daño visible. Chequear que estén instalados todos los pernos


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de montaje y los tornillos de fijación, y que no haya filtrciones delubricante.

7.6. Verificar que no haya pernos sueltos o no falten en el cuerpo delchancador.

La existencia de pernos sueltos en el cuerpo será másevidente mientras el chancador esté funcionando, sinembargo, esto también se puede verificar mediante laobservación de roeduras debajo de las tuercas y/ogolillas.

8. Verificar que el aire comprimido esté funcionando en la zona del sello depolvo, y que las válvulas de suministro de aire comprimido estén abiertas.

9. Inspeccionar visualmente el sistema de lubricación de la araña.

9.1. Chequear los componentes del sistema de lubricación de la araña paraverificar la presencia de signos visibles de daño.

9.2. Chequear la bomba de grasa y el circuito de grasa para verificarfiltraciones y otros daños.

9.3. Chequear el nivel de grasa en el tambor mediante golpes ligeros en elcostado del tambor.

NO abrir el tambor para chequear el nivel de grasa yaque esto podría permitir la entrada de contaminantes ala grasa.

9.4. Verificar que haya energía suficiente en el panel de control local delsistema de lubricación de la araña, y poner en operación el sistema delubricación de la araña.

9.5. Verificar que haya aire comprimido para el sistema de lubricación dela araña.

10. Inspeccionar visualmente el sistema de lubricación del chancador primario.Los componentes del sistema de lubricación puedenser echados a andar sin advertencia, desde el comandoremoto. NO tocar detrás de las protecciones deseguridad ni retirarlas durante la inspecciónpreoperacional.

10.1. Verificar que la unidad de lubricación esté energizado.

10.2. Chequear el nivel del aceite de lubricación.


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10.3. Conectar los calefactores del aceite de lubricación. Verificar, medianteel tacto, que los calefactores están funcionando (la superficie deltanque de aceite debiera estar tibia).

La temperatura del aceite de lubricación debe estardentro del rango de temperatura controlada portermostato de 36° a 38°C (97° a 100°F) antes de poneren operación la bomba de lubricación. Los calefactoresde aceite pueden elevar la temperatura del aceite en 6°C(43°F) por hora. Por lo tanto, si el sistema delubricación fue desconectado, asegúrese que la unidadde lubricación sea conectada varias horas antes deponer en operación el chancador.

10.4. Verificar que todas las protecciones de seguridad estén instaladas ybien seguras. Verificar que todas las señales de seguridad yadvertencia sean claramente visibles.

10.5. Chequear las bombas, ventiladores y todo otro componente del sistemapara verificar que no haya pernos de montaje ni tornillos de fijaciónsueltos o que falten, ni que haya daño visible.

10.6. Chequear el tanque de acumulación de aceite, los enfriadores de aceite,todas las cañerías de suministro y de retorno, y todas las válvulas paraverificar que no haya filtraciones.

10.7. Seleccionar la bomba de lubricación que será utilizada, y verificar queestén abiertas las válvulas de aislamiento de entrada y salida.

10.8. Abrir las válvulas de entrada y salida de la bomba de respaldo. Estopermitirá un rápido cambio de bombas de ser necesario.

10.9. Verificar que estén abiertas las válvulas de aislamiento de entrada ysalida en el filtro doble de aceite seleccionado

10.10. Verificar que estén cerradas las válvulas de entrada y salida del filtrodoble de aceite de reserva.

10.11. Verificar que estén cerradas las válvulas de los circuitos de venteo ydrenaje en cada filtro doble.

10.12. Seleccionar la bomba de circuito refrigerante a ser usada, y confirmarque esté abiertas las válvulas de aislamiento de entrada y salida.


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10.13. Abrir las válvulas de entrada y salida de la bomba del circuitorefrigerante de reserva. Esto permitirá un rápido cambio de sernecesario.

10.14. Abrir las válvulas de entrada y salida de cada enfriador de aceite.Cerrar la válvula de desvío próxima al primer enfriador.

Esta maniobra alinea los enfriadores de aceite paraflujos en serie.

10.15. Inspeccionar los radiadores enfriadores de aceite y eliminar cualquiermaterial de desecho que pudiera haberse acumulado en ellos.

10.16. Verificar que estén abiertas las tres válvulas de suministro de aceitepara el chancador primario.

11. Inspeccionar visualmente el sistema de ajuste hidráulico del chancadorprimario.

Los componentes del sistema de ajuste hidráulicopueden ser echados a andar sin advertencia, desde elcomando remoto. NO tocar detrás de las proteccionesde seguridad ni retirarlas durante la inspecciónpreoperacional.

11.1. Verificar que el sistema de ajuste hidráulico esté conectado a la fuentede poder.

11.2. Chequear el nivel de aceite del sistema de ajuste hidráulico.

11.3. Conectar los calefactores del aceite hidráulico. Verificar, mediante eltacto, que los calefactores estén funcionando (la superficie del tanquedeberá estar tibia).

11.4. Verificar que todas las protecciones de seguridad estén instaladas ybien seguras. Verificar que todas las señales de seguridad yadvertencia sean claramente visibles

11.5. Chequear las bombas, ventiladores y todo otro componente del sistemapara verificar que no haya pernos de montaje ni tornillos de fijaciónsueltos o que falten, ni daño visible.

11.6. Verificar que no haya filtraciones en el tanque de aceite, en elacumulador, en las válvulas de elevación y de descenso, en todas lascañerías de suministro y retorno.


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11.7. Verificar que estén abiertas las válvulas de aislamiento de entrada ysalida de la bomba de aceite hidráulica seleccionada.

11.8. Abrir las válvulas de entrada y salida de la bomba de aceite hidráulicode reserva. De esta manera será más fácil el cambio, de ser necesario.

11.9. Verificar que estén abiertas las válvulas de aislamiento de entrada ysalida del filtro de aceite.


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6.2.2 PUESTA EN MARCHA A PARTIR DE UNA PARADA DEPLANTA COMPLETA

Cada vez que una parte del chancador primario es puesta en marcha a partir de unaparada de planta completa, se deberá efectuar una inspección preoperacional de todoslos equipos mayores y auxiliares.

1. Acción: Efectuar la inspección preoperacional. (Remitirse a laSección 6.2, Procedimientos de Puesta en Marcha:Inspección Preoperacional.)

2. Acción: Seleccionar una bomba de lubricación del chancadorprimario y echarla a andar.

El sistema de lubricación del chancador primariodebería ser operado por más o menos 10 minutos antesde poner en marcha el chancador. Por lo tanto, estatarea debería hacerse primero.

3. Acción: Verifique que el sistema de aire comprimido estéoperando y que haya aire disponible para el sello delcasquete del chancador.

4. Acción: Poner en operación el sistema de lubricación de laaraña.

5. Acción: Previo a la puesta en marcha del chancador primario,verificar que la altura del manto sea la correcta y que seencuentre dentro de los límites normales de operación.

El manto debería estar al menos 50 mm (2 pulgadas)como máximo, por sobre su cota mínima. Esto permiteespacio para desplazar el manto tanto hacia arriba comohacia abajo.

6. Acción: Poner en operación la cinta transportadora en ladescarga del chancador primario.

7. Acción: Poner en servicio el chancador primario.

Observación: Una alarma sonará, una luz de faro destellará por 10segundos, y entonces partirá el chancador primario.


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6.2.3 PUESTA EN MARCHA A PARTIR DE UNA PARADA DEPLANTA STANDBY

Las acciones requeridas para una puesta en marcha a partir de una parada de plantastandby son esencialmente las mismas requeridas para una parada de planta completa.Sin embargo, durante una puesta en marcha a partir de una parada de planta standby,los equipos auxiliares (sistemas de lubricación e hidráulico), deben continuar enoperación. Para este tipo de puesta en servicio se da por sentado que el chancadorprimario fue puesto fuera de servicio mediante un proceso controlado.

1. Acción: Verifique que el sistema de aire comprimido estéoperando y que haya aire disponible para el sello delcasquete del chancador.

2. Acción: Verifique que el sistema de lubricación de la araña delchancador primario esté operando.

3. Acción: Previo a la puesta en marcha del chancador primario,verificar que la altura del manto sea la correcta y quese encuentre dentro de los límites normales deoperación.

El manto debería estar al menos 50 mm (2 pulgadas)como máximo, por sobre su cota mínima. Esto permiteespacio para desplazar el manto tanto hacia arriba comohacia abajo.

4. Acción: Inicie la partida de la cinta transportadora en ladescarga del chancador primario.

5. Acción: Determine el tiempo transcurrido desde la última vezque el chancador primario fue puesto en operación.

Partidas repetidas en un período de tiempo cortopodrían dañar el motor del chancador.

6. Acción: Si el tiempo transcurrido es suficiente, iniciar la partidadel chancador primario.

Observación: Una alarma sonará y una luz de faro destellará por 10segundos, y entonces el chancador primario partirá.


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6.2.4 PUESTA EN MARCHA A PARTIR DE UNA PARADA DEPLANTA DE EMERGENCIA

Los procedimientos para una puesta en marcha a partir de una parada de planta deemergencia son diferentes de aquellos aplicados a paradas de planta controladas. Enuna parada de planta de emergencia el chancador es paralizado bajo carga y elmineral no es desalojado de su interior.Los sistemas de lubricación e hidráulico continúan funcionando, a menos que ellos oparte de ellos hayan originado la emergencia.

1. Acción: Si la puesta fuera de servicio fue causada por unaccidente del trabajo, esta situación deberá serinformada al supervisor, y el equipo se pondránuevamente en operación una vez que el supervisorhaya dado la autorización pertinente.Antes de reiniciar el equipo, verificar que todo elpersonal esté en conocimiento, antes de reiniciarcualquier equipo.

2. Acción: Si la interrupción de la operación fue causada por unafalla de un equipo, inspeccionar visualmente dichoequipo y cerciorarse que la falla haya sido corregida.

3. Acción: Si la interrupción de la operación fue causada portrastornos del proceso, proceder con la puesta enmarcha cuando dicho trastorno haya sido solucionado ycuando se haya recibido la autorización del supervisor

4. Acción: Reiniciar los sistemas de lubricación e hidráulico sifuere necesario.

5. Acción: Si el mineral ha permanecido dentro del chancador,deberá ser vaciado antes de ponerlo nuevamente enoperación (remitirse a la Sección 6.4, Consideracionesde Operación: Vaciado del Chancador, para mayorinformación).

Al bajar el manto se reduce la carga sobre el motordurante las siguientes puestas en marcha del chancador.Cualquier negligencia en tener en cuenta estaprecaución puede causar daño en el motor delchancador.


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6. Acción: Una vez que el supervisor haya dado la autorización, sedeberá proceder con la puesta en marcha del chancador,siguiendo los procedimientos especificados en laSección 6.2, Procedimientos de Puesta en Marcha:Puesta en Marcha a partir e Una Parada de PlantaStandby.


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6.2.5 PUESTA EN MARCHA A PARTIR DE UNA FALLA DEENERGIA

Este procedimiento está basado en la suposición de que el chancador estaba operandonormalmente al producirse la falla de energía, y que la cinta transportadora en ladescarga estaba cargada con mineral. Una vez confirmada la falla de energía y que elproblema haya sido solucionado, para poner el chancador nuevamente en operaciónse deberá seguir el mismo procedimiento que a partir de una parada de plantacompleta y una standby.

1. Acción: Verifique que la falla de energía haya sido superada. 2. Acción: Verifique que la falla de energía no produjo daño en los

equipos. 3. Acción: Verifique que hayan sido reconectadas todas las partes

del motor que habían sido desconectadas. 4. Acción: Si el chancador no estaba cargado al momento de

producirse la falla de energía, el sistema deberá serpuesto en operación siguiendo el mismo procedimientoque en el caso de una parada de planta standby(remitirse a la Sección 6.2, Procedimientos de Puestaen Marcha: Puesta en Marcha a partir de una Paradade Planta Standby).

Al bajar el manto se reduce la carga sobre el motordurante las siguientes puestas en marcha del chancador.Cualquier negligencia en tener en cuenta estaprecaución puede causar daño en el motor delchancador

5. Acción: Si el chancador estaba cargado al momento deproducirse la falla de energía, deberá ser vaciado paraponerlo nuevamente en operación (remitirse a laSección 6.4, Consideraciones de Operación: Vaciadodel Chancador). Una vez que el chancador ha sidovaciado, estará en condiciones de ser puesto enoperación siguiendo el mismo procedimiento que elutilizado a partir de una parada de planta completa.(remitirse a la Sección 6.2, Procedimientos de Puestaen Marcha: Puesta en Marcha a partir de una Paradade Planta Completa).


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6.3 PROCEDIMIENTOS DE PARADA DE PLANTA

El procedimiento de parada de planta tiene dos objetivos principales: prevenir que elequipo sufra daño derivado de esta faena y asegurar una puesta en marcha eficiente ycontrolada. Después de una parada de planta completa el equipo deberá serinspeccionado acuciosamente y se confeccionará una lista con el detalle de losequipos sometidos a mantenimiento y reparaciones. Después de una parada de plantade emergencia, se deberá efectuar una inspección visual de los equipos antes deponerlos nuevamente en operación.

La Sección 6.3 contiene procedimientos para poner fuera de operación los equipos dechancado. Estos procedimientos han sido divididos en las siguientes subsecciones:

6.3.1 Parada de Planta Completa

6.3.2 Parada de Planta Standby

6.3.3 Parada de Planta de Emergencia

6.3.4 Falla de EnergíaCon la excepción del sistema de aire comprimido, todas las funciones del chancadorante una puesta fuera de operación, son controladas desde la consola en la sala decontrol. El sistema de aire comprimido deberá ser puesto fuera de operación desde elpanel de control local.


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6.3.1 PARADA DE PLANTA COMPLETAUna parada de planta completa, generalmente es considerada como una parada deplanta que deberá extenderse por más de 24 horas o cuya duración hará necesaria lapuesta fuera de servicio de los sistemas hidráulico y de lubricación.Los procedimientos de puesta fuera de operación de los sistemas de lubricación ehidráulico se incluyen al final de este capítulo. Cada vez que sea necesario ponerfuera de servicio los componentes del sistema de lubricación del chancador y sussistemas auxiliares, se deberá confirmar con el supervisor si será necesario ponerfuera de servicio todo el equipo del sistema de lubricación.

1. Acción: Notificar a la administración de la mina que elchancador será puesto fuera de servicio, por lo tanto sedeberá suspender el suministro de mineral.

2. Acción: El chancador deberá seguir funcionando hasta que elmineral en el depósito de carga y trituración haya sidotriturado y enviado a la sección de descarga.

3. Acción: Si algunas rocas de mineral impidieran la abertura delchancador o bloquearan la cámara de trituración,deberán ser quebradas con el dispositivo para dichoefecto. Si no fuera posible despejar el bloqueo de esamanera, deberá ser eliminado. (Remitirse a la Sección6.4, Consideraciones de Operación: Desbloqueo delChancador).

4. Acción: Poner fuera de servicio el motor de accionamiento delchancador primario.

5. Acción: En la eventualidad que la parada deba prolongarse pormás de dos horas, se deberá poner fuera de servicio losequipos auxiliares.A menos que sea necesario suspender el suministro deenergía para el sistema de lubricación y para el sistemade ajuste hidráulico, deberá asegurarse que el sistemade suministro de energía permanecerá conectado y quelos calefactores del tanque acumulador continuaránoperando. Esto garantizará una oportuna puesta enmarcha más tarde.5.1. Poner fuera de servicio el sistema de lubricación

de la araña.

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5.2. Poner fuera de servicio la bomba del sistema deajuste hidráulico.

5.3. Poner fuera de servicio la bomba de aceite delsistema de lubricación

5.4. Poner fuera de servicio la bomba impulsora delsistema de refrigeración del aceite delubricación.

5.5. Cerrar las válvulas de paso de aire hacia elcasquete contra polvo del chancador.


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6.3.2 PARADA DE PLANTA STANDBY

Se denomina parada de planta standby, a la puesta fuera de servicio de la planta porun período menor a dos horas. Generalmente los sistemas de lubricación e hidráulicocontinúan operativos.

1. Acción: Notificar al gerente de operaciones de la mina que elchancador será puesto fuera de servicio, por lo tanto sedeberá suspender el suministro de mineral.

2. Acción: El chancador deberá seguir funcionando hasta que elmineral en el depósito de carga y trituración haya sidotriturado y enviado a la cámara de equilibrio.

3. Acción: Si algunas rocas de mineral impidieran la abertura delchancador o estuvieran bloqueando la cámara detrituración, deberán ser rotos con el equipo para romperrocas. Si no fuera posible despejar el bloqueo de esamanera, deberá ser eliminado. (Remitirse a la Sección6.4, Consideraciones de Operación: Desbloqueo delChancador.

4. Acción: Poner fuera de servicio el motor de accionamiento delchancador primario.

Los sistemas de lubricación del chancador ni elhidráulico, no deberán ser puestos fuera de servicio amenos que así haya sido instruido por el supervisor.

5. Acción: Poner fuera de servicio el sistema de lubricación de laaraña.


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6.3.3 PARADA DE PLANTA DE EMERGENCIA

Una parada de planta de emergencia puede ser causada o iniciada por la operacióndefectuosa de un equipo mayor, por una situación de seguridad de algún trabajador, opor alguna anormalidad de algún sistema e bloqueo destinado a la prevención dedaño de algún equipo. Una parada de planta de emergencia puede ser ocasionada poralgún trabajador, por ejemplo, para prevenir daño en la cinta transportadora en ladescarga del chancador.Si la cinta transportadora en la descarga del chancador es puesta fuera de serviciodebido a una situación de emergencia, y deba permanecer en esta condición por unperíodo prolongado de tiempo, el chancador primario deberá ser puesto fuera deservicio manualmente. Sin embargo, se deberá tener presente ejecutar esta acción sólouna vez que la carga en sus depósitos haya sido triturada. Si todo el sistema detrituración deberá ser puesto fuera de servicio por más de dos horas, el equipo auxiliartambién deberá ser puesto fuera de servicio.

El siguiente procedimiento está basado en la suposición de que el chancador estabaoperando normalmente al producirse la emergencia. Una vez determinada la causaque originó la parada de planta de emergencia y dicha causa ha sido corregida elchancador primario podrá ser puesto nuevamente en operación de acuerdo a losprocedimientos establecidos en la Sección 6.2, Procedimientos de Puesta en Marcha:Puesta en Marcha a partir de una Parada de Planta de Emergencia.

1. Acción Notificar a la administración de la mina que estásuspendida la vaciadura de mineral.

2. Acción: Conectar todas las señales de la tolva de descarga enmodo No alimentar.

3. Acción: Poner fuera de servicio todo equipo que sea necesariopara aislar el sector donde se ha detectado laemergencia.

4. Acción: Determinar la causa que originó la parada de planta deemergencia y corregir dicha condición. Comprobar sidicha emergencia fue originada por un accidente detrabajo.Antes de reiniciar cualquier equipo, cerciórese que todoel personal esté debidamente informado de ello.

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5. Acción: Notificar al supervisor de la parada de planta deemergencia.

6. Acción: Si el sistema de chancado primario permanecerá fuera deservicio por más de dos horas, se deberá poner fuera deservicio los equipos auxiliares.


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6.3.4 FALLA DE ENERGIA

Al producirse una falla de energía, el chancador primario podría estar cargado. En elcaso de un corte de corriente todo el equipo de proceso se detiene sin la participacióndel operador y queda fuera de servicio.


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6.4 CONSIDERACIONES DE OPERACION

Los operadores deben efectuar ciertas tareas relacionadas con el equipo y operacionesdel chancador. Las tareas de los operadores relacionadas con el chancador primariode detallan a continuación:

6.4.1 Inspección de Rutina de Recepción y Trituración delMineral.

6.4.2 Fijación de la Abertura del Chancador. (OSS)

6.4.3 Desbloqueo del Chancador

6.4.4 Desbloqueo de un Chancador Giratorio Atorado conFragmento de Metal.

6.4.5 Desbloqueo del Chancador


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6.4.1 INSPECCION DE RUTINA DE RECEPCION Y TRITURACIONDEL MINERAL


INTRODUCCIONEl operador es responsable de monitorear la operación del sistema de trituraciónprimario para asegurarse que el mineral es triturado y amontonado de manera seguray eficiente. El operador debe corregir toda deficiencia observada o notificar alsupervisor si las reparaciones están más allá de su alcance.

Los siguientes procedimientos entregan una lista de las exigencias de una inspecciónde rutina del operador mientras la unidad está en operación. Esta inspección deberáser llevada a cabo varias veces durante el curso de un turno.

PROCEDIMIENTO 1. Cerciorarse que todo el personal trabajando en el área o alrededor de ella use

su equipo de protección y que respete todas las normas de seguridad y deprevención de riesgos.

2. En toda el área circundante al chancador, deberá chequear los pasillos ypasarelas para verificar que no haya material de desecho, materiales demantenimiento y que no exista riesgo de tropezar y resbalar debido a lapresencia de objetos o derrame de líquidos.

3. Cuando los camiones están descargando, deberá observar las cargas paraidentificar cualquier material extraño o fragmentos de metal que podríanatorar o dañar el chancador.

4. Deberá asegurarse que el sistema de aire comprimido del chancador estáfuncionando. Deberá escuchar con atención la operación del sistema paradescubrir probables ruidos inusuales como resultado de problemas mecánicos.Deberá chequear las líneas de aire comprimido, el estanque de airecomprimido y el secador de aire comprimido para verificar posibles fugas uotros daños.

5. Inspeccionar visualmente el chancador primario.El motor del chancador primario podrá ser puesto enoperación desde un comando remoto, sin advertencia.NO tocar detrás de las protecciones de seguridad niretirarlas durante la inspección.


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5.1. Mientras el chancador está en operación, deberá escuchar con atenciónla operación del motor, para descubrir posibles ruidos inusuales yvibraciones indicando problemas mecánicos.

5.2. Revisar los sellos del motor y del contraeje para verificar que nopresenten filtraciones.

5.3. Deberá asegurarse que todas las protecciones de seguridad estén en sulugar y bien fijas. Verificar que todas las señales de seguridad yadvertencia sean claramente visibles.

5.4. Deberá verificar que no haya pernos sueltos o que falten pernos en elcuerpo del chancador.

Cuando el chancador está en operación es más fácilnotar la existencia de pernos sueltos.

6. Inspeccionar visualmente el chancador primario.

6.1. Deberá verificar que los componentes del sistema de lubricación nopresenten signos de daño visible.

6.2. Deberá inspeccionar la bomba y circuito de grasa para verificar que nopresenten filtraciones ni daño de otro tipo.

6.3. Deberá asegurarse que haya suficiente cantidad de grasa en elcontenedor.

7. Inspeccionar visualmente el sistema de lubricación del chancador primario.Los componentes del sistema de lubricación podrán serpuestos en operación desde un comando remoto, sinadvertencia. No tocar detrás de las protecciones deseguridad ni retirarlas durante la inspección.

7.1. Deberá asegurarse que las protecciones de seguridad estén en su lugary bien fijas. Verificar que todas las señales de seguridad y advertenciasean claramente visibles.

7.2. Mientras el sistema está en operación, deberá escuchar atentamentepara descubrir posibles ruidos inusuales y vibraciones indicandoproblemas mecánicos.


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7.3. Deberá revisar el tanque de acumulación de aceite, enfriadores deaceite y las tuberías de suministro y retorno, y todas las válvulas paraconfirmar que no presentan filtraciones.

7.4. Revisar el nivel del aceite de lubricación.

7.5. Examinar los enfriadores de aceite. Eliminar los desechos acumuladosen los radiadores.

7.6. Escuchar atentamente los ventiladores del radiador mientrasfuncionan, para confirmar que no presentan ruidos anormales.

8. Inspeccionar visualmente el sistema de ajuste hidráulico del chancadorprimario.

Los componentes del sistema de ajuste hidráulicopodrán ser puestos en operación desde un comandoremoto, sin advertencia. NO tocar detrás de lasprotecciones de seguridad ni retirarlas durante lainspección.

8.1. Deberá asegurarse que las protecciones de seguridad estén en su lugary bien fijas. Verificar que todas las señales de seguridad y advertenciasean claramente visibles.

8.2. Mientras el sistema está en operación, deberá escuchar atentamentepara descubrir posibles ruidos inusuales y vibraciones indicandoproblemas mecánicos.

8.3. Deberá revisar el tanque de aceite, el acumulador, las válvulas deelevación y de descenso y todas las cañerías de alimentación y deretorno para verificar que no presentan filtraciones.

8.4. Revisar el nivel de aceite del sistema de ajuste hidráulico.

9. Inspeccionar visualmente el producto de descarga del chancador.

9.1. Deberá evaluar el tamaño del material y determinar si es necesario unajuste del manto. De ser así, remitirse a la Sección 6.4.Consideraciones de Operación:Fijación del Ajuste del CostadoAbierto del Chancador, para información adicional.


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6.4.2 AJUSTE DE LA ABERTURA DEL CHANCADOREQUIPO ESPECIAL REQUERIDOUna plomada o bola de material ligero de aproximadamente 200 mm (7.9 pulgadas)de diámetroUna regla o huincha de medirArneses de seguridad y cable de seguridadSogaINTRODUCCIONEl operador es responsable de fijar y ajustar la abertura (OSS) del chancador paramantener una abertura con la que el chancador producirá mineral triturado del cual el80 por ciento será de un tamaño menor que 152 mm (6 pulgadas). La cerradura esmedida; sin embargo, lo importante es fijar la abertura. Esto se debe a la orientacióncasi orientación de la cámara de molienda del chancador giratorio. Esta orientaciónpermite el paso de cierta cantidad de mineral ROM a través del lado abierto delchancador sin ser triturado. El lado abierto, por lo tanto, representa aproximadamenteel tamaño máximo del producto ya molido proveniente del chancador.Se verificará la OSS semanalmente, cada vez que se suponga que el ajuste puedehaber cambiado, o después de un trabajo de mantenimiento mayor que pudiera haberafectado el ajuste. Es imposible de medir la OSS durante las operación del chancadorestá funcionando, pero la cerradura (CSS), o separación, es fácil de medir. Laexcentricidad del chancador es definida como la distancia “offset” del muñónexcéntrico del chancador. Conociendo la excentricidad y la separación de lacerradura, la abertura puede ser calculada fácilmente mediante la ecuación

CSS + THROW = OSSLos valores del chancador de La Escondida con mantos aún sin desgaste y cóncavas,son los siguientes para cada variable:

Abertura (Open-side setting) 203 mm (8 pulgadas)Cerradura (Closed-side setting) 159 mm (6.3 pulgadas)Excentricidad (Throw) 44 mm (1.7 pulgadas)

La cerradura se mide haciendo pasar una bola de metal fácilmente maleable, talcomo de láminas de plomo, a través del chancador. El tamaño de la bola será sóloligeramente mayor que la abertura del chancador, y es atada a un cordel o alambrepara que sea fácilmente recuperable después de haberla pasado a través delchancador. La bola es bajada lentamente a través del chancador y, a su paso a travésde éste, el chancador la comprime hasta llegar a un espesor igual a la CSS. Una vez


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recuperada la bola es medida por el operador a fin de determinar la CSS, yposteriormente usar la ecuación anterior para determinar la OSS.El chancador primario es ajustado elevando o bajando el manto mediante el sistemade ajuste hidráulico. Al bajar el manto se incrementa la OSS; al elevar el manto, laOSS disminuye. La separación del chancador es comprobada y ajustada con elchancador en operación y la cámara de trituración vacía.

Con las cóncavas y el manto nuevos y sin uso, undesplazamiento de 2.5 cm (1 pulgada) del manto haciaarriba da una reducción de la OSS deaproximadamente 6 mm (1/4 de pulgada). Cuandoposteriormente las superficies de molienda se handesgastado la altura necesaria para obtener laseparación deseada aumenta.Sin embargo la relación entre el desplazamiento del ejey la disminución del ajuste tenderá a ser constante. Estacircunstancia puede ser utilizada para determinar eldesgaste del revestimiento y el momento en que esterevestimiento necesita ser reemplazado.

PROCEDIMIENTO 1. Asegúrese que el chancador está funcionando sin carga, o sea, vacío.

Asegúrese que el operador responsable de efectuar lamedición de la CSS se haya colocado los arneses deseguridad y que estos arneses estén asegurados a unaestructura conveniente y segura. La medición de la CSSrequiere que el operador esté parado en el borde de latolva de recepción del mineral sobre el chancador enoperación.

2. Ate la bola de material maleable a la soga y desciéndala a través delchancador en operación.

3. Recupere la bola y determine su dimensión menor. Esta dimensión equivale ala cerradura (CSS).

4. Calcule la abertura (OSS) del chancador y determine en cuánto, de sernecesario, la altura del manto necesita ser ajustada.

5. Si el valor obtenido para la OSS no estuviera dentro el rango deseadi, elmanto deberá ser elevado o bajado hasta obtener la OSS requerida. La alturadel manto puede ser ajustada utilizando el control local del sistema de ajustehidráulico, o utilizando los controles ubicados en la sala de control. La forma


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de ajustar las altura del manto del chancador es descrita en los siguientespuntos.

La altura del manto es mostrada en mm o pulgadas.

5.1. Estime en cuánto se deberá subir o bajar el manto para lograr el ajustedeseadodel chancador, y utilice la curva de calibración para determinarel porcentaje del desplazamiento del manto.

Un aumento de la altura del manto en 2.5 cm (1pulgada) equivale aproximadamente a una reducción de6 mm (1/4 pulgada) de la OSS. Inversamente, unadisminución de la altura del manto en 2.5 cm (1pulgada), equivale aproximadamente igual a unaumento de 6 mm (1/4 de pulgada) de la OSS.

5.2. Tome nota del porcentaje de la altura del manto dad por el indicadorcorrespondiente.

5.3. Si el manto debe ser elevado, poner en servicio el motor del sistema deajuste hidráulico. Permita que el motor funcione por unos minutos paraasegurarse que todo el sistema está lleno con aceite.

5.4. Si el manto necesitare ser elevado, presione el botón Raise y observela altura del manto dada por el indicador de altura; suelte el botóncuando la altura del manto haya alcanzado la posición deseada.

5.5. Si el manto necesitare ser bajado, presione el botón Lower y observela altura del manto dada por el indicador de altura; suelte el botón decontacto cuando la altura del manto haya alcanzado la posicióndeseada.

Si el manto necesitare ser bajado, no será necesarioponer el motor en operación.

5.6. Mida nuevamente la CSS del chancador y calcule la OSS.

5.7. Si la OSS no estuviera dentro del rango deseado, ajustar nuevamentela altura del manto del chancador.

5.8. Una vez el valor de la OSS del rango establecido, poner fuera deservicio el motor del sistema de ajuste hidráulico del chancador.


6.4.2PAGINA 4 DE 4


Durante la normal operación del chancador, no esadecuado lanzar objetos no relacionados con la faenadentro del chancador.

6. Examine el mineral que es descargado desde en chancador al transportador enla descarga.

6.1. Fije en los trozos de mayor tamaño. Si un porcentaje significativo deeste mineral tiene un tamaño mayor que el máximo deseado, la OSSdel chancador deberá ser reducida.

En algunos minerales los trozos son siempre mayoresque el tamaño máximo deseado. Esto se debe a laorientación del mineral durante el chancado. Enalgunos minerales, cierta orientación del eje mayor delos trozos permite que el material pase a través delchancador sin haber sido adecuadamente triturado.

6.2. Si sólo una pequeña cantidad de mineral se aproxima al tamañomáximo deseado, la OSS deberá ser aumentada.

La reducción excesiva del tamaño deseado del mineraltriturado, generalmente tiene como consecuencia unmayor consumo de energía del chancador.


6.4.3PAGINA 1 DE 2


6.4.3 DESPEJE DEL CHANCADOR

EQUIPO ESPECIAL REQUERIDOBarrerasExcavadoraCable especial resistente a la abrasión y eslingas de elevaciónAparejosArnesesBarrotes (“chuzos”)GanchosGrúa de servicio del chancador primarioRompedor hidráulico de rocas del chancador primario

INTRODUCCIONDurante la operación normal de chancado, puede haber ocasiones, tales como unafalla temporal de energía o la activación de algún sistema de bloqueo en que elchancador se detiene estando llenas tanto la tolva de alimentación como la cámara demolienda. En estas situaciones, se seguirá el siguiente procedimiento para ponernuevamente el chancador en operación:

PROCEDIMIENTO 1. Presione el botón Lower (Bajar) del sistema de ajuste hidráulico del manto,

hasta que el manto ha descendido aproximadamente 20 a 25 mm (0.79 a 0.98pulgada), según lo muestre el indicador de posición del manto.

2. Arrancar el motor del chancador.

3. Tan pronto como el motor del chancador haya arrancado, soltar el botónLower (Bajar) para permitir el chancador se vacíe por sí mismo.

4. Poner en servicio el sistema de ajuste hidráulico y dejarlo funcionar poralrededor de 20 segundos.

5. Presionar el botón Raise (Elevar) del sistema hidráulico de ajuste para hacerque el manto vuelva a su posición normal

Todos los ajustes del manto del chancador solamentedeberán ser efectuados con el chancador fuera deservicio o funcionando sin carga.


6.4.3PAGINA 2 DE 2


6. Si no fuere posible despejar el chancador de este modo, baje manto un pocomás y haga un nuevo intento.

Si los intentos sucesivos de bajar el manto y ponernuevamente el chancador fallaran, ello podría deberse aque el chancador está sobrecargado o que cayo en suinterior hay algún objeto ajeno a la operación, como,por ejemplo un diente de la pala o alguna broca deperforación de mayor tamaño que la OSS.Lamentablemente podría ser necesario retirar todo elmineral de la cámara de molienda para determinar lasrazones por las que el chancador no puede ser puesto enservicio. Para mayor información, remítase a la Sección6.4, Consideraciones de Operación: Despeje de unChancador Giratorio Atorado por una Pieza de Metal.

7. El chancador podría ser despejado utilizando una excavadora para alcanzar elfondo de la cámara de chancado para retirar el mineral. A medida que elmaterial es retirado, se puede hacer nuevos intentos para poner en servicio elchancador.

Se recomienda dejar transcurrir suficiente tiempo entrelos intentos de poner en servicio el chancador, paraevitar el sobrecalentamiento del motor y los dañosconsecuentes.

8. A medida que la excavadora va despejando la cámara de molienda podríadetectarse que una sola roca de gran tamaño es lo que están impidiendo lapartida del chancador. También pudiera deberse a algún trozo de metal (fierro)encajado entre el manto y las cóncavas.

8.1. Si un trozo de mineral de gran tamaño es lo que origina el problema,podrá intentarse primeramente de romperlo con el rompedorhidráulico. Si esta operación no tuviera el éxito deseado, la roca deberáser retirada del chancador con la grúa de servicio (remitirse a laSección 6.4, Consideraciones de Operación: Desbloqueo delChancador).

8.2. Si el chancador estuviera atascado con un trozo de fierro, podría sernecesario el uso de un soplete oxiacetilénico para eliminar dichoelemento (remitirse a la Sección 6.4, Consideraciones de Operación:Despeje de un Chancador Giratorio Atascado por FramentosExtraños de Hierro).


6.4.4PAGINA 1 DE 4

CE644-S.DOC CRUSHER NOV 2001REV 0

6.4.4 DESPEJE DE UN CHANCADOR GIRATORIO ATORADOCON UNA PIEZA DE METAL

EQUIPO ESPECIAL REQUERIDOSeguros de bloqueoRespirador apropiadoGuantesArneses de SeguridadCapacho de TrabajoVestimenta de protección resistente al calorMáscara protectoraAntiparras para soldarSoplete cortadorSoplete oxiacetilénico con extensionesOxígenoAcetilenoZapatos de seguridad de gomaLuz de destellos o una fuente de luz apropiada

INTRODUCCIONRetirar un trozo de metal atrapado en un chancador giratorio es uno de los mayoresproblemas, ya que se requiere mucho tiempo para resolverlo. Por lo tanto, se deberáhacer todo lo posible por evitar la caída de objetos de metal dentro del chancador. Lomás común es despejar este tipo de atascamientos con un soplete térmico o con unsoplete oxiacetilénico.

Cada circunstancia deberá ser evaluada por el supervisor para determinar el mejor ymás seguro curso de acción. El uso de un soplete térmico es considerado como elmétodo más seguro para remover el metal atrapado. Los sopletes oxiacetilénicos concámaras para mezcla de gas extra largas (también llamadas butts) se utilizan tambiénpara cortar metales. La faena de corte y calcinación de metales, tales comofragmentos de hierro, generalmente es más lenta si se hace mediante sopletesoxiacetilénicos.

El soplete térmico es una herramienta autosuficiente, que consiste en la combinaciónde cables de aleación metálica especial dentro de un largo tubo de acero. Estaherramienta normalmente está disponible en largos estándares de alrededor de 10 piesde largo, por lo tanto, para llegar al fondo del chancador será necesario acoplar dos omás de estas piezas. El soplete general temperaturas que superan los 2.475°C(4,487ºF) cuando las aleaciones se mezclan con oxígeno presurizado introducidodentro del tubo. El intenso y concentrado calor generado por el soplete funde la pieza


6.4.4PAGINA 2 DE 4


de hierro con tal rapidez que, por lo general, que los materiales circundantes no llegana sufrir daño estructural. El procedimiento es específico para el soplete térmico. Lastécnicas que se menciona también son válidas en caso de utilizar soplete oxiacetilénico.

PROCEDIMIENTO 1. Retirar el mineral del chancador. Remitirse a la Sección 6.4, Consideraciones

de Operación: Despeje del Chancador, para mayor información.

2. Notificar al supervisor que el chancador se encuentra atascado por un trozo demetal. El despeje de un chancador primario atascado e un trabajo de granresponsabilidad, que requiere acción especial bajo la dirección de personalcalificado.

3. Levantar barricada para bloquear el acceso al área de la cavidad de descarga.

4. Fijar señales en las barricadas con la leyenda “Descarga Suspendida –Trabajadores dentro del Chancador”

5. Bloquear el chancador primario y el rompedor rocas, de acuerdo a losprocedimientos de bloqueo.

Se deberá trabajar siempre desde la parte superior delchancador, nadie deberá jamás entrar en la cavidad demolienda. De preferencia, el operador del sopletedeberá trabajar desde una jaula suspendida.

6. El operador del soplete deberá permanecer dentro de una jaula, la que serábajada lo más cerca posible sobre y de modo que pueda ver el objeto encuestión, o deberá permanecer sobre una plataforma temporal de acero,montada para despejar el chancador. Un tubo de soplete térmico puede serfácilmente introducido dentro del chancador y doblado para llegar al trozo demetal sin necesidad de introducir a una persona dentro del chancador.

No se debe tratar de desalojar o soltar el trozo de metalutilizando un combo, una alzaprima o un tubo largo. Estopodría causar un serio daño a la persona a cargo.Es imprescindible que toda persona encargada deefectuar una faena en la parte superior del chancador usearnés de seguridad, el que deberá estar firmementeamarrado a una estructura fija.El trozo de metal puede estar bajo presión. Al despejardicha presión mediante calor podría ocurrir que dichometal saltara bruscamente. Para evitar que la persona acargo de la faena resulte lesionado, la plataforma detrabajo deberá ser colocada de manera que esto noocurra.


6.4.4PAGINA 3 DE 4


7. Conectar el soplete a un tubo de oxígeno, y fijar la presión del oxígeno de talmodo de permitir la entrada de un pequeño flujo de oxígeno en el soplete.

8. Encender el soplete siguiendo cuidadosamente las recomendaciones deoperación del fabricante.

Mientras se trabaja con soplete para cortar, esindispensable el uso de vestimenta resistente al calor yguantes, antiparras, casco y máscara protectora.

9. Abrir completamente la válvula reguladora del oxígeno. El soplete cortadordeberá, ahora, arder intensamente.

Mientras se efectúa faenas de corte con soplete en lazona del chancador, se deberá usar un respirador. Losvahos nocivos generados por el proceso de corte consoplete podrían causar grave daño a quien los respire,máxime si esto ocurre durante tiempo prolongado.Evitar la inhalación de estos vahos al tiempo que serecomienda ventilación adecuada.No se deberá permitir la presencia de ningún“observador”, ya que podría darse el caso que, materialque estaba bajo presión, al ser liberado pudiera salirvolando con gran fuerza y a gran velocidad fuera delchancador

10. Una vez ubicado el trozo de fierro, tomar el soplete oxiacetilénico y calentarel metal hasta derretirlo. Se deberá comenzar en la parte superior de dichotrozo de fierro de modo que todo el metal derretido fluya hacia abajo. Es desuma importancia que el metal derretido pueda escurrir libremente sinacumularse sobre el trozo de fierro. Se manejará el soplete de modo que estaoperación pueda ser efectuar con rapidez para evitar que el trozo de fierrosolidifique nuevamente.

No toque la pieza de hierro ni aplique presión sobre ellacon el soplete. Mantenga siempre cierta distancia alcortar metales. Mantenga siempre el soplete enmovimiento para evitar que se fusione con la pieza queestá siendo trabajada.

11. Durante la operación de corte, se deberá evitar que el alimentador de descargasea alcanzado por chispas, escoria fundida o metal, manteniendo el mineral enla tolva de compensación o bloqueando el material para evitar que llegue a lacinta transportadora de descarga.


6.4.4PAGINA 4 DE 4


12. Al trabajar con un soplete oxiacetilénico se debe trabajar rápidamente ya queel tiempo de combustión de un soplete de 10 pies de largo es de sólo 3 a 5minutos. Nunca se debe trabajar con el soplete con menos de 10 pies de largo,ya que la combustión consume el tubo.

La porción de tubo de un soplete oxiacetilénico essimilar a un electrodo de soldadura convencional en elcual toda la longitud del tubo se autoconsume(“desaparece” mientras se está usando).No utilice un soplete oxiacetilénico con un tubo menorque 1,5 m (5 pies). Para lograr la longitud de 3 m (10pies) acóplelo a un tubo adicional, ya sea atornillándoloo simplemente introduciéndolo en el tubo adicional.Los tubos cortantes están diseñados para unacoplamiento fácil a tubos adicionales. .

12.1. Conserve el remanente de tubo retirándolo del chancador.

13. Una vez retirada la pieza de metal, inspeccionar el chancador y la correatransportadora de descarga para verificar que hayan resultado dañados.

14. Retire los seguros de bloqueo y las barricadas y ponga el chancador enservicio nuevamente.


6.4.5PAGINA 1 DE 3


6.4.5 DESBLOQUEO DEL CHANCADOR

EQUIPO ESPECIAL REQUERIDOAtuendo y sogas resistentes a la abrasión

Un Engranaje para aparejo

Iluminación temporal

Una Escala

BarrasGanchos

La Grúa del Chancador primario

Un Rompedor de Rocas

INTRODUCCIONEl operador del chancador es responsable de retirar las piezas de mineral quebloqueen el flujo normal del mineral dentro de la cavidad del chancador. Respecto.Respecto al procedimiento para retirar una pieza de metal atascada en el chancador,remitirse a la Sección 6.4, Consideraciones de Operación: Despeje de unaChancador Giratorio Atascado con una Pieza de Metal. Si el operador debeintroducirse dentro del depósito de vaciado en algún momento, se deberá seguir elsiguiente procedimiento:

PROCEDIMIENTOHacer intervenir un técnico en la remoción de rocas degran tamaño solamente en aquellos casos en que no esposible hacerlo con la trituradora de rocas o que laretroexcavadora no la puede romper o no puedemanipularla sin riesgo de caer dentro o cuando latrituradora de rocas está fuera de servicio.

1. Cuando el mineral está obstruyendo el chancador, se deberá cambiar el switchde la luz indicadora “Descargando” a la posición “Descarga suspendida”.

2. Si la obstrucción está suspendida y se puede apreciar un espacio libre entres lapieza que produce la obstrucción y el chancador o hay mineral debajo de ella,se deberá utilizar la trituradora de rocas para desalojar o romper la pieza sindetener el chancador.


6.4.5PAGINA 2 DE 3


Mantener el chancador funcionando a fin de quecuando el mineral sea desalojado y caiga dentro de lacavidad del chancador, sea triturado, y la actividadnormal del chancador pueda continuar.

3. Reúna las herramientas necesarias y pida ayuda a un segundo operador. 4. Si la obstrucción es producida por una pieza de mineral de gran tamaño,

mantener el chancador en operación hasta que todo el mineral excepto lapieza que excede el límite de tamaño ha sido chancado y por lo tanto, ha sidodescargado del chancador.4.1. Levantar barricadas o bloquear el acceso a la zona de alimentación del

chancador, y cierre los portones de acceso.4.2. Colocar señales sobre las barricadas, indicando “Carga suspendida –

Trabajadores dentro del Chancador”.4.3. Use el rompedor de rocas para vaciar la tolva de alimentación.4.4. Detener el chancador.4.5. Bloquear el sistema de puesta en servicio de acuerdo a los

procedimientos de establecidos. 5. El operador desciende dentro de la tolva utilizando una escala para fijar un

cordel para levantar el trozo de mineral atascado.Sea especialmente cuidadoso, no mueva otros trozosde mineral que pudieran caer y lesionar a la personatrabajando dentro de la tolva.

5.1. Amarre dos cuerdas al extremo superior de la escala.5.2. Baje la escala hasta que quede al alcance del operador que está

trabajando en el chancador.5.3. Ate firmemente los dos extremos de la cuerda que está sujetando la

escala a un elemento fijo y resiste5.4. El operador que desciende dentro de la tolva deberá estar acordonado.

La cuerda para tal efecto estará amarrada con un nudo firme aloperador. El otro extremo de la cuerda deberá ser atado firmemente aun elemento fijo y resistente.

5.5. El segundo operador debe controlar la cuerda y dar sólo la cuerdasuficiente para permitir que el operador que baja la escala pueda


6.4.5PAGINA 3 DE 3


moverse libremente. Se evitará que la cuerda esté excesivamente floja;el operador que da la cuerda enrollándola alrededor de su cinturadeberá usar una protección adecuada.

El operador que desciende dentro de la tolva y eloperador que controla la cuerda deberán esta siempreen contacto visual.El hombre dentro la tolva deberá estar siempreacordonadoEl operador descendiendo la escala nada debe acarrear.Todas las herramientas serán bajadas desde arriba unavez que él haya alcanzado su lugar de trabajo dentro delchancador.

6. Una vez que el operador haya alcanzado el extremo inferior de la escala y estéjunto a la roca, todas las herramientas necesarias para su trabajo lo seránbajadas desde arriba.

7. Una vez que la roca a sido adecuadamente estrobado el operador abandonaráel chancador antes del comienzo de los trabajos de remoción de la roca.

8. Retirar la roca mediante una grúa y depositarla en un lugar donde pueda serpartida con el equipo para tal efecto. La roca también puede ser depositada enla superficie o en lugar desde donde un cargador la tomará para transportarla aotro lugar para ser partida.

9. Una vez completada la tarea, retirar los bloqueos para la partida delchancador, retirar las barreras y dar comienzo a la operación de chancado.Informar de ello a todo el personal involucrado.


7.0PAGE 1 OF 1


7.0 MAINTENANCEThe purpose of this maintenance section is to provide the maintenance techniciansand planners with the information and procedures required to effectively maintain,troubleshoot, and repair the crusher and its auxiliary systems.

Specifications are provided to prepare for component repair and replacement, as wellas maintaining the crusher assembly while in operation and during shutdown periods.

Preventive maintenance checksheets are provided to assist maintenance personnel andcrusher operators in maintaining and operating the crusher and its systems. Thechecksheets specify routine mechanical, lubrication, electrical, and instrument in-spection tasks. The checksheets are also used by operators for cursory running in-spections and to report potential and current problems to maintenance personnel.

Predictive maintenance forecasts and failure mode effect analysis provide proactiveand active guidelines for troubleshooting and maintaining the crusher and its systems.The consistent and correct use of these maintenance tools are intended to contributeto the optimum efficiency and economic life of the crusher assembly.

The component replacement and repair instructions are provided to serve as a base-line set of procedures for the replacement and/or repair of major wear components.The intent of these procedures is to make the replacement/repair effort consistentamong work crews, and provide a basis for continued revision and improvement. Theultimate goal is to improve the efficiency, productivity, and economic life of thecrusher and its auxiliary systems.


7.1PAGE 1 OF 3


7.1 TECHNICAL SPECIFICATIONSComponent Dimensions Type Horsepower Operating Characteristics

Crusher assembly 6,020 mm (19 ft-9 in) diameter9,557 mm (31 ft-4.25 in) high

60-by-113-inch gyratorycrusher, Traylor Type “TC”.

753 kW (1,000 hp). Out of balance force is 6,912 kg(15,238 lbs) acting at a distance of11,557 mm (37 ft-11 in) above thefoundation, rotating through 360 de-grees at a speed of 123 rpm.Crusher setting (OSS): 203 mm (8inches)Eccentric throw: 44 mm (1.75 inches)Countershaft speed: 494 rpmGyrations per minute: 125Crusher rotation: Clockwise facingcountershaft

Spider assembly 1,524 mm (60 in) wide5,397 mm (212-1/2 in) long1,451 mm (57-1/8 in) high

Flanged and tapered, exter-nally bolted to top shell.

N/A N/A

Main shaft assembly 2,921 mm (115 in) diameter7,645 mm (25 ft) high

Includes lifting device. N/A N/A

Top shell, without liners 6,029 mm (19 ft-9 in) diameter1,905 mm (6 ft-3 in) high

Flanged, externally bolted tomiddle shell.

N/A N/A

Middle shell 4,826 mm (190 in) diameter1,657 mm (65-1/4 in) high

Flanged, externally boltedbetween top and bottom shells.

N/A N/A


7.1PAGE 2 OF 3


Component Dimensions Type Horsepower Operating Characteristics

Bottom shell 5,080 x 4,966 mm (16 ft-8 in x16 ft-3-1/2 in) mounting flange4,686 mm (15 ft-4-1/2 in)diameter upper flange2,743 mm (9 ft) high

Flanged, externally boltedbetween concrete foundationand middle shell.

N/A N/A

Countershaft extensionassembly

527.1 mm (20.75 in) hubdiameter1,803 mm (5 ft-11in) long

Flanged hubs, externallybolted between countershaftassembly and drive motor.

N/A N/A

Eccentric cart 2,360 mm (7 ft-8-1/2 in) long2,149 mm (7 ft-0-5/8 in) wide160 mm (2 ft) high

1,829 mm (6 ft) track gauge. N/A N/A

Lube oil system skid Reservoir configuration: twocompartments, with threeelectric heaters3,685mm (12 ft-1 1/2 in) long2,420mm (8 ft-0 in) wide2,185mm (7 ft-2 in) high

Two positive displacement oilpumps, one standby.

Two positive displacementcooler pumps, one standby.

11.3 kW (15 hp) oilpump drive motors.

11.3 kW (15 hp)cooler pump drivemotors.

N/A

Lube oil coolers 1,765mm (5 ft-9 1/2 in) wide1,067mm (3 ft-6 in) deep2,057mm (6 ft-9 in) high

Two air/oil radiator-typecoolers.

Two cooling fans, one perradiator.

11.3 kW (15 hp) fandrive motors.

N/A

Hydraulic oil adjustment skid Reservoir configuration: twoelectric heaters1,618mm (5 ft-3 3/4 in) long1,333mm (4 ft-5 in) wide1,298mm (4 ft-3 in) high

Two positive-displacementhydraulic oil pumps.

5.7 kW (7.5 hp)hydraulic pump drivemotors.

N/A


7.1PAGE 3 OF 3


Component Dimensions Type Horsepower Operating Characteristics

Spider lubrication system Grease drum by others Plant air-powered greasepump.

N/A During normal operation, 20 counts oflubricant every five minutes.

Crusher drive motor with mainlead junction box.

2,095 mm (82.49 in) wide3,020 mm (118.92 in) long1,890 mm (74.42 in) high

ABB HXR560, TEFC. 750 kW (1,000 hp). 500/496 rpm, 4,000V/50 Hz/3 phase.


7.2PAGE 1 OF 4


7.2 COMPONENT OR SUBSYSTEM OPERATING LIMITSOperating Limits

Component or System Maximum Minimum

Crusher assembly

Crusher countershaft, inboard bearing temperature (TI-7002) 66°C (150°F) Alarm

71°C (160°F) Shutdown

Crusher countershaft, outboard bearing temperature (TI-7003) 66°C (150°F) Alarm


Crusher lubrication, eccentric oil supply (FIT-7026) 170 Lpm (45 gpm) 132 Lpm (35 gpm), decreasing

Crusher lubrication, outer eccentric oil supply (FIT-7029) 170 Lpm (45 gpm) 132 Lpm (35 gpm), decreasing

Crusher lubrication, countershaft oil supply (FIT-7030) 19 Lpm (5 gpm) 13 Lpm (3.5 gpm), decreasing

Crusher hydraulic adjustment support set, supply flow to hydraulic bottom 17 Lpm (4.5 gpm) N/A

Crusher motor, inboard bearing temperature (TI-7001A) 85°C Alarm90°C Shutdown

N/A

Crusher drive motor, outboard bearing temperature (TI-7001B) 85°C Alarm90°C Shutdown

N/A

Crusher drive motor, hottest winding temperature (TI-7001C) 120°C-140°C Alarm130°C-150°C Shutdown

N/A


7.2PAGE 2 OF 4


Operating Limits


Crusher drive motor, current 140 A Alarm

Crusher drive motor, outboard bearing vibration (VS-7001A) 4.5 mm/S Alarm

Crusher drive motor, inboard bearing vibration (VS-7001B) 4.5 mm/S Alarm

Crusher lube oil system skid

Reservoir, oil temperature (TI-7021) 38°C (100°F); Heaters Off

46°C (115°F): Cooler pumpand fan On

35°C (95°F); Heaters On

41°C (105°F); Cooler pumpand fan Off

Reservoir, oil level (LG-7021) Top of sight glass Bottom of sight glass

Reservoir, oil level (LIT-7021) 1,524 mm (60 in) 635 mm (25 in)

Return line, oil temperature (TI-7027) 60°C (140°F) Alarm


38°C (100°F)

Cooler return line, oil flow (FIT-7028) 379 Lpm (100 gpm) 264 Lpm (70 gpm), decreasing

Main oil pump discharge pressure (PI-7023A) 1,035 kPa (150 psi)

Standby oil pump discharge pressure (PI-7023B) 1,035 kPa (150 psi)

Main cooler pump discharge pressure (PI-7023C) 1,035 kPa (150 psi)

Standby cooler pump discharge pressure (PI-7023D) 1,035 kPa (150 psi)

Oil supply filter differential pressure (PDIT-7024) Later

Crusher supply line oil pressure (PI-7025) 1,035 kPa (150 psi)


7.2PAGE 3 OF 4


Operating Limits


Crusher supply line oil temperature (TI-7025) 54°C (130°F) 38°C (100°F)

Cooler supply line oil temperature (TI-7035) 57°C (135°F) 38°C (100°F)

Cooler supply line oil flow 397 Lpm (100 gpm) 285 Lpm (70 gpm)

Cooler supply line oil temperature (TI-7031) 57°C (135°F)

Crusher lube oil system skid (continued)

Cooler supply line oil pressure (PI-7031) 1,035 kPa (150 psi)

Cooler return line oil temperature (TI-7032) 52°C (125°F)

Cooler return line oil pressure (PI-7032) Site dependent

Cooler return line oil temperature (TI-7034) 52°C (125°F)

Cooler return line oil pressure (PI-7034) Site dependent

Crusher hydraulic adjustment system skid

Reservoir, oil temperature (TI-7011) 41°C (105°F) 38°C (100°F)

Reservoir, oil level (LG-7011) Top of sight glass Bottom of sight glass

Reservoir, oil level (LIT-7011) 993 mm (39 in) 490 mm (19 1/4 in)

Pump 1 discharge oil pressure (PI-7013A) 6,895 kPa (1,000 psi)

Pump 2 discharge oil pressure (PI-7013B) 6,895 kPa (1,000 psi)

Recirculated oil filter, inlet oil pressure (PI-7015) 6,895 kPa (1,000 psi)

Recirculated oil filter, differential oil pressure (PDIT-7015) 172 kPa (25 psi)


7.2PAGE 4 OF 4


Operating Limits


Spider lubrication system

Air pump, supply line air pressure (PI-7041) 760 kPa (110 psi) 620 kPa (90 psi)

Grease supply line pressure (PI-7042) 13,780 kPa (2000 psi)


7.3PAGE 1 OF 1


7.3 MATERIAL SPECIFICATIONSComponent Description Material Type Special Manufacturing

Processes

Main shaft FFEM Material Specification:720-86-1-6800

Top threaded for head nut.

Core (mantle) C. S. ASTM A-27 Grade 70-40 Cast, bored.

Mantle head, upper Cast manganese steel ASTM A-128Grade E-1

Cast.

Mantle head, middle Cast manganese steel ASTM A-128Grade E-1

Cast.

Mantle head, lower Cast manganese steel ASTM A-128Grade E-1

Cast.

Spider FFEM Material Specification:720-81-1-6800

Cast, bored.

Top shell FFEM Material Specification:720-81-1-6800

Cast, bored, drilled flange holepattern.

Middle shell FFEM Material Specification:720-81-1-6800

Cast, bored, drilled flange holepattern.

Bottom shell FFEM Material Specification:720-81-1-6800

Cast, bored, drilled and matchmarked flange hole patterns.

Eccentric C. S. ASTM A-27 Grade 70-40 Bored, turned.

Spiral bevel gear C. S. AISI 4340, 300/340 BHN Hobbed, ground.

Inner eccentric bushing Lead bronze ASTM B584 Bored. turned.

Upper concave (16) M. E. International No. WS-7DM Cast.

Upper middle concave (16) M. E. International No. WS-14EPX Cast.

Lower middle concave (16) M. E. International No. WS-14EPX Cast.

Lower concave (16) M. E. International No. WS-7HMS Cast.

Countershaft housing C.I. ASTM A-48 CL. 40 Cast, bored, faced.

Countershaft FFEM Material Specification No.:720-86-1-6800

Turned, keyed, threaded.

Spiral bevel pinion gear F. S. AISI 8620, 55 Rockwell “C”Minimum

Hobbed, ground, bored, keyed.

Countershaft extension AISI 1018 CFS Turned, keyed.

Eccentric cart ASTM A-36 structural shapes Fabricated assembly.


7.4PAGE 1 OF 2


7.4 PAINT AND COATING SPECIFICATIONSSurface Type Purpose Coating Type Manufacturer Manufacturer’s Trade Name

Machined or ground, mating Storage Corrosion protective Flame Control Coatings Chek-rust #1

Tectyl 891

Machined or ground, nonmating Storage Corrosion protective Flame Control Coatings Chek-rust #1

Tectyl 891

As cast Storage Corrosion protective

Mill Storage Corrosion protective

Machined or ground, nonmating In use, touch up Corrosion protective, exterior, primer Finaren & Haley, Inc. Primer #848750

Corrosion protective, exterior, finish

As cast In use, touch up Corrosion protective, exterior, primer Finaren & Haley, Inc. Primer #848750


Mill In use, touch up Corrosion protective, exterior, primer Finaren & Haley, Inc. Primer #848750


Machined or ground, mating Assembly Solvent

Machined or ground, nonmating,oil-immersed

Assembly Corrosion protective, interior, white, oilresistant enamel

M. A. Bruder and Sons(MAB)

Plythane oil resistant white012165

Dupont 25P, White high solids epoxymastic

Corrosion protective, exterior, weldable Carboline Carbo weld 11 HS


7.4PAGE 2 OF 2


Surface Type Purpose Coating Type Manufacturer Manufacturer’s Trade NameAs cast, oil immersed Assembly Corrosion protective, interior, white, oil

resistant enamelM. A. Bruder and Sons(MAB)



Corrosion protective, exterior, weldable Carboline Carbo weld 11 HSMill, oil-immersed Assembly Corrosion protective, interior, white, oil

resistant enamelM. A. Bruder and Sons(MAB)



Corrosion protective, exterior, weldable Carboline Carbo weld 11 HSMachined or ground, nonmating,non-oil-immersed

Assembly Corrosion protective, interior, whiteenamelCorrosion protective, exterior, greyprimer

Finaren & Haley, Inc. Primer #848750

As cast, non-oil-immersed Assembly Corrosion protective, interior, whiteenamelCorrosion protective, exterior, greyprimer


Mill, non-oil-immersed Assembly Corrosion protective, interior, whiteenamelCorrosion protective, exterior, greyprimer


1. When components with machined surfaces are being prepared for storage, the coating must be applied at a temperature above dew point. 2. All surfaces must be free of grease, oil, dirt, dust, weld flux and spatter, corrosion, and rust prior to the application of paints and coatings. 3. Equivalent paints may be used upon approval by FFE Minerals USA, Inc.


7.5PAGE 1 OF 5


7.5 PHYSICAL DIMENSIONS AND WEIGHT OF COMPONENTSComponent/Assembly Part Number Nominal Outside Dimensions Hoisting Weight

Spider cap 720-92-3-0201-02 1,524 mm (60 in) dia. x 924 mm (36.4 in) high 5,609 kg (12,366 lbs)

Spider 1.503696 1,524 mm (60 in) wide5,397 mm (212.5 in) long1,451 mm (57.125 in) high

24,259 kg (53,467 lbs)

Spider shields, each 720-94-4-0211-02 1,740 mm (68.5 in) wide2,260 mm (89 in) long635 mm (25 in) high

3,674 kg (8,100 lbs)

Spider bushing 2.501051 1,105 mm (43.5 in) diameter705 mm (27.8 in) long

635 kg (1,400 lbs)

Main shaft assembly 720-00-1-1003-01 2,921 mm (115 in) diameter7,645 mm (301 in) high

105,915 kg (233,500 lbs)

Main shaft wearing ring 720-3-474-012-01 856.36 mm (33.71 in) diameter91.26 mm (3.6 in) high

395 kg (870 lbs)

Center wearing ring 720-1-474-010-01 952.5 mm (37.5 in) diameter92.07 mm (3.6 in) high

461 kg (1,015 lbs)

Main shaft contact seal 3.500006 1,371 mm (54 in) diameter24 mm (.9 in) high

7 kg (15 lbs)

Main shaft sleeve 720-96-2-1001-01 787 mm (30.9 in) diameter1128 mm (40.5 in) high

381 kg (840 lbs)

Main shaft 1.506225 1141.5 mm (44.9 in) diameter6851.6 mm (269.8 in) long

43,330 kg (95,500 lbs)


7.5PAGE 2 OF 5


Component/Assembly Part Number Nominal Outside Dimensions Hoisting Weight

Top shell, without liners 1.503681 6,020 mm (237 in) diameter2,499 mm (98 3/8 in) high

69,270 kg (152,670 lbs)

Middle shell 720-94-4-0400-01 4,826 mm (190 in) diameter1,657 mm (65.25 in) high

55,649 kg (122,650 lbs)

Bottom shell 1.504287 5,080 × 4,966 mm (200 in x 195.5 in)mounting flange4,686 mm (184.5 in) diameter upper flange2,743 mm (108 in) high

83,280 kg (183,600 lbs)

Eccentric assembly 2.500124 2,226 mm (87.6 in) diameter1921 mm (75.6 in) high

13,385 kg (29,500 lbs)

Bottom plate assembly(with eccentric wearing ring)

720-94-2-0704-00 2,590 mm (102 in) diameter165 mm (6.5 in) high

4,628 kg (10,200 lbs)

Eccentric wearing ring 720-94-3-0706-01 1,625.6 mm (64 in) diameter50.8 mm (2 in) high

499 kg (1,100 lbs)

Hydraulic bottom assembly(with center wearing ring)

2.501104 2,590 mm (102 in) diameter1,590.6 mm (62.6 in) high

14,746 kg (32,500 lbs)

Hydraulic bottom 720-92-4-0900-01 2,590 mm (102 in) diameter1,054 mm (41.5 in) high

8,300 kg (18,300 lbs)

Upper and lower piston bushings 720-92-3-0903-01,720-92-3-0904-01

1,168.4 mm (46 in) diameter482.6 mm (19 in) high

400 kg (880 lbs)

Bottom piston wearing ring 720-92-3-0907-01 952.5 mm (37.5 in) diameter67 mm (2.6 in) high

390 kg (860 lbs)


7.5PAGE 3 OF 5



Countershaft assembly 1.503880 Length: 2,343.15 mm (92.75 inches)Diameter: 1,086 mm (42.75 inches)

3,221 kg (7,100 lbs)

Countershaft extension assembly 720-99-1-1304-01 527.1 mm (20.75 in) hub diameter1,803 mm (71 in) long

1,579 kg (3,480 lbs)

Concaves, bottom row (Row 1),16 in row

6.501904 737 mm (29 in) high x 686 mm (27 in) wide x188 mm (7.4 in) thick

567 kg (1,250 lbs)

Concaves, Row 2, 16 in row 6.501903 785 mm (30.9 in) high x 706 mm (27.8 in)wide x 135 mm (5.3 in) thick

422 kg (930 lbs)

Concaves, Row 3, 16 in row 6.501902 887 mm (34.9 in) high x 785 mm (30.9 in)wide x 89 mm (3.5 in) thick

392 kg (865 lbs)

Concaves, Row 4, 16 in row 720-94-4-1107-01 803 mm (31.6 in) high x 860 mm (33.8 in)wide x 86 mm (3.4 in) thick

370 kg (815 lbs)

Upper mantle 720-94-4-1017-01 1,675 mm (66 in) diameter1,081 mm (42.5 in) high

3,206 kg (7,065 lbs)

Middle mantle 720-94-4-1017-02 2,161 mm (85.1 in) diameter.1,091 mm (42.9 in) high

5,700 kg (12,600 lbs)

Lower mantle 1.502143 2,870 mm (113 in) diameter1,219 mm (48 in) high

13,150 kg (29,000 lbs)

Lower mantle on spare shaft assembly 1.502142 2,921 mm (115 in) diameter1,219 mm (48 in) high

13,608 kg (30,000 lbs)

Core 1.506226 2,311 mm (91 in) diameter3,378 mm (133 in) high

33,122 kg (73,000 lbs)


7.5PAGE 4 OF 5



Inner eccentric bushing 720-94-3-0808-01 1,314 mm (51.8 in) diameter1,511 mm (59.5 in) high

1,270 kg (2,800 lbs)

Eccentric 720-92-4-0801-01 1,683 mm (66.2 in) diameter1,857 mm (73.1 in) high

7,713 kg (17,000 lbs)

Outer eccentric bushing 720-92-3-0500-01 1,651 mm (65 in) diameter1,632 mm (64.3 in) high

2,087 kg (4,600 lbs)

Dust seal ring 720-92-2-1001-01 1,613 mm (63.5 in) diameter83 mm (3.3 in) high

211 kg (466 lbs)

Dust seal bonnet 1.504291 1,822 mm (71.8 in) diameter772 mm (30.4 in) high

573 kg (1,265 lbs)

Dust seal retainer 720-92-2-1002-01 2000 mm (78.8 in) diameter102 mm (4 in) high

862 kg (1,900 lbs)

Pinion 720-93-4-0802-02 622 mm (24.5 in) diameter356 mm (14 in) wide

510 kg (1,125 lbs)

Gear 720-93-4-0802-03 2,261 mm (89 in) diameter356 mm (14 in) high

3,176 kg (7,000 lbs)

Eccentric cart 720-99-1-1502-01 2,360 mm (92.5 in) long2,149 mm (84.625 in) wide610 mm (24 in) high

2,042 kg (4,500 lbs)

Lube oil system skid 6.501731 3,685 mm (145. in) long2,420 mm (96 in) wide2,185 mm (86 in) high

5,830 kg (12,850 lbs)


7.5PAGE 5 OF 5



Hydraulic oil adjustment skid 6.501817 1,618 mm (63.69 in) long1,333 mm (53.06 in ) wide1,298 mm (51.09 in) high

670 kg (1,470 lbs)


7.6.1PAGE 1 OF 1


7.6 PREVENTIVE MAINTENANCE CHECKSHEETS7.6.1 MECHANICAL/LUBRICATION

The following mechanical/lubrication preventive maintenance checksheets are in-cluded in this section:

7.6.1.1 Crusher Assembly—Daily

7.6.1.2 Crusher Assembly—Weekly

7.6.1.3 Crusher Assembly—Monthly7.6.1.4 Crusher Assembly—Major

7.6.1.5 Lube Oil System—Daily

7.6.1.6 Lube Oil System—Monthly

7.6.1.7 Lube Oil System—Annual

7.6.1.8 Hydraulic Adjustment System—Daily

7.6.1.9 Hydraulic Adjustment System—Monthly

7.6.1.10 Hydraulic Adjustment System—Annual

7.6.1.11 Spider Bushing Lubrication System—Daily


7.6.1.1PAGE 1 OF 2


FFE CRUSHERPM CHECKSHEET

Date: _________Time: ___________ Name of Tradesman: ____________________________________________

---------------------------------------------------------------------------------------------------------------------------------------------------------CRAFT: EST. TIME (HRS:MIN): INTERVAL:

EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Assembly

Mechanical Daily—Crusher Running PM Inspection

Mechanical/Lube

Daily

1. This is a running inspection. DO NOT reach behind or remove safety guards. DO NOTwork on running equipment except for specified running inspections and adjustments.

2. Ensure that all personal protective equipment is being used.

3. Ensure that all test equipment is correctly calibrated and in good operating condition.

4. After completion of the PM tasks, ensure that all safety guards, labels, and signs are inplace and properly secured.

1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lubrication system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of ore movement to and through the crusher as well as a variety of observations of theoperation of the unit and its auxiliary systems.

2. Immediately notify a supervisor of any problems or potential problems concerning safety orproblems that might cause equipment downtime.

3. Document unusual conditions observed, measurements made, and any work required.

0:30


7.6.1.1PAGE 2 OF 2


COMPONENT: TASKNO.

PM TASK: Inspected: (√√√√):Note Repairs Required

Crusher Assembly 001 General Operating Conditions—Closely ob-serve the operation of the crusher for unusualconditions such as sounds, odors, excessivetemperature, and vibration.

002 Spider Bushing—When visible, observe thearea between the spider and mantle for exces-sive grease. When grease delivery is correct,arrange for a thorough inspection of the bushingfor excessive wear or damage.

003 Shell and Spider Bolts/Nuts—Inspect the shelland spider bolts for missing items and signs oflooseness. Arrange for adjustments and re-placements as required.

004 Countershaft Assembly—Inspect the counter-shaft assembly mounting flange for signs of lu-bricant leakage. Arrange for required repairs andadjustment.

005 Countershaft Extension Couplings—Observethe operation of the countershaft extension forunusual noises and vibration. Arrange for re-quired repairs.

006 Lube Oil Supply—Check the lube oil supply flowmeters to ensure the flow is steady and is mov-ing at the correct flow rate. Check the hoses,pipe lines, and fittings for damage and leaks.Arrange for required repairs.

007 Lube Oil Return—Check the return hoses, pipeline, and fittings for damage and leaks. Checkthe return oil temperature through the DCS. Ar-range for more thorough inspections and repairsas required.


7.6.1.2PAGE 1 OF 2



Date: _________Time: ___________ Name of Tradesman: ____________________________________________---------------------------------------------------------------------------------------------------------------------------------------------------------CRAFT: EST. TIME (HRS:MIN): INTERVAL:

EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Assembly

Mechanical Weekly—Crusher Shutdown PM Inspection

Mechanical/Lube

Weekly

1. Ensure that the crusher drive motor, lubrication system, and hydraulic adjustment systemare inactive to avoid interference with their operation due to mechanical inspection andtests.

2. Prior to proceeding with mechanical PM tasks, check for the presence of main and controlpower at appropriate equipment. Control power may be in the form of media pressure,temperature, or low- or high-voltage electrical power.



5. After completion of the PM tasks, ensure that all safety guards, labels, and signs are inplace and properly secured. Remove locks and tags from the appropriate equipment, andrelease the system or unit for service according to established procedures.

1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lube oil system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of ore movement to and through the crusher as well as a variety of observations of theoperation of the unit and its auxiliary systems.



0:30


7.6.1.2PAGE 2 OF 2


COMPONENT: TASKNO.


Crusher Assembly 001 Daily PM Tasks—Complete the daily PM tasksspecified in PM Checksheet CE7611.DOC. Cor-rect all abnormal conditions observed and meas-ured.

002 Mantle—Check the mantle for excessive wearand cracks. Repair or replace as required.

003 Head Nut—Check the space between the headnut and the bottom of the spider to determine theamount of wear and remaining shaft adjustment.Record observations.

004 Concave Surfaces—Check the concaves forexcessive wear and cracks. Repair or replace asrequired.

005 Concave Joints—Check the concave joints tomake sure that they have not peened shut.

NOTE: Joints peening shut may cause greatpressure to accumulate in the concaves,transferring this pressure to the middleand upper shell sections.

Scarf as required to keep the concave jointsopen. Scarfing joints is accomplished by using ahigh-amperage welding machine (400 to 600Amp) and carbon-arc rods. The joints areopened to a depth of approximately 10 mm(0.375 inch) and 10 mm (0.375 inch) wide.

NOTE: Alloy concaves do not work-harden orexpand, so there is no need to scarftheir joints.

006 Dust Seal—Check the dust seal for excessivewear. Replace as required, or record observa-tions when wear is minimal or normal.

007 Dust Seal Retainer—Check the dust seal re-tainer for tightness to prevent bolt breakage.Tighten or replace as required.


7.6.1.3PAGE 1 OF 2




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Assembly

Mechanical Monthly—Crusher Shutdown PM Inspection

Mechanical/Lube

Monthly









1:00


7.6.1.3PAGE 2 OF 2


COMPONENT: TASKNO.


Crusher Assembly 001 Daily and Weekly PM Tasks—Complete thedaily and weekly PM tasks specified in PMChecksheets:

• CE7611.DOC.

• CE7612.DOC.

Correct all abnormal conditions observed andmeasured.

002 Bottom Shell Liners—Inspect the bottom shellliners for cracks, missing pieces, unusual wearpatterns, and excessive wear. Replace liners asrequired.

003 Spider Bushing—Check the clearance betweenthe spider bushing and the main shaft. Replacethe spider bushing if clearance is excessive, orrecord measurements if the clearance is withinnormal limits.


7.6.1.4PAGE 1 OF 2





EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Assembly

Mechanical Major—Crusher Shutdown PM Inspection

Mechanical/Lube

Major

1. Ensure that the crusher drive motor, lube oil system, and hydraulic adjustment system areinactive to avoid interference with their operation due to mechanical inspection and tests.





1. Major maintenance tasks are conducted on the crusher when monthly inspections indicatethat a more detailed inspection or substantial repairs or component replacements are re-quired. Major maintenance may be required at six-month to two-year intervals dependingon the nature of the ore crushed, and other site-specific operating conditions.

2. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lubrication system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes.



96:00


7.6.1.4PAGE 2 OF 2


COMPONENT: TASKNO.


Crusher Assembly 001 Daily, Weekly, and Monthly PM Tasks—Com-plete the daily, weekly, and monthly PM tasksspecified in PM Checksheets:

• CE7611.DOC.

• CE7612.DOC.

• CE7613.DOC.


002 Partial Disassembly—Disassemble the crusherto the degree necessary to inspect and measurecomponents for these major PM tasks.

003 Outer Eccentric Bushing—Inspect the outereccentric bushing for excessive wear and scor-ing. Replace the bushing as required.

004 Eccentric Wear Ring—Inspect the eccentricwear ring for excessive wear and scoring. Re-place the wear ring as required.

005 Inner Eccentric Bushing—Inspect the innereccentric bushing for excessive wear and scor-ing. Replace the bushing as required.

006 Eccentric—Inspect the outer surface of the ec-centric for excessive wear and scoring. Replacethe eccentric as required.

007 Main Shaft—Inspect the main shaft bearingjournals for scoring. Repair or replace the shaftas required.

008 Bevel Gear and Pinion—Check the condition ofthe bevel gear and its pinion gear. Also checkthe condition of the pinion bearings. Replaceexcessively worn components as required.

009 Hydraulic Adjustment Piston and Bushings—Inspect the piston and its bushings for excessivewear and scoring. Replace excessively wornand damaged components as required.

010 Hydraulic Adjustment Piston Seal—Clean anddry the seal and inspect it for excessive wear anddamage. Replace the seal as required.


7.6.1.5PAGE 1 OF 2





EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Lube Oil System

Mechanical Daily—Lube Oil System Running PM Inspection

Mechanical/Lube

Daily








0:30


7.6.1.5PAGE 2 OF 2


COMPONENT: TASKNO.


Lube Oil System Skid 001 Lube Oil Pumps—Check the operating oil pumpfor unusual conditions such as sounds, odors,excessive temperature, and vibration. Arrangefor more thorough inspections and repairs asrequired.

002 Reservoir—Check the level of the oil in the res-ervoir with the sight gauge. During normal op-eration the level should be at the mark on theglass.

003 Pressure Relief Valve—Check that the pressurerelief valves are not chattering and are not ex-cessively hot. Check the pressure in the linesdownstream of the valves for steady operation.

004 Hoses, Pipe Lines, and Fittings—Check allhoses, pipe lines, gaskets, seals, and fittings forleaks. Arrange for required repairs.

Coolers 001 Coolers (Radiators)—Check the radiators forsigns of damage and leaks. Arrange for requiredrepairs.

002 Cooling Fans—Inspect the fans and theirshrouds for signs of contact and damage.


004 Oil Temperature—Check the temperature of theoil entering and leaving the coolers. Record un-usual conditions.


7.6.1.6PAGE 1 OF 2




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Lube Oil System

Mechanical Monthly—Lube Oil System Shutdown PM Inspection

Mechanical/Lube

Monthly


2. Prior to proceeding with instrument PM tasks, check for the presence of control power atappropriate equipment. Control power may be in the form of media pressure, temperature,or low- or high-voltage electrical power.







1:00


7.6.1.6PAGE 2 OF 2


COMPONENT: TASKNO.


Lube Oil System Skid 001 Daily PM Tasks—Complete the daily PM tasksspecified in PM Checksheet CE7615.DOC. Cor-rect all abnormal conditions observed and meas-ured.

002 Oil Sample—Take an oil sample from the reser-voir in an approved container. Write the sourceand the date of the sample on the label of thecontainer, and submit it for analysis.

003 Filter Sample—Replace the filter elements andsubmit the used filters for analysis.

NOTE: Analysis of the contents of the filtersprovides an indicator of the metals andother contaminants removed from thelube oil system.

004 Pumps—Inspect the pumps and piping for signsof leakage. Repair as required. Clean the pumphousings. Ensure all guards are securely inplace.

Mounting Bolts—Check all equipment mountingbolts for tightness. Replace and tighten as re-quired.

005

006 Sump Tank Screen Basket—Collect and in-spect particles found. Clean basket and return totank. Record findings.

Coolers 001 Coolers (Radiators)—Check the radiators fordamage and leaks. Clean the exterior coolingsurfaces as required.

002 Mounting Bolts—Check all equipment mountingbolts for tightness. Replace and tighten as re-quired.

003 Fans—Clean and inspect the fans for cracks anderosion. Replace as required.


7.6.1.7PAGE 1 OF 2




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Lube Oil System

Mechanical Annual—Lube Oil System Shutdown PM Inspection

Mechanical/Lube

Annual









2:30


7.6.1.7PAGE 2 OF 2


COMPONENT: TASKNO.


Lube Oil System Skid 001 Daily and Monthly PM Tasks—Complete thedaily and monthly PM tasks specified in PMChecksheets:

• CE7615.DOC.

• CE7616.DOC.


002 Filters and Housings—Check filter elementsand housings for dirt and sludge. Check filterhousings and fittings for signs of leakage anddamage. Replace damaged components as re-quired.

003 Screen—Remove and inspect the reservoirscreen. Record observation of the material in thescreen. Clean the screen. Inspect for damageand holes in the screen material and its seals.Replace the screen as required.

004 Reservoir—Drain and clean the reservoir. Re-move all traces of sludge and sediment from bothcompartments of the reservoir and its dividers.

005 Gaskets and Seals—Closely inspect all gasketsand seals. Replace aged or leaking componentsas required.

006 Prepare for Service—Fill with the correct gradeand type of new oil to the mark on the sightgauge. Close and secure the openings. Cleanthe exterior of the reservoir.

Coolers 001 Exterior—Check the coolers for signs of leakageand physical damage. Clean the exterior of thecoolers with strong detergent and water. Inspectthe coolers again. Repair or replace as required.

002 Interior—Inspect the top tube sheet for corro-sion, sediment, and sludge. If sludge is ob-served, drain and clean the cooler.

003 Pipe, Hose, and Fittings—Inspect the piping,hoses, and their fittings for leakage and damage.Replace components as required.

004 Fan—Clean and inspect the fan for cracks. Re-place the fan as required.


7.6.1.8PAGE 1 OF 2





EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Hydraulic Adjustment System

Mechanical Daily—Hydraulic Adjustment System Running PM Inspection

Mechanical/Lube

Daily








0:15


7.6.1.8PAGE 2 OF 2


COMPONENT: TASKNO.


Hydraulic AdjustmentSystem Skid

001 Oil Pumps—Check the operating oil for unusualconditions such as sounds, odors, excessivetemperature, and vibration. Arrange for morethorough inspections and repairs as required.

002 Reservoir—Check the level of the oil in the res-ervoir with the sight gauge. During normal op-eration the level should be at the mark on theglass.

003 Pressure Relief Valve—Check that the pressurerelief valve is not chattering and is not exces-sively hot.



7.6.1.9PAGE 1 OF 2




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


Mechanical Monthly—Hydraulic Adjustment System Shutdown PM Inspection

Mechanical/Lube

Monthly









0:45


7.6.1.9PAGE 2 OF 2


COMPONENT: TASKNO.



001 Daily PM Tasks—Complete the daily PM tasksspecified in PM Checksheet CE7618.DOC. Cor-rect all abnormal conditions observed and meas-ured.

002 Oil Sample—Take an oil sample from the reser-voir in an approved container. Write the sourceand the date of the sample on the label of thecontainer, and submit it for analysis.

003 Filter Sample—Replace the filter elements andsubmit the used filters for analysis.

NOTE: Analysis of the contents of the filtersprovides an indicator of the metals andother contaminants removed from thehydraulic adjustment system.

004 Pumps—Inspect the pumps and piping for signsof leakage. Repair as required. Clean the pumphousings. Ensure all guards are securely inplace.

005 Mounting Bolts—Check all equipment mountingbolts for tightness and missing units. Replaceand tighten as required.


7.6.1.10PAGE 1 OF 2




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


Mechanical Annual—Hydraulic Adjustment System Shutdown PM Inspection

Mechanical/Lube

Annual









2:00


7.6.1.10PAGE 2 OF 2


COMPONENT: TASKNO.



001 Daily and Monthly PM Tasks—Complete thedaily and monthly PM tasks specified in PMChecksheets:

• CE7618.DOC.

• CE7619.DOC.Correct all abnormal conditions observed andmeasured.

002 Filters and Housings—Check filter elementsand housings for dirt and sludge. Check filterhousings and fittings for signs of leakage anddamage. Replace damaged components as re-quired.

003 Screens—Remove and inspect the reservoirscreens. Record observation of the material inthe screens. Clean the screens. Inspect fordamage and holes in the screen material and itsseals. Replace the screens as required.

004 Reservoir—Drain and clean the reservoir. Re-move all traces of sludge and sediment from bothcompartments of the reservoir and its dividers.

005 Gaskets and Seals—Closely inspect all gasketsand seals. Replace aged or leaking componentsas required.

006 Prepare for Service—Fill with the correct gradeand type of new oil to the mark on the sightgauge. Close and secure the openings. Cleanthe exterior of the reservoir.


7.6.1.11PAGE 1 OF 2





EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Spider Bushing Lubrication System

Mechanical Daily—Spider Bushing Lubrication System Running PM Inspection

Mechanical/Lube

Daily





1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lube oil system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of ore movement to and through the crusher as well as a variety of observations of theoperation of the unit and its auxiliary systems.



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7.6.1.11PAGE 2 OF 2


COMPONENT: TASKNO.


Spider Bushing Lubri-cation System Skid

001 Air Pressure—Ensure that the inlet air pressureto the pneumatic grease pump is at or near plantair pressure (90 to 150 psi [620 to 1,035 kPa]) onthe pressure gauge near the regulator.

002 Regulator—Check that the air regulator is notdamaged or leaking. Arrange for replacement asrequired.

003 Air Filter—Check the condition of the filterthrough the filter bowl. If the filter is not visiblethrough the bowl, arrange for disassembly andcleaning of the filter and bowl when the crusheris down. Drain the filter with its valve if it is notequipped with an automatic drain valve.

004 Lubricator—Check the oil dispensing rate of theair line lubricator; it should be two drops per min-ute. Adjust as required with the knob on top ofthe lubricator. If the oil drops are not visible, ar-range for disassembly and cleaning of the lubri-cator when the crusher is down.


006 Air/Grease Pump—Check the operation of thepump for unusual sounds, odors, and vibration.Arrange for repair or replacements as required.

007 Grease Drum—Check the level of grease in thedrum either visually or with the weight reading ofthe scale, if provided. Arrange for a full replace-ment drum if the grease level is less than half.


7.6.2PAGE 1 OF 1


7.6.2 ELECTRICAL

The following electrical preventive maintenance (PM) checksheets are included inthis section:

7.6.2.1 Crusher Main Drive Motor—Weekly

7.6.2.2 Crusher Main Drive Motor—Monthly

7.6.2.3 Crusher Main Drive Motor—Annual

7.6.2.4 Crusher Lube Oil System—Weekly

7.6.2.5 Crusher Lube Oil System—Monthly

7.6.2.6 Crusher Lube Oil System—Annual

7.6.2.7 Crusher Hydraulic Adjustment System—Weekly

7.6.2.8 Crusher Hydraulic Adjustment System—Monthly

7.6.2.9 Crusher Hydraulic Adjustment System—Annual


7.6.2.1PAGE 1 OF 3



Date: _________Time: ___________ Name of Tradesman: _____________________________________________

-----------------------------------------------------------------------------------------------------------------------------------------------------------CRAFT: EST. TIME (HRS:MIN): INTERVAL:

EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Main Drive Motor

Electrical Weekly—Electrical Running PM Inspection

Electrical Weekly

1. This is a running inspection. DO NOT reach behind or remove safety guards or terminalcovers. ONLY work on running equipment for specified running observations, adjustments,and measurements.



4. Ensure that all safety guards, labels, and signs are in place and properly secured.

1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lube oil system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of the operation of the crusher, its auxiliary systems, and its drive motor. The drivemotor develops 746 kW (1,000 hp) on 4,000 VAC, 50 Hz, 3 phase power.

2. Immediately notify supervision of any problems or potential problems concerning safety,and problems that might cause equipment downtime.

3. Document any work performed, work required, and measurements taken.

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7.6.2.1PAGE 2 OF 3


COMPONENT: TASKNO.


Main Drive Motor 001 Bearing Lubrication—Check the oil level inboth bearings with the gauges provided.Check the rotation of the oil rings and the colorof the oil through the oil ring inspection gauge.Check for oil discoloration and contamination.Check the bearing areas for oil leakage. If oilleakage is noted, trace leakage to the source,and arrange for repairs.

002 Bearing Temperature—Check bearing areatemperature with a portable thermal detector;temperatures should be in the range of 75° to90°C (167° to 194°F), depending on ambienttemperature. Confirm unusually high tem-peratures through the distributed control sys-tem (DCS). Excessive temperature of thebearings may be due to damaged or wornbearings, loose mounting bolts, excessivelyworn coupling elements, or misalignment.

003 Motor Housing—Check the temperature ofmotor housing with a portable thermal detector;temperature should not exceed 65.5°C(150°F). Excessive temperature of the housingmay be due to overload, mechanical defect, orphase imbalance.

004 Motor Vibration—Feel the motor for excessivevibration. If vibration feels excessive, confirmwith a portable vibration detector. Vibrationvelocity should not exceed 2 mm (80 mils)/secat 1X frequency. Excessive vibration may bedue to damaged or worn bearings, loosemounting bolts, a mechanical defect, mis-alignment, or phase imbalance.

005 Motor Noise—Listen to the motor for exces-sive and unusual noise. Excessive noise mayindicate mechanical or electrical defects orloose mounting bolts.

006 Main Lead Junction Box Cover—Check thetemperature of the junction box cover. Itshould be warm to the touch, cooler than thehousing. Excessive temperature may becaused by loose power terminal connections.


7.6.2.1PAGE 3 OF 3


COMPONENT: TASKNO.


Main Drive Motor(continued)

007 Ground Cable—Check the tightness of theground cable. A loose or broken ground con-nection may cause injury due to shock andfalse sensor readings.


7.6.2.2PAGE 1 OF 2

CE7622.DOC CRUSHER 07AUG. 2001 REV 1




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


Electrical Monthly—Electrical Shutdown PM Maintenance

Electrical Monthly

1. Ensure that the crusher drive motor, lube oil system, and hydraulic adjustment system areinactive to avoid interference with their operation due to electrical and instrument inspec-tions and tests.

2. Prior to proceeding with electrical PM tasks, check for the presence of control power at ap-propriate equipment. Control power may be in the form of media pressure, temperature, orlow- or high-voltage electrical power.




1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lube oil system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of the operation of the crusher, its auxiliary systems, and its drive motor. The drivemotor develops 746 kW (1,000 hp) on 4,000 VAC, 50 Hz, 3 phase power.

2. Immediately notify supervision of any problems or potential problems concerning safety andproblems that might cause equipment downtime.


01:00


7.6.2.2PAGE 2 OF 2

CE7622.DOC CRUSHER 07AUG. 2001 REV 1

COMPONENT: TASKNO.


Main Drive Motor 001 Weekly PM Tasks—Complete the weekly PMtasks specified in PM Checksheet CE7621.DOC.Correct all abnormal conditions observed andmeasured.

002 Power Terminals—Ensure the motor hasbeen isolated from its main and control powersources at the MCC, and try to start it from itslocal control panel. Open the main lead junc-tion box and check the main power terminalsand the heater terminals for signs of excessiveheat. Disconnect and clean loose terminals,and reconnect securely.

003 Junction Box Seal—Inspect the junction boxcover seals for signs of leakage and damage.Replace as required. Vacuum-clean the junc-tion box interior, and replace the cover.

004 Motor Assembly—Correct all abnormal tem-perature, vibration, and noise conditions ob-served and measured during weekly PM in-spections.

005 Local Controls—Inspect local control panelfor damaged or missing buttons, switches, andindicators. Repair or replace as required.

006 Conduit and Cable—Inspect power cable andconduit for signs of excessive heat and physi-cal damage. Repair or replace as required.

007 Grease Sample—Take a grease sample andplace it into an approved container, write thelocation and date from which the sample wastake on the label of the container, and submitthe sample for analysis.

008 Release for Service—Clean motor housingsurfaces to assist cooling. Remove locks andtags at MCC according to established proce-dure when all maintenance and repair workhas been completed, and release the motor forservice.


7.6.2.3PAGE 1 OF 4

CE7623.DOC CRUSHER 07 AUG 2001 REV 1




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


Electrical Annual—Electrical Shutdown PM Maintenance

Electrical Annual

1. Ensure that the crusher drive motor, lube oil system, and hydraulic adjustment system areinactive to avoid interference with their operation due to electrical and instrument inspec-tions and tests.

2. Prior to proceeding with electrical PM tasks, check for the presence of control power at ap-propriate equipment. Control power may be in the form of media pressure, temperature, orlow- or high-voltage electrical power.




1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lube oil system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of the operation of the crusher, its auxiliary systems, and its drive motor. The drivemotor develops 746 kW (1,000 hp) on 4,000 VAC/50 Hz/3 phase power.



04:30


7.6.2.3PAGE 2 OF 4


COMPONENT: TASKNO.


Main Drive Motor 001 Weekly and Monthly PM Tasks—Completethe weekly and monthly PM tasks specified inPM Checksheets:

• CE7621.DOC.

• CE7622.DOC.


002 Insulation Inspection—Inspect all interiorcomponents for signs of excessive heat discol-oration. Closely inspect all insulation for signsof blistering, discoloration, and charring. In-spect all electrical connections for frayed anddamaged insulation, cracked varnish, and coilmovement.

003 Stator Insulation Resistance—WARNING: Use care when measuring in-

sulation resistance. Contactwith high-voltage electrical cur-rent may be fatal. Groundwindings before and after test-ing to drain off all chargingvoltage. The grounding timemust be a minimum of fourtimes the charging time.

The insulation resistance is measured at ambi-ent temperature with either a motor-driven or aRectox-type megger. The test voltage is ap-plied between the entire winding, with all leadsconnected together, and grounded for ap-proximately one minute.

CAUTION: The DC test voltage should neverexceed the motor operating volt-age.

With 1,000 VDC applied, take resistancereadings every 15 seconds for the first twominutes, and then every minute during the re-mainder of the test. Record the results andcompare them with previous measurements.


7.6.2.3PAGE 3 OF 4


COMPONENT: TASKNO.


Main Drive Motor(continued)

003(contin-

ued)

The recommended minimum insulation resis-tance is determined with the following formula:RM = kV + 1RM = Recommended minimum insulation re-

sistance in megohms at 40°C (104°F) ofthe entire winding.

kV = Rated motor terminal-to-terminal voltage.

004 Air Gap—Measure the air gap between therotor and stator at eight equally spaced loca-tions around the rotor. Record the measure-ments and compare with previous measure-ments.

005 Connections—Inspect all uninsulated connec-tions for signs of excessive heat, arcing, andcorrosion. Remove all loose connections,clean their contact surfaces until bright, andreconnect securely.

006 Fasteners—Inspect all nuts and bolts to en-sure they are tight. This is particularly impor-tant for fasteners on the rotor and the fastenersthat could fall onto the rotor if loosened duringoperation.

007 Main Lead Terminals—Check the main leadterminals for signs of excessive heat and co-rona. Remove all loose connections, cleantheir contact surfaces until bright, and recon-nect securely.

008 Inspect and Clean—Inspect the interior againfor loose dirt and dust. Vacuum-clean again ifrequired.

009 Prepare for Operation—Install the end coversand main lead junction box cover/door. Cleanthe exterior surfaces.

Local Control Panel 001 Face Panel—Check the face panel for dam-aged and missing components. Replace itemsas required.

002 Interior—Open the panel/door to gain accessto interior of the control box. Inspect terminalstrips for signs of excessive heat. Inspect allwiring for exposed conductors. Inspect PCBsfor damaged components. Repair or replaceas required.


7.6.2.3PAGE 4 OF 4


COMPONENT: TASKNO.


Local Control Panel(continued)

003 Clean—Vacuum-clean the interior of the con-trol panel box. Clean the exterior surfaces.

004 Prepare for Operation—Replace and securethe junction box cover. When all maintenanceand repair work has been completed, removethe lock and tag at the MCC according to es-tablished procedure, and release the unit forservice.


7.6.2.4PAGE 1 OF 4



Date: _________Time: ___________ Name of Tradesman: _____________________________________________-----------------------------------------------------------------------------------------------------------------------------------------------------------CRAFT: EST. TIME (HRS:MIN): INTERVAL:

EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Lube Oil System:

210-CR-001-2A—Main Oil Pump Motor210-CR-001-2B—Main Oil Pump Motor, Standby210-CR-001-2C—Main Cooler Pump Motor210-CR-001-2D—Cooler Pump Motor, Standby210-CR-001-2HE1, -2HE2, -2HE3—Lube Oil Heaters210-CR-001-3A, -3B—Cooler Fan Motors

Electrical Weekly—Electrical Running PM Inspection

Electrical Weekly





1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lube oil system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of the operation of the crusher, its auxiliary systems, and its drive motor. The crusherlube oil system includes two oil pumps, two cooler pumps, three oil heaters in the reservoir,and two lube oil cooler fans. The four pumps are positive displacement-type, each drivenby a motor which develops 11.3 kW (15 hp) on 460 VAC, 50 Hz, 3 ph power at 1,450 rpm.



0:30


7.6.2.4PAGE 2 OF 4


COMPONENT: TASKNO.


Main Oil Pump Motor 001 Motor Bearings—Visually inspect the motorbearing areas for signs of excessive heat, suchas leaking lubricant and discolored paint.Check bearing area temperature with a port-able thermal detector; temperatures should notexceed 82°C (180°F). Excessive temperatureof the bearings may be due to damaged orworn bearings, loose mounting bolts, exces-sively worn coupling elements, or misalign-ment.

002 Motor Housing—Check temperature of motorhousing with a portable thermal detector; tem-perature should not exceed 65.5°C (150oF).Excessive temperature of the housing may bedue to overload, mechanical defect, or phaseimbalance.

003 Motor Vibration—Feel the motor for excessivevibration. If vibration feels excessive, confirmwith a portable vibration detector. Vibrationvelocity should not exceed 2 mm (80 mils)/secat 1X frequency. Excessive vibration may bedue to damaged or worn bearings, loosemounting fasteners, mechanical defect, mis-alignment, or phase imbalance.

004 Motor Noise—Listen to the motor for exces-sive and unusual noise. Excessive noise mayindicate mechanical or electrical defects orloose mounting fasteners.

005 Junction Box Cover—Check the temperatureof the junction box cover. It should be warm tothe touch, cooler than the housing. Excessivetemperature may be caused by loose powerterminal connections.

Cooler Pump Motor 001 Motor Bearings—Visually inspect the motorbearing areas for signs of excessive heat, suchas leaking lubricant and discolored paint.Check bearing area temperature with a port-able thermal detector; temperatures should notexceed 82°C (180°F). Excessive temperatureof the bearings may be due to damaged orworn bearings, loose mounting bolts, exces-sively worn coupling elements, or misalign-ment.


7.6.2.4PAGE 3 OF 4


COMPONENT: TASKNO.


Cooler Pump Motor(continued)





006 Ground Cable—Check the tightness of theground cable. A loose or broken ground con-nection may disturb sensor signals and causeinjury due to shock.

Cooler Fan Motors 001 Motor Bearings—Visually inspect the motorbearing areas for signs of excessive heat, suchas leaking lubricant and discolored paint.Check bearing area temperature with a port-able thermal detector; temperatures should notexceed 82°C (180°F). Excessive temperatureof the bearings may be due to damaged orworn bearings.



7.6.2.4PAGE 4 OF 4


COMPONENT: TASKNO.


Cooler Fan Motors(continued)

003 Motor Vibration—Feel the motor for excessivevibration. If vibration feels excessive, confirmwith a portable vibration detector. Vibrationvelocity should not exceed 2 mm (80 mils)/secat 1X frequency. Excessive vibration may bedue to damaged or worn bearings, loosemounting fasteners, mechanical defect, fanimbalance or defect, or phase imbalance.

004 Motor Noise—Listen to the motor for exces-sive and unusual noise. Excessive noise mayindicate mechanical or electrical defects.



7.6.2.5PAGE 1 OF 4




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


210-CR-001-2A—Main Oil Pump Motor210-CR-001-2B—Main Oil Pump Motor, Standby210-CR-001-2C—Main Cooler Pump Motor210-CR-001-2D—Cooler Pump Motor, Standby210-CR-001-3A, -3B—Cooler Fan Motors210-CR-001-2HE1, -2HE2, -2HE3—Lube Oil Heaters

Electrical Monthly—Lube Oil System Electrical Shutdown PM Inspection

Electrical Monthly

1. Ensure that the crusher drive motor, lubrication system, and hydraulic adjustment systemare inactive to avoid interference with their operation due to instrument inspection and tests.

2. Prior to proceeding with instrument PM tasks, check for the presence of control power atappropriate instruments. Control power may be in the form of media pressure, tempera-ture, or low- or high-voltage electrical power.

3. Ensure that all personal protective equipment is being used.4. Ensure that all test equipment is correctly calibrated and in good operating condition.5. After completion of the PM tasks, ensure that all safety guards, labels, and signs are in

place and properly secured. Remove locks and tags from the appropriate equipment, andrelease the system or unit for service according to established procedures.




1:30


7.6.2.5PAGE 2 OF 4


COMPONENT: TASKNO.


Main Oil Pump Motors 001 Weekly PM Tasks—Complete the weekly PMtasks specified in PM ChecksheetCE7624.DOC. Correct all abnormal conditionsobserved and measured.

002 Motor Current Draw—With the lube oil systemoperating normally, measure and record thetotal current draw of operating pump motor andthe current in each phase at the MCC. Com-pare the phase currents. Each should be atleast 93 percent of the greatest current read-ing. Low phase current measurements indi-cate a motor phase unbalance and may requiremotor replacement.Also check the current draws of the operatingcooler pump motor, and the cooler fan motors.

003 Power Terminals—Shut down the lubricationsystem, lock out and tag at the MCC, and try tostart from the local control panel.With the pump motor isolated from its powerand control circuits, check the power terminalsfor signs of excessive heat. Disconnect andclean loose terminals until their contact sur-faces are bright, and reconnect securely.

004 Junction Box Seal—Inspect the junction boxcover seals for signs of leakage and damage.Replace as required. Vacuum-clean the junc-tion box interiors, and replace the covers.


006 Local Controls—Inspect the local controlpanel for damaged or missing buttons,switches, and indicators. Repair or replace asrequired.


008 Prepare for Service—Clean motor housingsurfaces to assist cooling.


7.6.2.5PAGE 3 OF 4


COMPONENT: TASKNO.


Cooler Pump Motors 001 Motor Current Draw—With the lube oil systemoperating normally, measure and record thetotal current draw of operating pump motor andthe current in each phase at the MCC. Com-pare the phase currents. Each should be atleast 93 percent of the greatest current read-ing. Low phase current measurements indi-cate a motor phase unbalance and may requiremotor replacement.

002 Power Terminals—With the pump motorsisolated from their power and control circuits,check the power terminals for signs of exces-sive heat. Disconnect and clean loose termi-nals until their contact surfaces are bright, andreconnect securely.





Cooler Fan Motors 001 Motor Current Draw—With the lube oil systemoperating normally, remove the junction boxcovers for the operating pump motor andmeasure and record the total current draw andthe current in each phase. Compare the phasecurrents. Each should be at least 93 percent ofthe greatest current reading. Low phase cur-rent measurements indicate a motor phaseunbalance and may require motor replace-ment.


7.6.2.5PAGE 4 OF 4


COMPONENT: TASKNO.



002 Power Terminals—With the fan motors iso-lated from their power and control circuits,check the power terminals for signs of exces-sive heat. Disconnect and clean loose termi-nals until their contact surfaces are bright, andreconnect securely.



005 Conduit and Cable—Inspect power cablesand conduit for signs of excessive heat andphysical damage. Repair or replace as re-quired.


Heaters 001 Heating Elements—Check the continuity andresistance of each heater. Record results andcompare with previous measurements. Re-place the elements as required.

002 Power Terminals—With the heaters isolatedfrom their power and control circuits, check thepower terminals for signs of excessive heat.Disconnect and clean loose terminals until theircontact surfaces are bright, and reconnect se-curely.



005 Prepare for Service—Remove the locks andtags at the MCC according to established pro-cedure when all maintenance and repair workhas been completed, and release the systemfor service.


7.6.2.6PAGE 1 OF 4




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


210-CR-001-2A—Main Oil Pump Motor210-CR-001-2B—Main Oil Pump Motor, Standby210-CR-001-2C—Main Cooler Pump Motor210-CR-001-2D—Cooler Pump Motor, Standby210-CR-001-3A, -3B—Cooler Fan Motors210-CR-001-2HE1, -2HE2, -2HE3—Lube Oil Heaters

Electrical Annual—Lube Oil System Electrical Shutdown PM Inspection

Electrical Annual








6:30


7.6.2.6PAGE 2 OF 4


COMPONENT: TASKNO.


Main Oil Pump Motors 001 Weekly and Monthly PM Tasks—Completethe weekly and monthly PM tasks specified inPM Checksheets:

• CE7624.DOC.

• CE7625.DOC.


002 Stator Resistance—Remove the junction boxcover, disconnect the power leads, megger thestator at 500 VDC, and record the measure-ments.

003 Power Terminals—Inspect power terminalsfor signs of excessive heat and arcing. Re-place as required. Clean power terminal con-tact surfaces until bright.

004 Conduit and Cable—Megger the power ca-bles from the MCC. Repair or replace cableswith low resistance insulation. Reconnectpower terminals in the junction box and at theMCC.

005 Interior—Support the shaft, remove the out-board end bell, and blow out the motor interiorwith compressed air at 207 kPa (30 psi). Rein-stall the end bell, and clean the outside surfaceof the housing.

006 Fan—Remove the fan cover, inspect the fanfor cracks, and clean the blades. Inspect theoutboard bearing housing for leaks and signsof excessive heat. Replace the cover.

007 Bearing Clearances—Check bearing radialand axial clearances at the coupling hub with adial indicator. Record results, and comparewith previous measurements. Measurementsin excess of 0.076 mm (0.003 inch) may indi-cate a requirement for bearing replacement.

Cooler Pump Motors 001 Stator Resistance—Remove the junction boxcover, disconnect the power leads, megger thestator at 500 VDC, and record the measure-ments.


7.6.2.6PAGE 3 OF 4


COMPONENT: TASKNO.


Cooler Pump Motors(continued)


003 Conduit and Cable—Megger the power ca-bles from the MCC. Repair or replace cableswith low resistance insulation. Reconnectpower terminals in the junction box and at theMCC.


005 Fan—Remove the fan cover, inspect the fanfor cracks, and clean the blades. Inspect theoutboard bearing housing for leaks and signsof excessive heat. Replace the cover.


Cooler Fan Motors 001 Stator Resistance—Remove the junction boxcover, disconnect the power leads, megger thestator at 500 VDC, and record the measure-ments.




7.6.2.6PAGE 4 OF 4


COMPONENT: TASKNO.




Heaters 001 Heating Elements—When the oil has beendrained from the reservoir, check the surfacesof the heaters for hot spot discoloration, physi-cal damage, and erosion. Check the conditionof mounting gaskets and isolators. Replaceelements as required.

002 Thermal Switches—Check the physical con-dition of the thermal switches and their controlwiring. Repair or replace as required.

003 Release for Service—Ensure that preventivemaintenance has been completed on the con-trol cabinet. Remove the locks and tags at theMCC according to established procedure whenall maintenance and repair work has beencompleted, and release the unit for service.


7.6.2.7PAGE 1 OF 4




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Hydraulic Adjustment System:

210-CR-001-1A—Main Hydraulic Oil Pump Motor210-CR-001-1B—Hydraulic Oil Pump Motor Standby210-CR-001-1HE1, -1HE2—Hydraulic Oil Heaters3.501468—Balluff Mantle Position Indicator

Electrical Weekly—Crusher Hydraulic Adjustment System Electrical Running PM Inspection

Electrical Weekly





1. The primary crusher is started, stopped, and operated from the control console located inthe control room. The primary crusher lube oil system, hydraulic adjustment system, andspider lubrication system can also be started from the control console in the control room.These units also have local control panels normally used for maintenance purposes. Al-though the operation of the primary crusher is accomplished almost entirely from the controlconsole, maintenance personnel can assist the control room operator with field observa-tions of the operation of the crusher, its auxiliary systems, and its drive motor. The crusherhydraulic adjustment oil system includes two hydraulic oil pumps, two oil heaters in the res-ervoir, and a mantle position indicator. The two pumps are positive displacement-type,each driven by a motor which develops 5.6 kW (7.5 hp) on 460 VAC, 50 Hz, 3 ph power at1,450 rpm.



0:30


7.6.2.7PAGE 2 OF 4


COMPONENT: TASKNO.


Hydraulic Oil PumpMotor

001 Motor Bearings—Visually inspect the motorbearing areas for signs of excessive heat, suchas leaking lubricant and discolored paint.Check bearing area temperature with a port-able thermal detector; temperatures should notexceed 82°C (180°F). Excessive temperatureof the bearings may be due to damaged orworn bearings, loose mounting bolts, exces-sively worn coupling elements, or misalign-ment.







7.6.2.7PAGE 3 OF 4


COMPONENT: TASKNO.


Hydraulic Pump Motor 001 Motor Bearings—Visually inspect the motorbearing areas for signs of excessive heat, suchas leaking lubricant and discolored paint.Check bearing area temperature with a port-able thermal detector; temperatures should notexceed 82°C (180°F). Excessive temperatureof the bearings may be due to damaged orworn bearings, loose mounting bolts, exces-sively worn coupling elements, or misalign-ment.







7.6.2.7PAGE 4 OF 4


COMPONENT: TASKNO.







Balluff Mantle PositionIndicator

001 Cover—Inspect the welded steel cover of thesensing unit for signs of oil leaks. If oil is ob-served, trace the cause and correct. The posi-tion indicator sensing unit is located at thebottom of the crusher

002 Conduit—Check the power and signal conduitfor impact damage. Replace as required.


7.6.2.8PAGE 1 OF 3




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


210-CR-001-1A—Main Hydraulic Oil Pump Motor210-CR-001-1B—Hydraulic Oil Pump Motor Standby210-CR-001-1HE1, -1HE2,—Hydraulic Oil Heaters3.501468—Balluff Mantle Position Indicator

Electrical Monthly—Crusher Hydraulic Adjustment System Shutdown PM Inspection

Electrical Monthly








1:00


7.6.2.8PAGE 2 OF 3


COMPONENT: TASKNO.


Hydraulic Oil PumpMotors

001 Weekly PM Tasks—Complete the weekly PMtasks specified in PM Checksheet CE7627.DOC.Correct all abnormal conditions observed andmeasured.

002 Motor Current Draw—With the hydraulic oilsystem operating normally, measure and rec-ord the total current draw of operating pumpmotors and the current in each phase at theMCC. Compare the phase currents. Eachshould be at least 93 percent of the greatestcurrent reading. Low phase current measure-ments indicate a motor phase unbalance andmay require motor replacement.

003 Power Terminals—Shut down the hydraulic oilsystem, lock out and tag at the MCC, and try tostart from the local control panel.

With the pump motors isolated from theirpower and control circuits, check the powerterminals for signs of excessive heat. Discon-nect and clean loose terminals until their con-tact surfaces are bright, and reconnect se-curely.



006 Local Controls—Inspect the local controlpanel for damaged or missing buttons,switches, and indicators. Repair or replace asrequired.




7.6.2.8PAGE 3 OF 3


COMPONENT: TASKNO.








001 Cover—Inspect the welded steel cover of thesensing unit for signs of oil leaks. If oil is ob-served, trace the cause and correct. The posi-tion indicator sensing unit is located at thebottom of the crusher

002 Conduit—Check the power and signal conduitfor impact damage. Replace as required.


7.6.2.9PAGE 1 OF 3




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:


210-CR-001-1A—Main Hydraulic Oil Pump Motor210-CR-001-1B—Hydraulic Oil Pump Motor Standby210-CR-001-1HE1, -1HE2—Hydraulic Oil Heaters3.501468—Balluff Mantle Position Indicator

Electrical Annual—Crusher Hydraulic Adjustment System Shutdown PM Inspection

Electrical Annual








3:00


7.6.2.9PAGE 2 OF 3


COMPONENT: TASKNO.


Hydraulic Oil PumpMotors

001 Weekly and Monthly PM Tasks—Completethe weekly and monthly PM tasks specified inPM Checksheets:

• CE7627.DOC.

• CE7628.DOC.


002 Stator Resistance—Remove the junction boxcover, disconnect the power leads, megger thestator at 500 VDC, and record the measure-ments.

003 Power Terminals—Inspect the power termi-nals for signs of excessive heat and arcing.Clean the power terminal contact surfaces untilbright.

004 Conduit and Cable—High-potential-test thepower cables from the MCC. Repair or replaceblown cables and conduits. Reconnect powerthe terminals in the junction box and at theMCC.

005 Fan—Remove the fan covers, inspect the fanfor cracks, and clean the blades. Inspect theoutboard bearing housing for leaks and signsof excessive heat. Replace the covers.


Heaters 001 Heating Elements—When the oil has beendrained from the reservoir check the surfacesof the heaters for hot spot discoloration, physi-cal damage, and erosion. Check the conditionof mounting gaskets and isolators. Replaceelements as required.

002 Thermal Switches—Check the physical con-dition of the thermal switches and their controlwiring. Repair or replace as required.


7.6.2.9PAGE 3 OF 3


COMPONENT: TASKNO.


Heaters (continued) 003 Release for Service—Ensure that preventivemaintenance has been completed on the con-trol cabinet. Remove the locks and tags at theMCC according to established procedure whenall maintenance and repair work has beencompleted, and release the unit for service.


001 Visually inspect exterior of Balluff transducerand connections for signs of physical damage


7.6.3PAGE 1 OF 1


7.6.3 INSTRUMENTATION

The following instrumentation preventive maintenance (PM)checksheets are includedin this section:

7.6.3.1 Crusher Assembly—Quarterly

7.6.3.2 Crusher Lubrication System—Quarterly

7.6.3.3 Hydraulic Adjustment System—Quarterly

7.6.3.4 Spider Bushing Lubrication System—Quarterly


7.6.3.1PAGE 1 OF 5




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Assembly

Instrument Quarterly—Instrument Shutdown PM Maintenance

Instrument Quarterly






1. The crusher assembly includes the following instruments and their service or location:

NOTE: The following instruments are identified by their tag numbers shown on FFEMinerals USA, Inc. Drawing Number 1.503789, Control and Instrumentation DiagramCrusher Overview.

Crusher:

• TE-7002—Temperature element (wiring).

• TE-7003—Tempeature element (wiring).

Motor:

• HS-CR001—Hand switch.

• MPR-7001—Motor protection relay.

0:50


7.6.3.1PAGE 2 OF 5


COMMENTS:(continued)

COMPONENT: TASKNO.


TE-7002, -7003—Temperature Element

001 Remove the junction box cover and inspect theseal for signs of dust and moisture entry. Repairor replace as required.

002 Inspect the wiring terminals for signs of exces-sive heat. Disconnect loose terminals, cleancontact surfaces until bright, and reconnect theterminals.

003 Inspect wiring for damage and abrasion. Repairor replace damaged wiring.

004 Check the condition of the conduit for damage.Repair or replace as required.

HS-CR001—HandSwitch

001 Inspect the instrument housing for signs ofphysical damage and excessive heat. Replaceunit as required.

002 Check the condition of the position label. Re-place as required.

003 Remove the junction box cover and check theseal for signs of dust and moisture entry. Repairor replace as required.

004 Inspect wiring terminals for signs of excessiveheat and tightness. Remove loose terminals,clean until bright, and reconnect.

Lubrication:

• FIT-7026—Flow indicating transmitter.



Hydraulic adjustment:

• PIT-7016—Pressure indicating transmitter.

• PI-7016—Pressure indicator.

• PSV-7017—Pressure relief valve (set 2,760 kPa, increasing).

• ZT-7005—Mantle Position Indicator, ZIT-7005—Mantle Position Indicator




7.6.3.1PAGE 3 OF 5


COMPONENT: TASKNO.



HS-CR001—HandSwitch (continued)

006 Manually operate the switch to check the firm-ness of the detents. Check positions for continu-ity and stability.

007 Replace the junction box cover. Inspect conduitfor signs of damage and corrosion. Repair orreplace as required.

001 Inspect the instrument for physical damage.MPR-7001—MotorProtection Relay 002 Clean and check the condition of the display.

003 Check the signal wire terminals for tightness.

004 Inspect wiring for damage and abrasion. Repairor replace damaged wiring as required.

005 Inspect card rack for damage or burned compo-nents.

001 Inspect the instrument for physical damage andsigns of leakage. Replace as required.

FIT-7026, -7029, -7030—Flow IndicatingTransmitter 002 Clean the display glass and the exterior of the

enclosure.

003 Remove the junction box cover and check theseal for signs of dust and moisture entry. Repairor replace the seal as required.

004 Inspect wiring terminals for signs of excessiveheat. Disconnect loose terminals, clean contactsurfaces until bright, and reconnect the terminals.

005 Inspect wiring for damage, abrasion, and ex-posed conductors. Repair or replace damagedwiring.

006 With an independent DC power supply, checkspan (4-20 mA) and zero settings. Compare withno-flow condition. Set zero as required.

007 Check the date on the calibration sticker. Re-place the instrument if the calibration date is inexcess of one year old.


7.6.3.1PAGE 4 OF 5


COMPONENT: TASKNO.


PIT-7016—PressureIndicating Transmitter


002 Clean the display glass and the exterior of theenclosure.



005 Inspect wiring for damage, abrasion and exposedconductors. Repair or replace damaged wiring.

006 With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient pressure at the sensing element. Setzero as required.


PI-7016—PressureIndicator

001 Inspect the gauge for signs of leakage and dam-age. Repair or replace as required.

002 Clean the glass and enclosure.


PSV-7017—PressureRelief Valve

001 Check normal set point:

• PSV-7017: 2,760 kPa.


002 Check valve body and bonnet for damage andleaks. Replace as required. Do not attempt fieldrepairs.

003 Check for certification tag. Clean valve exterior.

004 Ensure valve mounting is secure.


7.6.3.1PAGE 5 OF 5


COMPONENT: TASKNO.






Inspect wiring for damage, abrasion, and ex-posed conductors. Repair or replace damagedwiring.

With an independent DC power supply, checkspan (4-20 mA) and zero settings. Compare withno-flow condition. Set zero as required.


ZT-7005, -ZIT-7005—Mantle PositionIndicator


7.6.3.2PAGE 1 OF 9





EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Crusher Lubrication System








1. The crusher assembly includes the following instruments and their service or location:

NOTE: The following instruments are identified by their tag numbers shown on FFEMinerals USA, Inc. Drawing Number 1.503792, Control and Instrumentation DiagramCrusher Lube Oil Skid.

On the lube skid:

• TI-7027—Temperature indicator.

• TE/TT-7027—Temperature element/transmitter.



4:00


7.6.3.2PAGE 2 OF 9


COMMENTS:(continued) On the lube skid (continued):

• LG-7021—Level gauge.


• LIT-7021—Level indicating transmitter.

• PSV-7022D—Pressure relief valve (set 1,035 kPa, increasing).

• HS-7025—Hand switch.

• ZSO-7025—Position switch open.

• ZSC-7025—Position switch close.





• PI-7023D—Pressure indicator.

• PSV-7022C—Pressure relief valve (set 1,035 kPa, increasing).

• PI-7023C—Pressure indicator.


• PSV-7022B—Pressure relief valve (set 1,035 kPa, increasing).

• PI-7023B—Pressure indicator.

• PSV-7022A—Pressure relief valve (set 1,035 kPa, increasing).

• PI-7023A—Pressure indicator.

• PDIT-7024—Pressure differential indicating transmitter.

• HS1, HS2-CR012A—Hand switch.

• HS1, HS2-CR012B—Hand switch.

• HS1, HS2-CR012C—Hand switch.

• HS1, HS2-CR012D—Hand switch.

Lube oil coolers:

• TE, TT-7022—Ambient temperature sensor




7.6.3.2PAGE 3 OF 9







• HS1, HS2-CR013A—Hand switch.

• HS1, HS2-CR013B—Hand switch.

• ZSO-7033—Position switch, open.

• ZSC-7033—Position switch, closed.




7.6.3.2PAGE 4 OF 9


COMPONENT: TASKNO.


001 Inspect the instrument for physical damage andsigns of excessive heat. Repair or replace asrequired.

TI-7027, -7021, -7025,-7028, -7035, -7031,-7032, -7034—Tempera-ture Indicator (gauge) 002 Inspect power and signal terminals for signs of

excessive heat and tightness. Disconnect looseterminals, clean contact surfaces until bright, andreconnect the terminals.

003 Inspect wiring for signs of abrasion, damagedinsulation, and exposed conductor. Repair orreplace as required.


TE/TT-7021, -7027—Temperature Element/Transmitter






006 With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient temperature at the sensing element.Set zero as required.


LG-7021—Level Gauge 001 Inspect the instrument for signs of leakage andheat damage. Repair or replace as required.


003 Check and reconcile with visual observation ofreservoir level.


7.6.3.2PAGE 5 OF 9


COMPONENT: TASKNO.










PSV-7022A, 7022B,-7022C, -7022D—Pressure Relief Valve










HS-7025, -7033, -7036—Hand Switch




7.6.3.2PAGE 6 OF 9


COMPONENT: TASKNO.


HS-7025, -7033, -7036—Hand Switch (contin-ued)








PI-7023A, -7023B,-7023C, -7023D, -7025,-7031, -7032, -7034—Pressure Indicator




PDIT-7024—PressureDifferential IndicatingTransmitter




006 With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient pressure differential at the sensing loca-tions. Set zero as required.



7.6.3.2PAGE 7 OF 9


COMPONENT: TASKNO.


ZSO-7033, - 7025—Posi-tion Switch Open

001 Inspect the instrument head for signs of physicaldamage and excessive heat. Replace the unit asrequired.

002 Inspect the cable connector and cable for dam-age. Replace as required.

003 Apply appropriate input voltage and ensure thatswitch opens. Reconcile with position of valve.

004 Inspect the power/signal cable for signs of physi-cal damage and missing or cracked insulation.Replace or repair as required.


006 Inspect wiring terminals for signs of excessiveheat and tightness. Remove loose terminals,clean contact surfaces until bright, and recon-nect.



ZSC-7033, -7025—Posi-tion Switch Closed

001 Inspect the instrument head for signs of physicaldamage and excessive heat. Replace the unit asrequired.

002 Inspect the cable connector and cable for dam-age. Replace as required.

003 Apply appropriate input voltage and ensure thatswitch closes. Reconcile with position of valve.

004 Inspect the power/signal cable for signs of physi-cal damage and missing or cracked insulation.Replace or repair as required.


006 Inspect wiring terminals for signs of excessiveheat and tightness. Remove loose terminals,clean until contact surfaces are bright, and re-connect.


7.6.3.2PAGE 8 OF 9


COMPONENT: TASKNO.











HS1,HS2-CR012A, -CR012B, -CR012C, -CR012D, -CR013A, -CR013B






TE-TT-7022—Tempera-ture Element



7.6.3.2PAGE 9 OF 9


COMPONENT: TASKNO.



TE-TT-7022—Tempera-ture Element (contin-ued)








FIT-7028—Flow Indi-cating Transmitter



7.6.3.3PAGE 1 OF 5





EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:









1. The hydraulic adjustment system includes the following instruments and their service orlocation:NOTE: The following instruments are identified by their tag numbers shown on FFEMinerals USA, Inc. Drawing Number 1.503790, Control and Instrumentation DiagramCrusher Hydraulic Oil Skid.On the skid:• PI-7013B—Pressure indicator.• HS1-CR011B—Hand switch (pushbutton).• HS2-CR011B—Hand switch (pushbutton).• PSV-7012B—Pressure relief valve (set 6,895 kPa, increasing).

1:20


7.6.3.3PAGE 2 OF 5



COMPONENT: TASKNO.






001 Inspect the instrument bezel for signs of physicaldamage and excessive heat. Replace unit asrequired.

HS1-CR011A, -CR011B;HS2-CR011A, -CR011B—Hand Switch,Pushbutton 002 Check the condition of the position label. Re-

place as required.

On the skid (continued):

• HS-7014B—Hand switch.

• PI-7013A—Pressure indicator.

• HS1-CR011A—Hand switch (pushbutton).

• HS2-CR011A—Hand switch (pushbutton).

• PSV-7012A—Pressure relief valve (set 6,895 kPa, increasing).

• HS-7014A—Hand switch.


• PDIT-7015—Pressure differential indicating transmitter.

• LIT-7011—Level indicating transmitter.



• LG-7011—Level gauge.




7.6.3.3PAGE 3 OF 5


COMPONENT: TASKNO.



HS1-CR011A, -CR011B;HS2-CR011A, -CR011B—Hand Switch,Pushbutton (continued)





004 Inspect wiring terminals for signs of excessiveheat and tightness. Remove loose terminals,and clean until bright, and reconnect.



PSV-7012A, -7012B—Pressure Relief Valve








PDIT-7015—PressureDifferential IndicatingTransmitter 002 Clean the display glass and the exterior of the

enclosure.




7.6.3.3PAGE 4 OF 5


COMPONENT: TASKNO.


PDIT-7015—PressureDifferential IndicatingTransmitter (continued)


006 With an independent DC power supply, checkspan (4-20 ma) and zero settings. Compare withambient pressure differential at the sensing loca-tions. Set zero as required.


LIT-7011—Level Indi-cating Transmitter






006 With an independent DC power supply, checkspan (4-20 ma) and zero settings.



TE/TT-7011—Tempera-ture Element/Transmitter 002 Clean the display glass and the exterior of the

enclosure.




7.6.3.3PAGE 5 OF 5


COMPONENT: TASKNO.



TE/TT-7011—Tempera-ture Element/ Transmit-ter (continued)



TI-7011—TemperatureIndicator (gauge)

001 Inspect the instrument for physical damage andsigns of excessive heat. Repair or replace asrequired.

002 Inspect power and signal terminals for signs ofexcessive heat and tightness. Disconnect looseterminals, clean contact surfaces until bright, andreconnect the terminals.

003 Inspect wiring for signs of abrasion, damagedinsulation, and exposed conductor. Repair orreplace as required.


LG-7011—Level Gauge 001 Inspect the instrument for signs of leakage andheat damage. Repair or replace as required.


003 Check and reconcile with visual observation ofreservoir level.

.


7.6.3.4PAGE 1 OF 4




EQUIPMENT:

PM DESCRIPTION:

SAFETY:

COMMENTS:

Spider Bushing Lubrication System



1. Ensure that the crusher drive motor and the spider lubrication system are inactive to avoidinterference with their operation due to instrument inspection and tests.





1. The spider lubrication system includes the following instruments and their service or location:

NOTE: The following instruments are identified by their tag numbers shown on FFEMinerals USA, Inc. Drawing Number 1.503791, Control and Instrumentation Diagram CrusherSpider Lubrication System.

Spider lubrication system:


• PCV-7041—Pressure control valve.



• KV-7041—Solenoid valve

0:25


7.6.3.4PAGE 2 OF 4



COMPONENT: TASKNO.


PI-7041, -7042—Pressure Indicator




PCV-7041—PressureControl Valve


• PCV-7041—6.89 kPa

002 Check valve body and bonnet for damage andleaks. Repair or replace as required.

003 Clean valve exterior.


HS-7041—Hand Switch 001 Inspect the instrument housing for signs ofphysical damage and excessive heat. Replaceunit as required.





Spider lubrication system (continued):

• FQS-7042—Flow totalizing switch.

• Trabon Mark II monitor/controller.




7.6.3.4PAGE 3 OF 4


COMPONENT: TASKNO.


HS-7041—Hand Switch(continued)



FQS-7042—Flow Total-izing Switch

001 Inspect the instrument for physical damage andleakage. Replace as required.


003 Inspect wiring terminals for signs of excessiveheat and tightness. Disconnect loose terminals,clean contact surfaces until bright, and recon-nect.


005 With an independent DC power supply, checkoutput and compare with no flow condition.

Trabon Mark IIMonitor/Controller

001 Inspect the instrument for physical damage. Re-place as required.

002 Inspect the power and signal cables and plugsfor damage and bare conductors. Repair or re-place as required.



005 Inspect internal wiring for damage, abrasion, andexposed conductors. Repair or replace dam-aged wiring.

006 Clean the display.


7.6.3.4PAGE 4 OF 4


COMPONENT: TASKNO.


001 Inspect the instrument for physical damage. Re-place as required.

002 Inspect the power and signal cables and plugsfor damage and bare conductors. Repair or re-place as required.



KV-7041—SolenoidValve

005 Inspect internal wiring for damage, abrasion, andexposed conductors. Repair or replace dam-aged wiring.


7.7PAGE 1 of 4

7.7 PREDICTIVE MAINTENANCE FORECASTS FOR CRUSHER COMPONENTS SUBJECT TO WEAR*Typical Normal

Operating LifeComponentDrawing/Part

NumberWear Limit(s)

Years

Crushing surfaces:

• Mantle sections:

• Upper.

• Middle.

• Lower.

• Concaves:

• Upper.

• Upper middle.

• Lower middle.

• Lower.

720-94-4-1017-01

720-94-4-1017-02

1.502143

720-94-4-1107-01

6.501902

6.501903

6.501904

Replace crushing surfaces when:

• Product size cannot be maintained.

• The usual capacity cannot be maintained.

• There is a pronounced and consistent increase in the crusher operatingpower requirement.

• There is a pronounced concave area worn into the lower row of con-caves.

• There is a pronounced concave area worn into the lower mantle.

• There are cracked or split parts.

1.5-2

1

.75-1

2-3

2-3

2-3

2-3

Spider bushing 2.501051 Replace when a feeler gauge greater in thickness than 1.22 mm (0.048inch) can be inserted between the main shaft (or main shaft sleeve) and thespider bushing at the bottom of the spider bushing.

1-1.5

Inner eccentric bushing 720-94-3-0808-01 Replace the bushing when the inside diameter is greater than 1,073.20 mm(42.252 inches).

1-2

Outer eccentric bushing 720-92-3-0500-01 Replace the bushing when the inside diameter is greater than 1,379.83 mm(54.324 inches).

3-5

Eccentric wearing ring 720-94-3-0706-01 Replace the ring when its thickness is less than 49.23 mm (1.938 inches). 4-5


7.7PAGE 2 of 4

*Typical NormalOperating LifeComponent

Drawing/PartNumber

Wear Limit(s)Years

Protective surfaces:• Spider arm shields.• Spider cap.• Top shell wearing plates.

• Bottom shell outer wall liners.

• Bottom shell rib liners.

• Countershaft housing liner.

Gearcase shields.

• Bottom shell hub liner.

720-94-4-0211-02720-92-3-0201-013.500217,3.500218,720-94-4-0306-03through -053.501021 through–262.501295,2.5012963.501028,3.5010292.501291 through–942.501299 through–3062.501301 through–062.5012971.501421 through-23

Replace these components when they are about to wear through, or whenthere are cracked or split parts. 2-2.5

2-3

1.5-2

2-3

1.5-2.5

1.5-2.5

1-2

2.5-3


7.7PAGE 3 of 4


Drawing/PartNumber

Wear Limit(s)Years

Main shaft wearing ring 720-3-474-012-01 Replace when its thickness is less than 84.91 mm (3.343 inches). 2-3

Center wearing ring 720-1-474-010-01 Replace when its thickness is less than 85.73 mm (3.375 inches). 3-5

Bottom piston wearing ring 720-92-3-0907-01 Replace when its thickness is less than 62.31 mm (2.453 inches). 3-4

Upper piston bushings

Lower piston bushings

720-92-3-0903-01

720-92-3-0904-01

Replace when the inside diameter of the upper and/or lower piston bushingis greater than 965.70 mm (38.020 inches).

4-5

Dust seal ring 720-92-2-1001-01 Replace when the inside diameter of the dust seal is greater than 1,436.25mm (56.545 inches), or the thickness of the dust seal ring is less than 42.29mm (1.665 inches).

3-4

Dust seal bonnet 1.504291 Replace when the inside diameter is greater than 1,372.28 mm (54.027inches), or the outside diameter is less than 1,435.48 mm (56.515 inches).

6-8

Dust seal retainer 720-92-2-1002-01 Replace when its thickness is less than 43.43 mm (1.710 inches) whenmeasured from the top wear surface to the bottom of the inside diameter.

6

Main shaft contact (split) seal rings 3.500006 Replace the main shaft split seal when its outside diameter is less than1,370.92 mm (53.973 inches).

2-3

Main shaft sleeve (or spider journal) 720-96-2-1001-01 Replace the main shaft sleeve or repair the main shaft spider journal areawhen the outside diameter of the main shaft sleeve or spider journal area isless than 787.00 mm (30.984 inches).

3-4

Main shaft inner eccentric bushingjournal

1.506225 Repair the main shaft inner eccentric bushing journal area when the di-ameter of the journal area is less than 1,064.67 mm (41.916 inches).

6-8


7.7PAGE 4 of 4


Drawing/PartNumber

Wear Limit(s)Years

Eccentric 720-92-4-0801-01 Replace the eccentric when its outside diameter is less than 1,368.86 mm(53.892 inches), or its outside diameter is oval to an amount greater than1.81 mm (0.071 inches) as determined by measuring the diameter of theeccentric at two places 90 degrees from each other and subtracting thesmallest measurement from the largest measurement.

6-7

Pinion 720-93-4-0802-02 6

Gear 720-93-4-0802-03 10

* Assumes full time operation of equipment and normal regularmaintenance is performed on equipment. Component life expectationsmay vary significantly due to unexpected, unintended events (trampmaterials, crusher packing, etc.)


7.8PAGE 1 OF 1


7.8 TROUBLESHOOTING (PROBLEM SOLVING)

The purpose of the troubleshooting chart is to provide guidelines and assistance topersonnel maintaining and operating the gyratory crusher and its associated equip-ment and systems. The troubleshooting chart is a guide that is used to identify poten-tial causes of functional and physical failure conditions of the crusher and its systems.

The information and direction contained in the troubleshooting chart is a summary ofcrusher design, maintenance, operating, and management skill, knowledge, and oper-ating experience. It provides a logical path to take when something is about to gowrong, or is going wrong, with the operation or physical condition of the crusher. Itis a starting point. It should be revised often to reflect actual operating and mainte-nance experiences.


7.8.1PAGE 1 OF 8


7.8.1 TROUBLESHOOTING THE TRAYLOR TC GYRATORY CRUSHERFault Cause Remedy

Packing in crushing chamber. Clean out chamber by loweringmain shaft assembly.

Raise main shaft before starting.

Reset crusher main drive motorand restart the crusher.

Check the crusher setting to makesure it is not smaller than recom-mended.

Check the discharge area of thecrusher chamber to be sure it isnot choked.

Tramp iron. Remove obstruction by loweringthe main shaft assembly. Refer toSection 6.4, Operating Consid-erations: Clearing the Crusher.

Reset the main drive motor andrestart.

If the main shaft assembly cannotbe lowered because the obstruc-tion is wedged too tightly, thecrusher chamber must be cleared.Do not attempt to raise the mainshaft assembly if it cannot be low-ered because of possible damageto the bushings.

Low or no lube oil flow. (In-creased oil viscosity causes lubri-cation pump to overload.)

Check lube oil heaters, RTD’s,etc. for correct functioning.

Broken pipe. Inspect all piping for excessiveleaks or breaks.

Crusher stoppage.

Lubrication pump shaft seized. Disassemble pump to check forreason for pump jamming (possi-bility of material jamming pump).

Hydraulic adjustment oil leakage. Check hydraulic adjustment sys-tem piping for leaks.

Crusher fails to maintain setting.

Relief valve leaking. Replace seals in valve.

Replace valve.


7.8.1PAGE 2 OF 8


Fault Cause Remedy

Solenoid or check valves leaking. Replace seals in valves.

Replace valves.Crusher fails to maintain setting(continued).

Hydraulic piston seals worn ordefective.

Determine cause of seal failure ifpremature, and correct.

Install new seals.

Fluctuation of main shaft assem-bly (as indicated by the mantleposition indicator). When crusheris empty head will return to thesetting erratically.

Air in hydraulic adjustment sys-tem.

Bleed hydraulic system of trappedair. Refer to Section 7.9, Compo-nent Replacement and SelectedRepair Procedures: Charge theHydraulic Adjustment System Ac-cumulator.

Mantle breakage. Excessive wear. Check the mantle for tightnessoccasionally by shutting off thefeed so the crushing chamber maybe observed.

Mantle loose. Weaving of mantle on the corecaused by elongation of the mantlethrough work hardening in local-ized areas.

As the last part of the feed is beingcrushed, study the joint betweenthe head nut and the mantle. If themantle is loose, movement willoccur at the joint.

Unusual crusher noises. Excessive load causes noise nearthe bottom of the crusher.

Excessive load may cause pres-sures to develop between gearteeth and bearing surfaces. In-spect the lubrication tank screenbasket for excessive amounts ofbronze or lead flakes.

Broken shell bolts Incorrect torquing. Replace broken bolts.

Check torque of all bolts. Refer toSection 4.5, Bolt Torque Schedule.


7.8.1PAGE 3 OF 8


Fault Cause Remedy

Movement between shell sections. Replace broken bolts.


If taper joint is destroyed, build uptaper by welding and machining.

NOTE: The crusher may be oper-ated temporarily by shimming thetaper joint.

Broken shell bolts. (continued)

Manganese concave growth. Replace broken bolts.


Scarf the joints. Refer to Section7.9, Component Replacement andSelected Repair Procedures: Re-placement of Concaves.

Radiator fan motor is not running. Inspect radiators. Clear debris.

Check operation of fan motors.

Check operation of the coolingcircuit.

Cooling circulating pump or mo-tor not functioning correctly.

Inspect operation of pump andmotor. Correct malfunctions.

Lube oil is too hot enteringcrusher.

Automatic motorized valve notfunctioning.

Replace automatic motorizedvalve.

Crusher setting is too tight. Check crusher setting and arrangefor correction as required.

Lube oil is too hot leavingcrusher.

Bushing problems beginning. Check lube oil reservoir screenbasket for excessive amount ofbronze and lead flakes.

If amount of bronze and leadflakes is excessive, disassemblethe crusher and inspect the bush-ings.


7.8.1PAGE 4 OF 8


Fault Cause Remedy

Lube oil is too hot leaving crushercontinued.

Rock packing in crushing cham-ber.

Check crushing chamber dis-charge for blockage.

Check crusher setting to be sure itis not smaller than recommended.

Check feed regulation.

Excessive dirt in lube oil. Discharge material rubbingagainst the dust seal allowing dirtto enter.

Inspect the discharge of thecrushing chamber frequently todetermine if material is rubbingagainst the dust seal.

Check if air pressurization systemis functioning properly.

Excessive wear of dust seal ring.

Over-tightening of spider bolts. Usually happens with torque nuts.Carefully follow recommendedtorque of tension bolts on nuts.

Spider pocket liners in poor con-dition.

Remove spider, chip out liner,reset the spider, and reline thepockets.

Spider ends in poor condition. Remove any burrs or upsets.

Lack of lubrication. Coat spider pocket with lubricantsuch as EP-2 grease.

Escessive difficulty in spiderremoval.

Spider cocks during removal Observe equal movements bothends of spider during removal.


7.8.1PAGE 5 OF 8


Fault Cause Remedy

Failure of the spider bushing. Lack of lubrication. Repair lubrication system for thespider.

Check the grease supply hosewithin the spider arm for leaks,and the lines for leaks, pump op-eration, and controller operation.

Main shaft in poor condition. Check the condition of the mainshaft journal. If possible, polishthe surface of the journal, or re-condition it by welding and ma-chining.

If the journal is fitted with asleeve, replace the sleeve.

Failure of the spider bushing dueto scoring.

Material passing the lubricationseal.

Install a new seal with its lipdown.

Decrease the level of rock fed tothe crusher.

Failure of the spider bushing dueto burning and cracking.

Lack of lubrication. Check lubrication system for op-eration and grease delivery quan-tity.

Fit between spider cap and spiderworn.

Replace cap.

Check the diameter of the fit ofthe cap on the spider. Rebuild ifworn excessively.

Loose spider cap with tendency tofall off.

Cap has been elongated by contin-ual pounding of material beingdumped on it.

Replace the cap.

Loose spider bolts. Tighten spider bolt nuts.Spider assembly loose in spiderpocket. Worn spider pocket liner. Reline spider pockets.

Spider shields worn. Wear by rock grating on surface. Replace spider shields.


7.8.1PAGE 6 OF 8


Fault Cause Remedy

Concaves cracking. Crusher jammed by an uncrushableobject.

Keep uncrushable objects out ofthe crushing chamber.

Concaves too thin. Check concave thickness. Arrangefor replacement if required.

Concaves falling out.

Poor installation. Follow the concave installationinstructions in this manual.

Keep surfaces clean and free of oilwhere backing material is to bepoured.

Abusive use of rock breaker.

Concaves wearing rapidly. Condition caused by the rock be-ing crushed.

Contact FFE Minerals USA, Inc.,for the possibility of altering alloyconcaves.

Broken concave segment ring. Damaged when removing con-caves.

Replace the segment ring.

If possible, repair the ring.

Bottom shell liners worn. Abrasive action of the crushedrock.

Replace liners as required.

Bottom shell liner bolts and/or nutsloose.

Poor installation of liners. Tighten bolts or nuts.

In some cases it is advisable totack weld nuts onto the bolts. Tackweld the nuts that are inside thebottom shell as they are not readilyvisible during operation of thecrusher.

Main shaft assembly spider or ec-centric journal in poor condition(grooved).

Foreign object between journal andbushing.

Dress out the grooves if possible.

If a journal is in very poor condi-tion, the main shaft may have to berepaired. Consult FFE MineralsUSA, Inc. for particulars.

Trace and eliminate the reason forthe foreign object(s) entering thearea between the shaft journal andthe bushing.


7.8.1PAGE 7 OF 8


Fault Cause Remedy

Main shaft assembly spider or ec-centric journal discolored.

Overheating of journal. Polish out the discoloration.

Check and correct malfunction of:

• Lubrication system.

• Cooling system.

• Packing in the crushing cham-ber.

Main shaft assembly dust seal ringbroken.

Damaged during installation. Replace broken dust seal ring, us-ing care during installation.

NOTE: It is possible that the sealwas allowed to rest on top of thebonnet bearing the total weight ofthe main shaft.

Main shaft assembly head nutcomes loose.

Crusher running counterclockwise. Retighten the head nut.

Reinstall pins.

Check rotation of drive and ensureit is as indicated.

Main shaft assembly teflon-graphite contact oil seal leaking.

Broken rings. Check for free movement of laby-rinth of main shaft.

Eccentric assembly bevel gearworn.

End of life. Replace gear.

Contact FFE Minerals USA, Inc.,to determine if it is possible to re-verse the direction of the drive.

Premature failure. Replace gear.

Check the condition of lube oil todetermine if it is dirty.

Check filter operation to determineif they are bypassing lube oil.Change filter elements.

Eccentric assembly bevel gearchipped.

Foreign object entering the meshof the pinion and bevel gear.

If possible, dress the sharp edgesof the bevel gear chipped teeth.

Replace bevel gear.

Inspect condition of pinion andreplace if required.


7.8.1PAGE 8 OF 8


Fault Cause Remedy

Lack of lubrication. Check lube oil system.

Replace bushings.

Eccentric assembly inner and outerbushings burnt and cracked.

Rock back-up or packing incrushing chamber.

Check for correct operation of binlevel indicators below crusher.

Regulate feed to crusher.

Replace bushings.

Eccentric assembly eccentricwearing ring worn.

End of life. Replace eccentric wearing ring.

NOTE: This part affects theheight of the eccentric gear whichin turn affects the gearset backlash.

Countershaft assembly leakinglube oil at seal.

Seal worn, end of life. Replace seal.

Seal sleeve worn, end of life. Replace seal and sleeve.

Countershaft housing drainplugged.

Clean drain hole in countershafthousing.

Lack of lubrication. Refill the coupling with the speci-fied lubricant. Pump grease intocoupling until grease begins to slippast seal.

Drive system gear-type couplingnoisy.

Worn, end of life. Replace coupling(s).


7.8.2PAGE 1 OF 1


7.8.2 RECOMMENDED TROUBLESHOOTING TEST EQUIPMENT

LUBRICATION• Clean and sealed oil sample bottles.

• Strong light source.

• Manual suction pump and clear hose.

MECHANICAL• Laser alignment or dial indicator coupling alignment set.

• Dial indicator set with magnetic base.

• 0-300 mm (0-11.8 inches) outside micrometer set.

• 0-100 mm (0-3.9 inches) inside micrometer set.

• 0-3 mm (0-0.12 inches) feeler gauges.

• Portable sonic detector.

• Portable thermal detector.

• Mechanic’s stethoscope.

• 0-7,000 kPa (1,000 psi) hydraulic test gauge.

• 0-28,000 kPa (4,000 psi) hydraulic test gauge.

ELECTRICAL• Volt-ohm meter (VOM).

• High potential tester.

• Clamp-on ammeter.

• Megger.

• Continuity tester with light.

• Medium-voltage motor condition monitor/tester.

INSTRUMENT• High impedance VOM.

• Independent voltage source, 1-30V DC.


7.9PAGE 1 OF 2

CE79.DOC CRUSHER 07 AUG. 2001REV1

7.9 COMPONENT REPLACEMENT AND SELECTED REPAIRPROCEDURES

The following procedures cover the replacement or repair of selected major compo-nents of a FFE Minerals USA, Inc. 60-inch-x-113-inch Traylor Type “TC” gyratorycrusher with direct drive. The purpose of these procedures is to provide management,supervision, and craftsmen with sufficient information to safely and effectively planand accomplish crusher component replacement or repair.

These procedures provide a general, overall sequence for component replacement andrepair with details of each step in the sequence. Existing conditions may require thatthe sequence must be altered slightly to accommodate the prevailing conditions. Thedetails of the steps in the sequence should require little modification.

Normal component replacement and repair include the correction of minor misfits bymoderate amounts of straightening, shimming, chipping, cutting, grinding, or polish-ing for proper fit and location of components. Misfits that cannot be corrected by thethese means, or which require major changes in equipment configuration, must bereported immediately to FFE Minerals USA, Inc. for correction of the misfit, or toapprove the most efficient and economic method of correction to be implemented.

When performing replacement or repair of major components, such as shell sectionsor the main shaft assembly, the Erection Record Book should be used as a reference.The Erection Record Book is a compilation of the original installation progress,problems encountered and their solutions, and measurements made. This informationis valuable for comparing current and original conditions and for identifying causesand lasting solutions of potential problems.

Prior to starting component replacement or repairs, the appropriate equipment mustbe locked and tagged out and the required work permits obtained in accordance withestablished procedures.

Throughout this section, Warnings, Cautions, Notes, and Environmental Alerts areused to provide particularly important information. The significance of each of theseterms is described in Section 1.0, Introduction.


7.9PAGE 2 OF 2


The following procedures are covered in this section:

7.9.1 Disassembly of Crusher

7.9.2 Inspection of Parts for Wear and Damage

7.9.3 Rebuild the Hydraulic Cylinder Assembly

7.9.4 Charge the Hydraulic Adjustment System Accumulator

7.9.5 Countershaft Assembly Component Replacement

7.9.6 Adjusting Backlash on a New Gearset

7.9.7 Mantle Replacement

7.9.8 Epoxy Backing Material Preparation

7.9.9 Main Shaft Core Replacement

7.9.10 Replacement of Contact Split Seal Rings

7.9.11 Replacement of Concaves

7.9.12 Lining Spider Pockets


7.9.1PAGE 1 OF 7


7.9.1 DISASSEMBLY OF CRUSHER

SPECIAL EQUIPMENT REQUIREDTwo hydraulic jacks and pump unit (provided)Two jack extensions

INTRODUCTIONThe purpose of this procedure is to describe the disassembly of the gyratory crusherfor component inspection and replacement.

PROCEDURE 1. Remove the spider assembly.

1.1. Ensure that the crusher drive is isolated from its main and controlpower sources and that there is no possibility of a local or remote start-up attempt.

1.2. Ensure that the lube oil, hydraulic adjustment, and spider lube systemsare isolated from their main and control power sources, and that thereis no pressure or flow in these systems.

1.3. Remove the spider cap.

1.4. Disconnect the lubrication line to the spider bushing at the outside ofthe top shell and cap or plug the disconnected ends.

1.5. Remove the spider bolt nuts.

1.6. Place two hydraulic jacks on the jacking pads.

1.7. Loosen the spider by jacking through the holes provided in the topshell. Be sure to jack the spider evenly. Refer to Figure 7.9.1.1 for theplacement of the jacks.

1.8. If hydraulic jacks are not available, drive wedges into the wedge slotslocated in the upper shell flange. It is important to drive the wedgesevenly. It may be necessary to use a crane in conjunction with thewedges to break the spider free. It is essential, however, to avoidcocking the spider to avoid damage to the machined surfaces of thespider and to the surfaces of the backing material in the top shell spi-der pockets.

1.9. When the spider is free, lift it off the crusher and set it on blocks.

1.10. Cover the spider bushing to keep dirt out.


7.9.1PAGE 3 OF 7


2. Remove the main shaft assembly.

2.1. Lift the main shaft assembly out of the crusher and stand it verticallyin the main shaft repair pit or maintenance stand with the use of acrane.

2.2. Protect machined surfaces. Unless the eccentric will be removed im-mediately, cover the dust bonnet inside the crusher to exclude dirt.

3. Remove the hydraulic assembly.

3.1. Open lines at appropriate places to drain the lubricating and hydraulicoils from the bottom of the crusher.

3.2. Remove the protection around the lube and hydraulic lines.

3.3. Remove the mantle position transmitter, and all piping and wiringconnected to the underside of the crusher.

3.4. Cap or plug disconnected hydraulic and lubrication lines.

3.5. Support the hydraulic cylinder assembly, remove the nuts which holdit to the bottom plate, lower it, and remove it from beneath the crusher.

4. Remove the bottom plate and eccentric assembly.

4.1. Record the gear set backlash prior to removing the eccentric assembly.Record the number of gaskets in place.

4.2. Support the bottom plate, remove the nuts which hold it to the bottomshell, then lower it and the eccentric assembly mounted on its top side.

4.3. Move the assembly from beneath the crusher and store it in an areawhere it can remain undisturbed.

5. Remove the spider bushing.

5.1. Remove the bolts, seal and retaining plate.

A tapered bushing can be removed from the spider borewith the spider and main shaft in place in the crusher.A series of drilled and tapped holes are also provided inthe spider bushing to use the hydraulic method to re-move the bushing.

5.1.1. If the spider and main shaft are in place in the crusher, placeblocking material between the head nut and the concaves at aminimum of three places to stabilize the main shaft assembly.


7.9.1PAGE 4 OF 7


5.1.2. Remove the spider bolts and place six of these bolts in the sixtapped holes in the spider bushing flange.

5.1.3. Tighten these bolts in a star pattern to jack the bushing out ofthe tapered spider bore.

5.1.4. If the main shaft and the spider have been removed from thecrusher, pull the tapered bushing with jack screws (bolts) inthe threaded holes provided in the upper flange of the bush-ing. Tighten the jack screws in a star pattern until the bush-ing is loose in its bore and can be lifted out.

5.2. Clean the spider’s bore before installing the new bushing.

6. Remove the dust bonnet.

6.1. Remove the bolts that attach the dust bonnet to the bottom shell.

6.2. Install eye bolts in the threaded holes provided in the dust bonnet.

6.3. Lift the bonnet from the bottom shell.


7.9.1PAGE 6 OF 7


7. Remove the inner eccentric bushing.

7.1. Remove the bolts and splash plates.

7.2. Chip grooves along the bore of the bushing until it collapses, and canbe pulled out.

7.3. Clean the bore before inserting the new bushing.

7.4. The bushing can be lifted out without chipping grooves along the boreof the bushing. Refer to Figure 7.9.1.2. Use a lifting bar or platebearing against the bottom of the bushing.

8. Remove the outer eccentric bushing.

8.1 Remove the bolts and bonnet. Chip grooves along the bore of thebushing until it collapses, and can be pulled out. Clean the bore beforeinserting the new bushing.

8.2 The bushing can be lifted out without chipping grooves along the boreof the bushing. Refer to Figure 7.9.1.2. Use a lifting bar or platebearing against the bottom of the bushing.

9. Remove the center wearing ring.

9.1. The center wearing ring removal is accomplished by simply lifting outthe ring by using eye bolts in threaded holes, as it does not have anyfasteners and rests on the piston wearing ring in a spigot fit.

9.2. Installation is accomplished by simply placing the cleaned and oiledring onto the piston wearing ring and centering it.

10. Remove the piston wearing ring.

10.1. The piston wearing ring removal is accomplished by simply lifting outthe ring. Installation is accomplished by simply placing the cleanedand oiled ring onto the piston and centering it.


7.9.1PAGE 7 OF 7


11. Remove the main shaft wearing ring.

11.1. The main shaft wearing ring is removed by removing the cotter pinand nut.

11.2. With a bar, pry the ring loose from the recess. Be aware that a singledowel to keep the ring from rotating is placed between the ring andmain shaft.

11.3. Remove the ring when it is free.

11.4. Clean the recess in the main shaft. Check the tightness of the stud,which is installed with LOCTITE.

11.5. If the stud is loose, remove the stud, and clean and reinstall it withLOCTITE. The stud can be tightened down with pliers or a pipewrench; use care not to damage the threads.

12. Remove the eccentric wearing ring.

12.1. The eccentric wearing ring rests in a recess in the bottom plate and itcontains no fasteners or dowels. Install eyebolts in the threaded holesprovided and lift the ring from the bottom plate.

13. Remove the countershaft assembly.

13.1. Record the gear set backlash prior to removing the countershaft as-sembly. Record the number and thickness of gaskets in place.

13.2. Remove the countershaft extension.

13.3. Remove the bolts retaining the countershaft assembly to the bottomshell.

13.4. Turn in the jacking bolts to slide the countershaft assembly out. Liftthe assembly slightly with a lifting device and slide the assembly outto remove it.

14. Estimate of time to perform above tasks: 120 Hours

Note: Time does not account for cleaning out dump pocket above nor surgebin below.


7.9.2PAGE 1 OF 6


7.9.2 INSPECTION OF PARTS FOR WEAR AND DAMAGESPECIAL EQUIPMENT REQUIREDTwo hydraulic jacks and pump unit (provided)Two jack extensionsThickness (feeler) gauges in range of 0.5 to 2.00 mmOutside micrometer(s) in range of 800 to 1,500 mm (31.5 to 59.0 inches), with a resolution of 0.001 mm.INTRODUCTIONThe purpose of this procedure is to describe the process of inspection and checkingmajor crusher components for wear and damage.PROCEDURE

For an accurate determination of the wear of bushings,rings, and gears, and to maintain designed clearanceswithin the crusher, refer to Section 7.7, PredictiveMaintenance Forecasts for Crusher Components Sub-ject to Wear.

1 Inspect the spider bushing for wear.1.1. At the bottom of the spider bushing, measure the clearance between

the bushing and the main shaft journal with a feeler gauge.1.2. Replace the bushing when the clearance exceeds the amount stated in

Section 7.7, Predictive Maintenance Forecasts for Crusher Compo-nents Subject to Wear.

2. Inspect the spider bushing for damage.2.1. Remove spider.2.2. Visually inspect the spider bushing inner surface for damage. Damage

may include grooving, burning, and scoring.2.3. Replace the bushing if the damaged area exceeds 10 percent of the

projected area. The projected area of the bushing is its diameter mul-tiplied by its length.

3. Inspect the inner eccentric bushing for wear.3.1. Measure the inside diameter of the inner eccentric bushing.3.2. Replace the bushing when the inside diameter is more than stated in



7.9.2PAGE 2 OF 6


4. Inspect the inner eccentric bushing for damage.4.1. Visually inspect the inner eccentric bushing inner surface for damage.

Damage may include grooving, burning, and scoring.4.2. Replace the bushing if the damaged area exceeds 10 percent of the


5. Inspect the outer eccentric bushing for wear.5.1. Measure the inside diameter of the outer eccentric bushing.5.2. Replace the bushing when its inside diameter is more than stated in


6. Inspect the outer eccentric bushing for damage.6.1. Visually inspect the outer eccentric bushing inner surface for damage.

Damage may include grooving, burning, and/or scoring.6.2. Replace the bushing if the damaged area exceeds 10 percent of the


7. Inspect the main shaft wearing ring for wear.7.1. Measure the thickness of the wearing ring.7.2. Replace the wearing ring when its thickness is less than the dimension

shown in Section 7.7, Predictive Maintenance Forecasts for CrusherComponents Subject to Wear.

7.3. Check the contact pattern of the spherical surfaces of main shaft andcenter wearing rings. If these surfaces do not provide contact over 90percent of the available contact area, including any reduction of area asa result of wear, repair or replace both wearing rings.

8. Inspect the main shaft wearing ring for damage.

8.1. Visually inspect the wearing ring for damage. Damage may includegrooving, burning, and/or scoring.

8.2. Replace the wearing ring if the damaged area exceeds 10 percent ofthe area of the surface.

9. Inspect the center wearing ring for wear.

9.1. Measure the thickness of the wearing ring.


7.9.2PAGE 3 OF 6


9.2. Replace the wearing ring when its thickness is less than the dimensionshown in Section 7.7, Predictive Maintenance Forecasts for CrusherComponents Subject to Wear.

9.3. Check the contact pattern of the spherical surfaces of the main shaftand center wearing rings. If these surfaces do not provide contact over90 percent of the available contact area, including any reduction ofarea as a result of wear, repair or replace both wearing rings.

10. Inspect the center wearing ring for damage.

10.1. Visually inspect the wearing ring for damage. Damage may includegrooving, burning, and/or scoring.

10.2. Replace the wearing ring if the damaged area exceeds 10 percent ofthe area of the surface of the wearing ring.

11. Inspect the piston wearing ring for wear.



12. Inspect the piston wearing ring for damage.

12.1. Visually inspect the wearing ring for damage. Damage includesgrooving, burning, and/or scoring.

12.2. Replace the wearing ring if the damaged area exceeds 10 percent ofthe area of the surface.

13. Inspect the eccentric wearing ring for wear.



14. Inspect the eccentric wearing ring for damage.

14.1. Visually inspect the wearing ring for damage. Damage includesgrooving, burning, and/or scoring.

14.2. Replace the wearing ring if the damaged area exceeds 10 percent ofthe area of the surface of the wearing ring.


7.9.2PAGE 4 OF 6


15. Inspect the hydraulic cylinder assembly bushings for wear.

15.1. Measure the inner diameters of the bushings.

15.2. Replace the bushings when the inner diameters are larger than the di-ameter shown in Section 7.7, Predictive Maintenance Forecasts forCrusher Components Subject to Wear.

16. Inspect the hydraulic cylinder assembly bushings for damage.

16.1. Damage includes grooving, burning, and/or scoring. Damaged areasof the bushing should not be repaired.

16.2. Replace any damaged bushings.

17. Inspect the eccentric for wear.

17.1. Measure the outside diameter of the eccentric.

17.2. Replace the eccentric when it is oval-shaped or when its diameter hasbeen reduced. The wear limits for oval shape and reduced diameterare shown in Section 7.7, Predictive Maintenance Forecasts forCrusher Components Subject to Wear.

18. Inspect the eccentric for damage.

18.1. Damage includes grooving, burning, and/or scoring.

18.2. Replace the eccentric when the total damaged areas exceed 10 percentof the projected area. The projected area is the diameter multiplied bythe length.

19. Inspect the dust seal ring for wear.

19.1 Measure the thickness and inside diameter of the seal ring.

19.1. Replace the seal ring when the inside diameter is large, or its thicknessis less than the dimensions shown in Section 7.7, Predictive Mainte-nance Forecasts for Crusher Components Subject to Wear.

20. Inspect the dust seal ring for damage.


20.2. Replace the seal ring when the total damaged areas exceed 10 percentof the projected area. The projected area is the diameter multiplied bythe thickness.

21. Inspect the dust seal retainer for wear.

21.1. Measure the thickness of the seal retainer.


7.9.2PAGE 5 OF 6


21.2. Replace the seal retainer when its thickness is less than the dimensionsshown in Section 7.7, Predictive Maintenance Forecasts for CrusherComponents Subject to Wear.

22. Inspect the dust seal retainer for damage.

22.1. Damage includes grooving and/or scoring.

22.2. Replace the seal retainer when the total damaged areas exceed 10 per-cent of the projected support area.

23. Inspect the dust bonnet for wear.

23.1 Measure the inside and outside diameters of the dust bonnet.

23.2 Replace the dust bonnet when its inside is greater, or its outside di-ameter is less than, the dimensions shown in Section 7.7, PredictiveMaintenance Forecasts for Crusher Components Subject to Wear.

24. Inspect the dust bonnet for damage


24.2. Replace the dust bonnet when the total damaged areas exceed 10 per-cent of the projected area. The projected area is the diameter multi-plied by the length.

25. Inspect the main shaft sleeve for wear.

25.1. Measure the outside diameter of the sleeve .

25.2. Replace the shaft sleeve if it’s outside diameter is less than the dimen-sion shown in Section 7.7, Predictive Maintenance Forecasts forCrusher Components Subject to Wear.

26. Inspect the main shaft sleeve for damage.


26.2. Replace the shaft sleeve when the total damaged areas exceed 10 per-cent of the projected area. The projected area is the diameter multi-plied by the length.

27. Inspect the main shaft inner eccentric bushing journal for wear.

27.1. Measure the outside diameter of the journal.

27.2. Repair the journal area if its outside diameter is less than the dimen-sion shown in Section 7.7, Predictive Maintenance Forecasts forCrusher Components Subject to Wear.


7.9.2PAGE 6 OF 6


28. Inspect the main shaft inner eccentric bushing journal for damage.


28.2. Repair or replace the main shaft when the total damaged areas exceed10 percent of the projected area. The projected area is the diametermultiplied by the length.



7.9.3PAGE 1 OF 4

CE793.DOC CRUSHER 12 DEC. 2001REV 2

7.9.3 REBUILD THE HYDRAULIC CYLINDER ASSEMBLY

SPECIAL EQUIPMENT REQUIRED

None

INTRODUCTION

The purpose of this procedure is to describe the replacement of the hydraulic seal in ahydraulic cylinder assembly that has not been removed from the crusher.

PROCEDURE

1. To inspect, to remove, and replace the hydraulic seal with the cylinder assem-bly in place:

1.1. Raise the main shaft assembly and place blocks on the bottom shellarms to support it.

1.2. Lower the piston until the main shaft assembly rests on the blocks andthe piston rests on the cover plate.

1.3. Shut down the hydraulic system.

1.4. Open lines at appropriate places to drain the hydraulic oil from the as-sembly.

1.5. Remove the main shaft position transmitter shield, transmitter wiring,and the transmitter.

1.6. Remove the hydraulic line to the bottom plate and cap or plug the dis-connected line.

1.7. Take out four equally spaced stud bolts and in their place installthreaded rods with a nut at each end. The threaded rods are to be 500mm (19.7 inches) long.

1.8. Tighten the rod nuts up under the cover plate, and remove the nutsfrom the remaining studs, so that the cover plate is held solely by thefour lowering rods.

1.9. Raise the eccentric cart into position beneath the crusher, place a hy-draulic jack on a block across the inner ring of the eccentric cart, andwith the jack and blocks lower the cover plate approximately 200 mm(8 inches). The piston sitting on the cover plate will travel downwarda similar distance. Leave the cover plate on the blocks.


7.9.3PAGE 2 OF 4


1.10. Using the jack placed on the block across the inner ring of the eccen-tric cart, insert the piston of the jack through the position transmitterhole of the cover plate, and lift the piston clear until it is possible toreach the cap screws holding the hydraulic seal retainer. Remove theretainer and slide seal down from the piston.

1.11. Reverse this procedure to reassemble the hydraulic assembly.

1.12. As the seal is a one-piece ring, manipulation of the jack and blocksmust be used to position the seal for assembly on to the piston.

INTRODUCTION

The purpose of this procedure is to describe the replacement of the hydraulic seal in ahydraulic cylinder assembly that has been removed from the crusher.

PROCEDURE

2. Disassemble the hydraulic cylinder assembly from the crusher.

2.1. Raise the main shaft assembly and place blocks on the bottom shellarms to support it.

2.2. Lower the piston until the main shaft assembly rests on the blocks andthe piston rests on the cover plate.

2.3. Shut down the hydraulic system.

2.4. Open lines at appropriate places to drain the hydraulic oil and lube oilfrom the assembly.

2.5. Remove the main shaft position transmitter shield, transmitter wiring,and the transmitter.

2.6. Remove the hydraulic line to the bottom plate and cap or plug the dis-connected line.

2.7. Disconnect lube inlet and return lines at the hydraulic cylinder assem-bly and cap or plug the disconnected lines.

2.8. Using the eccentric cart, lift into contact with the hydraulic cylinderassembly.

2.9. Support the hydraulic cylinder assembly, remove the nuts that hold itto the bottom shell, lower the eccentric cart, and remove it from theunderside of the crusher.

2.10. Place the assembly on a stand so that the studs which secure the bot-tom cover are accessible.


7.9.3PAGE 3 OF 4


2.11. Use eye bolts to lift the center wearing ring and bottom piston wearingring from the top of the piston.

2.12. Remove the nuts and locknuts from the studs which attach the bottomcover to the hydraulic cylinder.

2.13. Lift the cylinder vertically, leaving the piston sitting on the bottomcover.

2.14. Lift the piston and drain oil from its interior by removing the drainplug. When the oil has been drained, reinstall the drain plug and invertthe piston to expose the packing retainer.

2.15. With the packing retainer bolts exposed, remove them and the retainer.

2.16. Slide the high-pressure seal off the piston for inspection. Inspect thewearing surface of the piston for signs of scoring. Then inspect thehydraulic cylinder for corresponding score marks on the upper andlower bushings. Defects of this nature cause damage to high-pressureseals with resultant oil loss from the hydraulic system, and prevent thecrusher from maintaining its setting.

2.17. Recessed into the upper bushing is a rubber wiper acting as a pistonseal. To remove the wiper, take out the cap screws and lift off the re-tainer plate.

2.18. Place the hydraulic cylinder on blocks in an inverted position – thelarger diameter will be down.

2.19. Lower the piston into the hydraulic cylinder just within the end of thepiston bushing and such that a full annular recess is provided for thepiston seal.

2.20. Coat the piston seal with oil and install making certain to orient thelips per hydraulic cylinder assembly drawing.

2.21. Install the piston seal retainer plate.

2.22. Install and tighten the seal retainer plate bolts.

2.23. Assemble and bolt bottom cover to hydraulic cylinder. There is an O-ring between the bottom flange of the hydraulic cylinder and the bot-tom cover. Install a new O-ring. Do not attempt to use the old O-ring.

2.24. Block the loose piston and invert entire assembly.

2.25. Install piston wiper ring and retainer plate.


7.9.3PAGE 4 OF 4


2.26. When installing the main shaft transmitter, thoroughly clean all themating surfaces and install a new O-ring under the mounting flange.Be careful to not damage the leads from the sensing element.

INTRODUCTION

The purpose of this procedure is to describe the replacement of the hydraulic cylinderassembly bushings.

PROCEDURE

3. Disassemble the hydraulic cylinder assembly from the crusher.

3.1. With the bottom cover, piston and wiper ring removed from the hy-draulic cylinder, remove the bolts holding the lower piston bushing tothe cylinder.

3.2. Chip grooves along the bore of the bushing until it collapses and canbe pulled out.

3.3. With the bottom bushing removed, invert the cylinder and repeat steps1 and 2 above to remove the upper bushing.

3.4. Carefully clean the bore of the cylinder and coat with oil.

3.5. Insert a threaded rod into the two tapped holes in the hydraulic cylin-der to assure alignment of the bushing during assembly.

3.6. Carefully clean the upper bushing and chill with either dry ice or liquidnitrogen.

3.7. As the piston bushings are a shrink interference fit in the hydrauliccylinder, verify adequate clearance for assembly is provided.

3.8. Install bushing. Bolt in place.

3.9. Invert the assembly and repeat the above for the lower bushing.



7.9.4PAGE 1 OF 1


7.9.4 CHARGE THE HYDRAULIC ADJUSTMENT SYSTEMACCUMULATOR

SPECIAL EQUIPMENT REQUIREDNitrogen adapter and gauge assembly

Bottle of compressed, oxygen-free nitrogen containing 2,265 cubic liters (80 cubicfeet) pressurized to 15,169 kPa (2,200 psi).

INTRODUCTIONThe purpose of this procedure is to describe the charging of the nitrogen accumulatoron the hydraulic adjustment system.

PROCEDURE 1. Remove the guard and cap from the air valve in the blind end of the accumu-

lator, and attach the charging adaptor and gauge assembly.

2. Fasten one end of the hose to the charging valve, and the other end to theadaptor in the cylinder.

3. Slowly open the nitrogen cylinder valve to charge the accumulator. Close thecylinder valve and depress the charging valve handle. The gauge will indicatethe precharge pressure.

4. Continue this procedure until the correct pressure (2,070 kPa [300 psi]) isreached, and wait about two minutes for the accumulator to settle.

5. If the pressure has fallen in that time, slowly open the cylinder valve to bringit up to required pressure.

6. Ensure that the nitrogen cylinder valve is closed. Should the gauge show thatthere is excess pressure in the accumulator, reduce it by unscrewing the ex-haust valve in the side of the accumulator adapter and depressing the handle.

7. Estimate of time to perform above tasks: 1 Hour


7.9.5PAGE 1 OF 4


7.9.5 COUNTERSHAFT ASSEMBLY COMPONENTREPLACEMENT

SPECIAL EQUIPMENT REQUIREDCoupling pullerBearing heating oil-water emulsion bathTwo torches with No. 10 or No. 12 rosebud tips

INTRODUCTIONThe purpose of this procedure is to describe removal and installation of the bearingsand coupling hub on the countershaft assembly.

PROCEDUREThe countershaft assembly must be maintained in astate of adjustment where the shaft rotates easily with-out noticeable axial or lateral play (looseness).

1. Disassemble the countershaft assembly.

Remove the countershaft assembly carefully from thecrusher bottom shell to avoid damaging the machinedsurfaces and the pinion on the inboard end. Recordnumber and size of gaskets.

1.1. Remove the coupling hub on the outboard end of the assembly by si-multaneously applying heat and pulling it off with a puller. The hub isheated with rosebud torch tips to the range of 149° to 260°C (300° to500°F).

1.2. Remove the SKF lock plate and unscrew the countershaft nut.

1.3. Remove the seal retainer and countershaft bushing and push the shaftout from the outboard end. The entire outboard bearing will remain inthe housing; the inner race and cage of the inboard bearing will remainon the shaft.

1.4. Look at the orientation of all bearing parts so there will be no questionabout the direction new ones are to be installed.

1.5. With the shaft out of the housing, remove the pinion key and pinion.Pull off the inboard bearing’s inner race.

1.6. Pull the entire outboard bearing and the outer race of the inboardbearing from the housing.


7.9.5PAGE 2 OF 4


2. Install the bearings.

2.1. Press an outer bearing race into each end of the countershaft housingand set them against the shoulders.

2.2. Shrink an inner race with its cage onto the inboard end of the counter-shaft, seating it against the shoulder. The best method of heating abearing is in a bath of oil emulsion as described in later paragraphs ofthis section.

2.3. As an alternative to heating in oil, a bearing induction heater can beused following the manufacturer’s instructions.

2.4. Install the pinion gear on the inboard end of the shaft.

2.5. Install the key and lock ring.

2.6. Slide the countershaft into its housing.

2.7. Stand this assembly in a vertical position with the pinion down. Ele-vate and level the housing at a height which allows a jack to be placedunder the pinion to support and move the shaft.

2.8. Shrink the inner race and cage onto the outboard end of the counter-shaft. Position them so that the shaft’s end play is within 0.02 mm(0.001 inch) and 0.13 mm (0.005 inch). Determine this by carefullyjacking the shaft up and down and measuring the amount of motionwith a dial indicator while rotating the shaft.

2.9. With the end play set, install the countershaft sleeve, seal retainer andnut turning it until it seats against countershaft sleeve. Bolt andlock wire SKF lock plate.

2.10. Reinstall the coupling hub by heating it to 135°C (275°F), aligning thekey ways, and pressing it onto the shaft.

3. Bearing adjustment.

Bearing adjustment has a significant effect on bearinglife and must be made as precisely as possible. Tight-ening the countershaft nut draws the inner bearinghalves into tighter contact with their outer races, andloosening the countershaft nut increases the clearancebetween the inner bearing halves and their outer races.

Countershaft bearing adjustments can be made with thecountershaft assembly installed in the crusher.


7.9.5PAGE 3 OF 4


3.1. Place a hydraulic jack between the bottom shell and the countershaftcoupling.

3.2. Apply hydraulic pressure and, with a dial indicator, observe themovement of the coupling away from the bottom shell.

3.3. Stop applying hydraulic pressure when the movement ceases, and setthe dial indicator to “0.”

3.4. Place the hydraulic jack between the coupling and a part of the crusherfoundation or a suitable part of the drive motor (use cribbing if neces-sary).

3.5. Apply hydraulic pressure and, with a dial indicator, observe and meas-ure the movement of the coupling toward the bottom shell. Theamount measured is the bearing end play.

3.6. Adjust the end play by tightening or loosening the countershaft nut.

3.7. Run the crusher empty for 15 minutes and recheck the end play.

4. Shrink-fitting the countershaft bearings.

4.1. Heat the bearing parts to be shrink-fitted in an oil-water emulsion offive parts water to one part soluble oil. The emulsion must be per-fectly clean and the components completely immersed.

4.2. Heat the emulsion slowly to the boiling point and maintain that tem-perature for approximately one hour.

If desired, straight lubricating oil can be used instead ofthe emulsion. It is heated slowly to 148°C (300°F) andmaintained at that temperature for one hour. Do notexceed 148°C.

4.3. It is recommended that a pin gauge be made with a length the size ofthe bearing’s bore, and used to verify that the heated bearing has ex-panded enough to slide onto the shaft easily.

Never heat bearing parts with a direct flame. Suspendthe components in the emulsion. Do not allow the partsto rest on the bottom of the container. Heat from a di-rect flame can overheat and distort the components.Allowing them to contact the container in which theyare being heated, at the point where heat is being ap-plied, can have the same effect.


7.9.5PAGE 4 OF 4


4.4. If trouble is encountered in fitting and positioning a bearing compo-nent on the shaft, it should be removed quickly, and burrs or upsetsremoved, reheated, and another attempt made to install it.

5. Estimate of time to perform above tasks: 7.0 Hours


7.9.6PAGE 1 OF 6


7.9.6 ADJUSTING BACKLASH ON A NEW GEARSET

SPECIAL EQUIPMENT REQUIREDMetric dial indicator with a resolution of 0.01 mm

INTRODUCTIONThe purpose of this procedure is to describe backlash adjustment of a new gearset.

PROCEDURERefer to Section 7.7, Predictive Maintenance Forecastsfor Crusher Components Subject to Wear, for specificinformation on the installation, repair, and adjustmentof this crusher. Specific information is provided forgearset backlash in Section 4.4, Gear Backlash Settingand Measurements.

Gearset backlash is affected by wear of the pinionteeth, bevel gear teeth, outer eccentric bushing, eccen-tric outside diameter, eccentric, and the surfaces of theeccentric and bottom plate which contact the eccentricwearing ring. As these components wear, the backlashof the gearset increases. See Figure 7.9.6.1 for varioustooth contact patterns.

A new gearset member can usually be operated with aworn gearset member without damaging either mem-ber. However, the operation of a new gearset memberwith a worn gearset member which has a noticeablyuneven tooth profile, as indicated by metal upsets,smears, protrusions and indentations, can cause accel-erated wear of both members and should be avoided.

Whenever an eccentric, gear pinion, eccentric wearingring, or outer eccentric bushing is replaced, measureand record the crusher backlash. This information isused to assist in the scheduling of the replacement ofwearing members.


7.9.6PAGE 3 OF 6


1. Set the backlash of a new gearset.

1.1. When measuring backlash, remove all clearance between the eccentricand outer eccentric bushing by jacking the eccentric toward the pinionso that the teeth of the gears are in their closest relationship. Thisplacement of the eccentric will provide the measurement of the mini-mum backlash.

1.2. To obtain this placement of the eccentric with the main shaft assemblyin the crusher, place a hydraulic jack between the mantle and concavesat the lowest possible point on the concaves and jack the main shaftassembly and eccentric toward the pinion.

1.3. Release jack pressure before measuring backlash.

1.4. Refer to Section 4.2, Component Installation Sequence and Instruc-tions, Step 7. Backlash is measured using the procedure shown in Fig-ure 7.9.6.2. Place a dial indicator in contact with a bar wedged in aslot of the countershaft nut.

1.5. Refer to Section 4.4, Gear Backlash Setting and Measurements. Rec-ord the pinion gear pitch radius at the center of the tooth face in Col-umn A on a copy of the datasheet in Figure 7.9.6.3.

1.6. Measure the distance “R” from the centerline of the pinion shaft to thepoint where the dial indicator plunger touches the bar in the counter-shaft nut. Record this measurement in Column B on the datasheet.

1.7. Rotate the countershaft counterclockwise until the pinion contacts thegear.

1.8. Set the dial indicator to “0”.

1.9. Rotate the countershaft clockwise until the pinion again contacts thegear. Record the dial indicator reading in Column C on the datasheet.

1.10. Calculate the backlash.

1.10.1. Divide the pinion pitch radius (Column A) by the distancebetween the countershaft centerline and the dial indicator(Column B).

1.10.2. Multiply the result of the division by the dial indicator read-ing (Column C).

1.10.3. Record the result of this multiplication in Column D. This isthe backlash of the gearset.


7.9.6PAGE 4 OF 6


1.11. Compare the backlash calculated in Column D with the requiredbacklash shown in Section 4.4, Gear Backlash Setting and Measure-ments. Adjust the backlash as required, and check again.

1.12. When the correct backlash has been set, complete the datasheet by re-cording comments, the date, and the names of the technicians thatmade the measurements, calculations, and backlash adjustments.

2. Set the backlash of a used gearset.

It is advised not to adjust a gearset to backlash specifi-cations if it has been in operation and the set is worn.The adjustment of a gearset is only to be made on anew set of gears, with an eccentric wearing ring that iswithin accepted tolerance, and an outer eccentricbushing that is within accepted tolerance as specified inSection 7.7, Predictive Maintenance Forecasts forCrusher Components Subject to Wear.


7.9.6PAGE 6 OF 6


FIGURE 7.9.6.3GEARSET BACKLASH DATA

A B C DPinionPitch

Radius(mm)

“R”(mm)

DialIndicatorReading

(mm)

BacklashCalculation

(A÷÷÷÷B)C(mm)

Comments Date Name(s)

NOTES:1. All measurements are in millimeters (mm).2. The measurement “R” in Column B is the distance between the countershaft centerline and the point

where the dial indicator plunger touches the bar in the countershaft nut.3. If this is the initial installation of the gearset, also record the measurements and calculations in the

Erection Record Book, and send a copy of this datasheet to FFE Minerals USA, Inc.


7.9.7PAGE 1 OF 7


7.9.7 MANTLE REPLACEMENT

SPECIAL EQUIPMENT REQUIREDMain shaft assembly repair pit or standHead nut striking wrench

INTRODUCTIONThe purpose of this procedure is to describe replacement of the lower, middle, andupper mantles on the crusher core. It is assumed the core is installed on the mainshaft.

PROCEDURE 1. Place the main shaft assembly in a vertical position in its repair pit or stand.

Be sure to support the weight of the assembly on the bottom of the shaft, noton the core. Supporting the weight of the assembly on bottom of the corecould loosen the fit on the shaft. Place blocking and wedges between the ec-centric journal of the main shaft and the repair pit walls to support it verti-cally.

2. Remove the head nut by first removing the dowel pins between the head nutand the mantle. The head nut may be either one-piece or two-piece. If it isthe two-piece type, the outer nut may only be removed. The nut is most easilyloosened by welding ears onto it, then striking the ears with a ram suspendedfrom a crane. If the nut does not come loose, cut the burn out ring locatedbetween the nut and the mantle. This will relieve the pressure on the head nutthreads so the nut can be removed. A new burn out ring can be welded to thenut so that it can be reused.

3. With the head nut removed, loosen the mantle by striking it on the bottomwith the ram used on the head nut. Heat the lower portion of the lower mantleif necessary.

4. Weld lugs to the mantle and lift it off of the core.

5. Inspect the core for tightness on the shaft. Usually a loose core can be de-tected by rapping the core with a sledge hammer. A ringing sound indicates atight spot, while a dull sound indicates a loose spot. If the core is loose, itmust be removed from the shaft and reinstalled.

6. Chip all remaining backing material from the components to be reassembledand clean them thoroughly. Protect the machined surfaces on the bottom ofthe shaft.


7.9.7PAGE 3 OF 7


7. Lightly coat the surface of the core with lubricating oil before placing thelower mantle on the core.

8. Place the lower mantle on the core. Refer to Figures 7.9.7.1 and 7.9.7.2.Center the mantle on the core by equalizing the distance from the core to theoutside surface of the mantle at the upper end of the mantle.

9. Seal the bottom with a clay mixture to prevent leakage of the backing material(epoxy) that is poured between the core and mantles.

10. Prepare and pour backing material between the mantle and the core. Refer toSection 7.9, Component Replacement and Selected Repair Procedures: EpoxyBacking Material Preparation.

11. Lightly coat the core with lubricating oil and place the middle mantle on thecore. Place 12.7-mm (0.5-inch)-thick metal blocks on the top of the lowermantle and place the middle mantle on these blocks, creating a gap betweenthe middle and lower mantles.

12. Center the middle mantle by equalizing the distance from the core to the out-side surface at the top and bottom of the mantle.

13. Seal the gap at the joint between the middle and lower mantles with a claymixture, filling the gap back to the core. Refer to Figure 7.9.7.4.

14. Prepare and pour backing material between the middle mantle and the core.Refer to Section 7.9, Component Replacement and Selected Repair Proce-dures: Epoxy Backing Material Preparation.

15. Lightly coat the core with lubricating oil and place the upper mantle on thecore. Place 12.7-mm (0.5-inch)-thick metal blocks on the top of the middlemantle and place the upper mantle on these blocks, creating a gap between theupper and middle mantles.

16. Center the upper mantle by equalizing the distance between the core and theouter surface of the bottom of the upper mantle. Also make certain that thetop surface of the upper mantle is at a 90-degree angle with the main shaft andit will mate squarely with the head nut.

17. Put the head nut on and insert four equally spaced 75-mm (3-inch) metalblocks to hold it off of the upper mantle top. Refer to Figure 7.9.7.3. Thiswill keep the upper mantle from floating, and keep it centered and square withthe main shaft.

18. Seal the gap at the joint between the upper and middle mantles with a claymixture, filling the gap back to the core. Refer to Figure 7.9.7.4.


7.9.7PAGE 7 OF 7


19. Place troughs near the top of the upper mantle to direct backing material be-tween the upper mantle and the core.

20. Prepare and pour backing material between the upper mantle and the core. Donot pour backing material above the top of the core. Refer to Section 7.9,Component Replacement and Selected Repair Procedures: Epoxy BackingMaterial Preparation.

21. Tighten the head nut assembly with a slugging (striking) wrench and sledgehammer.

22. When the backing material has cured, loosen the head nut and remove themetal blocks and other mantle positioning devices.

23. Tighten the head nut assembly again by striking the ears previously welded tothe head nut with a ram suspended from a crane.

Two-piece head nuts are shipped with two angle ironpieces welded between the inner head nut and the outerhead nut. Before placing the crusher in service, removethese angle iron pieces.

24. Pin the head nut assembly in two places and weld the pins to the head nut.

25. During the first days of operation with the new mantle, check the head nut. Ifthere is noticeable movement between the mantle and the nut, remove the pinsand tighten the nut. Reinsert the pins and weld them to the head nut.

26. Tighten the head nut assembly again by striking the ears previously welded tothe head nut with a ram suspended from a crane.



7.9.8PAGE 1 OF 1


7.9.8 EPOXY BACKING MATERIAL PREPARATION

SPECIAL EQUIPMENT REQUIREDMixing sticks or paddles

INTRODUCTIONThe purpose of this procedure is to describe the preparation of epoxy backing mate-rial. Epoxy backing material is used to line the spider pockets, fill the spider shieldcavities in some crushers, and to fill the space between the shell and the concaves, thecore and mantle, and the core and main shaft.

PROCEDURE 1. Read and understand the instructions that are provided by the manufacturer of

the epoxy backing material.

2. Estimate the amount of backing material that is required for the job.

3. Check and seal all gaps and joints to prevent leakage while pouring the back-ing material. The backing material will not harden fast enough to plug smallleaks by itself.

4. Measure and mix the two-part epoxy (resin and hardener) materials accordingto the manufacturer’s instructions. Complete mixing of the resin and hardeneris very important to obtain the correct strength and curing time for the backingmaterial.

5. When the backing material is thoroughly mixed, work quickly to prevent itfrom setting up in the mixing container and thus reducing its ability to floweasily around the crusher components.

6. When the work is complete, dispose of the mixing tools, containers, and ex-cess epoxy backing materials according to established procedures.

7. Estimate of time to perform above tasks: .25 Hours


7.9.9PAGE 1 OF 3


7.9.9 MAIN SHAFT CORE REPLACEMENT

SPECIAL EQUIPMENT REQUIREDMain shaft assembly repair pit or standHead nut striking wrenchCore stands

INTRODUCTIONThe purpose of this procedure is to describe the replacement of the core on a crushermain shaft.

PROCEDURE 1. Remove and place the main shaft assembly in a vertical position in its repair

pit or stand. Be sure to support the weight of the assembly on the bottom ofthe shaft, not on the core. Supporting the weight of the assembly on the bot-tom of the core could loosen the fit of the core on the shaft and make the re-moval of the head nut more difficult.

2. Remove the head nut by first removing the dowel pins between the head nutand the mantle. As the head nut is the two-piece type, only the outer nut needbe removed. The nut is most easily loosened by welding ears onto it, thenstriking the ears with a ram suspended from a crane. If the nut does not comeloose, cut the burn out ring located between the nut and the mantle. This willrelieve the pressure on the head nut threads so the nut can be removed. A newburn out ring can be welded to the nut so that it can be reused.

3. With the head nut removed, loosen the mantle by striking it on the bottomwith the ram used on the head nut. Heat the lower portion of the lower mantleif necessary.

4. Weld lugs to the mantle and lift it off of the core.

5. Remove the inner head nut and the graphite-teflon split seal rings from themain shaft.

6. Place blocking and wedges between the eccentric journal of the main shaftand the repair pit walls to support it vertically.

7. Weld lugs to the core and lift it from the main shaft. Inspect the fit at the in-side bottom of the core.

8. As the core was loose on the shaft, the cause of the looseness must be cor-rected, or replace the shaft and/or core with a new unit.


7.9.9PAGE 2 OF 3


9. Slide the replacement (new or repaired) core over the shaft and center it. Tackweld blocks to the top to maintain equal spacing around the shaft. Allowroom for the core to drop a limited distance.

10. Place stands beneath the core to permit the core to drop (slide downward)when it is set. The drop distance range is 5.5 mm (0.22 inch) minimum and6.0 mm (0.25 inch) maximum. Refer to Figure 7.9.9.1.

11. Heat the outside area of the core corresponding to the taper fit with four largepropane torches, or the equivalent, to rapidly heat the core.

12. The core will begin to drop to the stands as it expands. When the core has re-tained enough heat and is resting on the stands, stop heating.

13. Allow the core to cool to 18°C (65°F) or ambient temperature.

14. Prepare and pour backing material to fill the space between the main shaft andthe core. Refer to Section 7.9, Component Replacement and Selected RepairProcedures: Epoxy Backing Material Preparation.

15. Install the mantles as described in Section 7.9, Component Replacement andSelected Repair Procedures: Mantle Replacement.



7.9.10PAGE 1 OF 2


7.9.10 REPLACEMENT OF CONTACT SPLIT SEAL RINGS


INTRODUCTIONThe purpose of this procedure is to describe the replacement of the contact split sealring on the main shaft of the crusher. This procedure assumes the main shaft assem-bly has been removed from the crusher and is in a repair pit, or is lying horizontal oncribbing or supports.

The seal ring is made of graphite-teflon and consists of two split rings and a wooddowel. The wood dowel is used to keep the rings in correct position with each other.The rings are fitted into a groove machined into the main shaft above its eccentricjournal.

PROCEDURE 1. Inspect the contact split seal rings.

1.1. Measure the outside diameter of the seal rings while in the main shaftgroove.

1.2. If the outside diameter of the rings is less than that stated in Section7.7, Predictive Maintenance Forecasts for Crusher Components Sub-ject to Wear, replace the seal rings.

2. Remove the old seal rings and discard them.

2.1. Pry one end of the lower ring out of the groove and twist and screw itcarefully downward toward the bottom end of the main shaft. If thewood dowel prevents complete removal of the lower ring, pull the topring out enough to remove the dowel.

2.2. Continue to unscrew the lower ring until it is completely out of thegroove, and slide it down the eccentric journal until it can be com-pletely removed.

2.3. Remove the top ring with the same prying and screwing motions asused on the lower ring.


7.9.10PAGE 2 OF 2


3. Install new seal rings.

3.1. Coat the inside surfaces of the shaft groove with grease.

3.2. Position the upper seal ring over the lower journal area of the shaft(1,066.8 mm [42 inches] in diameter) with the seal dowel pin holefacing down.

3.3. Slide the seal up to the lower flange of the groove.

3.4. Move the seal off-center as far as possible in the direction of the split.

3.5. Start one end of the split into the groove and continually feed the sealinto the groove with a threading motion.

3.6. With the upper seal installed in the groove, pack the area behind theseals with grease. This is done to help keep the seals centered in thegroove for assembly of the main shaft into the crusher.

3.7. Position the lower seal ring over the lower journal with the seal dowelpin hole facing up.

3.8. Install this seal in the same manner as the upper seal. The two sealsshould have their dowel pin holes facing each other when properly in-stalled.

3.9. Align the dowel pin hole at the split line of the upper seal with thedowel pin hole at 90 degrees from the split line on the lower seal, andinstall the wood dowel pin through the split of the upper seal.

4. Estimate of time to perform above tasks: 1.5 Hours


7.9.11PAGE 1 OF 5


7.9.11 REPLACEMENT OF CONCAVES

SPECIAL EQUIPMENT REQUIREDHigh-amperage welding machine and carbon rods (electrodes)

INTRODUCTIONThe purpose of this procedure is to describe the replacement of the concaves on theinside of the crusher middle and upper shells.

Concaves are manufactured of manganese or a steel alloy. Each of these types differfrom one another. Usually only the steel alloy concaves include a tapered pin. Alloyconcaves must not be welded or heated as indicated by the literature provided by themanufacturer.

PROCEDURE 1. Remove worn or damaged concaves.

1.1. Remove the spider and main shaft assembly.

1.2. Place a cover over the bonnet to prevent dirt from falling into the inte-rior of the crusher.

1.3. Starting with the top row of concaves, weld lifting eyes to each con-cave and remove the key by driving wedges behind it, while support-ing the key concave with a crane.

1.4. If a key is not provided, and the concaves are to be discarded, use acarbon electrode to split one concave with a 50-mm (2 inches)-wide,full-depth, and full-height cut.

1.5. Use wedges to remove the cut concave.

1.6. The others in the row can then be removed by driving wedges betweenthe shell and the remaining concaves.

1.7. The successive rows of concaves are removed with the same method.

1.8. Clean the backing material from the concaves that are to be reused.

1.9. Clean the backing material and any other foreign material from the in-sides of the shell sections.


7.9.11PAGE 2 OF 5


2. Install manganese concaves.

2.1. As a result of operation, the face of each manganese concave isworked, and as a direct result, expands. Space is allowed between theconcaves for this expansion. When positioning them, equalize thespace between all concaves in each row and between rows. To deter-mine the space to be left between each row, place a top shell wearingplate on the top shell and stack one concave from each row up the sideof the shell as shown in Figure 7.9.11.1. Notice that the concaves forthe top row have hooks which must fit into the machined recess in thetop shell.

2.2. Set the lower concaves in place on the concave ring segments usingthe lower key concave to complete the set.

2.3. Position the key concave, if provided, under one of the spider arms soits location is known when the time comes to remove the concave.

2.4. Equalize the spaces between all of the concaves.

2.5. Seal the joints and prepare and pour backing material between theshell and the concaves as discussed in Section 7.9, Component Re-placement and Selected Repair Procedures: Epoxy Backing MaterialPreparation.

2.6. Repeat the procedure for each row of concaves, also filling the spacesbetween rows with backing material. Stagger all vertical joints asshown in Figure 7.9.11.2.

2.7. Locate the key concave, if provided, in the second row 180 degreesaway from the key in the lower row, then continue alternating the lo-cation of the key concave in each successive row in this same manner.

3. Install alloy concaves.

3.1. Optional alloy concaves are installed in the same sequence as aremanganese concaves. The differences are that they do not contain akey in each row, and the concaves are provided with a tapered pin foreach concave that is hammered into a hole formed at the top of twoadjacent concaves.

3.2. Offset the vertical joints row by row to avoid a continuous groove(raceway) from the top to the bottom of the crushing chamber.

3.3. All the vertical gaps between the alloy concave rows are to be 6 mm(0.25 inch).


7.9.11PAGE 3 OF 5


FIGURE 7.9.11.1


7.9.11PAGE 5 OF 5


3.4. Seal the joints and prepare and pour backing material between theshell and the concaves as discussed in Section 7.9, Component Re-placement and Selected Repair Procedures: Epoxy Backing MaterialPreparation.

3.5. Trim off any excess pin above the top surface of the concaves. Alloyconcaves do not work harden nor expand so there is no need to scarfthe joints. Refer to Figures 7.9.11.1 and 7.9.11.2.

3.6. Alloy concaves are not to be welded, scarfed, or flame-cut.

3.7. Use only closed hooks for lifting and lowering the concaves.

4. Scarfing manganese concaves.

4.1. Check the concaves to be ensure that the joints have not peened shut,as this may cause great pressure to accumulate in the concaves andtransfer this pressure to the middle and upper shell sections.

4.2. Scarf as necessary to keep joints open. Scarfing of joints is done withthe use of a high amperage welding machine and carbon rods. Scarfopen the joints open to a depth of approximately 10 mm (0.375 inch)and a width of 10 mm.

Alloy concaves do not work harden nor expand so thereis no need to scarf their joints.


7.9.12PAGE 1 OF 3


7.9.12 LINING SPIDER POCKETS

SPECIAL EQUIPMENT REQUIREDEpoxy backing material mixing containers and sticks or paddles

INTRODUCTIONThe purpose of this procedure is to describe the replacement of spider pocket linings.The lining material is backing material, the same as is placed behind concaves andmantles. Spider pocket linings are replaced when they are loose, portions have beendislodged, or the spider has come to rest on the top shell shelves.

PROCEDURE 1. Remove old lining material.

1.1. Remove all the old backing material that forms the lining of the spiderpockets.

1.2. Clean the spider pockets and the mating ends of the spider arms.

2. Prepare for and pour new lining material

2.1. Place shims on the machined ledge at the open side of each pocket tokeep the spider elevated slightly. This will allow room to draw the spi-der down and set it firmly in its taper fit. Refer to Figure 7.9.12.1.Use shim thickness as specified in Table 7.9.12.1.

TABLE 7.9.12.1SPIDER POCKET SHIM SIZES

Crusher Size Shim Thickness

Millimeters Inches Millimeters Inches

762 and 914.4 30 and 36 12.7 1/2

1,066.8 42 19.5 3/4

1,371.6 54 and larger 25.4 1

NOTE: This is a 60-inch-x-113-inch Traylor Type “TC” gyratorycrusher.

2.2. Block the spider bolt holes with wooden plugs or a board and fill thebottom of the pocket with clay, plaster of Paris, or another sealingmixture until it is flush with the top of the shims.

2.3. Coat the machined tapers at the ends of the spider with a thin film oflubricating oil.


7.9.12PAGE 3 OF 3


2.4. Place the spider in the top shell, as shown in Figure 7.9.12.1.2.5. Insert a feeler gauge between the machined ledge on the top shell and

the lip under the spider to determine when the spider is centered.2.6. Measure at two or more points on each side.2.7. Cover any gap through which backing material could escape.2.8. Prepare and pour epoxy backing material in as discussed in Section

7.9, Component Replacement and Selected Repair Procedures: EpoxyBacking Material Preparation.

2.9. After the backing material has cured, remove the shims, plugs, andsealing material.

2.10. Match-mark an end of the spider and its corresponding end of thepocket. This will ensure the proper mating of the spider arm ends tothe correct pocket when the spider is removed in the future.



8.0PAGE 1 OF 1


8.0 BILLS OF MATERIAL

The following bills of material are included in this section:

Bill of Material Description Drawing No. Rev.

Baluff Mantle Position Indicator 720-01-1-0903-01 0

Bottom Plate Assembly 720-94-2-0704-00 0

Bottom Shell Assembly 720-99-1-0502-01 2

Bottom Shell Liner and Shield Assembly 720-00-1-0600-01 2

Components - Air Regulator, Filter, Switch, Gauge 720-01-1-2005-01 0

Concave Assembly 720-99-1-1100-01 2

Contract 720-99-1-0053-01 2

Countershaft Assembly 720-99-1-1204-01 3

Countershaft Extension Assembly 720-99-1-1304-01 2

Crusher Assembly 720-99-1-0003-01 3

Drive Guard Assembly 720-99-1-1305-01 2

Eccentric Assembly 720-97-1-0801-01 0

Eccentric Cart Assembly 720-99-1-1502-01 1

Hydraulic Cylinder Assembly 720-99-1-0904-01 0

Hydraulic Adjustment Pump Unit 6.501720 4

Hydraulic System Schematic 720-99-1-1404-01 3

Lubrication Pump Unit 6.501734 3

Lubrication System Schematic 720-99-1-1405-01 3

Main Shaft Assembly (113” diameter mantle) 720-00-1-1002-01 1

Main Shaft Assembly (115” diameter mantle) 720-00-1-1003-01 1

Middle Shell Assembly 720-94-2-0402-00 0

Pushbutton Station Cooler Unit 720-99-1-1409-01 0

Pushbutton Station Hydraulic Unit 720-99-1-1408-01 1

Pushbutton Station Lubrication Unit 720-99-1-1407-01 1

Spares 720-99-1-0102-01 1

Spider Assembly 720-99-1-0202-01 3

Spider Lubrication System 720-99-1-1406-01 1

Tool List 720-99-1-1501-01 1

Top Shell Assembly 720-99-1-0302-01 1


9.0PAGE 1 OF 1


9.0 LUBRICANT LISTThis section includes the Lubrication Summary sheet for FFE Minerals proprietaryequipment. Lubrication requirements of pumps, motors and couplings are located inVolume 2, Vendor Information.

Lubrication Data Sheets

Equipment Name Equipment No. Sheet No.

Primary Crusher—Mainshaft Dust Seal 210-CR-001 1 of 4

Primary Crusher—Hydraulic System Pumping Unit 210-CR-001-1 2 of 4

Primary Crusher—Lubrication Oil Pumping Unit 210-CR-001-2 3 of 4

Primary Crusher—Spider Lubrication System 210-CR-001-4 4 of 4

LUBRICATION SUMMARY SHEET #1

COMPONENT CRUSHERHYDRAULIC SYSTEM

CRUSHERLUBRICATION

SYSTEMNUMBER OF COMPONENTS/LUBRICATION POINTS 1 1

REFERENCE DRAWING FORLUBRICATION POINT

Hydraulic UnitAssembly Drawing

Lubrication UnitAssembly Drawing

1 Shell Omala Shell Omala

2 Mobil Gear Mobil Gear

LUB

RIC

AN

T

SPECIFICATIONISO VG 320

(1500 SSU @ 38C)ISO VG 320

(1500 SSU @ 38C)

INITIAL FILL QUANITY 150 Gallon(189 Liters)

1000 Gallons(3785 Liters)

FREQUENCY Monthly Check Monthly Check

AD

D

QUANTITY As needed to fill tank As needed to fill tank

FREQUENCY

Yearly orif tank becomes

contaminated withforeign matter

Yearly orif tank becomes

contaminated withforeign matter

SCH

EDU

LE

CH

AN

GE

QUANTITY Full change 150 Gallon(189 Liters)

Full change 1000Gallon (3785 Liters)

TOTAL QUANITY REQUIRED FOR ONEYEAR OF OPERATION (ESTIMATED)



COMMENTS none none

LUBRICATION SUMMARY SHEET #2

COMPONENT MAIN SHAFT DUSTSEAL

COUNTERSHAFTTRIPLE SEAL

SPIDERLUBRICATION

SYSTEMNUMBER OF COMPONENTS/LUBRICATION POINTS 1 1 1

REFERENCE DRAWING FORLUBRICATION POINT

Mainshaft AssemblyDrawing

Countershaft AssemblyDrawing

Spider GreaseLubrication System

Drawing

1 Lithium-Sodium Grease Lithium-Sodium Grease Lithium-Sodium Grease

2 Sodium CalciumGrease

Sodium CalciumGrease

Sodium CalciumGrease

LUB

RIC

AN

T

SPECIFICATION NLGI #1 NLGI #1 NLGI #1 SummerNLGI #0 Winter

INITIAL FILL QUANITY Less than 1 gallon(3.8 Liter)

Less than 1 gallon(3.8 Liter)

55 gallon (Barrel)(208 Liter)

FREQUENCY Monthly Check Monthly Check Monthly Check

AD

D

QUANTITY Less than 1 gallon(3.8 Liter)

Less than 1 gallon(3.8 Liter)

(till grease is purgedand leaks from

countershaft seal)

One barrel as needed

FREQUENCY ------------------------- ------------------------- -------------------------

SCH

EDU

LE

CH

AN

GE

QUANTITY ------------------------- ------------------------- -------------------------

TOTAL QUANITY REQUIRED FOR ONEYEAR OF OPERATION (ESTIMATED)

5 Gallons(18.9 Liter)

2 Gallons(7.6 Liter)

110 Gallons(416 Liter)

COMMENTS none none

Alarm is present whenthe grease container isempty and the system

cannot complete a cycle


10.0PAGE 1 OF 1


10.0 AIR AND WATER REQUIREMENTSThere are no special air and/or water requirements for the crusher. However, air sup-plied to the crusher should be 10 cfm and 50 psi.


11.0PAGE 1 OF 1


11.0 ELECTRICAL LOAD LISTThis section includes the electrical load list for the primary crusher.

DOCUMENT NO. 8.500378

ELECTRICAL LOAD LIST REVISION 2

ESCONDIDA CRUSHER 24 JANUARY 2002

FFEM CONTRACT 99-31325-720CHILE

R LOAD DESCRIPTION LOAD TYPE THREE-PHASE LOADS MOTORS

E C&ID CODE STARTING NOMINAL ENCLOSURE

V TAG NUMBER DRAWING NO. EQUIPMENT OR SYSTEM SUBSYSTEM C I S H.P. V kW LETTER TIME (SEC) * F.L.A. * S.F. RPM TYPE COMMENTS/SPECIAL DESIGN INFO.

2 210 CR 001 A 1.503789 CRUSHER MAIN MOTOR C 1000 4000 746 G 1.00 500 TEFC

MOTOR SUPPLIED WITH SPACE HEAETRS,WDG RTD'S AND BRG. RTD'S, VIBRATIONSWITCHES AND SEPARATELY POWERCOOLING BLOWER

TOTALS 4000 746 KWTOTAL CONNECTED LOAD, INCLUDING STANDBY AND INTERMITTENT LOADS

2 210 CR 001 B 1.503789 CRUSHER MAIN MOTOR COOLING BLOWER C 5 460 4 < 20 7.5 1500 TEFC

210 CR 001 1A 1.503791 CRUSHER HYDRAULIC OIL SUPPLY PUMP (MAIN) C 7.5 460 5.6 G <20 8.7 1.15 1500 TEFC

210 CR 001 1B 1.503791 CRUSHER HYDRAULIC OIL SUPLLY PUMP (STAND BY) S 7.5 460 5.6 G <20 8.7 1.15 1500 TEFC

210 CR 001 1HE1 1.503791 CRUSHER HYDRAULIC OIL RESERVOIR HEATER 1 I 220 1.5 1.5 Kw, SINGLE PHASE SUPPLY

210 CR 001 1HE2 1.503791 CRUSHER HYDRAULIC OIL RESERVOIR HEATER 2 I 220 1.5 1.5 Kw, SINGLE PHASE SUPPLY

210 CR 001 2A 1.503792 CRUSHER LUBRICATION OIL SUPPLY PUMP (MAIN) C 15 460 11.2 G <20 17.57 1.15 1500 TEFC

210 CR 001 2B 1.503792 CRUSHER LUBRICATION OIL SUPPLY PUMP (STAND BY) S 15 460 11.2 G <20 17.57 1.15 1500 TEFC

210 CR 001 2C 1.503792 CRUSHER LUBRICATION OIL COOLER OIL PUMP (MAIN) I 15 460 11.2 G <20 17.57 1.15 1500 TEFC

210 CR 001 2D 1.503792 CRUSHER LUBRICATION OIL COOLER OIL PUMP (STAND BY) S 15 460 11.2 G <20 17.57 1.15 1500 TEFC

210 CR 001 2HE1 1.503792 CRUSHER LUBRICATION OIL RESERVOIR HEATER 1 I 460 6



210 CR 001 3A 1.503792 CRUSHER LUBRICATION OIL COOLER 1 FAN I 15 460 11.2 G <20 17.57 1.15 750 TEFC

210 CR 001 3B 1.503792 CRUSHER LUBRICATION OIL COOLER 2 FAN I 15 460 11.2 G <20 17.57 1.15 750 TEFC

TOTAL 460 100.4 KWTOTAL CONNECTED LOAD, INCLUDING STANDBY AND INTERMITTENT LOADS

220 3 KW

* INFORMATION WILL ONLY BE SUPPLIED WHEN THIS DOCUMENT IS ISSUED FOR AS-BUILT.

1 NOMINAL AC SUPPLY FREQUENCY IS 50 HZ.

2 SINGLE PHASE LOADS ARE NOT INCLUDED ON THIS LIST UNLESS OTHERWISE LISTED IN THE COMMENTS COLUMN.

3 FLA ARRIVED BASED ON NEC, FOR MAIN MOTOR COOLING BLOWER.

8500378b PAGE 2PRINT DATE: 01/29/2002


12.0PAGE 1 OF 1


12.0 FIELD INSTRUMENT LISTThis section includes the field instrument list for the primary crusher.


FIELD INSTRUMENT LIST REVISION 3

ESCONDIDA CRUSHER 210-CR-001 24 JANUARY 2002


R INSTRUMENT DESCRIPTION CALIBRATED RANGE

E C&ID ENGR. SUPPLIED

V TAG NUMBER DRAWING NO. EQUIPMENT OR SYSTEM SUBSYSTEM MEASURED VARIABLE DEVICE UNITS MIN. MAX. SETPOINT BY MANUFACTURER MODEL NO. COMMENTS

1 210 CR 001 4CO 1.503791 SPIDER LUBRICATION LOCAL CONTROL PANEL GREASE LUBRICAITON CONTROLLER FFEM TRABON MAXI-MONITOR MARK-III

210 TE 7001 A 1.503789 CRUSHER MOTOR BEARING INBOARD BRG. TEMP. RTD PT 100 DEG.C 0 100 FFEM MINCO S51PA082Z60 HARDWIRED TO MOTOR PROTECTION RELAY

1 210 TE 7001 E 1.503789 CRUSHER MOTOR STATOR WINDING TEMPERATURE RTD PT 100 DEG.C 0 100 FFEM ABB HARDWIRED TO MOTOR PROTECTION RELAY

1 210 TE 7001 D 1.503789 CRUSHER MOTOR STATOR WINDING TEMPERATURE RTD PT 100 DEG.C 0 100 FFEM ABB HARDWIRED TO MOTOR PROTECTION RELAY

1 210 TE 7001 C 1.503789 CRUSHER MOTOR STATOR WINDING TEMPERATURE RTD PT 100 DEG.C 0 100 FFEM ABB HARDWIRED TO MOTOR PROTECTION RELAY

1 210 VS 7001 A 1.503789 CRUSHER MOTOR INBOARD BEARING VIBRATION SWITCH MM/SEC 3 40 5.6 FFEM ABB/PMC-BETA 440S

1 210 VS 7001 B 1.503789 CRUSHER MOTOR OUTBOARD BEARING VIBRATION SWITCH MM/SEC 3 40 5.6 FFEM ABB/PMC-BETA 440S

1 210 TE 7001 H 1.503789 CRUSHER MOTOR STATOR WINDING TEMPERATURE RTD PT 100 DEG.C 0 100 FFEM ABB HARDWIRED TO MOTOR PROTECTION RELAY

1 210 TE 7001 F 1.503789 CRUSHER MOTOR STATOR WINDING TEMPERATURE RTD PT 100 DEG.C 0 100 FFEM ABB HARDWIRED TO MOTOR PROTECTION RELAY

210 TE 7001 B 1.503789 CRUSHER MOTOR BEARING OUTBOARD BRG. TEMP. RTD PT 100 DEG. C 0 100 FFEM MINCO S51PA082Z60 HARDWIRED TO MOTOR PROTECTION RELAY

1 210 TE 7001 G 1.503789 CRUSHER MOTOR STATOR WINDING TEMPERATURE RTD PT 100 DEG.C 0 100 FFEM ABB HARDWIRED TO MOTOR PROTECTION RELAY

210 TE 7002 1.503789 CRUSHER COUNTERSHAFT INBOARD BEARING TEMPERATURE RTD PT 100 DEG. C 0 100 FFEM MINCO S51PA082Z60

2 210 PCV 7003 1.503789 CRUSHER SEAL AIR PRESSURE REGULATOR kPa 3 7 FFEM PARKER 035501020

210 TE 7003 1.503789 CRUSHER COUNTERSHAFT OUTBOARD BEARING TEMPERATURE RTD PT 100 DEG. C 0 100 FFEM MINCO S51PA095Z30

3 210 ZT 7005 1.503789 CRUSHER MANTLE POSITION TRANSMITTER MM 0 305 FFEM BALLUFF BTL-5-E10-MO457-K-5R32

3 210 ZY 7005 1.503789 CRUSHER MANTLE POSITION CONVERTER %MAX 0 100 FFEM M-SYSTEM 49AV-2A-K PART OF 210-ZIT-7005

3 210 ZIT 7005 1.503789 CRUSHER MANTLE POSITION INDICATING TRANSMITTER FFEM M-SYSTEM W2DY-24AA-M2

210 LG 7011 1.503790 CRUSHER HYDRAULIC RESERVOIR OIL LEVEL GAUGE MM 0 750 FFEM LUBE DEVICES G608-30-A-1.5

210 TI 7011 1.503790 CRUSHER HYDRAULIC RESERVOIR OIL TEMPERATURE GAUGE DEG. C -20 120 FFEM ASHCROFT 30EI60R060

210 TE 7011 1.503790 CRUSHER HYDRAULIC RESERVOIR OIL TEMPERATURE RTD PT 100 DEG. C -20 120 FFEM ROSEMOUNT 0068R21N00A045T22E5

210 TT 7011 1.503790 CRUSHER HYDRAULIC RESERVOIR OIL TEMPERATURE TRANSMITTER DEG.C 0 100 FFEM ROSEMOUNT 3144D1E5B4 TRANSMITTER WITH HART PROTOCOL

2 210 LIT 7011 1.503790 CRUSHER HYDRAULIC RESERVOIR OIL LEVEL INDICATING TRANSMITTER % 0 100 50 DECR* FFEM ROSEMOUNT 3051L2AG0MD21AAME5*FROM THE BOTTOM OF THE TANK.TRANSMITTER WITH HART PROTOCOL

210 PSV 7012 B 1.503790 CRUSHER HYDRAULIC PUMP2 DISCHARGE OIL PRESSURE RELEIF VALVE Kpa 6895 INCR. FFEM CONSOLIDATED 19096MC-1-CC-MS-31-MT-FT-LA

210 PSV 7012 A 1.503790 CRUSHER HYDRAULIC PUMP1 DISCHARGE OIL PRESSURE RELIEF VALVE kPa 6895 INCR. FFEM CONSOLIDATED 19096MC-1-CC-MS-31-MT-FT-LA

210 PI 7013 A 1.503790 CRUSHER HYDRAULIC PUMP1 DISCHARGE OIL PRESSURE GAUGE kPa 0 10000 FFEM ASHCROFT 35-1009-SWL-04L

210 PI 7013 B 1.503790 CRUSHER HYDRAULIC PUMP2 DISCHARGE OIL PRESSURE GAUGE Kpa 0 10000 FFEM ASHCROFT 35-1009-SWL-04L

210 HV 7014 A 1.503790 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE RAISE SOLENOID VALVE FFEM REXROTH 4WE10D3X/CW110N9Z55L/V

1 210 HS 7014 B 1.503790 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE PUSH-BUTTON FFEM ALLEN BRADELY 800T-B2A

210 HV 7014 B 1.503790 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE LOWER SOLENOID VALVE FFEM REXROTH 4WE10D3X/CW110N9Z55L/V

1 210 HS 7014 A 1.503790 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE PUSH-BUTTON FFEM ALLEN BRADELY 800T-B2A

2 210 PDIT 7015 1.503790 CRUSHER HYDRAULIC RECIRC. OIL FILTER DIFF PRESSURE INDICATING TRANSMITTER kPaD 0 1035 173 INCR FFEM ROSEMOUNT 1151DP7S52B2M4FM TRANSMITTER WITH HART PROTOCOL

210 PI 7015 1.503790 CRUSHER HYDRAULIC RECIRC. OIL FILTER INLET OIL PRESSURE GAUGE kPa 0 10000 FFEM ASHCROFT 35-1009-SWL-04L

1 210 PIT 7016 1.503789 CRUSHER HYDRAULIC ACCUMULATOR OIL PRESSURE INIDCATING TRANSMITTER kPa 0 27579 FFEM ROUSEMOUNT 1151GP8S52M4 TRANSMITTER WITH HART PROTOCOL

210 PI 7016 1.503789 CRUSHER HYDRAULIC ACCUMULATOR OIL PRESSURE GAUGE kPa 0 10000 FFEM ASHCROFT 35-1009-SW-04L

1 210 PSV 7017 1.503789 CRUSHER HYDRAULIC OIL PRESSURE RELIEF VALVE kPa 520 6900 2760 INCR. FFEM VICKERS CF-24-B-10

1 210 HS 7018 1.503790 CRUSHER HYDRAULIC NORMAL/MAINTENANCE SELECTOR SWITCH FFEM ALLEN BRADELY 800MR-HH2BLA

210 TI 7021 1.503792 CRUSHER LUBRICATION RESERVOIR OIL TEMPERATURE GAUGE DEG. C -20 120 FFEM ASHCROFT 30EI60E120

210 LG 7021 1.503792 CRUSHER LUBRICATION RESERVOIR OIL LEVEL GAUGE MM 0 1524 FFEM LUBE DEVICES G608-60A-1.5"

1 210 TE 7021 1.503792 CRUSHER LUBRICATION RESERVOIR OIL TEMPERATURE RTD PT 100 DEG. C 0 100 FFEM ROSEMOUNT 0068R21N00A105T22E5

2 210 LIT 7021 1.503792 CRUSHER LUBRICATION RESERVOIR OIL LEVEL INDICATING TRANSMITTER % 0 100 60 DECR* FFEM ROSEMOUNT 3051L2AG0MD21AAM5E5*FROM THE BOTTOM OF THE TANK.TRANSMITTER WITH HART PROTOCOL

1 210 TT 7021 1.503792 CRUSHER LUBRICATION RESERVOIR OIL TEMPERATURE TRANSMITTER DEG. C 0 100 FFEM ROSEMOUNT 3144D1E5B4 TRANSMITTER WITH HART PROTOCOL

2 210 PSV 7022 B 1.503792 CRUSHER LUBRICATION STANDBY OIL PUMP DISCH. OIL PRESSURE RELIEF VALVE kPa 400 1200 1035 INCR. FFEM FULFLO VJ-8R-XS

1 210 TIT 7022 1.503792 CRUSHER LUBRICATION OIL COOLING UNIT AMBIENT TEMPERATURE INIDCATING TRANSMITTER DEG.C -20 60 FFEM STATUS INSTRUMENTS DM-3410

1 210 TE 7022 1.503792 CRUSHER LUBRICATION OIL COOLING UNIT AMBIENT TEMEPRATURE ELEMENT RTD PT 100 DEG.C -200 850 FFEM STATUS INSTRUMENTS CONNECTED TO 210-TIT-7021

8500379c PAGE 2PRINT DATE: 01/29/2002








2 210 PSV 7022 C 1.503792 CRUSHER LUBRICATION MAIN COOLER PUMP DISCHARGE OIL PRESSURE RELIEF VALVE kPa 400 1200 1035 INCR. FFEM FULFLO VJ-8R-XS

2 210 PSV 7022 D 1.503792 CRUSHER LUBRICATION STANDBY COOLER PUMP DISCH. OIL PRESSURE RELIEF VALVE kPa 400 1200 1035 INCR. FFEM FULFLO VJ-8R-XS

2 210 PSV 7022 A 1.503792 CRUSHER LUBRICATION MAIN OIL PUMP DISCHARGE OIL PRESSURE RELIEF VALVE kPa 400 1200 1035 INCR. FFEM FULFLO VJ-8R-XS

210 PI 7023 A 1.503792 CRUSHER LUBRICATION MAIN OIL PUMP DISCHARGE OIL PRESSURE GAUGE kPa 0 1600 FFEM ASHCROFT 35-1009-SWL-04L

210 PI 7023 B 1.503792 CRUSHER LUBRICATION STANDBY OIL PUMP DISCHARGE OIL PRESSURE GAUGE kPa 0 1600 FFEM ASHCROFT 35-1009-SWL-04L

210 PI 7023 D 1.503792 CRUSHER LUBRICATION STANDBY COOLER PUMP DISCH. OIL PRESSURE GAUGE Kpa 0 1600 FFEM ASHCROFT 35-1009-SWL-04L

210 PI 7023 C 1.503792 CRUSHER LUBRICATION MAIN COOLER PUMP DISCHARGE OIL PRESSURE GAUGE kPa 0 1600 FFEM ASHCROFT 35-1009-SWL-04L

2 210 PDIT 7024 1.503792 CRUSHER LUBRICATION OIL SUPPLY FILTER DIFF PRESSURE INDICATING TRANSMITTER kPaD 0 1035 173 INCR FFEM ROSEMOUNT 1151DP7S52B2M4FM

210 ZSC 7025 1.503792 CRUSHER LUBRICATION OIL COOLER 1 DRAIN VALVE POSITION SWITCH FFEM JAMESBURY EU25-01M INTEGRAL W/ ACTUATOR

210 PI 7025 1.503792 CRUSHER LUBRICATION CRUSHER SUPPLY LINE OIL PRESSURE GAUGE kPa 0 1600 FFEM ASHCROFT 35-1009-SWL-04L

210 ZSO 7025 1.503792 CRUSHER LUBRICATION OIL COOLER 1 DRAIN VALVE POSITION SWITCH FFEM JAMESBURY EU25-01M INTEGRAL W/ ACTUATOR

210 TI 7025 1.503792 CRUSHER LUBRICATION CRUSHER SUPPLY LINE OIL TEMPERATURE GAUGE DEG. C -20 120 FFEM ASHCROFT 30EI60E040

210 HV 7025 1.503792 CRUSHER LUBRICATION OIL COOLER 1 OIL DRAIN VALVE FFEM JAMESBURY 9FB-2200MT/ER50-02

210 FIT 7026 1.503789 CRUSHER LUBRICATION ECCENTRIC SUPPLY LINE OIL FLOW INDICATING TRANSMITTER LPM 0 189 132 DECR. FFEM UNIVERSAL FLOW MN-FSB-50GM-16-1000V.9-1R-30D

210 TI 7027 1.503792 CRUSHER LUBRICATION CRUSHER RETURN LINE OIL TEMPERATURE GAUGE DEG. C -20 120 FFEM ASHCROFT 30EI60E060

2 210 TT 7027 1.503792 CRUSHER LUBRICATION RETURN OIL LINE OIL TEMPERATURE TRANSMITTER DEG. C 0 100 60 INCR. FFEM ROSEMOUNT 3144D1E5B4 TRANSMITTER WITH HART PROTOCOL

1 210 TE 7027 1.503792 CRUSHER LUBRICATION RETURN OIL LINE OIL TEMPERATURE RTD PT 100 DEG.C 0 100 FFEM ROSEMOUNT 0068R21N00A105T22E5

1 210 FIT 7028 1.503792 CRUSHER LUBRICATION COOLER RETURN LINE OIL FLOW INDICATING TRANSMITTER LPM 0 340 256 DECR. FFEM UNIVERSAL FLOW MN-FSB-90GM-16-1000V.9-1R-50D

1 210 TI 7028 1.503792 CRUSHER LUBRICATION RETURN LINE OIL TEMPERATURE GAUGE DEG.C -20 120 FFEM ASHCROFT 30EI60R060

210 FIT 7029 1.503789 CRUSHER LUBRICATION OUTER ECCENTRIC SUPPLY LINE OIL FLOW INDICATING TRANSMITTER LPM 0 189 132 DECR. FFEM UNIVERSAL FLOW MN-FSB-50GM-16-1000V.9-1R-30D

210 FIT 7030 1.503789 CRUSHER LUBRICATION COUNTERSHAFT SUPPLY LINE OIL FLOW INDICATING TRANSMITTER LPM 0 23 13 DECR. FFEM UNIVERSAL FLOW SN-FSB-6GM-6-1000V.9-1WR-3.5D

1 210 PI 7031 1.503792 CRUSHER LUBRICAITON COOLER SUPPLY LINE OIL PRESSURE GAUGE Kpa 0 1368 FFEM ASHCROFT 25-1009-SWL-04L

1 210 TI 7031 1.503792 CRUSHER LUBRICATION COOLER SUPPLY LINE OIL TEMPERATURE GAUGE DEG.C 17 93 FFEM ASHCROFT 30EI60L040

1 210 PI 7032 1.503792 CRUSHER LUBRICATION COOLER RETURN LINE OIL PRESSURE GAUGE Kpa 0 1368 FFEM ASHCROFT 25-1009-SWL-04L

1 210 TI 7032 1.503792 CRUSHER LUBRICATION COOLER RETURN LINE OIL TEMPERATURE GAUGE DEG.C 17 93 FFEM ASHCROFT 30EI60L060

1 210 ZSC 7033 1.503792 CRUSHER LUBRICATION OIL COOLER 2 DRAIN VALVE POSITION SWITCH FFEM APOLLO INTEGRAL W/ ACTUATOR

1 210 HV 7033 1.503792 CRUSHER LUBRICATION OIL COOLER 2 OIL DRAIN VAVLE FFEM APOLLO 76-108-37/EVA40

1 210 ZSO 7033 1.503792 CRUSHER LUBRICATION OIL COOLER 2 DRAIN VALVE POSITION SWITCH FFEM APOLLO INTEGRAL W/ ACTUATOR

1 210 PI 7034 1.503792 CRUSHER LUBRICATION COOLER RETURN LINE OIL PRESSURE GAUGE Kpa 0 1368 FFEM ASHCROFT 25-1009-SWL-04L

1 210 TI 7034 1.503792 CRUSHER LUBRICATION COOLER RETURN LINE OIL TEMPERATURE GAUGE DEG. C 17 93 FFEM ASHCROFT 30EI60L060

210 TI 7035 1.503792 CRUSHER LUBRICATION COOLER SUPPLY LINE OIL TEMPERATURE GAUGE DEG. C -20 120 FFEM ASHCROFT 30EI60R040

1 210 HS 7036 1.503792 CRUSHER LUBRICATION NORMAL/MAINTENANCE SELECTOR SWITCH FFEM ALLEN BRADELY 800MR-HH2BLA

210 PCV 7041 1.503791 SPIDER LUBRICATION SUPPLY LINE COMPRESSED AIR PRESS. REGULATOR kPa 0 1725 FFEM FISHER SERIES 64

210 KV 7041 1.503791 SPIDER LUBRICATION SUPPLY LINE COMPRESSED AIR SOLENOID VALVE FFEM SCHRADER 745130116 SOLENOID SWITCHED ON BY CONTROLLER

210 PI 7041 1.503791 SPIDER LUBRICATION SUPPLY LINE COMPRESSED AIR PRESS. GAUGE kPa 0 600 FFEM ASHCROFT 25-1009-SW-02B

210 PI 7042 1.503791 SPIDER LUBRICATION SUPPLY LINE GREASE PRESSURE GAUGE kPa 0 35000 FFEM ASHCROFT 25-1009-SW-02L

210 FQS 7042 1.503791 SPIDER LUBRICATION SUPPLY LINE GREASE FLOW CYCLE SWITCH FFEM TRABON 510-599-000

210 YL2 CR01 2C 1.503792 CRUSHER LUBRICATION MAIN COOLER PUMP OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

210 YL1 CR01 2C 1.503792 CRUSHER LUBRICATION MAIN COOLER PUMP ON INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

210 YL1 CR01 3B 1.503792 CRUSHER LUBRICATION COOLER FAN 2 ON INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

210 YL1 CR01 2D 1.503792 CRUSHER LUBRICATION STANDBY COOLER PUMP ON INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

1 210 HS1 CR01 3A 1.503792 CRUSHER LUBRICATION COOLER FAN 1 LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

210 HS2 CR01 1A 1.503790 CRUSHER HYDRAULIC OIL PUMP1 LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

210 HS2 CR01 3A 1.503792 CRUSHER LUBRICATION COOLER FAN 1 LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

210 YL2 CR01 2B 1.503792 CRUSHER LUBRICATION STANDBY OIL PUMP OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

8500379c PAGE 3PRINT DATE: 01/29/2002








1 210 HS1 CR01 3B 1.503792 CRUSHER LUBRICATION COOLER FAN 2 LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

210 HS2 CR01 3B 1.503792 CRUSHER LUBRICATION COOLER FAN 2 LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

210 YL1 CR01 3A 1.503792 CRUSHER LUBRICATION COOLER FAN 1 ON INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

210 YL2 CR01 3A 1.503792 CRUSHER LUBRICATION COOLER FAN 1 OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

210 YL2 CR01 2D 1.503792 CRUSHER LUBRICATION STANDBY COOLER PUMP OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

210 HS2 CR01 2A 1.503792 CRUSHER LUBRICATION MAIN OIL PUMP LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

210 YL2 CR01 3B 1.503792 CRUSHER LUBRICATION COOLER FAN 2 OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

1 210 HS1 CR01 2A 1.503792 CRUSHER LUBRICATION MAIN OIL PUMP LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

1 210 HS1 CR01 2B 1.503792 CRUSHER LUBRICATION STANDBY OIL PUMP LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

1 210 HS1 CR01 2C 1.503792 CRUSHER LUBRICATION MAIN COOLER PUMP LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

1 210 HS1 CR01 2D 1.503792 CRUSHER LUBRICATION STANDBY COOLER PUMP LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

1 210 HS1 CR01 1A 1.503790 CRUSHER HYDRAULIC OIL PUMP1 LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

210 YL1 CR01 1B 1.503790 CRUSHER HYDRAULIC OIL PUMP 2 ON INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

210 YL1 CR01 1A 1.503790 CRUSHER HYDRAULIC OIL PUMP 1 ON INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

210 YL1 CR01 2A 1.503790 CRUSHER LUBRICATION MAIN OIL PUMP ON INIDCATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

210 HS2 CR01 1B 1.503790 CRUSHER HYDRAULIC OIL PUMP2 LOCAL JOG PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16R

210 HS2 CR01 2D 1.503792 CRUSHER LUBRICATION STANDBY COOLER PUMP LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

210 HS2 CR01 2C 1.503792 CRUSHER LUBRICATION MAIN COOLER PUMP LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

210 YL2 CR01 2A 1.503792 CRUSHER LUBRICATION MAIN OIL PUMP OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

210 YL1 CR01 2B 1.503792 CRUSHER LUBRICATION STANDBY OIL PUMP ON INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16R INDICATING LAMP IS PART OF PUSH BUTTON

210 YL2 CR01 1A 1.503790 CRUSHER HYDRAULIC OIL PUMP 1 OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

210 HS2 CR01 2B 1.503792 CRUSHER LUBRICATION STANDBY OIL PUMP LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

1 210 HS1 CR01 1B 1.503790 CRUSHER HYDRAULIC OIL PUMP2 LOCAL STOP PUSH BUTTON STATION FFEM ALLEN-BRADLEY 800T-PBH16G

210 YL2 CR01 1B 1.503790 CRUSHER HYDRAULIC OIL PUMP 2 OFF INDICATING LAMP FFEM ALLEN-BRADLEY 800T-PBH16G INDICATING LAMP IS PART OF PUSH BUTTON

8500379c PAGE 4PRINT DATE: 01/29/2002


13.0PAGE 1 OF 1


13.0 INPUT/OUTPUT SIGNAL LISTThis section includes the input/output signal list for the primary crusher.


INPUT/OUTPUT SIGNAL LIST REVISION 2

ESCONDIDA CRUSHER 210-CR-001 02 AUGUST 2000


R I/O DESCRIPTION SIGNAL RANGE

E SOURCE C&ID I/O TYPE @ SIGNAL ENGR.

V TAG NUMBER DRAWING NO. DEVICE AI AO DI DO EQUIPMENT OR SYSTEM SUBSYSTEM MEASURED VARIABLE STATE STATUS UNITS MIN. MAX. COMMENTS

210 VS 7001 A 1.503789 SWITCH 1 CRUSHER MOTOR INBOARD BEARING VIBRATION HIGH 1 MM/SEC 3 40

210 VS 7001 B 1.503789 SWITCH 1 CRUSHER MOTOR OUTBOARD BEARING VIBRATION HIGH 1 MM/SEC 3 40

210 TE 7002 1.503789 RTD PT 100 1 CRUSHER COUNTERSHAFT INBOARD BEARING TEMPERATURE PT100 DEG. C 0 100

210 TE 7003 1.503789 RTD PT 100 1 CRUSHER COUNTERSHAFT OUTBOARD BEARING TEMPERATURE PT100 DEG. C 0 100

1 210 ZIT 7005 1.503789 INDICATING TRANSMITTER 1 CRUSHER MANTLE POSITION 4-20 Ma MM 0 305 ZERO IS FULLY-DOWN POINT OF TRAVEL.

2 210 TIC 7011 1.503790 INDICATING CONTROLLER 1 CRUSHER HYDRAULIC RESERVOIR TEMPERATURE HEATERS ON 1 CONTROLS HEATER 210-CR-001-1HE1

1 210 TT 7011 1.503790 TRANSMITTER 1 CRUSHER HYDRAULIC RESERVOIR OIL TEMPERATURE HEATERS ON 4-20 Ma DEG.C 0 100 CONTROLS HEATERS 210-CR-001-1HE1, -1HE2

2 210 TIC 7011 1.503790 INDICATING CONTROLLER 1 CRUSHER HYDRAULIC RESERVOIR TEMPERATURE HEATERS ON 1 CONTROLS HEATER 210-CR-001-1HE2

2 210 LIT 7011 1.503790 INDICATING TRANSMITTER 1 CRUSHER HYDRAULIC RESERVOIR OIL LEVEL 4-20 Ma % 0 100

1 210 HS 7014 A 1.503790 PUSH-BUTTON 1 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE RAISE COMMAND 1

210 HV 7014 A 1.503790 SOLENOID VALVE 1 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE RAISE 1

1 210 HS 7014 B 1.503790 PUSH-BUTTON 1 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE LOWER COMMAND 1

210 HV 7014 B 1.503790 SOLENOID VALVE 1 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE LOWER 1

210 PDIT 7015 1.503790 INDICATING TRANSMITTER 1 CRUSHER HYDRAULIC RECIRC. OIL FILTER DIFF PRESSURE 4-20 Ma kPaD 0 1035

1 210 PIT 7016 1.503789 INIDCATING TRANSMITTER 1 CRUSHER HYDRAULIC ACCUMULATOR OIL PRESSURE 4-20 Ma kPa 0 27579

1 210 HS 7018 1.503790 SELECTOR SWITCH 1 CRUSHER HYDRAULIC MAINTANANCE MODE SELECTED HIGH 1

1 210 HS 7018 1.503790 SELECTOR SWITCH 1 CRUSHER HYDRAULIC NORMAL MODE SELECTED LOW 0

2 210 TIC 7021 1.503792 INDICATING CONTROLLER 1 CRUSHER LUBRICATION RESERVOIR TEMPERATURE HEATERS ON 1 CONTROLS HEATER 210-CR-001-2HE1



2 210 LIT 7021 1.503792 INDICATING TRANSMITTER 1 CRUSHER LUBRICATION RESERVOIR OIL LEVEL 4-20 Ma % 0 100

1 210 TT 7021 1.503792 TRANSMITTER 1 CRUSHER LUBRICATION RESERVOIR OIL TEMPERATURE 4-20 Ma DEG. C 0 100

1 210 TIT 7022 1.503792 INIDCATING TRANSMITTER 1 CRUSHER LUBRICATION OIL COOLING UNIT AMBIENT TEMPERATURE 4-20 Ma DEG.C -20 60

210 PDIT 7024 1.503792 INDICATING TRANSMITTER 1 CRUSHER LUBRICATION OIL SUPPLY FILTER DIFF PRESSURE 4-20 Ma kPaD 0 1035

2 210 HV 7025 1.503792 COOLER DRAIN VALVE 1 CRUSHER LUBRICATION OIL COOLER 1 DRAIN VALVE VALVE OPEN 1

2 210 HV 7025 1.503792 COOLER DRAIN VALVE 1 CRUSHER LUBRICATION OIL COOLER 1 DRAIN VALVE VALVE CLOSE 1

210 ZSC 7025 1.503792 SWITCH 1 CRUSHER LUBRICATION OIL COOLER 1 DRAIN VALVE POSITION CLOSED 1

210 ZSO 7025 1.503792 SWITCH 1 CRUSHER LUBRICATION OIL COOLER 1 DRAIN VALVE POSITION OPEN 1

210 FIT 7026 1.503789 INDICATING TRANSMITTER 1 CRUSHER LUBRICATION ECCENTRIC SUPPLY LINE OIL FLOW 4-20 Ma LPM 0 189

1 210 TT 7027 1.503792 TRANSMITTER 1 CRUSHER LUBRICATION RETURN OIL LINE OIL TEMPERATURE 4-20 mA DEG. C 0 100

1 210 FIT 7028 1.503295 INDICATING TRANSMITTER 1 CRUSHER LUBRICATION COOLER RETURN LINE OIL FLOW 4-20 Ma LPM 0 340

210 FIT 7029 1.503789 INDICATING TRANSMITTER 1 CRUSHER LUBRICATION OUTER ECCENTRIC SUPPLY LINE OIL FLOW 4-20 Ma LPM 0 189

210 FIT 7030 1.503789 INDICATING TRANSMITTER 1 CRUSHER LUBRICATION COUNTERSHAFT SUPPLY LINE OIL FLOW 4-20 Ma LPM 0 23

2 210 HV 7033 1.503792 COOLER DRAIN VALVE 1 CRUSHER LUBRICATION OIL COOLER 2 DRAIN VALVE VALVE OPEN 1

8500380b PAGE 2 PRINT DATE: 10/04/2001








2 210 HV 7033 1.503792 COOLER DRAIN VALVE 1 CRUSHER LUBRICATION OIL COOLER 2 DRAIN VALVE VALVE CLOSE 1

210 ZSO 7033 1.503792 SWITCH 1 CRUSHER LUBRICATION OIL COOLER 2 DRAIN VALVE POSITION OPEN 1

210 ZSC 7033 1.503792 SWITCH 1 CRUSHER LUBRICATION OIL COOLER 2 DRAIN VALVE POSITION CLOSED 1

1 210 HS 7036 1.503792 SELECTOR SWITCH 1 CRUSHER LUBRICATION MAINTANANCE MODE SELECTED HIGH 1

1 210 HS 7036 1.503792 SELECTOR SWITCH 1 CRUSHER LUBRICATION NORMAL MODE SELECTED LOW 0

210 XA 7043 1.503791 RELAY 1 SPIDER LUBRICATION LOCAL CONTROL PANEL SYSTEM STATUS IN FAULT 0

210 YS 7043 1.503791 RELAY OUTPUT 1 SPIDER LUBRICATION LOCAL CONTROL PANEL REMOTE RUN COMMAND 1

210 YY 7043 1.503791 RELAY OUTPUT 1 SPIDER LUBRICATION LOCAL CONTROL PANEL REMOTE RESET COMMAND PULSE

210 YL1 CR01 1A 1.503790 INDICATING LAMP 1 CRUSHER HYDRAULIC OIL PUMP 1 ON RUNNING 1

210 YL2 CR01 1A 1.503790 INDICATING LAMP 1 CRUSHER HYDRAULIC OIL PUMP 1 OFF STOPPED 1

210 HS2 CR01 1A 1.503790 PUSH BUTTON STATION 1 CRUSHER HYDRAULIC OIL PUMP1 LOCAL STOP PRESSED 0

210 HS1 CR01 1A 1.503790 PUSH BUTTON STATION 1 CRUSHER HYDRAULIC OIL PUMP1 LOCAL JOG PRESSED 1

210 YL1 CR01 1B 1.503790 INDICATING LAMP 1 CRUSHER HYDRAULIC OIL PUMP 2 ON RUNNING 1

210 YL2 CR01 1B 1.503790 INDICATING LAMP 1 CRUSHER HYDRAULIC OIL PUMP 2 OFF STOPPED 1

210 HS2 CR01 1B 1.503790 PUSH BUTTON STATION 1 CRUSHER HYDRAULIC OIL PUMP2 LOCAL JOG PRESSED 1

210 HS1 CR01 1B 1.503790 PUSH BUTTON STATION 1 CRUSHER HYDRAULIC OIL PUMP2 LOCAL STOP PRESSED 0

210 YL2 CR01 2A 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION MAIN OIL PUMP OFF STOPPED 1

210 HS1 CR01 2A 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION MAIN OIL PUMP LOCAL JOG PRESSED 1

210 YL1 CR01 2A 1.503790 INIDCATING LAMP 1 CRUSHER LUBRICATION MAIN OIL PUMP ON RUNNING 1

210 HS2 CR01 2A 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION MAIN OIL PUMP LOCAL STOP PRESSED 0

210 HS2 CR01 2B 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION STANDBY OIL PUMP LOCAL STOP PRESSED 0

210 YL1 CR01 2B 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION STANDBY OIL PUMP ON RUNNING 1

210 HS1 CR01 2B 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION STANDBY OIL PUMP LOCAL JOG PRESSED 1

210 YL2 CR01 2B 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION STANDBY OIL PUMP OFF STOPPED 1

210 YL2 CR01 2C 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION MAIN COOLER PUMP OFF STOPPED 1

210 YL1 CR01 2C 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION MAIN COOLER PUMP ON RUNNING 1

210 HS1 CR01 2C 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION MAIN COOLER PUMP LOCAL JOG PRESSED 1

210 HS2 CR01 2C 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION MAIN COOLER PUMP LOCAL STOP PRESSED 0

210 YL2 CR01 2D 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION STANDBY COOLER PUMP OFF STOPPED 1

210 YL1 CR01 2D 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION STANDBY COOLER PUMP ON RUNNING 1

210 HS1 CR01 2D 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION STANDBY COOLER PUMP LOCAL JOG PRESSED 1

210 HS2 CR01 2D 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION STANDBY COOLER PUMP LOCAL STOP PRESSED 0

210 HS2 CR01 3A 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION COOLER FAN 1 LOCAL STOP PRESSED 0

210 HS1 CR01 3A 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION COOLER FAN 1 LOCAL JOG PRESSED 1

8500380b PAGE 3 PRINT DATE: 10/04/2001








210 YL1 CR01 3A 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION COOLER FAN 1 ON RUNNING 1

210 YL2 CR01 3A 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION COOLER FAN 1 OFF STOPPED 1

210 HS1 CR01 3B 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION COOLER FAN 2 LOCAL JOG PRESSED 1

210 HS2 CR01 3B 1.503792 PUSH BUTTON STATION 1 CRUSHER LUBRICATION COOLER FAN 2 LOCAL STOP PRESSED 0

210 YL2 CR01 3B 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION COOLER FAN 2 OFF STOPPED 1

210 YL1 CR01 3B 1.503792 INDICATING LAMP 1 CRUSHER LUBRICATION COOLER FAN 2 ON RUNNING 1

TOTAL 16 0 29 29

NOTE(S):

1 MOTOR CONTROL I/O IS EXCLUDED FROM THIS SIGNAL LIST

8500380b PAGE 4 PRINT DATE: 10/04/2001


14.0PAGE 1 OF 1


14.0 FFE MINERALS FUNCTIONAL SPECIFICATIONFOR ELECTRICAL CONTROL OF THE CRUSHERAND ITS AUXILIARY SYSTEMS

This section includes the FFE Minerals functional specification for electrical controlof the crusher and its auxiliary systems.


15.0PAGE 1 OF 1


15.0 DRAWINGSThis section includes the following:

15.1 Drawing List

ESCONDIDA PROJECT – CHILE, S.A.DRAWING LIST

CRUSHER 210-CR-001

FFEM CONTRACT 99-31325-720

DWGLIST.DOC 12 December 2001Rev. 2

DRAWING NUMBER REV. DRAWING TITLE

1.500457 0 60” X 113” Traylor Type “TC” Gyratory Crusher, Main Shaft Assembly (113” Head)1.500458 1 60” X 113” Traylor Type “TC” Gyratory Crusher, Main Shaft Assembly (115” Dia. Head)1.503513 3 60” X 113” Traylor Type “TC” Gyratory Crusher, Assembly1.503562 4 60” X 113” Traylor Type “TC” Gyratory Crusher, Foundation Clearance Requirements1.503563 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Foundation Clearance Requirements1.503574 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Lubrication System Schematic1.503575 3 60” X 113” Traylor Type “TC” Gyratory Crusher, Hydraulic System Schematic1.503579 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Eccentric Cart Assembly1.503651 0 60” X 113” Traylor Type “TC” Gyratory Crusher, Top Shell Assembly1.503786 0 Legend, Sheet 11.503787 1 Legend, Sheet 21.503788 0 Legend, Sheet 31.503789 2 60” X 113” Traylor Type “TC” Gyratory Crusher, C & ID Overview1.503790 1 60” X 113” Traylor Type “TC” Gyratory Crusher, C & ID Hydraulic Skid1.503791 1 60” X 113” Traylor Type “TC” Gyratory Crusher, C & ID Spider Lube System1.503792 1 60” X 113” Traylor Type “TC” Gyratory Crusher, C & ID Lube Oil Skid1.503880 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Countershaft Assembly1.504290 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Bottom Shell, Liner and Shield Assembly1.504404 1 60” X 113” Traylor Type “TC” Gyratory Crusher, Bottom Shell Assembly2.500124 0 60” X 113” Traylor Type “TC” Gyratory Crusher, Eccentric Assembly2.501028 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Spider Lubrication System2.501039 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Concave Assembly


CRUSHER 210-CR-001




2.501050 1 60” X 113” Traylor Type “TC” Gyratory Crusher, Countershaft Extension Assembly2.501060 0 60” X 113” Traylor Type “TC” Gyratory Crusher, Spider Assembly2.501061 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Drive Guard Assembly2.501063 1 60” X 113” Traylor Type “TC” Gyratory Crusher, Lube Pump Set Pushbutton Station2.501064 1 60” X 113” Traylor Type “TC” Gyratory Crusher, Hydraulic Pump Set Pushbutton Station2.501065 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Air Oil Cooler Fan Pushbutton Station2.501104 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Hydraulic Cylinder Assembly3.500100 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Weight, C.G., & Handling, Spider3.500102 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Weight, C.G., & Handling, Middle Shell3.500105 3 60” X 113” Traylor Type “TC” Gyratory Crusher, Weight, C.G., & Handling, Main Shaft Assembly3.500363 0 60” X 113” Traylor Type “TC” Gyratory Crusher, Weight, C.G., & Handling, Main Shaft Assembly

without mantle3.500713 0 60” X 113” Traylor Type “TC” Gyratory Crusher, Weight, C.G., & Handling, Bottom Shell3.501468 0 60” X 113” Traylor Type “TC” Gyratory Crusher, Balluff Mantle Position Indicator Assembly3.500871 2 60” X 113” Traylor Type “TC” Gyratory Crusher, Weight, C.G., & Handling, Top Shell6.501718 0 60” X 113” Traylor Type “TC” Gyratory Crusher, General Arrangement of Oil Hydraulic System6.501719 C 60” X 113” Traylor Type “TC” Gyratory Crusher, Hydraulic Adjustment Pumping Unit – Wiring6.501731 1 60” X 113” Traylor Type “TC” Gyratory Crusher, General Arrangement Of Oil Lube System6.501732 C 60” X 113” Traylor Type “TC” Gyratory Crusher, Lube System – Wiring6.501733 D 60” X 113” Traylor Type “TC” Gyratory Crusher, Lube System - Schematic6.501816 C 60” X 113” Traylor Type “TC” Gyratory Crusher, Hydraulic Adjustment Pumping Unit – Schematic6.501817 B 60” X 113” Traylor Type “TC” Gyratory Crusher, Key Plan Of Hydraulic Adjustment Pumping Unit


CRUSHER 210-CR-001




6.501818 G 60” X 113” Traylor Type “TC” Gyratory Crusher, Key Plan Of Crusher Lube Unit720-94-2-0402 1 60” X 113” Traylor Type “TC” Gyratory Crusher, Middle Shell Assembly720-94-2-0704 1 60” X 113” Traylor Type “TC” Gyratory Crusher, Bottom Plate Assembly


16.0PAGE 1 OF 12

COMMGLOS.DOC CRUSHER 1 OCT 2000REV 0

16.0 GLOSSARY OF TERMSAbrasion A wearing, grinding, or rubbing away by friction.

Abrasion-ResistantSteel

Steel, usually containing manganese, that is especially re-sistant to abrasion.

Accumulator A cylinder containing water or oil under pressure tomaintain a constant pressure in hydraulic lines for crush-ers, hydraulic presses, hoists, winches, etc. It also servesto absorb hydraulic shock.

Air Pressurization Refers to the air injected under a very small pressure tothe interior of the hub of the crusher to preclude the en-trance of dust. Usually the entrance is the bonnet.

Amperes The unit of electric current that is equivalent to a flow ofone coulomb per second or to the steady current producedby one volt applied across a resistance of one ohm. Anammeter measures amperes.

Annunciator Alarm system on a control panel that indicates a particularalarm.

Apex Opening at the bottom of a cyclone through which coarsematerials discharge. Also know as a spigot.

Apron Feeder A feeder on which the ore is carried on pans or aprons at-tached to a moving chain. The rate of feed is usually ad-justed by varying the speed of the feeder.

Arm Guard Liners A description used by some operations to describe the ribshields.

Assay Analysis (as of an ore) to determine the quantity of one orother mineral compounds or elements.

Automatic ControlWith a Remote SetPoint

Process control in which the output of one controller is theset point for another controller. (See Control.)

Backing Material Epoxy used as a supporting material between various partsof the crusher such as concaves and mantle liners.

Backlash Used to describe the clearance between the pinion and ec-centric gear.


16.0PAGE 2 OF 12


Ball Mill A rotating, cylindrical grinding mill that uses steel balls togrind ore to a finer size.

Basket The basket screen within the lubrication tank. The re-turning oil from the crusher flows through this screen andthe larger particles are removed. The contents of thisscreen can indicate the condition of the bushings.

Bleed Plug A small vent plug on the hydraulic assembly near the inletline. It is used to purge air from the system.

Bottom Plate Part of the eccentric assembly which consists of the bot-tom plate, eccentric wearing ring, and the eccentric.

Bottom Shell The lowest section of the frame of the crusher.

Bottom Shell Liners A name given to any of the wearing parts fastened withinthe bottom shell.

Burnout Ring See Torch Ring.

Butterfly Valve A disc type of valve. By turning the operating handle 90degrees, the valve can be fully opened or closed.

Cascade (noun) Process control in which the output of one con-troller is the set point for another controller. Also knownas automatic control with a remote set point.

(verb) The tumbling action of slurry and grinding mediainside a grinding mill.

Centrifugal Proceeding or acting in a direction away from a center ofrotation.

Choke Feed A method of feeding the crusher, whereby the crushingchamber is kept fully loaded.

Compressor A device used to reduce the volume of a given quantity ofgas, thereby increasing the resultant pressure exerted bythe gas at constant temperature.

Concave Segment Ring Located between the bottom shell and the upper shell sec-tions. Used to support the bottom row of concaves duringinstallation.

Concaves Plates installed within the upper shell sections(s) of thecrusher within the crushing chamber. The plates are madeof either an alloy steel material or manganese steel.


16.0PAGE 3 OF 12


Concentrate Enriched ore after removal of waste material. Examplesare:

• The clean product recovered as froth from a flotationcell.

• High-grade material recovered from a shaking table.

Concentrator A plant where ore is separated into values (concentrates)and rejects (tails).

Conductivity A measurement of how well a material conducts electric-ity.

Control The maintenance of a process condition at a desired value.

Manual control means the operator manipulates the sta-tion’s control output.

Automatic control means the system automatically initi-ates necessary adjustments to the function based on the setpoint.

Cascade or Remote Set Point control means the set pointis manipulated from another control scheme.

Ratio control means an input signal’s value is multipliedby a constant to establish an output signal.

Cooling Water Water, usually treated or demineralized, used for heat ex-changers in a plant.

Core The core is installed over the main shaft, and is a shrink-fitpart, usually with a backing material filling the area that isnot fitted directly to the main shaft.

Countershaft An assembly that consists of a housing, bearings, seals,shaft, and pinion gear. The pinion gear drives the eccen-tric.

Countershaft Extension An assembly which usually consists of two couplings, orone coupling and clutch, that connects the main drivemotor to the counter shaft assembly

Coupling The connection between two driven parts. The normaltype in a Fuller/Traylor crusher is a gear type.


16.0PAGE 4 OF 12


Crusher A device that reduces the size of material by exerting me-chanical, compressive force.

CSS An abbreviation for closed-side setting. It refers to theclosest relationship of the bottom on the lower mantle tothe lowest tier of concaves for a given setting of the mainshaft.

DCS The acronym DCS stands for distributed control system.This is a computer-based system that reads the plantmeasurements such as flow and temperature, and outputsto plant control devices such as valves and equipmentmotors. The system hardware, normally distributedthroughout the plant, is connected by a communicationhighway. The communication highway also has attachedconsoles from which operators adjust control parameters,study trends, start/stop motors, etc.

Density The weight of a substance per unit volume, often ex-pressed in grams per liter. The density of slurry is pro-portional to the percentage of solids in the slurry.

Disconnect An electrical device used to isolate power from an indi-vidual circuit. When the disconnect is in the Open posi-tion, power is shut off to the equipment in the circuit.When the disconnect is in the Closed position, power issupplied to equipment in the circuit. Disconnects shouldnever be used to stop operating equipment.

Dump Pocket The area above the crusher bowl where material from themine is dumped.

Dust Seal In reference to the crusher, it is the seal made up of thedust seal ring on the main shaft assembly and the bonnet.

Dust Seal Bonnet orBonnet

The dust seal bonnet is located on top of the hub of thebottom shell. Used in conjunction with the dust seal ringon the main shaft to preclude dust from entering the inte-rior and contaminating the lubricating oil.

Eccentric The part of the assembly of the crusher that produces thegyrating effect of the main shaft.


16.0PAGE 5 OF 12


Eccentric Gear One of the two gears within the crushers. This gear is fit-ted to the eccentric.

Epoxy A compound that is of two parts, which when mixed hard-ens. Is used in the Fuller/Traylor crusher as a backingmaterial, specifically for the spider shields, concaves,mantle liners, and core.

Expert System A customized computer program which contains knowl-edge about a process system used by the computer to fine-tune a process; a form of artificial intelligence whichmimics the actions of expert operators.

Feedbox An input box to distribute slurry to tanks, hoppers,screens, or launders.

Fire Water Fresh water stored in the fire water tank and used in thefire water distribution system.

Flotation A mineral-processing method where valuable minerals areseparated and collected in a froth. Special reagents areused to cause some minerals to float in the froth and oth-ers to remain in suspension in the pulp.

Flow Meter A device that measures the rate of flow of a liquid or gas.

Gangue Material of no value contained in ore; the waste discardedfrom the process.

Gearcase Liners orGearcase Shield

Wear plates fitted below the hub of the bottom shell whichprotect the gearcase from the wearing effects of thecrushed material.

Grind To reduce to very small particles by a combination of im-pact and abrasion as in a grinding mill.

Gyratory Crusher A crusher which features a tapered center shaft surroundedby a metal bowl. The center shaft moves in a gyratingmotion to crush material against the sides of the bowl.

Head Nut Part of the main shaft assembly used to tighten down themain shaft assembly. The head nut may be either a one-piece or two-piece design.


16.0PAGE 6 OF 12


Heat Exchanger A device for adding or removing heat to or from a mate-rial. Example: a car radiator is a heat exchanger that re-moves heat from the motor coolant and rejects it to the airpassing through the radiator.

Hub Liners Wear plates fitted to the hub of the bottom shell whichprotect the hub from wearing effect of the crushed material.

Hydraulic Moved or operated by a fluid such as oil or water.

Hydraulic Assembly Located on the very bottom of the crusher, this assembly(which essentially consists of a housing and piston), pro-vides the vertical movement of the main shaft for adjust-ment purposes and for relieving a plugging condition.

Hydraulic Skid A pump unit assembly which may include the following;tank, pump(s), valves, filter, strainer, electric heating ele-ment, and connecting piping.

Instrument Air Compressed air used for instrumentation. Instrument airhas been treated to remove moisture and oil.

Key Concave Some concave designs call for a key concave, which helpsduring installation and removal of a concave tier.

Kilopascal (kPa) Pressure above that applied by the earth’s atmosphere.

Local Control Panel A control panel located near the item of equipment beingcontrolled.

Lockout Positively disconnecting and physically locking the powersupply on an item of equipment so that it cannot be startedwhile work is being performed on the equipment, and/orlocking a valve so that it cannot be opened while work isbeing performed on the system or equipment.

Lube Skid The lubrication unit consisting of a tank, pumps (lubrica-tion and cooling), filter(s), electric heating element, screen,and connecting piping.

Magnetic Flow Meter A device used to measure flow. As electrically conductivefluid passes through the flow meter, the fluid disturbs themagnetic field created by the flow meter. The amount ofmagnetic field disturbance is proportional to the rate ofmaterial flow through the meter.


16.0PAGE 7 OF 12


Main Shaft The shaft over which the core and mantle liner(s) are fitted.

Main Shaft Spin The rotational movement of the main shaft assembly whenthe crusher is not crushing material. A speed near 20 per-cent of the eccentric speed indicates a possible problemwith the inner eccentric bushing.

Makeup Water Water added to a plant circuit to make up for evaporationand process-water losses.

Mantle Liner Wear part mounted on the core of the main shaft. Usuallymade of manganese steel.

Mantle Position The vertical location of the main shaft assembly in rela-tionship to the concaves. Vertical movement of the mantleaffects the open side setting of the crusher.

MCC An acronym meaning motor control center. The MCC isthe electrical room where most of the main motor controlsare located. From this point, electrical power is distributedto the plant motors and other electrical equipment.

Mesh The size of screen opening measured as the number ofopenings per lineal inch. Standard mesh screen sizes alsospecify the diameter of the wires.

Micron (µ) 1/1,000th of a millimeter. Used as an alternate to meshsizing, particularly in the fine-size range. Example: Theopening size of a Tyler 150-mesh screen is .004 inches, or104 microns.

Middle Shell The center section of the main frame of the crusher.Whether the crusher has this section is dependent on thesize of the crusher.

Modulate To partially open or partially close a valve for the purposeof regulating flow.

Oil Groove Relief cut into a bushing or wearing ring for the purpose ofdistribution of lubricant between parts.


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On-Line (computers) Available directly on the computer. Example:A help file on a disk drive provides on-line help.

(operations) Performing its intended function. Example:A piece of process equipment is on-line if it is operating inits designed service.

Ore A source from which economically valuable mineral mattermay be extracted at a profit.

OSS Abbreviation of open-side setting. The furthest relation-ship between the main shaft and the concaves for a givenvertical position of the main shaft.

Outer Bottom ShellLiner

Liners fitted to protect the bottom shell outer wall to pro-tect the bottom shell from wear.

P80 An expression for the size of an ore product, usually in mi-crons, through which 80 percent of the ore will pass.

Packed From Below A condition in which the crushed material is not carriedaway from below the crusher. The material thus builds uparound the bonnet and main shaft and can cause seriousdamage to the bushings of the crusher.

PCS Process control system or distributed control system(DCS).

Percent Solids Proportion of slurry that consists of solids, expressed as apercentage by weight.

Pinion The gear mounted on the end of the counter shaft. It trans-fers the driving force of the main motor to the eccentric.

Piston A part located in the hydraulic assembly. On the top sur-face of the piston is mounted the piston wearing ring, andcenter wearing ring.

Piston Packing The seal between the piston bottom and the bore of the hy-draulic assembly. It is held in place by a retainer.


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PLC An acronym for programmable logic controller. This is adevice that monitors and controls the logic of the electricalcontrols for most of the plant equipment. This includesboth interlocks and permissives. The PLC is also capableof controlling other plant parameters, such as flow anddensity.

Plugged A condition in which the crusher stalls with ore in thechamber.

Pneumatic Powered or operated by compressed air.

Pocket Liner The backing material which is poured into the pockets ofthe top shell section for the fit of the spider.

Potable Water Water suitable for human consumption.

Process Water Water that is used for mill processing and frequently recy-cled for mill use.

psig Pressure in pounds per square inch gauge, i.e., pressureabove atmospheric. One psi is equal to 6.895 kPa (kilopas-cals).

Pulp Ground ore mixed with water. Also called slurry.

Pump Train Two or more pumps connected in series to generate suffi-cient pressure to move the fluid being pumped at the re-quired rate.

Pumpbox See Sump.

Recover To extract minerals from an ore.

Recovery The fraction of the total valuable material present that isactually recovered. Expressed as a percentage.

Remote Control Controlling a process from a distant location, such as thecontrol room. The opposite of local control.

Rib Liners or RibShield

Refers to any of the wear parts for the ribs of the bottomshell.

Rim Liners A term used at some operations that refers to the top shellwearing plates.

Rock Box Type of liner design that will hold stone material in placeand use that material as a wearing surface.


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ROM Run-of-Mine (ore). Ore as it is delivered from the mineprior to any crushing or processing.

RTD Abbreviation for resistance temperature detector.

Sample A representative part or item from a larger whole or group.

Set Point The position of a pointer or the digital setting of an instru-ment corresponding to the desired control point or targetfor process control. May be manually input by a plant op-erator or automatically input by ratio control or cascadecontrol. (See Control.)

Shell Bolt Fasteners that bolt together the shell sections.

Slurry Ground ore mixed with water. Also called pulp.

Solenoid A coil of wire normally in the form of a cylinder. Whenelectrical current is applied, the coil takes on the propertiesof a magnet. A steel rod is drawn into the coil when cur-rent flows.

Specific Gravity The weight of a substance compared with the weight of anequal volume of pure water. Example: A liter of slurryweighing 1,650 grams has a specific gravity of 1.65 (1,650grams of slurry compared to 1,000 grams for a liter of wa-ter).

Spider The member that positions and laterally supports the upperend of the main shaft assembly

Spider “Torque” Nut A special nut for fastening the spider assembly which iseasily tightened by a small torque wrench. This is anavailable option for the “TC” crushers.

Spider Bolt Bolts for fastening of the spider assembly to the top shellsection.

Spider Cap A wear part usually made of manganese steel that ismounted on the spider and prevents material from enteringthe spider bushing and main shaft.

Spider Lube Refers to the lubrication of the spider bushing.

Spider Nut Nut for the bolts that fasten the spider assembly to the topshell section


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Spider Pocket Recesses cast into the top shell section and lined withbacking material in which the spider assembly is mounted.

Spider Seal The lubrication seal set into a recess on the bottom of thespider bushing. This seal can be set with the lip up ordown depending on the minerals being processed, and isusually installed with the lip down.

Spider Shield Wear liners placed on the arms of the spider for wear pro-tection.

Spiral Bevel Gear See eccentric gear.

Splitter A distribution box designed so that a stream of solids, wa-ter, or slurry is divided into two or more streams.

Step Plates Support bearing plates for the main shaft assembly. Theyconsist of a wearing ring (bronze), a center wearing ring(steel), and a main shaft wearing ring (bronze).

Sump (mine) A pit at the lowest point in a drainage system thatserves as a receptacle for liquids or slurries.

(plant) A collection box or tank for collecting slurry orwater. Usually connected to a pump for slurry removal.

Surge Pocket The area below the crusher where crushed material falls.

Suspension The state of a substance when its particles are mixed with,but undissolved in, a fluid or gas.

Telltale A device used to give visual indication of the status or con-dition of a system not accessible to the operator.

Throughput The amount of material that a crusher can crush. Usuallystated in tph or tons per hour.

Top Shell The uppermost section of the crusher, which has the cast inspider pockets.

Top Shell WearingPlates

The wear-resistant liners or plates bolted to the top surfaceof the top shell. These also are designed to protect the topedge of the top row concaves.

Torch Ring The same as a filler ring. It is sometimes called a burnoutring because it is sacrificed to facilitate the removal of themain shaft head nut.


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Totalize To sum.

Tph Abbreviation for tons per hour.

Trend A line of development or direction of movement of someprocess variable.

Trip To automatically stop an item of equipment, usually be-cause of interlock or overload.

Ultrasonic Having a frequency above the human ear’s audibility limitof about 20,000 cycles per second.

Uncrushable Objects such as steel that the crusher is unable to crush.The entry of such items into the crushing chamber cancause great damage to the bushings.

Variable-Speed Having more than one speed available in the output of adrive unit.

Voltage Electric potential or potential difference expressed in volts.A voltmeter measures voltage.

Wearing Ring Any of the following crusher parts: piston wearing ring,center wearing ring, main shaft wearing ring, and eccentricwearing ring.

Zero-Speed Switch A switch that senses low speed (or no speed) on an item ofequipment and is connected to shut down an item ofequipment on interlock.

Documents

Crusher IOM 5400491a