AA - SPEC - 330001 - Gyratory Crusher

AA SPECIFICATION SPEC 330001
ISSUE 2
GYRATORY CRUSHER COPYRIGHT
CONTENTS PAGE
1 SCOPE 2
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2
3 DEFINITIONS 2
4 REQUIREMENTS 3
4.1 GENERAL 3
4.2 INFORMATION TO BE SUPPLIED BY THE CONTRACTOR OR SUPPLIER 4
4.3 CRUSHER COMPONENTS 5
4.4 LIFTING LUGS 11
4.5 SURFACE PREPARATION AND PAINTING 11
4.6 MANUFACTURING 11
5 QUALITY ASSURANCE PROVISIONS 11
6 PACKING AND MARKING REQUIREMENTS 12

6.1 LIFTING LUGS 12
6.2 NAMEPLATES 12
6.3 PROTECTIVE COATING 12
6.4 PACKING 12
APPENDIX A: RELATED DOCUMENTS 13
APPENDIX B: RECORD OF AMENDMENTS 13
AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 1 of 13
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
ISSUE 2
1 SCOPE
This specification covers the requirements for the supply of gyratory crushers and large
cone crushers with main shaft bearing support at the top. It is intended to cover vendor’s
standard crushers of proven designs. It does not cover specially designed crushers of
unproven design.
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

The following requirements shall be specified on every order, contract, or invitation to
tender:
 Reference number, title, date and issue of this specification
 Process and project specific requirements (see Data Sheet AA_EDS_48)
 Operational requirements
 Site specific requirements
 Energy performance requirements
 If required, the name of the independent Quality Assurance Representative
(see AA STD 100)
 All additional codes, standards and specifications as listed by the Project Engineer
in the enquiry document
3 DEFINITIONS
For the purpose of this specification the following definitions shall apply:
ASME : American Society of Mechanical Engineers
ASTM : American Society for Testing and Materials
AWS : American Welding Society
BS : British Standard
DATA BOOK : A hard cover, loose-leaf book containing a record of identification

markings, heat treatments, mechanical, chemical and NDE
certification and any other certification requirements of this
specification
FEA : Finite Element Analysis
ISO : International Standards Organization
MPI : Magnetic Particle Inspection
STD : Anglo Discipline Standard
QAR : Quality Assurance Representative
ISSUE 2
RT : Radiographic Testing
RTD : Resistance Type Temperature Detector
UT : Ultrasonic Testing
VISUAL : Unaided Vision, except normally used personal sight aids
AGMA : American Gear Manufacturers Association
ISO : International Standards Organization
NEMA : National Electrical Manufacturers Association
The following terms are defined in the conditions of contract:

 Anglo American, Approved, Company, Contractor, Engineer
4 REQUIREMENTS
4.1 GENERAL
4.1.1 Design, Operation and Maintenance
The crusher shall be Supplier's standard design for the specified service. Replacement
parts for standard components shall be readily available.
Minimum open side setting shall allow installation and removal of main shaft assembly
without the need to remove concave liners.
The unit shall meet the performance requirements as defined under section 2 above.
The crusher shall be able to start without requiring manual removal of material from the
crushing chamber.
The equipment shall be designed for easy inspection, cleaning, repairs and maintenance
and for operation in which continuity of service is the main consideration
All components of the crusher shall be designed to withstand the effects of mechanical
and electrical overloading including stalled torque of the drive system. The crusher design
shall also include provisions to protect all components from damage in the event of tramp
iron or other non-crushable materials being in the feed.
Proximity type low speed sensor driven from the pinion shaft extension shall be provided.
In the event that low speed is detected, power to the motor shall be disconnected.
Replaceable liners shall have provision for attaching a lifting device for installation.
All inspection and lubricant application points shall be readily accessible.
4.1.2 Construction Material
ISSUE 2
The materials of construction shall meet all requirements for the services stated at the rate
and conditions specified. The materials shall be in accordance with Manufacturer’s
standard practice for the intended service, unless the requirements listed below preclude
their use.
All material of construction for this equipment, its components and accessories shall be
new and suitable for the service and meet the requirements of codes as specified under
Section 2 of this document.
4.1.3 Safety
All rotating equipment shall be provided with safety guards and devices as required to
eliminate the risk of fatalities and injuries where and when there is the potential for human
interaction with moving parts or potential moving parts of plant and equipment. Plant and
equipment safeguards shall be designed and constructed to comply with relevant
legislation, standards, codes of practice and relevant recognised leading industry
practices, with due consideration for maintainability and operability. The requirements of
AA AFRS 5, Equipment Safeguarding shall apply.
All equipment shall have the capability of being isolated physically from all energy sources
prior to any access, work or repair being carried out, in order to protect the health and
safety of persons. The requirements of AA AFRS 6, Isolation Standard shall apply.
Any additional safety requirements as listed in Section 2 by the Project Engineer shall also
be complied with.
4.1.4 Energy
The criteria for assessing energy use over the planned or expected operating lifetime of
energy using products, equipment and services which are expected to have a significant
effect on the organization’s energy & emission performance shall be defined.
In addition the relationship between energy cost, (both peak cost and energy unit cost)
shall be defined, projected forward and integrated into equipment procurement estimates
such that the total cost of equipment ownership can be determined including the energy &
emission consumption costs/savings. These costs/savings are to be integrated into the
project capital cost estimate. Estimated annualised cost of emission per type and overall
for life of project (assuming an emission price as defined by Group policy or at the local
ruling rate) are to be included in these cost estimates.
The Contractor shall supply all information relevant to their product to assist the Project
Team in conducting this exercise. The Contractor shall also notify the Project Team of any
features or technologies that make the product more energy efficient.
4.2 INFORMATION TO BE SUPPLIED BY THE CONTRACTOR OR SUPPLIER

 General arrangement drawings.
 Foundation or structural mounting footprint drawing.
 Crusher static and dynamic loads (and their frequencies) on the foundation or
support structure.
 Electrical motor interface (if excluded from scope of supply).
ISSUE 2
 Type and size of critical fasteners to be used (if any).

 Information defining lubricants and maintenance requirements to ensure trouble free
operation shall be furnished as part of the technical information supplied with the
equipment.
 The maximum allowable distance between the crusher and the oil reservoir.
 Hazardous materials data sheets
 Information required by the crusher plant designer, in order to ensure a smooth and
adequate integration of the crusher into the crushing plant.
 Illustrated parts catalogue for the crusher and ancillary equipment.
 Operating and maintenance manuals
 Recommended critical and strategic spares lists
 A list detailing the expected mass of each component to be lifted during transport,
erection and maintenance. The heaviest component will determine the size of the
maintenance crane to be purchased by the Company.
4.3 CRUSHER COMPONENTS

Components shall be of the supplier's standard heavy duty construction as recommended
for the conditions described herein.
4.3.1 Spider Assembly
The spider dome cap shall be of impact resistant steel construction. Spider arms shall be
covered with wear plates which shall be secured to the spider arms by a means which
facilitates easy replacement of the wear plates.
4.3.2 Main Shaft Assembly
The main shaft shall be made of forged steel.
4.3.3 Crusher Shells
The top shell rim and hopper surface shall be entirely protected with bolted wearing
plates. Wearing plates shall be made in sections for convenient handling.
The shell(s) of the crusher shall be heat treated cast steel for heavy duty operation.
The arms of the bottom shell shall be protected by liners of an applicable material or a
rock box arrangement.
4.3.4 Concave Assembly
The concaves or tier concaves shall be of a suitable alloy steel of a convenient size for
handling and provided with a concave pin for ease removal.
4.3.5 Eccentric Assembly
ISSUE 2
Protective dust seal for eccentric bushing shall be fitted with a low pressure sealing air
connection. Supplier shall also include the sealing air blower and internal piping or
ductwork in the scope of supply.
4.3.6 Pinion and Bevel Gear Assembly
The spiral bevel gear shall be made of forged steel and the pinion shall be made of forged
alloy steel. Gear sets shall be rated for continuous operation at maximum crusher power
for the greatest gear ratio arrangement considered and incorporate an industry norm
factor of safety. Service factor shall be based on motor rating. Peak torques up to
transmission capacity shall not damage the gear set. Gearing shall be designed and
manufactured to AGMA quality level Q6 or better.
Pinion or countershaft bearing shall be rated to take shock
Crusher gear chamber, lubrication and hydraulic systems shall be of dust-tight and
moisture-tight construction.
4.3.7 Lubrication and Hydraulic Systems General Requirements
The hydraulic and lubrication systems shall comply with the following minimum
requirements:
 All items shall be integrally mounted on a steel base and pre piped, as applicable.
 The oil reservoir shall be part of the lube oil skid.
 Where possible, system components shall not be mounted directly on top of the
reservoir.
 All openings in the top surface shall be raised at least 50mm above the reservoir
top.
 The drain shall be provided with a plugged valve in a sloped bottom.
 Reservoir internal surfaces shall be cleaned and treated against corrosion.
 A full range sight glass covering the reservoir from empty to maximum liquid level
shall be provided.
 The reservoir shall be designed to prevent short circuiting of the oil flow and carry
over of any sediment.
 The reservoir shall include an inspection cover and clean-out port.
 The reservoir shall have sufficient capacity to fill all supply pipes and supply the
crusher upon start-up as well as to completely drain the system by gravity without
overflowing when shutting down.
The system shall be designed for easy maintenance and replacement of parts, without
draining of oil from reservoir and or lines.
ISSUE 2
4.3.8 Lubrication System
The crusher shall be provided with a main lubricating oil system supplying lubricating oil to
the step bearing and the eccentric. The system shall consist of welded dust tight tank, two
separate pumps (one operating and one stand-by) with motors and filters, oil cooler and
heaters with temperature controls where applicable, flow and control valves, and pressure
gauges. The system shall be supplied with complete controls and instrumentation.
The oil cooling/heating system shall be suitable for operation under the conditions
specified in Section 2. The Supplier shall recommend the location of the oil
coolers/heaters in relation to the lubrication unit and the crusher.
In addition to items stated in section 4.3.7 above, the oil system shall include:
 Motor driven pump with installed spare.
 Reservoir oil heater capable of heating oil from minimum ambient temperature to
minimum operating temperature without burning the oil, complete with temperature
control switch, temperature sensing element and protective well for cold locations.
 Not greater than 50 micron inline filter with differential pressure indicator.
 Not greater than 50 micron filler filter.
 Not greater than 50 micron desiccant breather.
Instrumentation shall include pre-shutdown alarms on systems that can be restored before
an actual shutdown; they shall include low flow alarm on the supply line and pressure
alarm on the supply lines. Alarms shall be furnished from separate alarm contacts wired to
separate terminal strips.
All instrumentation shall be approved by the Engineer. Complete data sheets shall be
supplied for this approval.
4.3.9 Spider Lubrication System
Crusher spider bearings shall be lubricated by dedicated forced grease or oil lubrication
systems including electrical or pneumatically operated pumps, instruments and controls.
If the spider is grease lubricated, the Supplier shall furnish a complete grease lubrication
unit including the following:
 Electrical or pneumatically operated drum pump suitable for installation on locally
available drums
 Hydraulic or air supply hose for the pump with quick disconnect fittings to allow easy
drum replacement
 Hydraulic or air supply control including filter, pressure indicating regulator and
lubricator
 Air supply solenoid valve where applicable
 Pump discharge pressure indicator
 Automatic lubrication replenishment feature
 Local control panel
ISSUE 2
 Interconnecting piping, wiring, conduit, instrumentation and controls to provide a

complete working assembly as per the agreed scope of supply of the Contractor
4.3.10 Hydraulic System
Vertical adjustment of the main shaft shall be provided by means of a hydraulic lift
mechanism which will position and maintain the main shaft at any desired opening
between the mantle and concave within the design limits of the crusher. This system will
allow the operator to adjust the main shaft position to compensate for mantle wear and to
assist in clearing cavity jams.
The mechanism will be actuated by an independent, remote, hydraulic oil system,

complete with motor, pump, valves and all accessories required for an integrated system.
The system shall include nitrogen-charged balanced cylinder or accumulators and
automatic pressure relief to prevent damage from tramp metal and crusher stalls. The
system shall be capable of operation from the control room.
A visual position indicator to show the relative vertical position of the main shaft shall be
included in the control system and mounted on the crusher control panel. The supplier
shall include a mantle position sensor
In addition to items stated in section 4.3.7 above, the oil system shall include:
 Motor driven pump
 Not greater than 20 micron inline filter with differential pressure indicator
 Not greater than 20 micron filler filter
 Not greater than 20 micron desiccant breather
 Hydraulic control valve capable of accepting remote mantle position control signal
 Local control panel
 Interconnecting piping, wiring, conduit, instrumentation and controls to provide a
complete working assembly as per the agreed scope of supply of the Contractor
 All instrumentation signals shall be available for transmission to the Main Control
Room
The hydraulic system shall conform to ISO 4413:1998, Hydraulic Fluid Power – General
Rules Relating to Systems or an internationally recognised equivalent standard. The
working pressure shall not be more than 66% of the maximum design pressure.
4.3.11 Crusher Drive
Drive component selection shall be based on motor nominal power rating.
The crusher drive shall be complete including jackshaft assembly, floating shaft and
coupling.
Main motor supplied by the crusher supplier shall be approved in writing by the Engineer.
The floating shaft shall be of forged steel properly machined, provided with keyway for
coupling attachment.
ISSUE 2
4.3.12 Electrical
The Supplier shall indicate all requirements for the provision of control elements,
interlocking, lubrication and hydraulic oil and cooling system.
Motor starter control system shall be designed by the Engineer to be operated from the
following three areas:
 Local operation, from each individual motor, including stand by equipment
 From Supplier's control panel
 From owners control room
Selection shall be done externally by means of control switches in control room, supplied
by the owner.
4.3.13 Electrical Components
Electrical equipment shall be approved in writing by the Engineer.
The motor rating and characteristics shall be suitable to start and run the driven
equipment in an ambient temperature and at the elevation given in Section 2.
Motors shall be approved in writing by the Engineer.
4.3.14 Instruments and Control

 General
Supplier shall provide a complete set of instruments for crusher drive system and its
auxiliary equipments.
All instruments display shall be in the metric system (SI) units.
Instrumentation equipment design shall comply with AA STD 673025.

 Crusher Instrumentation
The instrumentation requirements; drawings and schedules to be approved in

writing by the Engineer:
 Flow indication and switches
 Pressure and temperature indicators
 Pressure and temperature transmitters
 Temperature sensing elements
 Solenoid valves
 Level indicators
 Level transmitter
 Vibration sensors
 Position sensor
ISSUE 2
 Control and protection system with interlocking elements and ancillary facilities
necessary to start and stop the crusher without damaging the mechanical
transmission and auxiliary system.
 Lubrication Oil level, temperature, pressure and flow sensors and transmitters.
 Hydraulic Oil level, temperature, pressure and flow sensors and transmitters.
All field instrumentation shall be connected via Remote IO to the Process Control
System as per AA STD 673025 Option 2.
Each lube oil system shall have instruments including low flow switches on supply
lines and temperature transmitters on return lines. Reservoir shall include low level
transmitter and temperature indication. All signals shall be wired to separate
terminal strips.
 Crusher Control System
The control and protection system shall be a completely integrated control system
as per AA STD 673025 Option 2.
Vendor shall supply Control Logic Narratives; Control Logic Diagrams; P&ID
diagrams; instrument datasheets; alarms and interlock settings; wiring diagrams
between supplied instruments and supplied junction boxes; Instrument list (with
manufacturer and model) and Instrument and Equipment manuals.
Vendor shall supply the equations for particle size distribution for each crusher
settings. This information will allow developing a crusher dynamic model for control
logic debugging and operator training purposes. Vendor shall consider man hours of
a process specialist engineer to assist the simulator model development.
 Local Control Panel
The field control panel shall be supplied for local operation next to the crusher.
The panel I/O’s shall include, but not be limited, to the following:
 Local remote mode indication.
 Stop-Start push button, with a locking system to avoid unsafe starting.
 If the local control panel is installed in the field, its protection shall be NEMA 4.
 Two conditions general alarms and alarm acknowledge
- Warning – tone 1
- Shutdown – tone 2
 Emergency shutdown push button
 Feeder indicating lights
 Main power on
 Crusher ready for operation
 Horn for start-up warning
 Alarm annunciator system
ISSUE 2
 Mantle position indicator

 Crusher discharge cavity high level
Field wiring (as per the agreed scope of supply of the Contractor) to and from Local
Control Panel as per AA STD 673025.
4.4 LIFTING LUGS

All heavy accessory equipment shall be furnished with lifting lugs for crane handling.
Lifting lugs shall be positioned to give maximum balance with an even weight distribution
and minimize handling hazards. Each lug shall be designed to have a safe working load of
at least twice the suspended load.
Lugs shall be bolted to each component in the shop prior to shipment and remain
attached until erection work is completed.
Lifting lugs shall be:

 Designed for handling and installation
 Designed for use with standard shackles, Grade 5 wherever practical
 Shown on drawings together with slinging details
 Permanently fixed to all items requiring removal for inspection and maintenance
wherever practical
For fabricated lifting lugs and attachments all welds shall be examined 100% using UT
and wet MT. Acceptance criteria shall be in accordance with the Engineers certified
design requirements and must be demonstrated by means of test certificates.
4.5 SURFACE PREPARATION AND PAINTING

All equipment shall have a clean and finished appearance when delivered.
Prior to painting, all surfaces shall be free of dirt, rust, grease, weld splatter, loose scale or
other deleterious substances.
Surface preparation, prime and finish paint and application procedures shall be as
prescribed by the Engineer for the specific application (refer to AA SPEC 164000). The
Contractor shall submit his standard surface protection system for acceptance by the
Engineer. Paint colour will be specified by the Engineer.
Machined surfaces shall not be painted. Touch up paints shall be supplied in sufficient
quantity for field touch up painting.
4.6 MANUFACTURING
Construction of the crusher shall comply with Section 5 of this specification.
5 QUALITY ASSURANCE PROVISIONS

The requirements of AA STD 100 shall apply.
ISSUE 2
6 PACKING AND MARKING REQUIREMENTS
6.1 LIFTING LUGS

The gross weight of the lift shall be stencilled or painted in a conspicuous location and
identified as the gross lifting weight.
6.2 NAMEPLATES
Crusher structural components shall be identified by permanent serial number. Other
equipment shall have permanent corrosion and impact resistant nameplates attached that
contain all pertinent identification and size information.
6.3 PROTECTIVE COATING

Machined surfaces shall be protected by a coating of rust preventative grease or similar
material during shipping and storage. The grease coating shall be easily removable in the
field with solvents and without the need for wire brushing or other mechanical removal
methods.
6.4 PACKING
Each item or sub-assembly shall be packed such that it is protected from damage and the
elements during transport.
ISSUE 2
APPENDIX A: RELATED DOCUMENTS

AA SPEC 330001 Gyratory Crushers
The latest issue of the following documents shall form part of this specification:
AA AFRS 5 : Equipment Safeguarding Standard
AA AFRS 6 : Isolation Standard
AA EDS 48 : Data Sheet for Crushers
AA GTS 23 : Energy and Emission Management Standard
AA SPEC 114013 : Foundations for Heavy Machines
AA SPEC 164000 : Users Guideline for Corrosion Protection: System Selection
AA SPEC 330002 : Cone Crushers
AA STD 100 : Quality Requirements for Suppliers of Critical and Major Equipment
AA STD 571001 : Electrical Requirements for Mechanical Vendor Packages
AA STD 673025 : Packaged Equipment and Plants
ISO 4413:1998 : Hydraulic Fluid Power – General Rules Relating to Systems
SANS 10160 : Code of Practice for the General Procedures and Loadings to be Adopted
in the Design of Buildings
APPENDIX B: RECORD OF AMENDMENTS
Issue 0 : New document (C Chakawodza, A Lill - July 2009)
Issue 1 : Clauses 2 and 4 & Appendix A updated (R. Diering, March 2010)
Issue 2 : Clauses 2 and 4 amended (R. Diering, November 2010)

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AA SPECIFICATION SPEC 330001

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2

6 PACKING AND MARKING REQUIREMENTS 12

APPENDIX B: RECORD OF AMENDMENTS 13

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 1 of 13

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

ASME : American Society of Mechanical Engineers

ASTM : American Society for Testing and Materials

AWS : American Welding Society

DATA BOOK : A hard cover, loose-leaf book containing a record of identification

FEA : Finite Element Analysis

ISO : International Standards Organization

MPI : Magnetic Particle Inspection

STD : Anglo Discipline Standard

QAR : Quality Assurance Representative

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 2 of 13

RTD : Resistance Type Temperature Detector

VISUAL : Unaided Vision, except normally used personal sight aids

AGMA : American Gear Manufacturers Association

ISO : International Standards Organization

NEMA : National Electrical Manufacturers Association

The following terms are defined in the conditions of contract:

All inspection and lubricant application points shall be readily accessible.

4.1.2 Construction Material

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 3 of 13

4.2 INFORMATION TO BE SUPPLIED BY THE CONTRACTOR OR SUPPLIER

 Type and size of critical fasteners to be used (if any).

4.3 CRUSHER COMPONENTS

4.3.1 Spider Assembly

4.3.2 Main Shaft Assembly

The main shaft shall be made of forged steel.

4.3.3 Crusher Shells

4.3.4 Concave Assembly

4.3.5 Eccentric Assembly

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 5 of 13

4.3.6 Pinion and Bevel Gear Assembly

Pinion or countershaft bearing shall be rated to take shock

4.3.7 Lubrication and Hydraulic Systems General Requirements

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 6 of 13

4.3.8 Lubrication System

4.3.9 Spider Lubrication System

 Interconnecting piping, wiring, conduit, instrumentation and controls to provide a

4.3.10 Hydraulic System

The mechanism will be actuated by an independent, remote, hydraulic oil system,

4.3.11 Crusher Drive

Drive component selection shall be based on motor nominal power rating.

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 8 of 13

4.3.13 Electrical Components

Electrical equipment shall be approved in writing by the Engineer.

Motors shall be approved in writing by the Engineer.

4.3.14 Instruments and Control

All instruments display shall be in the metric system (SI) units.

Instrumentation equipment design shall comply with AA STD 673025.

The instrumentation requirements; drawings and schedules to be approved in

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 9 of 13

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 10 of 13

 Mantle position indicator

4.4 LIFTING LUGS

Lifting lugs shall be:

4.5 SURFACE PREPARATION AND PAINTING

5 QUALITY ASSURANCE PROVISIONS

AA_SPEC_33000102.doc APPROVED 4 November 2010 Page 11 of 13

6 PACKING AND MARKING REQUIREMENTS