A Comprehensive Guide to Gyratory Crusher Supplier Inspection

In the world of mineral processing and aggregate production, the gyratory crusher stands as a cornerstone of comminution circuits. As a primary crusher, it is tasked with reducing run-of-mine ore or large quarry rock into manageable sizes for downstream processing. Given its critical role, immense capital cost, and the significant operational expenses associated with downtime, the selection of a reliable crusher and, more importantly, a rigorous pre-delivery supplier inspection are paramount. A thorough gyratory crusher supplier inspection is not merely a procedural step; it is a strategic investment in asset longevity, operational efficiency, and overall project success.

This guide outlines a comprehensive framework for conducting a professional and objective inspection at a manufacturer’s facility, covering key phases from documentation review to physical verification and performance testing.

Phase 1: Pre-Inspection Preparation and Documentation Review

Before setting foot on the supplier’s shop floor, a significant portion of the inspection occurs desk-side. This phase establishes the baseline against which the physical equipment will be measured.

1.1 Design and Engineering Documentation:

• General Arrangement (GA) Drawings: Verify that the final GA drawings match the project’s layout and spatial constraints. Check overall dimensions, foundation requirements, discharge clearances, and interface points with feeders and conveyors.
• Fabrication Drawings: Scrutinize detailed drawings for major components like the main frame (top and bottom shells), concaves (liners), mantle, spider arm, and eccentric assembly. Confirm material specifications (e.g., ASTM A148 for cast steel frames), heat treatment requirements (normalized, quenched & tempered), and non-destructive testing (NDT) callouts.
• P&IDs (Piping and Instrumentation Diagrams): Meticulously review lubrication system schematics, hydraulic system circuits for setting adjustment and clamping, and cooling water systems if applicable. Verify component specifications for pumps, filters, coolers, valves, and instrumentation.
• Control System Philosophy & Documentation: Review the control logic narrative, I/O lists, and HMI (Human-Machine Interface) screen designs. Ensure they align with the desired operational sequences for start-up, run-time monitoring (e.g., power draw, pressure/temperature alarms), shutdown (including emergency stops), and automated safety interlocks.

1.2 Quality Assurance / Quality Control (QA/QC) Documentation:
This is arguably the most critical part of the documentation review. The inspector must demand to see:

• Material Certifications: Mill test certificates (MTCs) or certificates of conformity for all major steel castings and forgings must be provided. These should confirm chemical composition and mechanical properties against the purchase order specifications.
• Non-Destructive Testing (NDT) Reports: The main frame, a highly stressed component subject to fatigue cycles over decades of operation requires stringent NDT.
  • Ultrasonic Testing (UT): Reports should confirm internal soundness of thick-walled sections.
  • Magnetic Particle Inspection (MPI) or Dye Penetrant Inspection (DPI): Reports are essential for identifying surface defects on critical welds and cast surfaces.
  • The extent of NDT coverage (% of weld length or surface area) must comply with agreed standards like ASME Section VIII or specific project specifications.
• Dimensional Inspection Reports: The supplier should provide certified reports verifying that key tolerances have been met—e.g., main frame bore concentricity, mounting flange flatness, gear tooth profiles on the eccentric assembly.

Phase 2: Physical Inspection at the Supplier’s Facility

This phase involves direct observation and measurement of the crusher components during various stages of fabrication and assembly.

2.1 Major Component Fabrication & Machining:

• Main Frame & Top Shell: Inspect for quality of casting—look for signs of porosity or cold shuts that were not properly repaired per procedure. Verify weld profiles on fabricated sections; they should be smooth and free from undercut or excessive reinforcement. Check machined surfaces for bearing seats and mating flanges for surface finish accuracy.
• Concaves & Mantle: These wear parts are consumables but their initial quality sets performance benchmarks. Inspect their fit-up into their respective holders/mantle cores. Check that locking mechanisms are robustly designed to prevent loosening under vibration.
• Eccentric Assembly & Main Shaft: This is the heart of the gyratory motion. Inspect:
  • The eccentric bushing/bearing sleeve for proper surface hardness.
  • The main shaft straightness as per machining reports.
  • The gear teeth on both pinion shaft drive gear; ensure proper profile contact pattern during trial assembly.

2.2 Assembly Verification:
Witnessing key stages of assembly provides invaluable insights into build quality.

• Bearing Installation: Observe the installation process for both lower eccentric bearings/ bushings upper spider bushings . Procedures should be clean; bearings should be installed using induction heaters or hydraulic methods—never brute force—and with appropriate lubricants.
• Lube System Assembly: Trace piping from fabrication drawings to reality. Check that tubing is clean before assembly supports are adequate to prevent vibration-induced fatigue welds are full penetration where specified tubing runs are free from sharp bends that could restrict flow inspect reservoir internals before closure ensure heating/cooling elements are correctly installed
• Clearances & Tolerances: With micrometers feeler gauges laser alignment tools verify critical clearances specified in manuals such as piston ring clearances countershaft bushing clearances gear backlash

Phase 3: Functional Testing & Performance Verification

A static crusher reveals only part of its story Functional testing albeit often without material simulates operational conditions

3 1 Lubrication System Pre-commissioning:
The lube system is lifeline crusher Its failure can lead catastrophic damage minutes

• Flush Procedure Witnessing: Ensure system undergoes rigorous flushing procedure until oil cleanliness codes achieved e g ISO 4406 17/15/13 Flushing bypassing crusher bearings mandatory
• Functional Tests:
  • Verify operation all pumps main standby
  • Test pressure relief valves set correct pressures
  • Confirm functionality all safety interlocks low oil pressure high oil temperature low flow switches
  • Check heater cooler operation thermostat settings
  • Monitor pressure drops across filters ensure within acceptable limits

3 2 No-Load Mechanical Run Test:
With lubrication system confirmed operational crusher motorized run without feed

• Start-Up Sequence: Observe smooth controlled start-up monitor inrush current power draw stabilize normal running level
• Vibration Analysis: Use portable vibration analyzer measure bearing housing vibrations radial axial directions Compare readings against ISO 10816 standards acceptable vibration limits Excessive vibration indicates misalignment imbalance looseness defective bearings
• Noise Analysis: Listen unusual noises – grinding clicking rhythmic knocking – could indicate improper gear meshing foreign object debris trapped assembly rubbing contact points
• Temperature Monitoring: Use thermal imaging camera contact thermometers check bearing housings lube oil inlet outlet temperatures ensure stable within design parameters no signs overheating

3 3 Hydraulic System Testing:
For crushers hydraulic systems adjustment clearing verify:

• Accumulator pre-charge pressure correct nitrogen side
• System holds pressure specified duration without significant drops indicating leaks
  Ram movement smooth controlled both directions during mantle position adjustment tramp release cycle

Phase 4 Final Documentation Paint Preservation Packaging

Inspection concludes once machine stopped Final checks ensure delivered site ready installation

4 1 As-Built Documentation:
Collect final set “as-built” drawings manuals reflecting any minor changes made during fabrication Ensure complete package includes parts lists recommended spares list lubrication schedules detailed assembly disassembly procedures

4 2 Surface Preparation Painting:
Verify internal external surfaces properly prepared abrasive blasting required standard e g Sa 2½ Paint coating system thickness dry film thickness DFT measurements conform specification particularly harsh environments high humidity salinity

4 3 Preservation Packaging:
Critical prevent corrosion during shipping storage Open machined surfaces shafts threads coated with high-quality anti-corrosive grease VCI Volatile Corrosion Inhibitor paper used protect internal cavities Crusher openings discharge mouth feed hopper sealed robust temporary covers prevent ingress moisture debris Lifting lugs clearly marked rated capacity

Conclusion

A comprehensive gyratory crusher supplier inspection is multifaceted process demanding team expertise spanning mechanical engineering metallurgy lubrication dynamics electrical controls It transcends simple checklist exercise embodying proactive risk management philosophy By rigorously challenging design verifying quality materials workmanship confirming functional performance before equipment leaves factory buyer can mitigate vast majority potential failures costly field remediations delays project startup Ultimately thorough inspection fosters collaborative relationship supplier ensuring final product not merely complies contract but embodies reliability durability required sustain decades demanding service heart mineral processing operation