AA SPECIFICATION 331001

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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 SAFETY 4
4.3 INFORMATION TO BE SUPPLIED BY CONTRACTOR 4
4.4 FEEDER BREAKER COMPONENTS 5
4.5 LIFTING LUGS 11
4.6 SURFACE PREPARATION AND PAINTING 11
4.7 MANUFACTURING 12
5 QUALITY ASSURANCE PROVISIONS 12
6 PACKING AND MARKING REQUIREMENTS 12
6.1 LIFTING LUGS 12
6.2 NAMEPLATES 12
6.3 PROTECTIVE COATINGS 12
6.4 PACKING 12
APPENDIX A: RELATED DOCUMENTS 13
APPENDIX B: RECORD OF AMENDMENTS 13

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1 SCOPE
This specification covers the requirements for the design and manufacture of feeder
breakers for use in coal mines. Waiver of flame proofing shall be obtained in writing from
Anglo Technical for application in non-fiery mines. The specification is an adaptation of
New South Wales Department of Primary Industries MDG 31.

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.
• Site specific requirements (feed rate, lump size)
• If required, the name of the independent Quality Assurance Representative (See AA
STD 100).

3 DEFINITIONS
For the purpose of this specification the following definitions shall apply

AGMA : American Gear Manufacturers Association

AWS : American Welding Society.

CONTROLS - : Controls that are frequently or continuously used by the operator,

PRIMARY: e.g. traction, steering, brakes, working tools.

CONTROLS - : Controls that are infrequently used by the operator, e.g. start,
SECONDARY lights, test buttons.

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.

DEADMAN : A control which is physically maintained by the operator and

CONTROL permits movement of a machine (i.e. tramming of the feeder
breaker). In the event of the Deadman Control release, the feeder
breaker will come to rest.

FAIL TO SAFE : Any failure of the machinery (i.e. Feeder Breaker), its associated
(fail safe): safeguards, control circuits to its power supply that leaves the
machinery (Feeder Breaker) in a safe condition.

FEA : Finite element analysis.

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IN-FEED : For the purposes of this guideline the in-feed conveyor may be
CONVEYOR any device which conveys material into the breaker section and
includes armoured scraper conveyors, vibro feeders, screens,
hoppers or gravity chutes.

ISO : International Standards Organization

MDG : Mining Design Guideline

MPI : Magnetic Particle Inspection.

NEMA : National Electrical Manufacturers Association

OUT-FEED : For the purposes of this guideline the out-feed conveyor may be
CONVEYOR any device which conveys the sized product from the breaker
section to the conveyor belt system and includes armoured
scraper conveyors.

QAR : Quality Assurance Representative.

STD : Quality Assurance Procedure.

UT : Ultrasonic testing.

VISUAL : Unaided vision, except normally used personal sight aids.

The following terms are defined in the General Conditions of Contract:

• Anglo American, Approved, Company, Contractor, Engineer

4 REQUIREMENTS
4.1 GENERAL
The feeder breaker shall be Contractor's standard design for the specified service.
Replacement parts for standard components shall be readily available.

The unit shall meet the performance requirements as defined under section 2 above.

The Feeder Breaker shall so far as practicable, be constructed of non-flammable material.

No external surface shall exceed a temperature of 150°C under any condition of usage of
the equipment.

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 as specified under Section 2
of this document.

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4.2 SAFETY
All rotating equipment shall be provided with safety guards and devices as required to
comply with Anglo Fatal Risk Standard AA AFRS 5.

The feeder breaker shall comply with all flame-proofing regulations as detailed in section 2
above.

Nip guards shall be fitted to the tail pulley. In accordance with AA SPEC 375001-
Gaurding of Belt Conveyers. All nip points shall be painted red.

The feeder breaker shall be fitted with a Booyco anti-collision system or equivalent.

Isolation shall comply with AFRS 6.

The following potential hazards should at least be considered via Risk

Assessment undertaken for Feeder Breaker design and/or operation:

• the possibility of persons being inadvertently carried into the breaker by in-feed
conveyor
• unplanned machine movement due to brake failure or malfunction, or brake release
for towing purposes
• unplanned machine movement whilst in tramming mode which could place persons
in the vicinity of the machine at risk of injury
• inadvertent starting of conveyor and/or breaker under any condition, including
automatic or manually remote start/stop controls, without giving a warning alarm 10
seconds prior to start
• entrapment of personnel at the in-feed or discharge ends of the conveyor
• outbreak of fire from any source, including failures of breaker or conveyor drive shaft
bearings, drive coupling, gearbox, conveyer belt continuously running against steel
structure due to mistracking
• crush potential from items raised and lowered by hydraulic power
• trailing cable damage during tramming operations.
Note: The above listing is not intended to be representative of the only hazards which need to be considered.

4.3 INFORMATION TO BE SUPPLIED BY CONTRACTOR

• General arrangement drawings
• Electrical motor interface (if excluded from scope of supply)
• Information defining lubricants and maintenance requirements to ensure trouble free
operation shall be furnished as part of the technical information supplied with the
equipment
• An issue based risk assessment for safe operating and maintenance of the feeder
breaker
• Total Cost of Ownership (T.C.O.) model to be submitted with tender
• Mass of all sub assemblies

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• Operating and maintenance manuals

• Parts book

4.4 FEEDER BREAKER COMPONENTS

Components shall be of the contractor's standard heavy duty construction as
recommended for the conditions described herein.

4.4.1 Body assembly

The body shall have a design life of 40,000 operating hours. The deck shall have wear
protection where applicable. All welding shall conform to AWS 1.1.

4.4.2 Anchoring
Sufficient anchoring or feeder breaker mass shall be provided that would be necessary to
withstand twice the belt tension at the tail pulley, when taking into account that the tail
tension will increase as the conveyor length increases when sections develop.
4.4.3 Brakes

Wheeled Feeder Breaker units shall be provided with a means of locking the wheels when
the unit is not attached to a prime mover. This may be achieved by jacking systems which
remove the weight of the Feeder Breaker from the wheels or by wheel sprags. These
provisions shall be effective before the Feeder Breaker is detached from the prime mover.
Note: Consideration shall be given to the intended prime mover un-braked trailer mass and brakes fitted as
appropriate.

Self propelled Feeder Breakers shall be provided with brakes which can manually be
applied and automatically applied on loss of power to the traction drive system.
Note: Specific approval is required for electric brake motors and brake motor control and protection systems.

Traction brakes shall:

a) be fully enclosed spring applied brakes fitted directly to the traction drive assembly
(oil immersed multi-disc type is preferred). For any operational condition, the
surface temperature of the brake assembly shall not exceed 150°C;

b) fail to safe;

c) have provision to ensure that traction power cannot be applied unless the brakes
are released;

d) have provision to be manually released.

Fully loaded self propelled Feeder Breakers shall be capable of coming to a controlled
stop whilst tramming down the maximum operating gradient.

The contractor shall nominate the maximum gradients for safe operation of the Feeder
Breaker when fully loaded and empty.

A “dead-man” control if fitted shall apply the brake(s) as part of its function. Alternatively
the brakes shall apply automatically when power is removed from the traction drive
system.
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The foregoing requirements for traction drive braking systems are specifically confined to
mechanical systems and are additional to any alternative methods of braking.

Hydrostatic traction braking is permissible if the findings of a detailed risk assessment

determine that the system as reviewed is safe.

4.4.4 Wheels or tracks

The Feeder Breaker may be mounted on wheels or tracks to allow movement during belt
advancement and or retraction or be part of a fixed installation. Where tracks are
provided, these shall be powered.

4.4.5 Tail pulley

Preference will be given to feeder breakers with “integrated tail-end” i.e. conveyor pulley /
tail-end must tram with the machine forward.

The tail pulley must be fitted with hydraulic cylinders for conveyor belt alignment. This
alignment must be achieved by means of remote control.

Pulleys shall be installed and selected in accordance with AA SPEC 371001

Pulley lagging shall be 10mm thick and will have diamond grooves.

Pulley lagging shall be fire retardant.

The drop height of material from the Feeder breaker onto the belt shall not exceed
500 mm.

4.4.6 Dimension

The width of the feeder breaker gate shall not exceed 2/3 of installed belt width or the
receiving belt width will exceed this gate width by a factor 1.5.

4.4.7 Towing

Towing attachments, suitable for use with rigid draw bars, shall be designed to a minimum
factor of safety of 2.5 times the maximum rated gross weight of the Feeder Breaker when
travelling on the maximum allowable grade.

Provision shall be made for the connection of safety chains between the prime mover and
the Feeder Breaker where the combined rating of safety chain attachments equals the
maximum rated gross weight of the Feeder Breaker when travelling on the maximum
allowable grade.

Provision shall be made for the release of the traction brakes by external means for the
purpose of towing a disabled Feeder Breaker. With any provisions made to satisfy this
requirement it should not be possible to leave the Feeder Breaker parked without the
brakes applied when not attached to the prime mover (See also section 4.4.3).

4.4.8 Breaker

The breaker shall be designed to take standard continuous miner picks.

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4.4.9 Marking and illumination

Consideration should be given to provision of workplace lighting, for the purpose of

illuminating the extremities of the Feeder Breaker. The lighting may be portable fittings
which can be carried on the Feeder Breaker and hung from the roof at the operating
location.

All instrumentation should be colour coded to indicate normal and hazardous ranges as
per SAE J209 or clearly labelled to indicate hazardous ranges if the instrument does not
continually indicate.

Self propelled feeder breakers should have a green revolving light on the driver’s side and
a red revolving light on the blind side. These shall be clearly visible to people
approaching the breaker.

4.4.10 Dust suppression

Suitably located water sprays shall be provided at the in-feed conveyor side of the breaker
for dust suppression. The following should be considered in the design of any dust
suppression system;

a) Water flow should be monitored to ensure that excess dust does not occur.

b) Spray nozzles should be manufactured from corrosion resistant material and be

installed and located with proper considerations to the safety of person(s) required
to carry out inspections and maintenance of the system.

c) Adequate water filtration should be provided to prevent sprays becoming blocked.

d) Consideration should be given to limiting the speed of rotation of the

breaker/crusher mechanism in order to reduce dust.

4.4.11 Gearboxes

Gearboxes shall be of standard supply from reputable gearbox manufacturers.

Gearboxes shall be rated for continuous operation at maximum motor power for the
greatest gear ratio arrangement considered. 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 Q 6 or better.

Feeder breaker gear chamber, lubrication and hydraulic systems shall be of dust-tight and
moisture-tight construction.

4.4.12 Lubrication and hydraulic systems general requirements

Monitoring shall be provided for hydraulic systems oil level and temperature. Where
potential for overheating exists as a result of component malfunction then control shall be
installed to cut power to the hydraulic pump motor when set points of the monitoring
system are exceeded.

Flexible hoses shall be compatible with the hydraulic fluid used, the maximum system
pressure and operating temperature.

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The hose factor of safety shall be a minimum of 4 to 1 based on hose burst pressure to
maximum working pressure.

Hydraulic hoses shall be of flame resistant type and comply with type 1 or 3 hose
specifications as listed in ISO 6805.

Where a hydraulic system incorporates an accumulator the attachment to the accumulator

should be by means of a minimal length adaptor and flexible hose. Fittings should be
located or otherwise guarded to provide mechanical protection. A manual bleed valve
should be fitted to allow pressure relief for maintenance or lockout isolation valve fitted.

Accumulators shall be securely installed.

Conveyor booms, levelling jacks and other items raised and lowered by hydraulic power
shall be fitted with a device which holds them stationary should loss of hydraulic pressure
occur anywhere between the hydraulic power source and the cylinder e.g. Hydraulic Load
Locking Valve.

The system shall be designed for easy maintenance and replacement of parts, without
draining of oil from reservoir and or lines.

The feeder breaker shall have an automated central greasing system.

4.4.13 Electrical components

All electrical components shall be flame proof where practicable. Where this is not
possible precaution shall be taken or be clearly labeled on the machine to reduce chances
of ignition of methane.

Electrical equipment shall be approved by the Engineer in writing.

Instruments shall comply with AA STD 673025 Option 2.

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 by the Engineer in writing.

4.4.14 Controls

Sequence interlocking must be such that the any receiving conveyor(section belt) will
move before the discharging out-feed conveyor is started and that any discharging
conveyor is stopped before the receiving conveyor is stopped in order to prevent
excessive material over-run, unless chutes have been designed to store this material and
this excludes any emergency stops that must be done.

Feeder conveyor and breaker drive mechanism should not be energised when the Feeder
Breaker is being trammed.

Sequencing of the breaker drive and in-feed conveyor drive shall be such to prevent
overloading of the breaker assembly during start-up.

For radio control or other forms of remote control the following shall be specified by the
manufacturers;

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a) The maximum distance between the controller and Feeder Breaker.

b) A safe system of operation including use of a spare transmitting unit, charging of the
batteries, changeover procedure and location of the spare unit.

c) Operator safe standing zones.

Systems for control of the operation of Feeder Breaker which are duplicated i.e., have
local manual controls and radio remote control should be provided with the following
features:

a) The selection of either mode of control shall be designed with an effective interlock
to prevent the inadvertent operation of any controls associated with the unselected
mode with the exception of emergency stop devices.

b) Visual indication shall be provided at each point of control to indicate which mode
has been selected.

c) A single means of selecting each mode of control shall be provided (including

“OFF”).

The electrical supply cable should be prevented from over tension, crushing or other
damage during tramming operations without requiring a person being located in a
potentially hazardous position.

Provision should be made to suitably restrain the trailing cable to the Feeder Breaker.

The mine should develop a trailing cable handling procedure which provides for safe
standing zones for personnel.

A means of isolating and locking out the incoming mains power supply to the Feeder
Breaker shall be provided for maintenance purposes. Such means of Isolation shall be
lockable and capable of withstanding the prospective maximum short circuit current at the
point of installation.

This isolation should include any interlocking with associated equipment such as in-feed
mechanisms and out-feed receiving conveyor systems.

Gear boxes which are operational while the Feeder Breaker is unmanned shall be fitted
with devices so that the oil level and temperature can be visually monitored and should be
provided with controls to cut power to the drive system in the event of excessive high
temperature.

Temperature monitoring of bearing assemblies fitted to conveyor idler, conveyor drive and
crusher shafts should be considered:

A five (5) second pre-start warning device shall be fitted to automatically alarm prior to the
starting of the conveyor or crusher. This warning device must be audible and/or visual.
Note: Pre-start warning devices shall be operational regardless of which form of control has been selected.

The feeder breaker shall be fitted with audible tramming and start-up alarms.

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All operating controls for hydraulically powered systems shall be designed to automatically
return to the “OFF” position on loss of power to the machine and/or loss of hydraulic
system pressure unless a control does not introduce a hazard on restart e.g. conveyor
speed select in which instance risk assessment process shall be used to assure the safety
of that function.

The receiving conveyor shall not be operated at speeds below that necessary to keep the
cross-sectional area of material on the belt below is allowed 100% loading profile. Such
minimum speeds shall be approved by the conveyor design engineer. This shall be
calculated at the maximum capacity delivered by the feeder breaker.

Emergency stop switches shall be provided to cut the power from all functions of the
equipment and be accessible;

a) from at least either end of the Feeder Breaker, but preferably along the full length of
the equipment;

b) from any remote control device;

c) by any person discharging material into the hopper e.g. shuttle car driver. (Tarzan
bar)
Note 1: Any emergency control device should be capable of being operated at all times regardless of
which form of control has been selected.

Note 2: If radio remote control is utilised and the portable control unit is taken out of transmitting range,
power to be automatically removed from the Feeder Breaker. Power shall only be capable of being
restored to the Feeder Breaker by selection of local manual controls at the Feeder Breaker.

• Controls Layout

a) Controls shall be laid out and designed to allow easy and safe operation and
to prevent confusion over allocation of controls to function or direction of
operation.

b) Controls should be organised into primary and secondary groups as detailed

in SAE J898.

c) All primary controls including their displacement should be located with their
neutral position and, if possible, all other positions in the zone of comfort as
per SAE J898.

d) All secondary controls should be located within the zones of reach.

e) Controls, control linkages, hoses, tubes and connections shall be located in

such a manner that they are not likely to be damaged by foreseeable external
forces and are easily accessible for inspection.

f) The distance between control levers, adjacent foot pedals, knobs, handles,
operator’s body and other machine parts shall be sufficient to allow
unhindered operation without unintentional actuation of adjacent controls.

g) Controls shall be protected to prevent accidental operation by either the

operator or from falling roof/rib material

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• Control Functions

Operating controls shall be clearly marked to show their functions and preferred
direction of movement controls as specified below:-
FUNCTION DIRECTION DIRECTION
EMERGENCY STOP “Stay Put” Red Push button or pull trip wire
ON Up, right, forward, clockwise, pull (push/pull type switch)
OFF Down, left, backward, anti-clockwise, push.
RIGHT Clockwise, right
LEFT Anti-clockwise, left
FORWARD Forward, down
REVERSE Backward, up
RAISE Up, back
LOWER Down, forward
EXTENDED Down, forward, pull
INCREASE Forward, away, right, clockwise
DECREASE Backward, toward, left, anti-clockwise
OPEN VALVE Anti-clockwise
CLOSE VALVE Clockwise

4.5 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. On loads where only a single lugs is require it shall be
designed to have a safe working load of at least six times the suspended load. Where
multiple lugs are used (2 or more) the safe working load for any two lugs shall be at least
three times 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 S
• Shown on drawings together with lifting illustrations
• Permanently fixed to all items requiring removal for inspection and maintenance
• 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

4.6 SURFACE PREPARATION AND PAINTING

All equipment shall have a clean and finished appearance when delivered.
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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 (AA SPEC 164000 can be used as
guideline). The Contractor may 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.

4.7 MANUFACTURING
Construction of the feeder breaker shall comply with Section 5 below of this specification
Quality Assurance, Inspection and Testing.

5 QUALITY ASSURANCE PROVISIONS

Quality assurance shall comply with provisions of AA STD 100.

6 PACKING AND MARKING REQUIREMENTS

6.1 LIFTING LUGS
The gross weight of the lift shall be stenciled or painted in a conspicuous location and
identified as the gross lifting weight.

6.2 NAMEPLATES
Feeder breaker components shall be identified by permanent serial number. Other
equipment shall have permanent stainless steel nameplates attached that contain all
pertinent identification and size information.

The mass for sub-assemblies shall be clearly marked on the assembly.

6.3 PROTECTIVE COATINGS

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.

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APPENDIX A: RELATED DOCUMENTS

AA SPEC 331001 Feeder Breaker

Unless otherwise stated the latest issue of the following documents shall be deemed to form part of
this specification.

AA AFRS 5 : Equipment safeguarding

AA AFRS 6 : Isolation Standard

AA SPEC 164000 : User guideline for Corrosion Prevention: System Selection

AA SPEC 371001 : Conveyor pulleys and shafts

AA SPEC 375001 : Gaurding of Belt Conveyers

AA STD 100 : Quality Requirements for Suppliers of Critical Equipment

AA STD 673025 : Packaged equipment and plants

ANSI B93 : Hydraulic Standards for Industrial Equipment

ISO 6805 : Rubber Hoses and Hose Assemblies for Underground mining - Wire
Reinforced Hydraulic Types for Coal Mining - Specification

MDG 31 : Design guidelines for the construction of feeder breakers

SAE J209 : Instrument Face Design and location for Construction and Industrial
Equipment
SAE J898 : Control Locations for Off- Road Vehicles

APPENDIX B: RECORD OF AMENDMENTS

Issue 0 : New document (C Chakawodza) September 2009

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contained therein, irrespective of the cause and quantum thereof.