Senior Electrician – Gyratory Crusher

Senior Electrician – Gyratory Crusher

Job Purpose

The Senior Electrician is responsible for maintaining, troubleshooting, and optimizing all electrical, automation, and control systems associated with primary gyratory crushers. This role ensures uninterrupted crusher operation, electrical safety compliance, and reliability of power, sensor, and instrumentation systems.

Key Responsibilities

• Electrical Maintenance & System Integrity
• Perform routine preventative maintenance on crusher electrical components, ensuring dry, clean, corrosion‑free connections to prevent phase loss, shorts, and unscheduled downtime.
• Inspect and maintain electrical cabinets, ensuring doors remain sealed to prevent moisture, dust, and debris accumulation on relays and contactors.
• Secure and verify all high‑voltage and low‑voltage terminations, applying dielectric grease on breaker lugs and relay wire entries to prevent seizure and contamination.
• Check starter and overload protection circuits to prevent arcing, improper phase contact, and soft‑start failures.
• Controls, Instrumentation & Automation
• Maintain and troubleshoot crusher control platforms such as
• Metso (automated crusher positioning system) + (Hydraulic Positioning automated setting) systems, ensuring correct adaptation to feed conditions and optimal 24/7 performance.
• Tank Instrumentation Monitoring Systems (TIMS) supporting real‑time lubrication and system health monitoring.
• Digital performance monitoring associated with next‑generation TSUV crushers.
• Interpret diagnostic data from intelligent crusher systems to support predictive maintenance strategies, leveraging real‑time sensor outputs and anomaly detection.

Fault Finding, Repairs & System Optimization

• Diagnose electrical faults impacting crusher operation including motor trips, phase drops, relay failures, sensor faults, undervoltage, and overload events.
• Support troubleshooting of automated start‑under‑load systems, torque limiters, and power supply irregularities in high‑demand crushing environments.
• Identify electrical root causes of unplanned downtime and implement corrective actions aligned with predictive maintenance benchmarks used in intelligent crusher operations.

Safety Compliance & Energy Management

• Ensure full compliance with LOTO procedures, verification of residual energy, and safe use of compressed air when clearing debris from panels.
• Support plant‑wide energy efficiency initiatives, particularly with high‑power gyratory crusher drives requiring optimized consumption.
• Document all electrical maintenance activities, system modifications, and incident findings.

Skills & Competencies

Technical Competencies

Strong understanding of:

• Three‑phase power systems and crusher drive motors.
• Automation platforms (Metso Monitoring Systems).
• Sensor networks diagnostics, and predictive maintenance principles used in intelligent gyratory crusher monitoring.
• Competent in reading electrical schematics, PLC I/O maps, and instrumentation diagrams.
• Operational Competencies
• Skilled at diagnosing faults under high‑pressure production conditions.
• Ability to interpret performance dashboards and act on real‑time crusher data.
• Comfortable supporting both commissioning and shutdown maintenance processes.

Qualifications & Experience

• Qualified Electrician (Red Seal / Trade Test) or equivalent.
• 5+ years experience in heavy industrial/mining electrical maintenance.
• Experience with primary gyratory crushers, their electrical systems, and OEM monitoring platforms (Metso series, TSUV series, etc.).

Work Environment & Requirements

• Ability to work in dusty, hot, vibration‑intense mining conditions.
• Willing to work shifts, overtime, call‑outs, and planned shutdowns.
• Physically fit for confined spaces and working at heights.