DOWNLOAD PDF CAT AUSTAR COAL MINE 2006 LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL BI619135

BI619135

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BUCYRUS R

Technical Manual

BI619135

AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

DESIGNED & MANUFACTURED BY SOUTHERN ENGINEERING SERVICES PTY LTD

BI619135

AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

HYDRAULIC PUMP STATION SERVICE AND MAINTENANCE MANUALS SUPPLIED BY SES: Credits: – Original written and compiled by Joel Clement (July - August 2006) (with additions extracted from previous SES manuals written by Robin Genero) – Full Print Production - Version 1.0 (September 2006) – Crawler tracks assembly manual supplied by DBT Australia.

– Electric motor details supplied by Toshiba – Hose schedules supplied by Pirtek – Electrics and associated documentation supplied by Ampcontrol Electrical Contractors.

SOUTHERN ENGINEERING SERVICES PTY LTD. MINING & HYDRAULIC DIVISION 11 Prince of Wales Avenue UNANDERRA NSW 2526 Telephone: 02 4271 1444 Facsimile:

02 4271 1755

Email:

mining@sesgroup.com.au

Web:

http://www.sesgroup.com.au

AUSTAR COAL MINE PTY LTD

Middle Road PAXTON NSW 2325 Telephone: 02 4993 7201 Facsimile: 02 4993 7302

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BI619135

AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

TABLE OF CONTENTS…

Manual production details …………………………. [ i ] Table of contents …………………………………… [ ii ] Nomenclature ……………………………………….

[ xvi ]

SI unit conversions & engineering constants ……. [ xviii ]

1.

INTRODUCTION …………………………………………………

1.1

General description …………………………………… 1

1.2

General arrangement………………………………….

3

1.3

General arrangement drawing with field devices…..

4

1.4

Icons used throughout this manual ...……………….. 5

1.5

Safety instructions …………………………………….. 6

1.6

2.

1

1.5.1

Emergency stop procedure………………….. 6

1.5.2

Pump isolation steps…………………………. 7

Pump station start up procedures……………………. 8

EMULSION CHOCK PUMP

9

2.1

Pump technical information …………………………... 9

2.2

Pump components……………………………………... 10

2.3

General description ……………………………………. 12

2.4

Pump operation ………………………………………... 13

2.5

Unloading control system ……………………………..

2.6

Lubrication system …………………………………….. 16

2.7

Correction direction of operation ……………………..

2.8

Accumulators …………………………………………… 20

ii

15

19

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

2.9

Servicing and maintenance of pumps……….……….. 22 2.9.1

Inspection and maintenance requirements 22

2.9.1.1

Daily inspection and maintenance……

2.9.1.2

Every 3 months – OR – 1000 hours of operation ………………………………..

2.9.1.3

22

22

Every 12 months – OR – 5000 hours of operation inspection to be carried out by SES service engineer..………… 23

2.9.2

Maintenance procedures ………………….

24

2.9.2.1

Pre-maintenance……………………….. 24

2.9.2.2

Procedure for checking the pump oil level……………………………………… 25

2.9.2.3

Procedure for adding lubricating oil to the crankcase…………………………... 26

2.9.2.4

Procedure for changing lubricating oil.. 27

2.9.2.5

Procedure for changing oil filter………. 30

2.9.2.6

Procedure for changing oil seal and nozzle in oil distributor…………………. 32

2.9.2.7

Procedure for bleeding air from the pump …………………………………..... 36

2.9.2.8

Procedure for removing a pump insert assembly………………………………… 39

2.9.2.9

Procedure for the disassembly of a pump insert……………………………… 42

2.9.2.10 Pump insert inspection requirements... 45

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

2.9.2.11 Procedure for the reassembly of a pump insert……………………………… 46 2.9.2.12 Procedure for the refitting of a pump insert assembly…………………………. 49 2.9.2.13 Procedure for the removal of plungers

51

2.9.2.14 Refitting plungers………………………. 54 2.9.2.15 Replacing the plunger packing……….. 55 2.9.2.16 Removal of ADM solenoid filter block assembly………………………………... 58 2.9.2.17 Replacing ADM solenoid filter block assembly filter element………………… 60 2.9.2.18 Replacing ADM solenoid filter block assembly filter element………………… 61 2.9.2.19 Exchange of safety relief valve……….. 63 2.9.3

Service tools ………………………………… 66

2.9.3.1

Set screws for valve holders of pump inserts …………………………………… 66

2.9.3.2

Set screw for oil distributor …………… 66

2.9.3.3

Withdrawing device for plungers …….. 66

2.9.3.4

Withdrawing device and assembly mandrel locking pin of crosshead ……. 67

2.9.4

Additional pump information ……………… 68

2.9.4.1

Bolt tightening torques ………………….. 68

2.9.4.2

Grease ….………………………………… 69

2.9.4.3

Sealant …………………………………… 69

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

2.9.5

Trouble shooting guide for Hauhinco pumps ……………………………………….. 70

3.

POSITIVE SET PRESSURE PUMP

73

3.1

Pump technical information……………………………

73

3.2

General description…………………………………….

74

3.3

Pump operation…………………………………………

77

3.4

Unloading control system & 32L accumulator.……… 77

3.5

Lubrication system………………………………….….. 78

3.6

Correct direction of operation…………………………. 80

3.7

Service & maintenance of pumps…………………….. 81 3.7.1

Inspection and maintenance requirements 81

3.7.1.1

Daily inspections and maintenance……

3.7.1.2

Every 3 months or 1000 hours of operation…………………………………

3.7.1.3

81

81

Every 12 months or 5000 hours of operation Inspection to be carried out by

3.7.2

SES service engineer……………………

82

Maintenance procedures………………….

83

3.7.2.1

Pre-maintenance procedures…………... 83

3.7.2.2

Procedure for checking the pump oil level………………………………………..

3.7.2.3

84

Procedure for adding oil to the crankcase…………………………………. 85

3.7.2.4

Procedure for changing lubricating oil…. 85

3.7.2.5

Procedure for changing oil filter………… 85 v

BI619135

AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

3.7.2.6

Procedure for changing nozzle and oil seal in the oil distributor……………..…..

3.7.2.7

Procedure for bleeding air from the pump ………….…………………………..

3.7.2.8

85

89

Procedure for removing pump intake and delivery valves………………………. 92

3.7.2.9

Procedure for removing pump insert assemblies………………………………... 93

3.7.2.10 Procedure for refitting of pump insert assemblies………………………………..

95

3.7.2.11 Procedure for removal of plungers…….. 97 3.7.2.12 Procedure for fitting of plungers………... 100 3.7.2.13 Replacing the plunger packing…………. 101 3.7.2.14 Procedure for replacing safety valves…. 104 3.7.3

Additional pump information ………………. 107

3.7.3.1

Bolt tightening torques ………………….. 107

3.7.3.2

Grease ….………………………………… 108

3.7.3.3

Sealant …………………………………… 108

3.7.4

Trouble shooting guide for Hauhinco pumps ………………………………………..

4.

109

EMULSION STORAGE TANK …………………………………. 111 4.1

Technical information ………………………………….

111

4.2

Emulsion suction outlet ports………………………….

112

4.3

Suction Isolation valves………………………………... 113

4.4

Air breathers…………………………………………….. 114 vi

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

4.5

Emulsion tank fluid level viewing port ……………….. 115

4.6

Drain ports ……………………………………………… 116

4.7

Emulsion temperature transducer ……………………

117

4.8

Low pressure emulsion sample point ………………..

118

4.9

Procedure for taking sample of emulsion from tank .. 119

4.10

Service and maintenance …………………………….. 122 4.10.1

Inspection and maintenance requirements 122

4.10.1.1 Daily inspections and requirements …. 122 4.10.1.2 Twelve monthly – OR – every 5000 hours of operation inspection requirements …………………………… 122 4.11

Maintenance procedures ……………………………… 123 4.11.1 Suction isolation ……………......................... 123 4.11.2 Procedure changing air breather elements... 125

5.

PUMP STATION MONITORING SYSTEM ……………………

127

5.1

Pump station monitoring system components ……… 127

5.2

General description ……………………………………. 130

5.3

Emulsion tank monitoring ……………………………..

5.3.1

5.4

130

Emulsion temperature transducer ………….. 130

Chock and positive set pump monitoring ……………

132

5.4.1

Emulsion system pressure transducer……… 132

5.4.2

Pump lubrication oil pressure switch ……….. 133

5.4.3

Emulsion and shearer water pumps lubricating oil temperature transducer………. 134

5.4.4

Lubrication oil pressure transducer…………. 135 vii

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

5.5

Filtration system monitoring …………………………..

5.5.1

136

Emulsion return line filter pressure transmitter & DP switches …………………… 136

5.6

Calibration of transducer………………………………. 138 5.6.1

Lubricating oil pressure transducer calibration………………………………………

5.6.2

6.

138

Lube oil temperature transducer calibration.. 138

FILTRATION SYSTEM ………………………………………….. 139 6.1

General description ……………………………………. 139

6.2

Emulsion return line filters …………………………….

6.3

Emulsion inlet filter …………………………………….. 141

6.4

Mineral oil filter …………………………………………. 142 6.4.1

139

General description …………………………... 142

6.5

Shearer water pump inlet filters ……………………… 143

6.6

Emulsion storage tank air breathers and filtration magnets ………………………………………………...

144

6.7

Solenoid pre-control valve filter ………………………. 146

6.8

Service and maintenance procedures ………………. 147 6.8.1

Procedure for changing return line filter elements and emulsion infill filter element…. 147

6.8.2

Procedure for changing shearer water inlet filter element…………………………………… 149

7.

MINERAL OIL CONTROL SYSTEM …………………………..

7.1

150

General description ……………………………………. 150 viii

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

8.

7.2

Levelling cylinders …………..…………..…………….. 151

7.3

Load locks ……………………………….…………...… 152

7.4

Directional control valves……………………………… 152

7.5

Diverter ball valve………………………………………. 153

7.6

Remote pendant control system……………………… 154 7.6.1

Remote pendant control box…………………

154

7.6.2

Remote pendant control connection panel…. 155

7.7

Crawler track units……………………………………… 156

7.8

Mineral oil pressure filter………………………………. 156

7.9

Brake valve……………………………………………… 157

7.10

Brake valve hydraulic gauge………………………….. 157

7.11

Austar Coal Mine hydraulic pump station positioning procedure………………………………………………..

158

CRAWLER TRACKS ASSEMBLY …………………………….

161

8.1

Crawler tracks unit specifications ……………………. 161

8.2

General description…………………………………….. 162

8.3

Towing the pump station………………………………. 164 8.3.1

Connecting towing unit to the ‘A-frame’ tow bar……………………………………………....

8.3.2

164

Procedure for connecting towing ‘A-frame to tow vehicle………………………………….….. 165

8.3.3

Procedure for freewheeling crawler tracks.… 167

8.4

Tramming pump station using the crawler track unit.. 174

8.5

Procedure for replacing oil filling of planetary hubs… 177

8.6

Inspection and tensioning crawler tracks…………….

ix

179

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

8.6.1

Procedure for inspecting and tensioning crawler tracks………………………………….. 179

9.

SHEARER WATER PUMP ……………………………………... 182 9.1

Pump technical information …………………………... 182

9.2

Shearer water pump components ……………………

183

9.3

General description…………………………………….

184

9.4

Pump operation ………………………………………... 185

9.5

Unloading system ……………………………………… 186 9.5.1

General Description…………………………..

186

9.5.2

Shearer water pump unloader valves………. 187

9.6

Lubrication system……………………………………... 189

9.7

Correct direction of operation…………………………. 191

9.8

Transducers for shearer water pump monitoring…… 192 9.8.1

Delivery pressure transducer………………… 195

9.8.2

Inlet water Pressure transducer……………... 195

9.8.3

Lube oil pressure transducer………………… 195

9.8.4

Lube oil temperature transducer…………….. 195

9.8.5

Transducer pressure dampener…………….. 196

9.9

Shearer water pump inline inlet water filter………….. 197

9.10

Service and maintenance …………………………….. 198 910.1

Inspection and maintenance requirements for shearer water pump unit ………..………. 198

9.10.1.1 Daily inspection and maintenance……

198

9.10.1.2 Weekly inspection and maintenance… 198

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

9.10.1.3 Every 3 months – OR – 1000 hours of operation………………………………… 198 9.10.1.4 Every 12 months – OR – 5000 hours of operation inspection to be carried out by SES service engineer………….. 199

10.

11.

9.10.2

Procedure for changing the unloader valve . 200

9.10.3

Maintenance procedures……………………. 204

MISCELLENOUS ITEMS ….……………………………………. 205 10.1

Quick release electrical receptacles………………..... 205

10.2

Emergency stop buttons……………………………….

206

10.3

Start and stop buttons………………………………….

207

10.3.1

Chock pump & positive set pump…………. 207

10.3.2

Shearer water pump start & stop buttons… 208

10.4

Emulsion tank junction box……………………………. 209

10.5

Lockable ball valves……………………………………. 210 10.5.1.

Face delivery isolation ball valves…………. 210

10.5.2

Chock pump delivery isolation ball valves... 212

10.6

Lifting points…………………………………………….. 213

10.7

Pump station level indicator…………………………… 214

10.8

Face emulsion return ports……………………………. 216

10.9

Important signs attached to the pump station……….

217

ISOLATION AND PRESSURE BLEED OFF PROCEDURES

218

11.1

Hauhinco pump isolation and pressure venting procedures………………………………………………. 218 xi

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

11.1.1

Chock pump isolation and pressure vent procedure…………………………………….. 218

11.1.2

Positive set pump isolation and pressure vent procedure………………………………. 224

11.1.3

Shearer water pump isolation and pressure vent procedure………………………………. 229

11.2

Accumulator isolation and pressure venting………… 234 11.2.1

Dual accumulator manifold isolation and pressure vent procedure……………………. 234

11.2.2

Positive set accumulator manifold assembly isolation and pressure vent procedure…………………………………….. 240

11.2.3

Shearer water accumulator manifold assembly isolation and pressure vent procedure…………………………………….. 246

12.

INSPECTION REQUIREMENTS ……………………………….

251

12.1

Daily inspections ……………………………………….

251

12.2

Weekly inspections ……………………………………. 252

12.3

Every 3 months – OR – 1000 hours of operation…… 252

12.4

Every 6 months ………………………………………… 252

12.5

Every 12 months – OR – 5000 hours of operation Inspection and service to be carried out by SES service engineer………………………………………... 253

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

A.

PAGES

CRITICAL COMPONENTS

B.

4

APPENDIX ‘A’ – AUSTAR SPARE PARTS SCHEDULE

Item

Description

1

Field devices………………………………………….

1 of 4

2

Chock pumps…………………………………………

1 of 4

3

Shearer water pump…………………………………

1 &2 of 4

4

Chock pumps & shearer water pump………………

2 of 4

5

General spares………………………………………...

2 of 4

6

Consumables…………………………..………………

3 of 4

7

Service exchange items………………………………

4 of 4

APPENDIX ‘B’ – HAUHINCO PUMPS SPARE PARTS LIST B.1

No of PAGES

Emulsion Chock Pump Refer

Part No.

Description

Sect 2

5131162 EHP-3K 200/53 FL (50Hz) ……………….…

1

Sect 2

5133556

EHP-3K 200 Flange ………………………....

4

Sect 2

6042600

Spare parts drawing ………………………....

1

Sect 2

6310176

Oil distributor including filter………………...

2

Sect 2

5132797

Oil pressure control device ……………..…..

2

Sect 2

2321823

Oil pressure control device Condor FF-4 series.

1

Sect 2

6208770

Lubrication pump ……………………………….

2

Sect 2

6136249

Bearing cover with flange pump ………………

2

Sect 2

6424287

Complete oil suction filter ………………….…..

1

Sect 2

6426840

Suction pipe for oil pump ………………….…..

1

Sect 2

6343821

Feeding pipe for oil cooler ………………….…

1

Sect 2

6499155

Return line from oil cooler …………………….

1

Sect 2

6230660

Oil cooler ………………………………………..

2

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BI619135

AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006 Sect 2

2321823

Oil filler/air breather filter ………………………

2

Sect 2

2350343

Oil filler/air breather filter ………………………

2

Sect 2

6540260

Pump insert with plunger 53 D………………..

3

Sect 2

5118905

Valve cover with spring guide …………………

2

Sect 2

5118867

Valve holder with spring guide ……………….

2

Sect 2

6339042

Main control valve H30 ………………………...

2

Sect 2

6256279

3/2 way solenoid valve DN 3 ………………….

2

Sect 2

6136508

3/2 way-seat-valve DN 3 positive intrinsically safe 12V………………………………………….

B.2

3

Sect 2

6147291

Connection plate ………………………………..

2

Sect 2

6531547

High pressure filter ……………………………..

1

Sect 2

6513158

Pulse-tone accumulator 2.5 l - 400 Bar…… …

2

Sect 2

6344917

Mounting support for pulse-tone accumulator.

2

Sect 2

6467768

Pressure gauge connection complete ………

1

Sect 2

2311763

Pulse-tone accumulator ……………………….

2

Sect 2

4564596

Hollow screw ……………………………..……..

1

Sect 2

1720007

Safety valve s 301/108 ………………………...

1

Sect 2

4151852

Safety valve s 301/108 ……………….………..

5

Sect 2

6536352

Pressure connection cover ………………..…..

1

Sect 2

4571657

Coupling half pkd 30 – D 60 - pump side……

1

Positive Set Pressure Pump Sect 3

5135486

EHP-3K 110FF…………………………………..

7

Sect 3

1720023

Safety Valve S .01/95…………….…………….

1

Sect 3

2310201

2.5L Accumulator ……………………………….

4

Sect 3

2321823

Control Pressure Switch ……………………….

5

Sect 3

3762254

Lubrication pump………………………………..

2

Sect 3

4160282

Air vent cock with armatures…………………..

1

Sect 3

4571657

Coupling half pkd 30 D60 pump side………....

1

Sect 3

5100674

Main control valve H300/20…………………....

3

Sect 3

5108101

Suction connection with hole G2………………

2

Sect 3

5118603

Lubrication pump without spur gear…………..

2

xiv

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006 Sect 3

5125359

Suction connection – blind…………………….

Sect 3

6136508

3/2 way-seat valve DN3 positive intrinsically safe 12V………………………………………….

Sect 3

6217486

Oil pressure controller with armatures & pendant switch…………………………………..

B.3

2 3

3

Sect 3

6242499

3/2-way-solenoid valve DN3…………………...

1

Sect 3

6378218

Complete hollow screw…………………………

1

Sect 3

6536344

Pressure connection cover………………...…..

1

Sect 3

6536395

Intermediate plate DS300………………………

1

Sect 3

6555942

Pump insert with plunger 40D…………………

1

Sect 3

6378226

Hydraulic accumulator with armatures 450Bar

2

Shearer Water Pump Assembly Sect 9

5133602

EHP-3K 150/70 flange…………………………

1

Sect 9

5133599

EHP 3K 150/70 flange (50Hz)………………...

6

Sect 9

3762254

Lubrication pump ……………………… ……

2

Sect 9

5118603

Lubrication pump without spur gear………….

2

Sect 9

6513360

Pump insert with plunger 70 D………………..

3

Sect 9

5118913

Valve cover with spring guide………………...

2

Sect 9

5118883

Valve Holder with Spring guide ……………….

2

Sect 9

5108101

Suction connection with hole G2 ……………..

2

Sect 9

6518109

Suction connection plate G 2…………………

2

Sect 9

6225748

Intermediate plate …………………..………….

1

Sect 9

6217486

Oil pressure controller with armatures & pendant switch………………………………….

3

Sect 9

2321823

Oil pressure control device – Condor ff-4 series.

1

Sect 9

6479545

Overflow valve U 504/400……………..……….

1

Sect 9

6229441 Overflow valve U 540/400…………..…………...

3

Sect 9

6480071 Overflow valve U 504/400……………………….

1

Sect 9

4571657 Coupling half pkd 30 D 60 pump side………......

1

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C.

APPENDIX ‘C’ – FIELD DEVICES Sect 5 Sect 5

D.

F.

4152-21B Drawing- pump station field devices……….…

3 1

APPENDIX ‘D’ – DBT CRAWLER TRACKS (Size 9) ………….

Sect 8

85300050 Torque hub drawing & bill of materials… ……….

2

Sect 8

8700060 Crawler track #9 assembly & bill of materials.…..

3

Sect 8

E.

Pump station monitoring system components...

187000603 Crawler track #9 assembly LH-00 & bill of

5

materials…………………………………………….

Sect 8

DBT Technical data sheets …………………….………

3

Sect 8

8958 028 010 Hydraulic circuit tramming bill of materials.....…..

1

Sect 8

8958 028 010 Hydraulic circuit tramming & positioning…..…….

1

Sect 8

CT45 Assembly – disassembly manual……….………..

12

APPENDIX ‘E’ PIRTEK HOSE & FITTINGS SCHEDULE Emulsion hosing circuit…………...……………………

1

Pump accumulator circuit …………...………………..

1

Pressure and return circuit - mineral oil ...…………...

1

Tram Motor Circuit………………………………….….

2

Levelling Cylinder Circuit……………………………..

1

Split flange & ball valve spare parts list ……….…….

1

APPENDIX ‘F’ – AMPCONTROL ELECTRICAL CIRCUIT Pump 1

2181-1021

Local J/Box wiring diagram……………………………

1

Pump 2

2181-1031

Local J/Box wiring diagram…………………………….

1

Pump 3

2181-1041

Local J/Box wiring diagram………….………………..

1

2181-1061

Emulsion tank marshalling J/Box……………….……

1

2181-1071

Pump cart marshalling box……………………………

1

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G.

APPENDIX ‘G’ – HYDRAULIC SCHEMATIC 4512-03C

H

I.

Pump station hydraulic schematic……………………..

1

APPENDIX ‘H’ – ENGINEERING DRAWINGS 4152-04H

Plan on turning circle ……………………………………

1

4152-21B

General arrangement drawing with field devices……..

1

8708-A

Shearer water pump general arrangement …………...

1

APPENDIX ‘I’ – TOSHIBA 200kW ELECTRIC MOTOR INSTRUCTION MANUAL * The Toshiba 200kW electrical motor instruction manual is included in the form ‘as is’ as supplied by Toshiba. The index and contents of the motor section a separate page numbering, not continuing on from the rest of the SES Group service manual.

(I) 1.0

Instruction Manual No.: TMAN000-SCIM-R06

1

(I) 1.0

Receiving Checks ………………………………………..

3

I) 1.1

Check on Received Merchandise ……………

3

I) 1.2

Storage ………………………………………….

3

Installation …………………………………………………

4

I) 2.1

Environment …………………………………….

4

I) 2.2

Foundation ……………………………..……….

6

I) 2.3

Alignment Procedures …………………………

6

Start-Up …………………………………..….……………

8

I) 3.1

Check before Start-Up ……….…..……………

8

I) 3.2

Checking point during Start-Up ……………….

9

(I) 2.0

(I) 3.0

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(I) 4.0

(I) 5.0

Disassembly & Reassembly of Motor …………………

11

I) 4.1

Disassembly of Motor …………………………

11

I) 4.2

Reassembly of Motor ………………………….

11

I) 4.3

Grease Requirement ………………………….

11

Maintenance ……………………………………………..

13

I) 5.1

Routine Maintenance ………………………….

13

I) 5.2

Knock-Down Examination …………………….

14

I) 5.3

Useful Information regarding Operation and Maintenance ……………………………………

15

(I) 6.0

Troubleshooting and repair ……………………………..

21

(I) 7.0

Storage …………………………………………………….

25

I) 7.1

Introduction ………………………………….…..

25

I) 7.2

Storage Area ……………………………………

25

I) 7.3

Storage Maintenance ……………………….….

25

I) 7.4

Storage Inspection Record ……………………

27

(I) 8.0

Appendix ………………………………………………….

Motor Construction Drawing ……………………………

Bearing Construction Drawing ………………………….

K.

APPENDIX ‘K’ – MATERIAL SAFETY DATA SHEETS Shell

Omala Oil 320 ……………………………………………...

7

Fuchs

RENEP K220 ………………………………………………………….

6

Fuchs

Solcenic 2020 4% V/V Emulsion ……………………………………

8

xviii

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006 Nomenclature used throughout this manual

Description

Symbol

Volume

Vol.

Pressure

Rotation speed

Explanation

Unit

Litre

L

Cubic Meters

m3

Pascal

Pa

Kilopascal

kPa

Megapascal

MPa

Barometric pressure

Bar

P

Revolutions per

N ω

minute

RPM

Radians per second

Rad.s-1

Metres

m

Millimetres

mm

Micrometres

µm

(Inches)

in.

Distance

Mass

m

kilograms

kg

Torque

Tq

Newton-metres

Nm

Weight

W

Newtons

N

Newtons

N

Dia.

Metres

m

- OR -

- OR -

- OR -

φ

Millimetres

mm

Litres per minute

L.min-1

Tension

Diameter

Flow rate

Cubic metres per second

xix

m3.s-1

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

Description

Symbol

Explanation

Unit

Temperature

T

Degrees Celsius

o

Seconds

s

Minutes

min

Hours

H

Amperes

A

Milli-amperes

mA

Time

t

C

Current

I

Voltage

V

Volts

V

R

Ohms

Ω

µ

Pascal seconds

Pa.s

Electrical Resistance Static viscosity Dynamic viscosity

Metres squared

ν

per second

xx

m2.s-1

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

SI UNIT CONVERSIONS & ENGINEERING CONSTANTS

Force

1N

0.22481 lbf

Kinematic viscosity

1 m2/s

3.875 x 104 ft2/h

Length

1m

3.2080 ft

mass

1kg

2.2046 lbm

Mass density

1 kg/m3

0.062428 lbm/ft3

Mass flow rate

1kg/s

7936.6 lbm/h

Pressure

1 Pa (=1 N/m2)

1.4504 x 10-4 lbf/in2

101.325 kPa

14.696 psi

9.807 m/s2

32.1748 ft/s2

1 Atmosphere (1 Bar) @ sea level Acceleration due to gravity (g)

xxi

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1.

INTRODUCTION 1.1

GENERAL DESCRIPTION

This service and maintenance manual provides an overview of the equipment installed and general information pertaining to the operation and maintenance of the mobile pump station and other equipment as supplied by Southern Engineering Services Pty Ltd, in April 2006.

The Austar Coal Mine’s mobile longwall hydraulic pump station has been designed to provide the necessary hydraulic power to efficiently operate the roof supports within a longwall mine and provide cooling water for the shearer drum and dust suppression at the coalface.

It is comprised of the following equipment: • Two (2) off 3K200/53 chock pump/200 kW motor sets.

• One (1) off 3K110/40 positive set pump/200 kW motor set.

• One (1) off shearer water 3K150/70 pump/200kW motor.

(Original design was for a 3K150/80 – changed to 3K150/70 following request by Austar Coal Mine).

• One (1) off 530 Litre shearer water tank.

- INTRODUCTION -

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• One (1) off 9,400L emulsion storage tank.

• One (1) off pump platform.

• Four (4) off protection bumper guard rails •

One (1) off 50 ton tow frame.

•

Two (2) off levelling cylinders with provision for another (2).

•

Three (3) off 400 Bar accumulators and one (1) off 500 Bar accumulator.

•

Monitoring devices.

•

Filtration equipment.

•

Control valving.

•

Ability for a third (3rd) emulsion chock pump to be installed at a later date.

•

Ability for an EHP 3K150/80 shearer water pump to be installed at a later date.

- INTRODUCTION -

Page 2 of 253

- INTRODUCTION C D

E

F

G

A) Hydraulic Levelling Cylinder B) Emulsion Chock Pump C) Accumulator Bottles E) Emulsion Storage Tank F) Crawler Tracks G) Electric Motor I) Platform J) Shearer Water Pump K) Tow Frame

Figure 1: Photo of Pump Station showing:

B

I

J

K

D) Return Filters H) Shearer Water Tank

H

1.2

A

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

PUMP STATION GENERAL ARRANGEMENT

Page 3 of 253

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1.3

GENERAL ARRANGEMENT DRAWING with Field Devices

Figure 2: - INTRODUCTION -

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1.4

ICONS The following icons are used to indicate important points.

DANGER

– Instructions, which if not

followed correctly, could result in serious injury to personnel and damage to equipment.

CAUTION

– Instructions, which if not

followed may cause danger to the machine and it’s function.

! WARNING ! – Instructions, which if not observed could result in injury to personnel

IMPORTANT INFORMATION – Information that must be followed closely to ensure proper equipment operation, as well as operator safety.

MAINTENANCE PROCEDURES Should be followed as per manuals provided

by Southern Engineering Services Pty. Ltd.

? PROBLEM ?

Trouble shooting situations and solutions

- INTRODUCTION -

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1.5

SAFETY INSTRUCTIONS 1.5.1 Emergency Stop Procedure

In the event of an emergency situation pressing any of the RED EMERGENCY STOP buttons located on each pump junction box will cut all power to the pump station. This will stop all four pumps immediately.

DANGER

After pressing the Emergency

Stop button, hydraulic pressure is still held in the system. Refer to Section 11 for Isolation and Venting Procedures to decay any stored pressure.

In an Emergency Situation • Press Emergency Stop Button.

• After emergency situation has passed and it is safe to do so, vent stored pressure in system.

- INTRODUCTION -

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1.5.2 Pump Isolation Steps

DANGER BEFORE WORKING ON ANY PUMPS, THE FOLLOWING FIVE (5) STEPS SHOULD BE CARRIED OUT BY AUTHORISED PERSONNEL, AS PER AUSTAR COAL MINE’S PROCEDURES:

1.

ISOLATE ELECTRICALLY

2.

ISOLATE HYDRAULICALLY

3.

ISOLATE MECHANICALLY

4.

BLEED OFF PRESSURE

5.

CHECK PRESSURE GAUGES

SEE SECTION 11 FOR DETAILED ISOLATION PROCEDURES

- INTRODUCTION -

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1.6

PUMP STATION START UP PROCEDURE

1. Safety a. Personal Protection Equipment; • Standard mine location Personal Protection Equipment.

• Safety glasses.

2. Procedures a. Preliminary Checks; • Pump station is positioned according to Section 7.11.

• Ensure all hose ends are secure and free of dirt and debris.

b. Operation Procedure; • Connect face delivery hoses from monorail to face isolation ball valves.

• Connect return hoses from monorail to return ports on emulsion tank header pipe.

• Connect emulsion infill hose to infill filter on the outbye end of the emulsion tank.

• Check that all bleed valves on the pumps and accumulators are closed.

• Open all face isolation valves.

• Connect all electrical cables. Refer to Ampcontrol’s literature for procedure for electrically starting the pump station.

- INTRODUCTION -

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2.

EMULSION CHOCK PUMP

2.1

PUMP TECHNICAL INFORMATION

PUMP TYPE: Output Flow Rate: Maximum Working Pressure: Lubricating Oil Capacity:

HAUHINCO MODEL EHP 3K200/53 309 Litres/minute 350 Bar [35 MPa] 55 Litres

Lubricating Oil Grade:

Grade 220

Normal Oil Pressure:

3-4 Bar [300-400 kPa]

Unloading Valve:

Electrohydraulic H30

Input Speed:

1500 RPM Nominal

- EMULSION CHOCK PUMP-

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2.2

PUMP COMPONENTS

Figure 3: Cross section view of pump LEGEND: 1 2 3 4 5 6 7 8 9 10

Pump Insert Assembly Pt No H6540260 Valve Cover Pt No H5118905 Valve Holder Pt No H5118867 Plunger Pt No H6365108 Crosshead Pt No H4151976 Lubrication Pump Pt No H6208770 Oil Distributor and Filter Pt No 6310176 Re-circulating Lube Pump Pt No H6310133 Oil Cooler Pt No H6230660 Input Pinion Shaft Pt No. H6208703 - EMULSION CHOCK PUMP-

11 12 13 14 15

Gear Case Spur Gear Pt No H6309224 Lube Pump Drive Gear Pt No H6422209 Connecting Rod Pt No H6108113 Crankshaft Pt No H6132677

16

Pump Crankcase

17

Pressure Valve Plate Pt No H6448194

18

Pressure Gallery

19

Suction Valve Plate Pt No H6442064

20

Suction Gallery Page 10 of 253

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AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

A

B

C

D

E

F

G

H

Figure 4: Photo of Unloading Control System showing: A)

Solenoid Valve Pt No H6251943

B)

H30 Unloader Valve Pt No H6339042

C)

2.5l Accumulator Pt No H6513158

D)

High Pressure Vent Valve (DN10 Ball Valve) Pt No DN10

E)

Pressure Gauge Pt No H2400006

F)

Safety Relief Valves Pt No H1720007

G)

Oil Recirculation Pump Pt No H6310133

H)

Lube Temperature Tranducer Pt No PT100

- EMULSION CHOCK PUMP-

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2.3

GENERAL DESCRIPTION The two (2) off high pressure emulsion chock pumps provide the hydraulic power to operate the roof supports and other hydraulic equipment on the longwall. The pumps are located on the crawler track platform with the emulsion storage tank.

Emulsion fluid flows from the tank to the pump suction inlet ports. The high pressure fluid then flows from the pump, to an accumulator manifold block, and then onto the delivery manifold block mounted on the inbye end of the pump station.

Fluid is delivered to the face from the two (2) off 50mm ‘Super Stecko’ outlet connections (there is provision for a 3rd outlet) on the inbye end of the pump station.

P CAUTION P – Before operating either chock pumps ensure that the suction isolation valves AND the emulsion chock pump isolation valves are COMPLETELY OPEN.

- EMULSION CHOCK PUMP-

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2.4

PUMP OPERATION The Hauhinco pump, is a positive displacement triplex plunger pump, fitted with individual pump insert assemblies to allow easy servicing.

It features a single, integrated reduction

gearbox, that drives the crankshaft. The crankshaft drives the connecting rods that are connected to the crossheads. The 53mm diameter plungers are attached to the crossheads and the reciprocating action of the plungers, in the pump inserts, provides the pumping action.

The pump insert assemblies

contain the packing, the suction and the pressure valves and are easily removed for servicing.

- EMULSION CHOCK PUMP-

Page 13 of 253

BI619135

Pt No. H442064 Pt No. H151976

Pt No. H6421369

Pt No. H2112299

Pt No. H6365108

Pt No. H6448194

AUSTAR COAL MINE PTY LTD LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

Figure 5: - EMULSION CHOCK PUMP-

Page 14 of 253

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2.5

UNLOADING CONTROL SYSTEM As the pumps are positive displacement some method of unloading must be used to allow for periods of no fluid demand at the face. The pumps are fitted with electrohydraulic unloader valves to control the flow of fluid from the pumps. Emulsion is either delivered to the face at high pressure or returned to the storage tank at no pressure. A pressure transmitter monitors the system pressure and sends an analogue signal to the pump controller. The pump controller determines if the pumps should be loaded or unloaded according to set pressure parameters.

The pump controllers will also energize or de-energize a solenoid valve, fitted to the unloader valve, to allow the pump to either load or unload according to need.

Each pump is fitted with a high pressure manifold, to which is mounted a 2.5 Litre accumulator, to dampen the pressure pulsations produced by the pumping action.

Fitted to the

manifold are two (2) off safety relief valves, set at 400 Bar [40 MPa], which will open and discharge to atmosphere the pump flow in the event of a failure of the unloader valve or pressure monitoring system.

A pressure switch monitors the pump

pressure and will stop the pump if the pressure exceeds 360 Bar [36 MPa] or falls below 100 Bar [10 MPa]. A 10mm staple ball valve, with diffuser, is fitted to the manifold block to allow for the venting of the hydraulic pressure for maintenance.

- EMULSION CHOCK PUMP-

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2.6

LUBRICATION SYSTEM

The pump casing forms a lubricating oil reservoir to lubricate the pump components.

A lubricating pump, driven by the

crankshaft via a back gear, conveys the lubricating oil through the oil distributor to a port in the crankshaft and to the connecting rod bearings. An oil cooler is also fitted to the pump and uses the colder incoming emulsion fluid to cool the hot oil.

A separate cooling circuit pump drives the oil through the oil cooler and then back through the gearbox to the pump casing.

Normal oil pressure is 3-to-4 Bar [300-400 kPa], and an oil pressure switch set at 1.5 Bar [150 kPa] is fitted to protect the pump. This pressure switch, at P = 1.5 BAR [150 kPa], will automatically cut off the electric motor to protect against mechanical failure.

- EMULSION CHOCK PUMP-

Page 16 of 253

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A

B

Figure 6: Photo of Chock Pump showing:

A)

Oil Pressure Gauge 0 –10 Bar Pt No H2400146

- EMULSION CHOCK PUMP-

B)

Oil Pressure Switch Pt No H6451225

Page 17 of 253

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Sight glasses are located on the non-drive end of the pump crankcase.

The oil level should read in the centre of the sight glass when the pump is running. Oil is filled through the breather filler located on top of the crankcase.

A

Figure 7: Photo of Chock Pump showing; A)

Oil Level Sight Glass Pt No H2440113

NOTE: Oil Level Half Way Up Sight Glass When Pump Is Operating

- EMULSION CHOCK PUMP-

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2.7

CORRECT DIRECTION OF OPERATION

CAUTION

– The pump must only operate in the

direction as shown by the arrows on the pump crankcase and on the fan shroud of the electric motor NOTE: Failure to run the pump in the correct direction will lead to damage to the pump.

A

Figure 8: Photo of Top of Pump Case showing; A)

Correct direction to operation pump

- EMULSION CHOCK PUMP-

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2.8

ACCUMULATORS Four (4) off high pressure, thirty two (32) litre accumulators, are fitted to the pump station to provide storage of hydraulic fluid under pressure. This stored pressure within the accumulators is used to reduce the frequency of operation of the unloader valves and also to dampen shocks from pump operation.

Two (2) off of the 400 Bar rated accumulators are fitted to the dual accumulator manifold between Chock Pump No 1 and Chock Pump No 2. The dual accumulator manifold is connected to the delivery manifold block located on the inbye end of the platform. The third 400 Bar accumulator is mounted on the shearer water manifold located on the walkway side of the shearer water pump. The 500 Bar rated accumulator is connected to the positive set pump.

Each accumulator supply hose is fitted with an isolation valve to allow for servicing of the accumulators. A vent valve is also fitted to the accumulator stand to allow for the venting of the pressure that remains in the manifold once the isolation valves are closed.

- EMULSION CHOCK PUMP-

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A

B

Figure 9: Photo of Accumulators showing; A)

32L Accumulators Pt No SB400-32

B)

- EMULSION CHOCK PUMP-

Nitrogen bleed points are located under hat cover

Page 21 of 253

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2.9

SERVICE & MAINTENANCE OF PUMPS

2.9.1

Inspection and Maintenance Requirements

2.9.1.1 Daily Inspection and Maintenance

• Inspect oil level in the pump crankcase – it should be to the middle of the sight glass when pump is in operation. Add oil if required, (refer Section 2.9.2.3.).

• Inspect oil pressure – must be more than 1.5 Bar. • Inspect hydraulic fittings and suction hoses for leaks.

• Inspect pump insert gland packing for leaks – a small drip is acceptable.

• Check hydraulic operating pressure – compare gauges and pressure sensors.

2.9.1.2 Every 3 Months, or 1000 hours of Operation

• Examine pressure hoses for damage.

• Change lubricating oil (refer Section 2.9.2.3).

• Change lubricating oil filter (refer Section 2.9.2.4).

- EMULSION CHOCK PUMP-

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2.9.1.3

Every 12 months OR 5000 hours of operation Inspection to be carried out by SES Service Engineer

• Inspect plunger surface for scoring or marks and change gland packing and pressure rings if necessary.

• Inspect suction and pressure valve plates and seats for indentations and divots. Replace all O-rings and backing rings in pump inserts.

• Inspect ‘big-end’ bearing shells on con-rods for wear marks.

• Inspect oil seals for possible leaks and nozzle for blockages and clean lube oil suction strainer.

• Check Nitrogen pre-charge pressure in 2.5 Litre and 32 Litre accumulators – Pre-charge pressure is 200 Bar. • Shearer water pump accumulator – pre-charge pressure is 60 Bar. • Positive High Set Pump accumulator – pre-charge pressure is 270 Bar. • Inspect oil cooler tubes for leaks or cracks.

- EMULSION CHOCK PUMP-

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2.9.2

Maintenance Procedures

2.9.2.1

Pre-Maintenance

1 DANGER 1 – before working on the pumps the following steps must be carried out.

1. Isolate electrically

2. Isolate hydraulically

3. Isolate mechanically

4. Bleed off pressure

5. Check pressure gauges

For detailed Isolation Procedures refer Section 11

- EMULSION CHOCK PUMP-

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2.9.2.2 Procedure For Checking The Pump Oil Level

CAUTION

– Pump will suffer damage if run

without the correct oil level A pump lubricating oil level sight glass

[2- Fig 10] is

located on the non-drive end of the pump crankcase [1 – Fig 10].

With the pump station level the oil level should be filled to the centre of the sight glass when pump is running. If lubricant level is below centre of sight glass check lubricant hoses and connections for leaks.

Figure 10: PUMP CRANKCAS E

OIL LEVEL HALF WAY UP SIGHT GLASS WHEN PUMP IS OPERATING

- EMULSION CHOCK PUMP-

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2.9.2.3 Procedure For Adding Lubricating Oil to the Crankcase

SAFETY GLASSES REQUIRED

If a small amount of oil is required to raise oil to correct level remove the breather-filler cap located on the top of the crankcase and add oil. It is not required to stop the pump to add oil to top up the oil level.

A

Figure 11: Photo of Pump Crankcase showing: A)

Oil filler / air breather cap Pt No H2350343

- EMULSION CHOCK PUMP-

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2.9.2.4 Procedure for Changing Lubricating Oil

! WARNING! – Risk of scalding by hot lubricating oil

1. SAFETY a. Personal Protective Equipment ; • Safety Glasses.

• Heat Proof Gloves.

• Austar Coal Mine’s Standard PPE. b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure (refer Section 11.1.1).

• Austar Coal Mine Manual Handling Procedure.

2.

PROCEDURES a. Environmental Procedures; • Old oil to be disposed of in accordance to Austar Coal Mine Environmental Procedure. b. Equipment Required; • Personal locks.

• Container to drain oil into, approximate volume is 55 Litres.

- EMULSION CHOCK PUMP-

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c. Operation Procedure • Isolate pump according to Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

• Remove cap from hose labelled ‘DRAIN’ connected to bottom of pump housing.

• Unlock and slowly, fully open 1-inch isolation ball valve to drain oil into a container.

• Dispose of old oil in accordance with Austar Coal Mine’s environmental procedure.

• After oil has drained out of pump close and lock 1 inch isolation valve and refit cap.

• Remove breather cap.

• Pour/Pump oil into crankcase through vent hole until oil level is slightly above midpoint of sight glass.

• Replace breather cap.

- EMULSION CHOCK PUMP-

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A

B

Figure 12: Photo of Crankcase showing; A) Pump Drain Hose

B)

Pump Oil Drain Ball Valve Pt No ½” BSPP Ball Valve

Refill crankcase with oil by removing breather cap on top of the crankcase and pouring oil through the vent hole.

Figure 13: Crankcase - EMULSION CHOCK PUMP-

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2.9.2.5 Procedure for Changing Oil Filter

The lubricating oil filter is located inside the console, on the drive side of the pump, adjacent to the drive coupling.

1. SAFETY

a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure (refer Section 11.1.1).

2. PROCEDURES

a. Equipment Required; • Personal locks.

• Oil filter wrench (service tool Pt No H9000003).

b. Operation Procedure • Isolate pump according to Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

• Remove coupling guard from pump console.

- EMULSION CHOCK PUMP-

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• Using oil filter wrench unscrew filter from mounting.

• Lubricate gasket on new filter with oil and screw new filter onto mounting and hand tighten.

• Refill pump with oil until oil level is slightly above the centre of the sight glass.

• Start pump and ensure there are no leaks from filter.

A

Figure 14: Photo of Console showing; A)

Oil Filter Pt No H2350378

- EMULSION CHOCK PUMP-

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2.9.2.6 Procedure for Changing Oil Seal and Nozzle in Oil Distributor

The nozzle is located on the end of the crankshaft behind the oil distributor and runs in the oil seal in the oil distributor.

NOZZLE Pt No. H4568575

OIL SEAL Pt No. H2110989

Figure 15: Cross Section View of Crankcase

1. SAFETY a. Personal Protective Equipment (PPE); • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Pump Isolation Procedure.

- EMULSION CHOCK PUMP-

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2.PROCEDURES a. Equipment Required; • Personal locks.

• Oil filter wrench (service tool Pt No H9000003).

• Nozzle socket (service tool Pt No H9000001).

• ½ Inch square drive ratchet.

• Internal circlip pliers.

• O-ring grease refer Section 2.9.4.2.

• Grease for mounting refer Section 2.9.4.2.

b. Operation Procedure; • Isolate pump according to Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

• Remove coupling guard from console of pump.

• Remove oil filter using filter wrench.

• Loosen and remove four (4) off M8 cap-screws holding oil distributor to pump gear casing.

• Fit two (2) off M8 set-screws (service tool Pt No H7010184), to tapped holes in oil distributor body, then jack the distributor up from the pump gear casing.

• Using nozzle socket (service tool Pt No H9000001) and ½ inch square drive ratchet remove the nozzle from the end of the crankshaft. Inspect polished journal surface of nozzle for damage. If a groove is evident the nozzle must be replaced.

- EMULSION CHOCK PUMP-

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• Fit the new nozzle to the end of the crankshaft using the nozzle socket and hand tighten.

• Using internal circlips pliers remove the circlip holding the washer and oil seal in the oil distributor.

• Inspect oil seal inner diameter for damage and the horizontal and vertical diameters for ovality, if seal is damaged or non-circular it must be replaced.

• Fit new oil seal to oil distributor (if required) ensuring that the seal is square to bore and fully seated. The spring on the seal inner diameter should be facing into the oil distributor. Take care to ensure that the seal is not damaged during the fitting process.

• Refit washer and internal circlip using circlip pliers.

• Inspect the O-ring Pt No H2108003 on the external diameter of the oil distributor and replace if damaged.

• Lubricate the O-ring with O-ring grease and external mating surface of the oil distributor with grease used for mounting and refit to the pump gear casing.

• Refit the four (4) off socket head cap screws and tighten.

• Lubricate the gasket of a new oil filter with oil and screw on to the oil distributor and hand tighten.

• Start pump using Ampcontrol’s procedure for pump start up and ensure that there are no leaks from the filter or oil distributor.

- EMULSION CHOCK PUMP-

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Oil filter Pt No. H2350378

Oil distributor Pt No H6310176 Circlip Pt No H2067293 Nozzle Pt No H4568575 Oil seal Pt No H2110989 Washer Pt No H4565428

M8 Cap-screws

Figure 16: Cross Section View of Oil Filter

- EMULSION CHOCK PUMP-

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2.9.2.7 Procedure for Bleeding Air from the Pump

CAUTION

– After carrying out any maintenance to

the wet end of the pump, or to the suction hoses between the pumps and the emulsion storage tank, it is most important that any trapped air is bled from the pumps.

1. SAFETY a. Personal Protective Equipment (PPE); • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

2. PROCEDURES a. Equipment Required; • Personal locks.

• 12mm inhex socket.

• 6mm Allen key.

b. Operation Procedure; • Ensure that pump is stopped and pressure has been bled from system. Follow Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1 if pump is still running or pressure is still in system.

- EMULSION CHOCK PUMP-

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• Remove the four (4) off bolts holding the coupling guard on to the console and remove the guard using 6mm Allen key.

• Using the 12mm inhex socket remove the plug from the top of the valve cover on each pump insert assembly.

• Rotate crankshaft slowly by moving the exposed drive coupling. Observe the open hole on the top of the pump insert assembly and watch as the air and emulsion fluid is discharged from the hole. Continue to do so until all entrapped air is removed from the holes.

• Replace the plugs in the pump insert assemblies and hand tighten.

• Replace the coupling guard on the console.

• Start pump according to Ampcontrol’s Start Up Procedure and allow to run to ensure pump runs smoothly.

- EMULSION CHOCK PUMP-

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B

A

Figure 17: Photo of Pump Insert Assembly showing; A)

Pump Insert Assemblies Pt No H6540260

- EMULSION CHOCK PUMP-

B)

Plugs Pt No H2150654

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2.9.2.8

Procedure for Removing a Pump Insert Assembly

! WARNING ! Danger of injury due to the weight of the pump insert assembly. Each assembly weighs approximately 35kg

Pump insert assemblies will need to be removed to allow for servicing of the plunger and the plunger packing.

1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Safety Boots.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure (refer Section 11.1.1).

• Austar Manual Handling Procedure.

2. PROCEDURES a. Equipment Required; • 14mm inhex socket.

• Spacer.

- EMULSION CHOCK PUMP-

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b. Operation Procedure; •

Isolate pump according to Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

•

Remove coupling guard to allow access to drive coupling so that pump can be turned by hand.

•

Using 14mm inhex socket, remove the four (4) off outer M16 socket head cap screws [4 - Fig 18] and spring washers holding the pump insert assembly to the pump casing.

•

Fit a spacer (e.g. a socket) between the end of the crosshead and the end of the pump insert. By turning the drive coupling slowly, push the pump insert from the pump body until the insert can be pulled out by hand.

•

Remove insert from pump using correct lifting techniques as given by the Austar Coal Mine’s Manual Handling Procedure

! WARNING !

Danger of injury due to the

weight of the pump insert assembly. Each assembly weighs approximately 35kg

- EMULSION CHOCK PUMP-

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Figure 18: Pump Insert Assembly showing;

1)

Pump insert

Pt No H6231659

2)

Valve holder Pt No H5118867

3)

Valve cover

4)

M16 socket head capscrews Pt No H2016257

Pt No H5118905

- EMULSION CHOCK PUMP-

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2.9.2.9 Procedure for the Disassembly of a Pump Insert

Disassembly of the pump insert is required to inspect the valve plates and the valve seats on the pump insert and valve holder and to change the O-rings and backing rings in the assembly. This can be done with the pump insert mounted on the pump or in a vice on a bench and is made in the following order:

1. Safety a. Personal Protective Equipment; • Safety Glasses. b. Safety Procedures; • Austar Manual Handling Procedure.

• Austar Coal Mine’s Standard PPE’.

2. Procedures a. Equipment Required; • 14mm inhex socket.

• 10mm inhex socket.

• M12 set screw (2 off).

• Service tool Pt No H2004550.

- EMULSION CHOCK PUMP-

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b

Operation Procedure; • Remove pump insert (refer Procedure 2.9.2.8).

• Use 14mm inhex socket to loosen and remove the four inner M16 socket head cap screws [7 - Fig 19] and spring washers which hold the valve cover to the insert.

! WARNING ! The Valve cover incorporates five (5) off pressure springs that apply a pre-load to the cover. When the cap screws are loosened the cover will be forced off.

•

Remove the valve cover [1 - Fig 19] taking care not to lose the five (5) off pressure springs. The pressure valve plate [4 - Fig 19] will now be able to be removed from the valve seat.

•

Use the 10mm inhex socket to loosen and remove the M12 socket head cap screw [6 - Fig 19] and spring washer located at the bottom of the valve holder.

• Screw two (2) off M12 set screws (service tool Pt No H2004550) into the two (2) off tapped holes located in the top half of the valve holder and jack the valve holder out of the pump insert

[3 – Fig 19]. Take

care when removing the valve holder [2 - Fig 19], as there are nine (9) off pressure springs between the valve holder and the suction plate [5 - Fig 19] and two small O-rings at the top of the valve holder.

- EMULSION CHOCK PUMP-

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• Remove the suction valve plate from the pump insert.

Figure 19: Pump Insert Assembly showing; 1)

Valve cover

Pt No H5118905

2)

Valve holder

Pt No H5118867

3)

Pump insert

Pt No H6231659

4)

Pressure valve plate Pt No H6448194

5)

Suction valve plate

6)

7)

8)

Pt No H6442064

M12 socket head cap-screw and spring washer Pt No H2015722 M16 x 110 socket head cap-screw and spring washer Pt No. H2016249 M16 x 140 socket head cap-screw and spring washer Pt No. H2016257

- EMULSION CHOCK PUMP-

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2.9.2.10 Pump Insert Inspection Requirements

After the pump insert assembly has been dismantled, the various components can be inspected for wear.

• Inspect valve plates for cracks or damage to the sealing face caused by cavitation (areas which look like they have been grit blasted).

• Inspect valve seats on pump insert and valve holder for damage due to cavitation.

• Inspect pressure springs for damage or wear on the inside of the coil (evident by shiny flat surface).

• Inspect spring guides for loose fit valve cover and valve holder.

- EMULSION CHOCK PUMP-

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2.9.2.11

Procedure for the Reassembly of a Pump Insert

Reassembly of the pump insert assembly is a reverse of the disassembly procedure, with the following notes: 1. SAFETY a. Personal Protective Equipment ; • Safety Glasses.

• Austar Coal Mine Standard PPE.

b Safety Procedures; • Austar Coal Mine’s Manual Handling Procedure.

2. PROCEDURE a. Equipment Required; • 14mm inhex socket.

• 10mm inhex socket.

• Mallet. a. Operation Procedure; • Refer to Diagram in Section 2.9.2.9.

• Always use new O-rings and backing rings whenever reassembling the pump insert assembly.

- EMULSION CHOCK PUMP-

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• Ensure that the mating faces of the pump insert, valve holder and valve cover are clean and free from damage. If necessary, clean the faces and edges with emery paper then wipe clean.

• The valve plates are reversible and if one side is slightly damaged, the • plate can be turned over and reused • Fit suction valve plate into insert.

• Refit suction springs and valve holder to insert.

• To assist in the fitting of the valve holder and valve cover use a small amount of O-ring grease to hold the suction springs onto the respective spring guides. Note that the suction plate pressure springs are softer than the pressure plate pressure springs.

• Lubricate the O-rings and backing rings with O-ring grease.

Ensure that the valve holder is

square to the mallet to gently tap the valve holder into place taking care that the O-rings and backing rings are seated correctly.

• Insert and tighten the M12 socket head cap screw and washer into the bottom of the valve holder to a torque of 25 Nm.

- EMULSION CHOCK PUMP-

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• Fit pressure valve plate into valve seat.

• Refit pressure springs and valve cover to insert.

• Insert and tighten the four (4) off inner M16 socket head cap screws to hold valve cover to insert to a torque of 210 Nm.

- EMULSION CHOCK PUMP-

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2.9.2.12

Procedure for the Refitting of a Pump Insert Assembly

! WARNING ! Danger of injury due to the weight of the pump insert assembly. Each Assembly weights approximately 35kg.

1.

SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Safety Boots.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Austar Coal Mine Manual Handling Procedure.

2. PROCEDURE a. Equipment Required; • 14mm inhex socket.

• Torque wrench. b. Operational Procedure; • Check to ensure that the O-rings on the insert are not damaged or missing.

• Apply O-ring grease to the O-rings to ease the insertion into the pump casing.

- EMULSION CHOCK PUMP-

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• Lubricate the plunger surface and the packing rings with oil from the pump oil reservoir.

• Slide insert into pump housing ensuring that Austar Manual Lifting Procedures are followed.

•

Insert and tighten evenly the M16 socket head cap screws to 210 Nm torque.

• Bolt coupling guard to console.

• Bleed air from the pump as per Procedure 2.9.2.11.

- EMULSION CHOCK PUMP-

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2.9.2.13

Procedure for the Removal of Plungers

Plungers will only need to be removed if there is damage to the running surface in contact with the packing. This will be evident by external leakage of the emulsion fluid past the packing. The plungers are manufactured from stainless steel with an overlay of “Stellite” on the running surface and are firmly secured in the crosshead by the locking pin.

1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures • Chock Pump Isolation and Pressure Venting Procedure.

Refer Section 11.1.1.

2. PROCEDURE a. Equipment Required; • 14mm inhex socket.

• Locking pin extractor (service tool Pt No H6319144) • Plunger withdrawal device (service tool Pt No H6319144).

• 19mm spanner.

- EMULSION CHOCK PUMP-

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b. Operation Procedure; •

Isolate pump according Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

• Remove coupling cover from console and rotate exposed drive coupling until crosshead of the plunger to be removed is fully retracted.

• Remove pump insert assembly as per procedure set out in Section 2.9.2.8.

• Remove four (4) off M6 bolts and washers holding the clear plastic inspection cover in place and remove the inspection cover.

• Screw locking pin extractor into the threaded bore of the locking pin and withdraw the locking pin from the crosshead and plunger.

Figure 20: 1) Locking pin extractor Pt No H6319149 2) Crosshead Pt No H6207774 3) Plunger

- EMULSION CHOCK PUMP-

Pt No H6365108

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• Screw the setscrew of the plunger withdrawal device into the threaded bore of the plunger and by turning the M12 nut withdraw the plunger from the crosshead.

Figure 21: Legend: 4) Threaded bore of plunger 5) Set screw 6) Plunger withdrawal device Pt No H6459048 • Inspect the running surface of the plunger from the crosshead. The surface should be smooth and free from any defects such as scoring or marks. If any defects are present the plunger must be replaced and the damaged plunger repaired.

- EMULSION CHOCK PUMP-

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2.9.2.14 Refitting Plungers

1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE. 2. PROCEDURE a. Equipment Required; • Locking pin drift (service tool Pt No H4577159).

Operation Procedure; • Fit the plunger into the crosshead bore by hand and push home. The plunger should be a precision locating fit.

• Line up the locking pinholes in the plunger and crosshead.

• Fit the locking pin by hand into the crosshead and use the locking pin drift to drive in the pin. The locking pin should be a tight fit in the assembly and should not be able to be pushed in by hand.

CAUTION

– Always use a new locking pin when

fitting a new plunger.

• Refit Insert as per Procedure 2.9.2.12 - EMULSION CHOCK PUMP-

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2.9.2.15 Replacing The Plunger Packing

The plunger packing will need to be replaced, when the amount of emulsion fluid leaking out of the pump insert assembly is excessive, i.e. when it is spraying out or is constantly running out. A slight leakage of fluid (steady dripping) is normal. The leakage rate can be observed either by looking through the clear inspection cover or by observing fluid leaking from the elbow located on the drive side of the pump below the lubricating oil temperature switch.

1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

2. PROCEDURES a. Equipment Required; • Retaining Clips Pt No H9000004 • Spring Compressor Pt No H7010044.

b. Operation Procedure; • Remove insert as per Procedure 2.9.2.8.

- EMULSION CHOCK PUMP-

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• Ensure that pump insert is clean and free from dirt or foreign material.

• Compress packing spring by either a vice or spring compressor.

• Fit retaining clips to the inside of the spring then release the clamping device. Caution to be used when conducting this step due to stored energy in compressed spring.

• Place compressed spring in barrel of pump insert.

• Insert one of the brass pressure rings Pt No H6500730.

CAUTION

– Always use a new locking pin when

fitting a new plunger.

• Insert packing Pt No H2112299.

• Insert second brass ring Pt No H6500730 • Screw brass threaded ring into insert until it touches the pressure ring Pt No H6536409.

• Carefully remove the retaining clips from the spring to force the brass threaded ring into tension.

• Screw the loaded brass threaded ring down until two threads are showing.

• Fit locking ring to the insert Pt No H4564561.

- EMULSION CHOCK PUMP-

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Figure 22: Legend: 1)

Locking ring

Pt No H4564561

2)

Threaded Ring

Pt No H6536409

3)

Pump insert

Pt No H6540260

- EMULSION CHOCK PUMP-

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2.9.2.16

Removal of ADM Solenoid Filter Block Assembly

The solenoid pre-control valve is located on the non-drive end of the pump, bolted to the main control valve. The only serviceable parts on the solenoid pre-control valve are: •

The solenoid and electrical connecting plug.

•

The filter element in the mounting block filter.

•

If the pre-control valve is faulty it must be replaced.

1.

SAFETY a.

Personal Protective Equipment;

•

Safety Glasses.

•

Austar Coal Mine’s Standard PPE.

b.

Safety Procedures;

•

Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

2.

PROCEDURES a.

Equipment Required;

•

Phillips head screwdriver.

•

10mm inhex socket

- EMULSION CHOCK PUMP-

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b. Operating Procedure •

Isolate pump according to Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

•

Disconnect electrical connecting plug from solenoid by unscrewing the screw in the centre of the plug, and pulling the plug off the solenoid.

• Using a 10mm inhex socket, remove the 4 x M12 socket head cap screws holding the solenoid precontrol valve to the main control valve.

P CAUTION

– Emulsion fluid will leak from the

5mm diameter orifice on the face of the main control valve. This emulsion fluid is flowing through the pump from the tank. If the solenoid valve is left off the pump and the suction isolation valves are not closed the emulsion fluid will drain from the tank.

- EMULSION CHOCK PUMP-

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2.9.2.17

1.

Replacing ADM Solenoid Filter Block Assembly

SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine‘s Standard PPE.

2.

PROCEDURES a. Equipment Required; • Phillips head screwdriver.

• 10mm inhex socket. b. Operating Procedure; • Mount solenoid pre control valve onto main control valve with four (4) off M12 socket head cap screws and 10mm inhex socket.

• Reconnect electrical connection plug and tighten screw with Phillip’s head screwdriver.

- EMULSION CHOCK PUMP-

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2.9.2.18

Replacing ADM Solenoid Filter Block Assembly Filter Element

The filter element in the filter block for the solenoid precontrol valve is provided to ensure that the pilot fluid entering the valve is clean. If the element is dirty or clogged, the pilot fluid cannot flow properly into the solenoid valve and the operation of the unloading valve will be slow or will not operate at all. The element must then be cleaned or replaced.

REPLACEMENT PROCEDURE 1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

2. PROCEDURES a. Equipment required; • 24mm Spanner.

• Phillips head screwdriver.

- EMULSION CHOCK PUMP-

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b. Operation Procedure; • Stop pump and isolate according to Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

• Unscrew filter housing barrel with 24mm spanner.

• Remove housing and filter element.

• Replace filter element Pt No H2351102 • Replace O-ring Pt No H2106612 on filter housing barrel if damaged or worn.

• Replace filter housing barrel and tighten.

Figure 23: Photo of ADM Solenoid & Filter Block Assembly

- EMULSION CHOCK PUMP-

Pt No H6256279

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2.9.2.19

Exchange of Safety Relief Valve

There are two (2) off safety relief valves fitted to the unloading valve manifold block on each pump.

These

valves are set to open at 400 Bar (40 MPa) and will dump to atmosphere the total pump flow in the event that the unloading valve fails to operate correctly. Two (2) off valves are required per pump to pass the total pump discharge volume of 309 Litres per minute.

Under normal operating conditions there should be no leakage from the vent port. If there is any leakage then the valve on the pump should be replaced and the faulty valve returned to Southern Engineering Services Group Pty Ltd for repair and resetting.

1. SAFETY a.

Personal Protective Equipment;

•

Safety Glasses.

•

Austar Coal Mine’s Standard PPE.

b.

Safety Procedures

•

Chock Pump Isolation and Pressure Venting Procedure. Refer Section 11.1.1.

- EMULSION CHOCK PUMP-

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2.

PROCEDURES a.

Equipment required;

•

12mm Spanner.

b.

Operation Procedure;

•

Stop pump and Isolate.

•

Undo M8 bolt and remove bolt and retaining plate from safety valve mounting spindle.

•

Remove safety valve from the mounting spindle.

•

Lubricate the O-rings on the mounting spindle with O-ring grease prior to fitting the valve.

•

Fit new valve on mounting spindle so that vent port faces down.

•

Refit retaining plate, insert M8 bolt and tighten.

1 DANGER 1 – Ensure that the vent port on the safety valve is facing down or to the rear of the pump when fitting the valve to the pump

- EMULSION CHOCK PUMP-

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A

Figure 24:

B

Photo of Safety Relief Valves showing:

A) Safety Relief Valves

B) M8 Bolt

Pt No H1720007

- EMULSION CHOCK PUMP-

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2.9.3

SERVICE TOOLS

Service tools are provided to facilitate the mounting and dismounting of some pump components.

2.9.3.1

Set Screws for Valve Holders of Pump Inserts

Two (2) off DIN 933 – M12 x 50 – 8.8 bolts Pt No H2004550

2.9.3.2

Set Screw for Oil Distributor

Two (2) off DIN 933 – M8 x 65 – 8.8 bolts Pt No H7010184

2.9.3.3

Withdrawing Device for Plungers

Plunger withdrawing device Part number: H6459048 PLUNGER WITHDRAWAL DEVICE

Figure 25: - EMULSION CHOCK PUMP-

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2.9.3.4

Withdrawing

Device

and

Assembly

Mandrel

Locking Pin of Crosshead.

LOCKING PIN WITHDRAWING DEVICE

LOCKING PIN ASSEMBLY MANDREL

Figure 26: Tools: Locking pin withdrawing device Pt No H6319149 Locking pin assembly mandrel Pt No H4577159 Oil filter wrench Pt No H9000003 Nozzle socket Pt No H9000001 - EMULSION CHOCK PUMP-

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2.9.4

ADDITIONAL PUMP INFORMATION

2.9.4.1

Bolt tightening torques

Bolts not shown on following table should be hand tightened professionally.

Component

Bolt diameter [mm]

Property class

Tightening torque [Nm]

Pump insert

M16

12.9

210

Valve holder

M12

10.9

25

Valve cover

M16

12.9

210

M10

8.8

45

M12

10.9

120

M10

8.8

45

M10

4.6

18

M14

12.9

285.0

Thrust ring to crankshaft bearing Gearbox Cover to gearbox Lubricating pump Connecting rod

- EMULSION CHOCK PUMP-

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2.9.4.2 Grease

All mounting procedures require the use of grease according to the quality class: DIN 51 502 KPL 2 E-25 …or higher e.g. SHELL ALIBIDA EP2 – or – CASTROL APXT as recommended by Southern Engineering Services Pty Ltd 2.9.4.3 Sealant

O-ring grease to be used should be Molykote Valve and O-ring Lubricant or similar.

The use of ‘Locktite 518’ Master gasket sealant for all mounting procedures requiring the use of sealing material.

- EMULSION CHOCK PUMP-

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2.9.5

TROUBLE SHOOTING GUIDE FOR HAUHINCO PUMPS

? PROBLEM ? – No pressure build up at pump CAUSE

SOLUTION

Plate valves jammed by foreign material

Disassemble pump insert & clean if necessary Check power is on and connected to solenoid

Solenoid pre-control valve not energised

Procedure

2.9.2.9

? PROBLEM ? – No pressure build up at the pump with solenoid pre-control valve energized CAUSE Filter in pre-control mounting block is clogged

SOLUTION Remove filter element and clean or replace

Pilot Piston in main control valve bypassing

Change Main Control Valve

Solenoid Coil Faulty Excessive Clearance between solenoid push pin and lever

Replace Solenoid Coil Change Solenoid pre control valve

- EMULSION CHOCK PUMP-

Procedure 2.9.2.18

2.9.2.17

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? PROBLEM ? – Excessive frequency of operation of unloader valve.

CAUSE Air in pump

SOLUTION Bleed air from pump

Suction hose leaks

Replace suction hose and bleed air from pump

Procedure 2.9.2.7 2.9.2.7

? PROBLEM ? – Pump does not build up pressure and work erratically CAUSE Packing in pump inserts defective, emulsion fluid increasingly leaks out at plungers

SOLUTION

Procedure

Replace Packing

2.9.2.15

? PROBLEM ? – Valve plates of pump inserts are fluttering CAUSE

SOLUTION

Procedure

Air in pump

Bleed air from pump

2.9.2.15

Insufficient posive head of fluid feeding pump

Ensure emulsion tank is filled

- EMULSION CHOCK PUMP-

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? PROBLEM ? Irregular oil pressure within pump CAUSE Oil seal and/or 6mm nozzle may be blocked

SOLUTION Replace Components

Procedure 2.9.2.6

? PROBLEM ? Lubrication circuit oil pressure soaring CAUSE 6mm nozzle in oil distributor may be blocked

- EMULSION CHOCK PUMP-

SOLUTION Clean 6mm nozzle

Procedure 2.9.2.6

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3.

POSITIVE SET PRESSURE PUMP 3.1 PUMP TECHNICAL INFORMATION

PUMP TYPE:

Maximum Output Flow Rate: Maximum Working Pressure:

HAUHINCO MODEL EHP 3K 110/40

129 Litres/Minute 465 Bar (46.5 MPa)

Lubricating Oil Capacity:

25 LITRES

Lubricating Oil Grade:

ISO VG 220

Normal Oil Pressure (When In Operation):

3-4 Bar (300-400 kPa)

Unloading Valve:

Electrohydraulic H30

INPUT SPEED:

1500 RPM Nominal

- POSITIVE SET PRESSURE PUMP-

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3.2

GENERAL DESCRIPTION The positive set pressure pump has been installed to provide higher emulsion pressure for the roof supports.

The higher pressure ensures that the roof support provides the required load capacity to adequately support the roof strata. The Hauhinco 3K110/40 pump provides the higher pressure and supplies it to the face via a dedicated hose supply system.

This system is parallel to the main

emulsion supply system.

The delivery volume from the

high set pump is 129 Litres per minute and the pump can operate at pressures up to 420 Bar.

It is fitted with an

electro-hydraulic unloader valve which is controlled by the pump station PLC.

A pressure transmitter monitors the

positive set system pressure.

- POSITIVE SET PRESSURE PUMP-

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A

B

C

D

E

Figure 27: Photo of Pump Station showing; A)

3K 150/70 Shearer Water Pump Pt No H5127580

B)

C)

3K 200/53 Chock Pumps Pt No H5131162

D) 3K 110/40 Positive Set Pump Pt No H5135508

E)

9,400L Storage Tank

- POSITIVE SET PRESSURE PUMP-

32L Positive Set Accumulators Pt No SB400-32

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A

B

C

D

E

F

G

H

I

Figure 28: Photo of Positive Set Pump showing: A)

Surge Suppressor Pt No H9000010-A

B)

C)

Unloader Valve Pre-control Solenoid Valve Pt No H6242499

D) H300 Unloader Valve Pt No H5100674

E)

Outgoing Emulsion Pressure Gauge Pt No H2400006S

F)

G)

Sight Glass for Oil Gauge Pt No H2440113

H) Lube Oil Temperature Transducer Pt No PT100

I)

Lube Oil Filler/Air Breather Pt No H2360020

- POSITIVE SET PRESSURE PUMP-

DN10 Ball Valve

Lube Oil Pressure Gauge Pt No H2400146

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3.3

PUMP OPERATION The Hauhinco pump is a positive displacement triplex plunger pump, fitted with individual pump insert assemblies, to allow for ease of servicing. It features a single integrated reduction gearbox that drives the crankshaft. The crankshaft drives the connecting rods that are connected to the crossheads. The 40mm diameter plungers are attached to the crossheads and the reciprocating action of the plungers in the pump inserts provides the pumping action. The pump insert assemblies contain the packing, suction and pressure valves and are easily removed for servicing.

3.4

UNLOADING CONTROL SYSTEM & 32L ACCUMULATOR The unloading system used for the Positive Set Pump is the same as the unloading system used for the Main Emulsion Chock Pumps.

The positive set pump is fitted with a thirty two Litre (32 Litre) accumulator, rated at 500 Bar, to help reduce the flow surges from the pump and the associated forces from its operation. By pre-charging the accumulator (280 Bar pre-charge) the accumulator effectively smoothes the output flow from the pump into the delivery line. The accumulator has a vent valve used to bleed stored pressure from within the accumulator when required, such as isolating the positive set pump. The vent valve is a 10mm ball valve located near the base of the accumulator stand.

- POSITIVE SET PRESSURE PUMP-

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3.5

LUBRICATION SYSTEM Normal lube oil pressure, when pump is in operation, is between 2-and-4 Bar [200-400 kPa]. An oil pressure switch set at 1.5 Bar [150 kPa], is fitted to protect the pump. The lube oil pressure switch has a minimum set point of Pmin = 1.5 Bar [150 kPa] and will automatically stop the electric motor to protect against mechanical failure.

There is a lube oil level sight glass located on the non-drive end of the pump (the same as the main emulsion pumps and the shearer water pump). This level indicator should be covering half the area of the sight glass.

- POSITIVE SET PRESSURE PUMP-

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A

B

Figure 29: Photo of Positive Set Pump (non-drive end) showing: A)

Sight Glass Pt No H2440113

B)

Breather & Filler cap Pt No H2360020

OIL LEVEL HALF WAY UP SIGHT GLASS WHEN PUMP IS IN OPERATION

- POSITIVE SET PRESSURE PUMP-

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3.6

CORRECT DIRECTION OF OPERATION

CAUTION

– The pump must only operate in the

direction as shown by the arrows on the pump crankcase and on the fan shroud of the electric motor NOTE: Failure to run the pump in the correct direction will lead to damage to the pump.

A

Figure 30: Photo of Top of Pump Case showing; A)

Correct direction to operation pump

- POSITIVE SET PRESSURE PUMP-

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3.7

SERVICE & MAINTENANCE OF PUMPS

3.7.1 Inspection and Maintenance Requirements 3.7.1.1

Daily inspections and maintenance

• Inspect oil level in the pump crankcase – it should be to the middle of the sight glass when pump is in operation.

• Inspect oil pressure – must be more than 1.5 Bar. • Inspect hydraulic fittings and suction hoses for leaks • Inspect pump insert gland packing for leaks – a small drip is acceptable.

• Check hydraulic operating pressure – compare gauges and pressure sensors.

3.7.1.2 Every 3 months, OR 1000 hours of operation • Examine pressure hoses for damage.

• Change lubricating oil.

• Change lubricating oil filter.

- POSITIVE SET PRESSURE PUMP-

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3.7.1.3 Every 12 months OR 5000 hours of operation Inspection to be carried out by SES Service Engineer • Inspect plunger surface and change gland packing and pressure rings if necessary.

• Inspect suction and pressure valve plates and seats, and replace all O-rings and backing rings in pump inserts.

• Inspect ‘big-end’ bearing shells on con-rods.

• Inspect oil seals and nozzle in lubricating system and clean lube oil suction strainer.

• Check Nitrogen pre-charge pressure in 2.5 Litre and 32 Litre accumulators – Pre-charge pressure is 280 Bar. • Inspect oil cooler tubes.

- POSITIVE SET PRESSURE PUMP-

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3.7.2 Maintenance Procedures

3.7.2.1

Pre-Maintenance Procedures

DANGER

– before working on the pumps the

following procedures should be carried out.

1. Isolate electrically

2. Isolate hydraulically

3. Isolate mechanically

4. Bleed off pressure

5. Check pressure gauges For detailed Isolation Procedures see Section 11

- POSITIVE SET PRESSURE PUMP-

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3.7.2.2

Procedure for Checking the Pump Oil Level

A pump lubricating oil level sight glass [2 – Fig 31] is located on the non-drive end of the pump crankcase [1 – Fig 31]. With the pump station level, the oil level should be filled to the centre of the sight glass when pump is running.

PUMP CRANKCASE

OIL LEVEL HALF WAY UP SIGHT GLASS WHEN PUMP IS IN OPERATION

Figure 31: View of Crankcase

- POSITIVE SET PRESSURE PUMP-

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3.7.2.3

Procedure for Adding Oil to the Crankcase Refer Section 2.9.2.3

3.7.2.4

Procedure for Changing Lubricating Oil

! WARNING! – Risk of scalding by hot lubricating oil • Refer Section 2.9.2.4

3.7.2.5 Procedure for Changing Oil Filter

• Refer Section 2.9.2.5

3.7.2.6 Procedure for Changing Nozzle and Oil Seal in the Oil Distributor 1. SAFETY a Personal Protective Equipment; • Safety Glasses.

b. Safety Procedures; • Positive Set Pump Isolation Procedure (refer Section 11).

- POSITIVE SET PRESSURE PUMP-

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2. PROCEDURES a. Equipment Required; • Circlip Pliers.

• 17mm Spanner.

• Nozzle Socket (Service Tool Pt No H9000001).

• Oil filter wrench (Service Tool Pt No H9000003).

• ½ Inch Square Drive Ratchet.

• Personal Locks.

b. Operation Procedure; • Unscrew and remove the five (5) off bolts holding the hat cover to the pump housing using the 17mm spanner.

• Using two bolts jack hat cover away from the pump housing to remove.

• Remove oil filter with filter wrench.

• Loosen and remove four (4) off cap-screws holding oil distributor to pump gear casing.

• Fit two (2) off M8 set-screws (service tool pt No H7010184) to tapped holes in oil distributor body, then jack the distributor away from the pump gear casing.

- POSITIVE SET PRESSURE PUMP-

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• Using

nozzle

socket

(service

tool

Pt

No

H9000001) and ½ inch driver remove the nozzle from the end of the crankshaft. Inspect polished journal surface of nozzle for damage. If a groove is evident, the nozzle must be replaced.

• Fit the new nozzle to the end of the crankshaft using the nozzle socket and tighten.

• Using internal circlips pliers remove the circlip holding the washer and oil seal in the oil distributor.

• Inspect oil seal at perpendicular diameters for damage and ovality. If seal is damaged or oval it must be replaced.

• Fit new oil seal to oil distributor, if required, ensuring that the seal is square to bore and fully seated. The spring on the seal inner diameter should be facing into the oil distributor. Take care to ensure that the seal is not damaged during the fitting process.

• Refit washer and internal circlip using circlip pliers.

• Inspect the O-ring on the external diameter of the oil distributor and replace if damaged.

• Lubricate the O-ring and external mating surface of the oil distributor with O-ring grease and refit to the pump gear casing.

- POSITIVE SET PRESSURE PUMP-

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• Refit the four (4) off socket head cap screws and tighten.

• Lubricate the gasket of a new oil filter with oil from the oil gallery and screw on to the oil distributor and hand tighten.

• Remove jacking bolts from hat cover and refit hat cover to pump housing.

• Refit the five (5) off mounting bolts into pump housing to secure the hat cover.

- POSITIVE SET PRESSURE PUMP-

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3.7.2.7 Procedure for Bleeding Air from the Pump

P CAUTION P

–

After

carrying

out

any

maintenance to the wet end of the pump or to the suction hoses between the pumps and the emulsion storage tank it is most important that any trapped air is bled from the pumps.

1. SAFETY a. Personal Protective Equipment (PPE); • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

2. PROCEDURES a. Equipment Required; • Personal locks.

• 12mm inhex socket.

b. Operation Procedure; • Isolate pump according to Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

- POSITIVE SET PRESSURE PUMP-

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• Remove the four (4) off bolts holding the coupling guard on to the pump base and remove the guard for access to the drive coupling.

• Using the 12mm inhex socket remove the plug from the top of the intermediate plate located on the pressure end of the pump housing.

• Turn the pump over slowly by rotating the exposed drive coupling. Observe the open hole on the top of the intermediate plate and watch as the air and emulsion fluid is discharged from the hole.

Continue to do so until all entrapped air is removed from the hole.

• Replace the plug in the pump intermediate plate and tighten.

• Replace the coupling guard on the pump base.

• Start pump and allow to run to ensure pump runs smoothly.

- POSITIVE SET PRESSURE PUMP-

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A

B

Figure 32: Photo of Positive Set Pump showing; A) Intermediate Plate Pt No H4150996

- POSITIVE SET PRESSURE PUMP-

B) ¾”Inhex Plug Pt No H2150654

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3.7.2.8

Procedure for Removing Pump Intake and Delivery Valves

1. SAFETY a.

Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b.

Safety Procedures; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

2. PROCEDURES a. Equipment Required; • 2 M12 x 120mm grade10.9 set bolts.

• Valve withdrawing device Pt No H4566394. b.

Operation Procedure; • Stop pump and isolate according to Positive Set Pump Isolation Procedure (refer Section 11).

• Loosen four (4) off hex head screws holding valve cover.

• Screw set bolts into outside threaded bores of valve cover to jack cover away from pump body.

• Remove valve cover.

• Screw valve withdrawing device into threaded bore of valve to be removed.

• Pull valve from pump casing.

- POSITIVE SET PRESSURE PUMP-

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3.7.2.9

Procedure for Removing Pump Insert Assemblies

! WARNING !

Danger of injury due to the

weight of the pump insert assembly. Each assembly weighs approximately 35kg

Pump insert assemblies will need to be removed to allow for servicing of the plunger and the plunger packing.

1. SAFETY a. Personal Protective Equipment • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

• Austar Manual Handling Procedure.

2. PROCEDURES

a. Equipment Required; • 17mm inhex socket.

- POSITIVE SET PRESSURE PUMP-

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b. Operation Procedure; • Isolate positive set pump according to Positive Set Pump Isolation and Pressure Venting Procedure.

Refer to Section 11.1.2.

• Dismount intake and delivery valves as per procedure 3.6.2.8.

• Loosen the four (4) off M20 socket head cap screws, and spring washers holding the pump insert assembly to the pump casing.

• Screw two (2) off M12 x 120, 10.9 grade bolts, into M12 threaded holes in pump insert until pump insert can be removed manually.

- POSITIVE SET PRESSURE PUMP-

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3.7.2.10

Procedure Refitting Of Pump Insert Assemblies

1. SAFETY a. Personal Protective Equipment • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

• Austar Manual Handling Procedure.

2. PROCEDURES a. Equipment Required; • 17mm inhex socket.

• Torque wrench.

b. Operation Procedure; • Check to ensure that the O-rings on the insert are not damaged or missing.

• Apply O-ring grease to the O-rings to ease the insertion into the pump casing.

• Lubricate the plunger surface and the packing rings with oil from the oil gallery.

• Manually fit insert into pump housing.

- POSITIVE SET PRESSURE PUMP-

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• Refit four (4) off M20 socket head cap screws and spring washers into pump housing to secure insert.

• Tighten evenly the M20 socket head cap screws to 210 Nm torque.

• Refit intake and delivery valves.

• Bleed air from the pump as per Procedure 3.6.2.7.

- POSITIVE SET PRESSURE PUMP-

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3.7.2.11

Procedure for Removal of Plungers

Plungers will only need to be removed if there is damage to the running surface in contact with the packing. This will be evident by external leakage of the emulsion fluid past the packing. The plungers are manufactured from stainless steel with an overlay of “Stellite” on the running surface and are firmly secured in the crosshead by the locking pin.

1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE. b. SAFETY PROCEDURES; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

2.

PROCEDURES a. Equipment Required; •

17mm inhex socket.

•

Locking pin extractor (service tool Pt No H4556283.)

•

Plunger withdrawal device (service tool Pt No H66406076).

•

19mm spanner.

•

Set Screw

- POSITIVE SET PRESSURE PUMP-

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b. Operation Procedure • Isolate pump according to Positive Set Pump Isolation Procedure (refer Section 11).

• Remove pump insert assembly as according to Section 3.6.2.9.

• Remove coupling cover from console and rotate exposed drive coupling until crosshead is at bottom dead center.

• Screw withdrawing device into threaded bore of locking pin between plunger and crosshead and pull out locking pin.

• Screw withdrawing device into plunger and remove plunger.

Figure 33: Legend: 1) Locking pin extractor Pt No H6319149 2) Crosshead

Pt No 4163079

3) Plunger

Pt No 6365086

- POSITIVE SET PRESSURE PUMP-

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Figure 34: Legend: 4) Threaded bore of plunger 5) Set screw 6) Plunger withdrawal device Pt No H6640607

- POSITIVE SET PRESSURE PUMP-

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3.7.2.12

Procedure for Fitting of Plungers

1. SAFETY a. Personal Protective Equipment; • Safety Glasses. b. Safety Procedures; • Pump Isolation Procedure (Refer Section 11).

2. OPERATION PROCEDURE a. Equipment Required • Locking pin drift (service tool Pt No H4577159). b. Operation Procedure; • Fit the plunger into the crosshead bore by hand and push home. The plunger should be a precision locating fit.

• Line up the locking pinholes in the plunger and crosshead.

• Fit the locking pin by hand into the crosshead and use the locking pin drift to drive in the pin. The locking pin should be a tight fit in the assembly and should not be able to be pushed in by hand.

P •CAUTION P – Always use a new locking pin when fitting a new plunger.

• Replace coupling guard on positive set pump console.

• Refit pump insert as per procedure 3.7.2.10.

• Bleed air from pump as per procedure 3.7.2.7.

- POSITIVE SET PRESSURE PUMP-

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3.7.2.13

Replacing the Plunger Packing

The plunger packing will need to be replaced when the amount of emulsion fluid leaking out of the pump insert assembly is excessive, i.e. when it is spraying out or is constantly running out. A slight leakage of fluid (steady dripping) is normal. The leakage rate can be observed either by looking through the clear inspection cover or by observing fluid leaking from the elbow located on the drive side of the pump below the lubricating oil temperature switch.

1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

2. PROCEDURES a. Equipment Required; • 14mm inhex socket.

• Bar. • Retaining Clips Pt No H9000004.

- POSITIVE SET PRESSURE PUMP-

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b. Operation Procedure; • Isolate Positive Set Pump according to Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 11.1.2.

• Remove the pump insert assembly as described in the Procedure 3.7.2.9.

• Remove locking ring from the threaded ring Pt No 4494253.

• Unscrew the threaded ring Pt No 4553039.

• Remove brass pressure ring packing Pt No 6496717 and packing set Pt No 2111012 .

• Ensure that pump insert is clean and free from dirt or foreign material.

• Compress packing spring by either a vice or spring compressor.

• Fit retaining clips to the inside of the spring then release the clamping device. Caution to be used when conducting this step due to stored energy in compressed spring.

• Place compressed spring in barrel of pump insert.

• Insert one of the brass pressure rings Pt No 6496717.

- POSITIVE SET PRESSURE PUMP-

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• Insert packing Pt No 2111012.

• Insert second brass ring.

• Screw brass threaded ring into insert until it touches the pressure ring Pt No 4553039.

• Carefully remove the retaining clips from the spring to force the brass threaded ring into tension.

P CAUTION P – Ensure that the pressure spring is acting against the pressure rings and packing.

• Screw the loaded brass threaded ring down until two threads are showing.

• Fit locking ring to the insert.

Figure 35: Legend: 1)

Locking ring

2)

Threaded Ring Pt No H 4553039

3)

Pump insert

- POSITIVE SET PRESSURE PUMP-

Pt No H4494253

Pt No H6540260

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3.7.2.14

Procedure for Replacing Safety Valves

There are two (2) off safety relief valves fitted to the unloading valve manifold block on each pump. These valves are set to open at 400 Bar (40 MPa) and will dump to atmosphere the total pump flow in the event that the unloading valve fails to operate correctly. Two (2) off valves are required per pump to pass the total pump discharge volume of 309 Litres per minute.

Under normal operating conditions there should be no leakage from the vent port. If there is any leakage then the valve on the pump should be replaced and the faulty valve returned to Southern Engineering Services Pty Ltd for repair and resetting.

1. SAFETY a. Personal Protective Equipment; • Safety Glasses. b. Safety Procedures; • Positive Set Pump Isolation Procedure (refer Section 11).

• Austar’s Manual Handling Procedure.

2. OPERATION PROCEDURES a. Equipment Required; • 24mm spanner.

- POSITIVE SET PRESSURE PUMP-

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b.

Operation Procedure; • Isolate pump according to procedure in Section 11.

• Remove pipe work from between H300 unloader valve and hollow screw adaptor.

• Unscrew adaptor nut on end of accumulator bottle safety valve from the hollow screw.

• Remove safety valve and hollow screw to bench, remove hollow screw.

A

B

Figures 36 & 37: Photo of Positive Set Pump showing; A) Pipe work to be removed

B) Adaptor nut on end of Accumulator Bottle

- POSITIVE SET PRESSURE PUMP-

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• Replacement of the safety valve is the reverse of the removal procedure (as outlined in this section).

Lubricate the O-rings on the hollow screw grease prior to fitting the valve.

DANGER

– Ensure that the vent port on the

safety valve is facing down or to the rear of the pump when fitting the valve to the pump.

A

Figure 38: Photo of Positive Set Pump showing: A) Position of Safety Valve Vent

- POSITIVE SET PRESSURE PUMP-

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3.7.3 Additional Pump Information

3.7.3.1

Bolt Tightening Torques

Bolts not shown on following table should be hand tightened professionally.

Property class

Pump insert

Bolt diameter [mm] M20

10.9

Tightening torque [Nm] 210

Delivery Valve

M16

10.9

210

Intake Valve

M16

10.9

210

Connecting rod

M14

12.9

210

M10

8.8

45

M12

10.9

120

M10

8.8

45

M10

4.6

18

Component

Thrust ring to crankshaft bearing Gearbox Cover to gearbox Lubricating pump

- POSITIVE SET PRESSURE PUMP-

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3.7.3.2

Grease

All mounting procedures require the use of a grease according to the quality class:

DIN 51 502 KPL 2 E-25 …or higher

e.g. SHELL ALIBIDA EP2 – or – CASTROL APXT as recommended by Southern Engineering Services Pty. Ltd.

O-ring grease to be used should be Molykote Valve and O ring Lubricant or similar.

3.7.3.3

Sealant.

The use of ‘Locktite 518’ Master gasket sealant for all mounting procedures requiring the use of sealing material.

- POSITIVE SET PRESSURE PUMP-

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3.7.4 Trouble shooting guide for Hauhinco pumps

? PROBLEM ? No Pressure Build up in Pump CAUSE Plate valves jammed by foreign material Solenoid pre-control valve not energised

SOLUTION Procedure Remove valves, clean if 3.7.2.8 needed Check power is on and connected to solenoid

? PROBLEM ? Pump does not build up pressure and works erratically CAUSE Shut off valve in suction pipe closed Air in pump Suction Pipe Leaks

SOLUTION

Procedure

Open Shut off valve Bleed air from pump Retighten valves, replace if necessary, bleed air from pump

3.7.2.7 3.7.2.7 3.7.2.8

Packing at pump insert defective.

Medium increasingly leaks out at plungers

Replace packing

3.7.2.13

O rings of intake or delivery valve leak

Replace O-rings on valves

3.7.2.8

- POSITIVE SET PRESSURE PUMP-

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? PROBLEM ? Irregular oil pressure within pump lubrication circuit. Oil pressure falling below 1.5 Bar, drive unit shuts off CAUSE

SOLUTION

Procedure

Oil seal and/or 6mm nozzle may be blocked

Replace Components

3.67.2.6

? PROBLEM ? Lubrication circuit oil pressure soaring CAUSE 6mm nozzle in oil distributor may be blocked

SOLUTION Clean 6mm Nozzle

- POSITIVE SET PRESSURE PUMP-

Procedure 3.7.2.6

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4.

EMULSION STORAGE TANK 4.1

TECHNICAL INFORMATION

Nominal Emulsion Capacity: 9,400 Litres

The emulsion storage tank is constructed from 8mm, 304 stainless steel plate, with 6mm 316 stainless steel lids. It is fitted with internal baffle plates.

Major Components Mounted on the tank are; • Three (3) off 100mm nominal bore stainless steel emulsion suction outlets for chock pumps.

• One (1) off 65mm nominal bore stainless steel suction outlet for the positive set pump.

• Four (4) off Suction isolation valves.

• Five (5) off air breathers.

• Emulsion tank fluid level viewing port.

• Two (2) off drain ports.

• One (1) off emulsion temperature transducer.

• Two (2) off emulsion sample points.

- EMULSION STORAGE TANK -

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4.2

EMULSION SUCTION OUTLET PORTS

An emulsion outlet port is positioned on each of the bottom corners of the inbye and outbye faces of the tank. Three of the outlets are 100mm nominal bore (NB); while the fourth outlet is 65mm nominal bore. Two of the 100mm NB outlets supply the two chock pumps and the 65mm NB outlet supplies the positive set pump. The third 100mm NB port has been included on the emulsion tank for the future installation of a third emulsion pump.

- EMULSION STORAGE TANK -

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4.3 SUCTION ISOLATION VALVES

P CAUTION P – Before operating any hydraulic pump ensure that the pump suction isolation valve is COMPLETELY OPEN.

A

Figure 39: Photo of Emulsion Tank showing; A)

Suction Isolation Valve Pt No 530-125 65NB

Suction isolation valves, for the two chock pumps and the positive set pump, are provided so that an individual pump may be isolated from the emulsion source during maintenance. The valves are red butterfly valves located on the emulsion suction pipes on the tanks.

- EMULSION STORAGE TANK -

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4.4

AIR BREATHERS

Five (5) off air breathers and two (2) off overflow ports are fitted to the top of the tank, in the central channel section beneath the lift-off covers, in order to prevent air born particles from entering the tank. The breathers are rated at 3 micron.

A

B

Figure 40: Photo of Emulsion Storage Tank showing; A) Air Breather units Pt No BLP162S10W2.0

- EMULSION STORAGE TANK -

B) Tank overflow port Pt No VBCE50

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4.5

EMULSION TANK FLUID LEVEL VIEWING PORT

A tank level viewing port has been installed in the inbye end of the emulsion tank so that the level of emulsion still in the storage tank can be seen. This allows for quick estimation of current fluid levels still in the storage tank.

A

Figure 41: Photo of Emulsion Tank showing; A)

Fluid Level Viewing Port

- EMULSION STORAGE TANK -

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4.6

DRAIN PORTS

Two drain ports are located on the bottom of the side of the emulsion tank in case fluid needs to be removed from the tank and both lids are removable for easy access when cleaning.

A

Figure 42: Photo of Emulsion Tank showing; A)

Closed drain port

- EMULSION STORAGE TANK -

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4.7

EMULSION TEMPERATURE TRANSDUCER

An emulsion temperature transducer, located on the outbye end of the emulsion tank, monitors the temperature of the fluid in the storage tank. If the temperature of the fluid in the emulsion tank reaches 50ºC the PLC will sound a warning alarm. If the emulsion temperature increases further to 60ºC than the PLC will automatically stop the pumps to allow the emulsion temperature to cool.

A

Figure 43: Photo of Emulsion Tank showing; A)

Emulsion Temperature Transmitter Pt No Labom PT100

- EMULSION STORAGE TANK -

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4.8

LOW PRESSURE EMULSION SAMPLE POINT

The turbulent emulsion sample point is located on the inbye end of the emulsion tank near the header pipe.

An emulsion sample point is located on the outbye end of the emulsion tank above the positive set pump suction isolation butterfly valve.

A

B

Figure 44: Photo of Emulsion Tank showing; A)

Turbulent Emulsion Sample Point

B)

Emulsion Sample Point

- EMULSION STORAGE TANK -

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4.9

PROCEDURE FOR TAKING SAMPLES OF EMULSION FROM TANK

1.

2.

SAFETY a.

Personal Protective Equipment

•

Goggles/Safety glasses

•

Austar Coal Mine’s Standard PPE

DEFINITIONS Turbulent Emulsion Sample Point Sample point located on inbye end on the emulsion tank beneath the return header pipe. Samples are taken following the flow of emulsion through the return line filters and experiencing turbulent flow conditions

A

B

C

Figure 45: Photo of Emulsion Tank showing: A) C)

Return Header Pipe DN10 Ball Valve

- EMULSION STORAGE TANK -

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Emulsion Sample Point Sample point located on the outbye end of the emulsion tank above the positive set pump suction port. Samples are taken where the emulsion is experiencing laminar flow conditions.

A

B

C

Figure 46: Photo of Emulsion Tank Showing; Emulsion Sample Point.

3.

PROCEDURES a.

Equipment Required

•

Appropriate container for collecting emulsion sample

b.

Operation Procedure

•

Place container beneath sample point to be used - EMULSION STORAGE TANK -

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•

Slowly open DN 10 ball valve to allow required amount of emulsion to pour into appropriate container

CAUTION: Emulsion will flow quickly from the turbulent emulsion sample point care is to be taken when opening valve •

Once require sample size has been taken close DN10 ball Valve.

- EMULSION STORAGE TANK -

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4.10 SERVICE AND MAINTENANCE

4.10.1 Inspection and Maintenance Requirements 4.10.1.1 Daily Inspections and Requirements • Inspect the level of emulsion in the storage tank through the viewing port. Compare reading of emulsion level with readout on PLC data screen.

• Inspect suction outlet pipes for leaks • Inspect emulsion hoses and fittings for leaks or damage.

4.10.1.2 Twelve Monthly, – Or – Every 5000 Hours of Operation Inspection Requirements

• Change air breather elements on emulsion storage tank.

- EMULSION STORAGE TANK -

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4.11 MAINTENANCE PROCEDURES

4.11.1 Suction Isolation

Emulsion suction isolation forms a major component of the isolation procedure for the chock pumps and the positive set pump. It is vital that the pumps be separated from the fluid supply before venting of any stored pressure to prevent an excessive amount of emulsion fluid being lost. Refer to Section 11.1 for the Hauhinco Pump Isolation Procedures.

- EMULSION STORAGE TANK -

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A

B

C

D

Figure 47: Photos of Emulsion Tank Isolation points showing; A)

Chock Pump No 1

B)

Pt No 530-125 100NB C)

Positive Set pump

Chock Pump No 2 Pt No 530-125 100NB

D)

spare

Pt No 530-125 65NB

- EMULSION STORAGE TANK -

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4.11.2

Procedure Changing Air Breather Elements The emulsion storage tank is fitted with five (5) off air breathers to accommodate the changing volumes of air in the tank and prevent the ingress of airborne contamination. The air breathers are located in the channel section, near the top of the emulsion tank, beneath the lift off covers.

A

Figure 48: Photo of Emulsion Tank showing; A)

Air Breather Units Pt No BLP162 S10 W2.0

- EMULSION STORAGE TANK -

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1. SAFETY

a. Personal Protective Equipment; •

Safety Glasses.

2. PROCEDURES

b. Operation Procedure; • The breathers are screw-on style and to remove the breather unscrew it from its mounting.

• To replace the breather(s) screw the unit on and tighten by hand only.

- EMULSION STORAGE TANK -

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5.

PUMP STATION MONITORING SYSTEM 5.1 PUMP STATION MONITORING SYSTEM COMPONENTS

DEVICE

Positive Set Pump outgoing pressure transducer Positive set pump lubricating oil pressure transducer

BRAND

MODEL No.

SET POINTS

ACTIONS

Labom

CB 2031-A1068-H1-S63 Max 420 Prod. No.: Bar Min 0211292/07/003 200 Bar

Motor cut off

Labom

CB 2021-A1058-H1-S63 Low 1.5 Prod. No.: Bar 0308952/02/006

Motor cut off

RANGE

LOCATION

Positive Set Pump Field Device Panel mounted 0-600 Bar on walkway side of 4-20 mA Positive Set Pump Console Positive Set Pump Field Device Panel mounted 0-10 Bar on walkway side of 4-20 mA Positive Set Pump Console

Positive set pump Low: 1.5 Motor cut 0-10 Bar Non drive end of Positive lubricating oil Hauhinco 2321823 Bar off 4-20 mA Set Pump pressure switch Positive set pump lubricating oil PT 100 1/2 BSP Motor cut Non drive end of Positive Labom 50° -60° 0 - 100° 6x150/PTX/H/RTD/IS off Set Pump temperature transducer Pump station CB 2031-A1068-H1-S63 overall outgoing 350 Bar – Motor cut off 0-600 Bar Face Delivery Manifold Prod. No.: Labom 370 Bar 380 Bar 4-20 mA on Inbye End of Station system pressure 0211292/07/001 transducer Shearer Water Pump Shearer water Field Device Panel U504 safety CB 2031-A1068-H1-S63 0-250 Bar pump - outgoing 40 Bar to mounted on non walkway Labom valve set Prod. No.: pressure 4-20 mA 145 Bar side of Shearer Water relief 0211292/03/001 transducer Pump Shearer Water Pump Shearer water tank Field Device Panel CB 2031-A1068-H1-S63 incoming water Motor cut 0-40 Bar Labom Prod. No.: Min 6 Bar mounted on non walkway pressure off 4-20 mA side of Shearer Water 0211292/02/002 transducer Pump Shearer water CB 2021-A1058-H1-S63 Low 1.5 Motor cut 0-10 Bar Non drive end of Shearer pump - lubricating Labom Prod. No.: Bar off 4-20mA Water Pump oil pressure 0308952/02/007 transducer Shearer water tank Motor cut PT 100 1/2 BSP fluid temperature Labom Shearer Water Tank 50° -60° 0° - 100° 6x150/PTX/H/RTD/IS off transducer Shearer water Low: 1.5 0-10 Bar Non drive end of Shearer pump - lubricating Hauhinco 2321823 Motor cut off Bar 4-20mA Water Pump oil pressure switch Shearer water pump - lubricating PT 100 1/2 BSP Motor cut Non drive end of Shearer Labom 50° -60° 0 - 100° 6x150/PTX/H/RTD/IS off Water Pump oil temperature transmitter

- MONITORING SYSTEM -

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DEVICE

BRAND

MODEL No.

Emulsion pump #1 outgoing pressure transducer

Labom

CB 2031 S63

Emulsion pump #1 Lubricating oil pressure transducer

Labom

CB 2021 S63 Prod. No.: 0308952/02/002

Emulsion pump #1 Lubricating oil Hauhinco pressure switch Emulsion pump #1 Lubricating oil Labom temperature transducer

Emulsion pump #2 - outgoing pressure transducer Emulsion pump #2 - Lubricating oil pressure transducer Emulsion pump #2 - Lubricating oil pressure switch Emulsion pump #2 - Lubricating oil temperature transducer Emulsion pump #3 - Outgoing pressure transducer Emulsion pump #3 - Lubricating oil pressure transducer Emulsion pump #3 - Lubricating oil pressure switch Emulsion pump #3 - Lubricating oil temperature transducer Emulsion level indicator and transducer

Labom

Labom

SET ACTIONS POINTS

RANGE

LOCATION

Emulsion Pump #1 Motor cut 0-600 Bar Field Device Panel off 4-20 mA mounted on Console of Pump Emulsion Pump #1 Motor cut 0-10 Bar Field Device Panel Low 1.5 Bar off 4-20 mA mounted on Console of Pump 200 Bar – 370 Bar

2321823

Low: 1.5 Bar

Motor cut off

0-10 Bar 4-20 mA

Non drive end of Emulsion Pump #1

PT 100 1/2 BSP 6x150/PTX/H/RTD/IS

50° -60°

Motor cut off

0° - 100°

Non drive end of Emulsion Pump #2

CB 2031-A1068-H1Emulsion Pump #2 S63 330 – 370 Motor cut 0-600 Bar Field Device Panel Bar off 4-20 mA Prod. No.: mounted on 0211292/07/005 Console of Pump CB 2021-A1058-H1Emulsion Pump #2 S63 Low: 1.5 Motor cut 0-10 Bar Field Device Panel Prod. No.: mounted on Bar off 4-20 mA 0308952/02/003 Console of Pump

Hauhinco

2321823

Low: 1.5 Bar

Motor cut 0-10 Bar Non drive end of off 4-20 mA Emulsion Pump #2

Labom

PT 100 1/2 BSP 6x150/PTX/H/RTD/I S

50° -60°

Motor cut off

Labom

CB 2031-A1068-H1- 330 – 370 Motor cut 0-600 Bar To be installed with S63 Bar off 4-20 mA Emulsion Pump #3

Labom

CB 2021-A1058-H1- Low: 1.5 S63 Bar

Motor cut 0-10 Bar To be installed with off 4-20 mA Emulsion Pump #3

0° - 100°

Non drive end of Emulsion Pump #2

Hauhinco

2321823

Low: 1.5 Bar

Motor cut 0-10 Bar To be installed with off 4-20 mA Emulsion Pump #3

Labom

PT 100 1/2 BSP 6x150/PTX/H/RTD/I S

50° -60°

Motor cut off

0 - 100°

To be installed with Emulsion Pump #3

Weka

TYPE: 31967

30% - 90%

Cut off

4-20 mA

Inbye End of Emulsion Tank

- MONITORING SYSTEM -

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DEVICE

BRAND

MODEL No.

Emulsion face return pressure transducer

Labom

CB 2021-A1058-H1S63 Prod. No.: 0308952/02/004

(in tank) Emulsion temperature transducer

Labom

Solenoid fill valve

SET ACTIONS POINTS

RANGE

LOCATION

Alarm trip

0-10 Bar 4-20 mA

Inbye End of Emulsion Tank

PT 100 1/2 BSP 50° - 60° 6x150/PTX/H/RTD/IS

Trip

4-20 mA

Outbye End of Emulsion Tank

Ceme

Safety 8616 110V Solenoid valve 15Valve 20 Bar

Alarm & vent through safety valve

110V

Emulsion Tank

Hydac

VD5 GCW-SQ113

4.5 – 5.0 Bar

Alarm

4 – 5 Bar

Emulsion Tank

Hydac

VD8 GCW-SQ113

7.5 - 8.0 Bar

Alarm

7 – 8 Bar

Emulsion Tank

6 Bar

Return filter differential pressure switch Inline fill filter differential pressure switch

- MONITORING SYSTEM -

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5.2

GENERAL DESCRIPTION

The monitoring system is provided to ensure that the equipment operates within its designed parameters and that any deviation from these requirements can be identified and steps taken to prevent danger to personnel and minimize any possible damage to the equipment.

5.3

EMULSION TANK MONITORING

5.3.1 Emulsion Temperature Transducer

An emulsion temperature transducer, located on the outbye

end

of

the

emulsion

tank,

monitors

the

temperature of the fluid in the storage tank. If the temperature of the fluid in the emulsion tank reaches 50ºC the PLC will sound a warning alarm. If the emulsion temperature increases to 60ºC than the PLC will automatically stop the pumps to allow the emulsion temperature to cool.

- MONITORING SYSTEM -

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A

Figure 49: Photo of Emulsion Tank showing; A)

Emulsion Temperature Transmitter Pt No Labom PT100

- MONITORING SYSTEM -

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5.4

CHOCK AND POSITIVE SET PUMP MONITORING

5.4.1 Emulsion System Pressure Transducer

Located on the top of the face delivery manifold on the inbye end of the platform. The system pressure transducer monitors the hydraulic pressure in the delivery line to the face and provides an analogue signal of 4-to20 mA to the pump controller for manipulating the loading and unloading of the pumps.

A

B

Figure 50: Photo of Face Delivery Manifold showing; A) Systems Pressure Gauge

B) Face Delivery Manifold

Pt No H2400006S

Pt No X22814-4

- MONITORING SYSTEM -

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5.4.2 Pump Lubrication Oil Pressure Switch

Fitted to each pump on the station the switch monitors the lubricating oil pressure and stops the pump if the pressure falls below 1.5 Bar [150 kPa].

A

B

Figure 51: Photo of Chock Pump showing; A)

Hydraulic Pump Lubricating Oil Pressure Gauge Pt No H2400146

B)

Hydraulic Pump Lubricating Oil Pressure Switch Pt No H6451225

- MONITORING SYSTEM -

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5.4.3 Emulsion and Shearer Water Pumps Lubricating Oil Temperature Transducer

Fitted to the non-drive end of each pump this transducer monitors the temperature of the lubricating oil. It utilizes a bulb and capillary tube and has two (2) off set points set in the PLC. The first set point is 55 C at which point an alarm is tripped. The second set point is 65 C and this will stop the pump.

Figure 52: Photo of pump console showing; A A)

Emulsion Pump Lubrication Oil Temperature Transducer Pt No PT100

- MONITORING SYSTEM -

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5.4.4 Lubrication Oil Pressure Transducer

Each pump is fitted with a transducer that monitors the lube oil pressure. Each transmitter sends a signal back to the pump station PLC. The transducer for each pump is mounted on a bracket of the side of each pump console, except for the shearer water pump, which is mounted on the non-drive end of the pump.

A

Figure 53: Photo of Chock Pump Console showing; A

Lube Oil Pressure Transducer And Gauge Pt No CB2031-A1058-H1-S63 0-10 Bar

- MONITORING SYSTEM -

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5.5

FILTRATION SYSTEM MONITORING

5.5.1 Emulsion Return Line Filter Pressure Transmitter & DP Switches

Fitted to the end cap of each of the three (3) off emulsion return line filters the pressure transmitter monitors the condition of the element in the filter and sends a signal to the differential pressure switch located beside the return filters. The differential pressure switch will send a signal to the PLC when the element requires replacing.

If the element is not replaced in time and the differential pressure continues to rise a second signal will stop the system.

- MONITORING SYSTEM -

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A

B

Figure 54: Photo of Emulsion Tank showing; A)

Emulsion Return line filters Pt No RFBNHC1300DP005

B) Emulsion Inlet Filters Pt No RF W/HC 330-025

A

Figure 55: Photo of Emulsion Tank showing; A)

Differential Pressure Switches Pt No VD5GCW-SQ113 & XQ113 - MONITORING SYSTEM -

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5.6

CALIBRATION OF TRANSDUCER

5.6.1 Lubricating Oil Pressure Transducer Calibration

The lube oil pressure transducer converts pressure measurements from the pump oil pressure into a standard load-independent current signal. Transducers DO NOT require any additional calibration by operators or maintenance personnel. The manufacturer calibrates all of the transducers before being installed on the pump station.

5.6.2 Lube Oil Temperature Transducer Calibration

PT100 temperature transducers DO NOT require any additional calibration by operators or maintenance personnel. All of these transducers are calibrated by the manufacturer before installation on pump station.

- MONITORING SYSTEM -

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6.

FILTRATION SYSTEM 6.1

GENERAL DESCRIPTION

Clean emulsion fluid is essential for continued reliable operation of the longwall hydraulic roof supports. The pump station is fitted with filtration equipment that when used and maintained correctly will keep the fluid clean at all times.

6.2

EMULSION RETURN LINE FILTERS

On the outbye end of the emulsion storage tank, three (3) off return line filters have been fitted. These filters collect particles from within the emulsion fluid as it returns to the tank from the face. The filter elements are rated at five micron (5 µm).

• NOTE: A 10mm ball valve has been installed to break the vacuum in the return lines. This is located on the header pipe beside the pump unloader check valves.

- FILTRATION SYSTEM -

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A

B

Figure 56: Photo of Emulsion Tank showing; A)

Return Line Hydac Filters Pt No RFBNHC1300DP005

- FILTRATION SYSTEM -

B) Emulsion Inlet Hydac Filter Pt No 1300 R005 BN3HCKB

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6.3

EMULSION INLET FILTER

Located on the outbye end of the emulsion storage tank, next to the return line filters, the inlet filter is provided to filter the emulsion as it first enters the storage tank. Each filter is fitted with a 25 micron (25µm) element and a pressure transmitter to monitor the condition of the elements.

A

B

Figure 57: Photo of Emulsion Storage Tank showing; A)

Emulsion Inlet Filter Pt No RF W/HC 330-025

B)

Emulsion 110V Solenoid Filter Valve

- FILTRATION SYSTEM -

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6.4

MINERAL OIL FILTER

6.4.1 General Description

Mounted on the walkway side of the outbye end of the pump station is the mineral oil inlet filter. It is used to filter out contaminants from the mineral oil supply. This filter has a 10 micron (10µm) filter element and 50mm SAE (code 62) fitting. Clogging indicator visible in top of filter housing.

A

B

Figure 58: Photo of Pump Station Showing: A)

Mineral Oil pressure filter Pt No DFBNHC330F10A1.1

B)

Clogging Indicator Pt No O-DPI-1055

Element Pt No 0330D010BN3HC

- FILTRATION SYSTEM -

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6.5

SHEARER WATER PUMP INLET FILTER

Fitted to the shearer water pump unit is a stainless steel inline, 50 micron, filter to remove contaminants before the incoming fluid enters the tank. The filter contains a visual clogging indicator to show when the fliter requires cleaning.

A

Figure 59: Photo of Shearer Water Inlet Filter showing; A) Clogging Indicator Pt No O-DPI-1055

- FILTRATION SYSTEM -

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6.6

EMULSION STORAGE TANK AIR BREATHERS AND FILTRATION MAGNETS

Five (5) off air breather units, of 10 micron (10µm) rating, are fitted to the emulsion storage tank to prevent contamination from airborne particles.

A

Figure 60: Photo of Emulsion Tank showing; A) Air Breathers Pt No BLP 162 S10 W2.0

- FILTRATION SYSTEM -

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A stainless steel rod suspends 16 filtration magnets within the emulsion tank in order to filter out particles from the emulsion fluid. The rod may be easily removed for periodic cleaning.

A

B

Figure 61: Photo of Support Rod Spacer showing; A)

Filtration Magnets

B

Stainless Steel Spacer

Pt No Item 2610

- FILTRATION SYSTEM -

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6.7

SOLENOID PRE-CONTROL VALVE FILTER

A filter is located in the solenoid pre-control valve filter block of the electro-hydraulic unloader valve fitted to the Hauhinco pumps. It is provided to filter the emulsion fluid prior to entering the solenoid valve. Refer to Section 2.9.2.18 for cleaning and replacement procedure.

A

B

Figure 62: Photo of ADM Solenoid & Filter Block Assembly showing; A)

ADM Solenoid Valve

B) Filter Block

Pt No H6256279

- FILTRATION SYSTEM -

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6.8

SERVICE AND MAINTENANCE PROCEDURES

6.8.1 Procedure for Changing Return Line Filter Elements and Emulsion Infill Filter Element 1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE. b. Safety Procedures; • Pump Isolation Procedures (refer Section 11.1).

2. PROCEDURES a. Equipment required: • 30mm Spanner. b. Operation Procedure; • Ensure that all pumps are stopped.

• Isolate pressure from all four pumps following Isolation and Venting Procedures in Section 11.1.

• Loosen the four (4) off bolts holding the filter cover to the housing using the 30mm spanner.

• Rotate filter cover clockwise to remove.

• Using the wire handle on the filter element pull the element out of the filter housing.

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• Insert a new filter element into the housing.

• Replace filter housing cover and tighten bolts.

A

Figure 63: Photo of Emulsion Tank showing;

Figure 64: Photo of Hydac Filter Element Pt No 1300R005-BN3HCKB

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6.8.2 Procedure for Changing Shearer Water Inlet Filter Element

1.SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Austar Coal Mine’s Standard PPE.

b. Safety Procedures; • Pump Isolation Procedures (refer Section 11.1).

2. PROCEDURES

a. Operation Procedure; • Isolate and vent pressure from shearer water pump according to Shearer Water Pump Isolation and Pressure Venting Procedure. Refer 11.1.3.

• Loosen the two (2) off wing nuts holding the top filter cover to the housing.

• Remove cover by rotating.

• Pull the element out of the filter housing.

• Insert a new filter element into the housing.

• Rotate filter-housing cover and tighten wing nuts.

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7. Mineral Oil Control System 7.1

GENERAL DESCRIPTION The mineral oil control system, in accordance with AS/NZS1994 Standard, is responsible for the tramming and levelling of pump station.

The system is comprised of; • Two (2) off Hydraulic Levelling Cylinders.

• Load Locks.

• Directional Control Valves.

• One (1) off Diverter Ball Valve.

• One (1) off Remote Pendant Control System, comprising of o One (1) off Remote Pendant Control Box and o Two (2) off Connection Panels • Two (2) off Crawler Track Units.

• One (1) off Mineral Oil Pressure Filter.

• Brake Valve.

• Brake Valve Gauge.

For procedure on tramming and leveling see Section 7.11

For information and procedures regarding the crawler tracks see Section 8.

For information regarding the mineral oil pressure filter see Section 6.4.1

- MINERAL OIL CONTROL SYSTEM -

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7.2

LEVELLING CYLINDERS

The hydraulic levelling cylinders are provided to support the inbye end of the pump station when on sloping ground. Using the levelling cylinders will enable operators to level the pump station when setting up the pump station for operation.

A

B

C

Figure 65: Photo of Levelling Cylinders showing; A)

Levelling Cylinder

B)

Load Locks

Pt No refer drg no 8715-0 C)

Isolation Pister ½” Pister Ball Valves on non-walkway side in closed position Pt No BKHG1113

- MINERAL OIL CONTROL SYSTEM -

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7.3

LOAD LOCKS Each of the two levelling cylinders mounted on the pump station are equipped with dual load locks.

The load locks

prevent the cylinders from moving other than when being operated. One of the load locks prevents the cylinder from retracting into the housing while the other load lock prevents the cylinder from extending out of the cylinder.

7.4

DIRECTIONAL CONTROL VALVES Levers are used to raise and lower the levelling cylinders by operating two directional control valves. The control valves are located in the Danfoss valve bank positioned on the walkway side of the inbye end of the pump station.

Figure 66: Photo of Directional Control Valves showing; A)

A

Leveling Cylinder’s Control Levers

- MINERAL OIL CONTROL SYSTEM -

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7.5

DIVERTER BALL VALVE

Fitted to the inbye end of the pump station, beside the control levers for the hydraulic levelling cylinders, is a 3-way pendant control ball valve. This pilot valve is used to control the direction of flow of the fluid required for the remote control. When the pilot remote control is connected to the connection panel, on the inbye end on the pump station, the valve needs to be set to the inbye position. Likewise, when the remote control box is to be connected to the outbye end of the pump station, the pilot valve needs to be set to the outbye position.

A

Figure 67: Photo of Control Panel showing; A) Diverter Ball Valve

Pt No 0000.008.562.01.85

- MINERAL OIL CONTROL SYSTEM -

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7.6

REMOTE PENDANT CONTROL SYSTEM

7.6.1 Remote Pendant Control Box The remote pendant control box is used to tram the station for relocation. The remote control box may be connected to either of the remote pendant control connection panels positioned on the inbye and outbye ends of the station. A dead man switch and single control lever are used during tramming operations. The dead man switch must be held up in order to operate the remote pendant control box.

A

B

Figure 68: Photo of Remote Pendant Control showing; A) Dead Man Switch

B) Pendant Control

- MINERAL OIL CONTROL SYSTEM -

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7.6.2 Remote Pendant Control Connection Panel

Figure 69: Photo of Remote Control Panel showing; Quick Connections

A labelled remote control connection panel is mounted on both the inbye and outbye ends of the pump station so that the remote pendant control can be mounted for use at either end of the station. The diverter switch must be positioned to select the end of the pump station that the remote pendant is connected to for the remote pendant to operate.

- MINERAL OIL CONTROL SYSTEM -

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7.7

CRAWLER TRACK UNITS

The crawler tracks are located on either side of the pump station and are used to move the station into the desired position for operation.

Each unit consists of; •

Track Frame.

•

Fairfield CT45 Series Planetary Hub.

•

Char-Lynn 2000 Series Hydraulic Motor.

•

Berco Size 9 Crawler Track.

For further information regarding the crawler track unit specifications and operation refer to Section 8.

7.8

MINERAL OIL PRESSURE FILTER

The mineral oil pressure filter is mounted on the outbye end of the station, on the walkway side of the positive set pump. The pressure filter collects particulates from the mineral oil circuit.

For more information regarding this filter refer to Section 6.4.1

- MINERAL OIL CONTROL SYSTEM -

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7.9

BRAKE VALVE

The brake valve operates to provide hydraulic pressure to the brake within the planetary hub. A pressure of 8 to 10 Bar will operate the brake in the hub to arrest the motion of the crawler tracks. The brake valve is located beside the Danfoss valve bank on the walkway side of the inbye end of the station.

7.10 BRAKE VALVE HYDRAULIC GAUGE

A hydraulic gauge is provided for fault finding in case the brake valve or brake in the planetary hub is malfunctioning. The gauge is used to identify the hydraulic pressure being provided to the brake. The gauge is located beneath the brake valve cover plate beside the Danfoss valve bank.

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7.11 AUSTAR COAL MINE HYDRAULIC PUMP STATION POSITIONING PROCEDURE 1. SAFETY a Personal Protective Equipment •

Safety glasses/goggles

•

Safety Boots/Shoes

2. PROCEDURES

a. Equipment Required • Personal Locks.

• Timber Supports (hardwood).

b. Safety Checks Before Operation • Ensure that there is sufficient ground support for pump station levelling supports.

• Ensure the area where the pump station is to be positioned is clear of any service lines and debris.

• Ensure that all pumps are stopped.

• Ensure face delivery isolation valves on face delivery manifold have been closed.

• Ensure supply and return lines from the monorail have been disconnected.

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c.

i.

Operating Procedure.

Refer to Section 8.6 for positioning of the pump station

ii.

Fully lower both hydraulic levelling cylinders using the levers mounted on the directional control valves

iii.

Ensure that pump station is level using the mounted levelling indicators.

Please Note: There are two isolation ball valves located on non-walkway side levelling cylinder. These must be locked out before commencing work on cylinder or positioning packing under platform.

iv.

Lock out both isolation ball valves on non-walkway side levelling cylinder and pack timber supports between ground and the pump station to ensure that a secondary support is in place for the pump station.

v.

Detach towing ‘A-frame’ safety chain and lower ‘Aframe’ to the ground - ensuring that all personnel are clear.

vi.

Connect the two (2) off emulsion face return lines and the decompression return line to the appropriate fittings on the header return pipe on the emulsion tank.

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vii.

Connect the two (2) off DN50 and the one DN40 high pressure lines from the monorail to the delivery manifold.

viii.

Open pump isolation valves and bleed air from the system.

ix.

Shearer Water Pump Operating Procedures; a.

Connect water supply from monorail to shearer water pump inline filter inlet port.

b.

Connect delivery pressure hose to s/steel DN63 ball valve located on top of delivery manifold.

c.

Open shearer water pump face delivery isolation valve.

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8.

CRAWLER TRACKS ASSEMBLY 8.1

CRAWLER TRACK UNIT SPECIFICATION

Drive Unit & Hub Planetary hub

Fairfield CT45 Series

Type

Planetary

Ratio

110:1

Peak Output Torque

45,000 Nm

Drive motor

Char-Lynn 2000 Series

Motor type

Hydraulic Motor Spring applied, hydraulic release

Brake type

static internal brake

Brake torque (Output)

53900 Nm

Release pressure

10 Bar minimum

Tracks Type

Berco Size 9

No. of teeth

23

Pitch diameter

650.5mm

Chain type

Sealed & lubricated

No. of Links

44

Shoe Pin diameter

58.73mm

Shoe type

Triple Bar Grouser

Shoe width

508mm

Track Pitch

175.5mm

Track joining method

Bolted 4 per side

Idler type

Berco Size 9, Plain

Tensioning system Track length (Sprocket Idler Centres) Load capacity

- CRAWLER TRACKS ASSEMBLY-

Spring/Grease cylinder with Valve 3025mm (minimum) 50,000 kg (including tracks)

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8.2

GENERAL DESCRIPTION The crawler units fitted to the mobile pump station are hydraulically driven track units designed to carry loads of up to 50 tonnes (including tracks). The hydraulic supply for driving the track units is from an external source, usually from the power take-off of a Load, Haul, Dump vehicle (LHD) or other mobile machine.

Control of the crawlers is via the remote

pendant control that can be attached to either end of the pump station.

The pump station has been designed to be towed by a LHD when moving a significant distance and trammed with the track units when manouvering the stations into or out of a cutthrough.

- CRAWLER TRACKS ASSEMBLY-

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A

B

Figure 70: Photo of Crawler Tracks showing; A)

DBT Crawler Tracks

- CRAWLER TRACKS ASSEMBLY-

B)

Planetary Hub

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8.3

TOWING THE PUMP STATION

8.3.1 Connecting towing unit to the ‘A-frame’ tow bar

P CAUTION P – Before towing (or tramming) pump station ensure that both hydraulic levelling cylinders are fully retracted. Refer Section 7.4

In order to tow the pump station, the towing ‘A-frame’ must be lowered to the correct level to couple the towing device. This is done via a hydraulic hand pump located on the outbye end of the pump station.

A

B

C

D

Figure 71: Photo of Towing Unit showing; A)

5 Tonne hook Pt No WLSH 130-G-BLK

C)

Cylinder Pt No M3000

- CRAWLER TRACKS ASSEMBLY-

B)

Relief Valve Pt No RV2-10-5-0-36

D) Hand Pump Pt No P80

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8.3.2 PROCEDURE FOR CONNECTING TOWING ‘A-FRAME’ TO TOW VEHICLE

1.

SAFETY

a. Personal Protective Equipment; • Safety Glasses.

b. Safety Checks; • Ensure both hydraulic cylinders are fully retracted.

Refer Section 7.4.

• All personnel in surrounding area are notified that the ‘A-frame’ will be lowered.

• Area beneath ‘A-frame’ is clear of personnel before commencing to lower ‘A-frame’.

• All hands to be kept clear of pinch points formed between the ‘A-frame’ and pump station platform and the ‘A-frame’ and the towing vehicle.

2.

PROCEDURE; • If the ‘A-frame’ safety chain is still connected, use hand pump to raise ‘A-frame’ and disconnect safety chain.

• To lower ‘A-frame’ to correct height for coupling open the locking valve located on the Hydraulic hand pump by rotating locking valve handle anticlockwise.

- CRAWLER TRACKS ASSEMBLY-

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• To raise ‘A-frame’ to correct height for coupling, check locking valve on hand pump is closed (locking valve handle rotated clockwise until tight) pump Enerpac handle until ‘A-frame’ reaches correct height.

• Couple tow frame coupling to the towing vehicle.

• Open locking valve on hand pump and leave open for duration of towing.

- CRAWLER TRACKS ASSEMBLY-

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8.3.3

Procedure For Freewheeling Crawler Tracks Before the pump station can be towed the planetary hubs must be disengaged so the tracks may free wheel.

1. SAFETY a. Personal Protective Equipment; Safety Glasses.

b. Safety Checks;

1 DANGER 1 – Before attempting to free wheel pump station ensure the following • Hydraulic power to the crawler circuit is switched off.

• Pump Station is positioned on a level ground and not moving.

• Towing vehicle has the capacity to provide braking for this additional load in up and down grades.

• Towing vehicle is attached to this machine as per Section 8.3.2.

• Ensure the towing vehicle is immobilized and the sled is attached to the towing vehicle before the hubs are disconnected.

1 DANGER 1 - Once both hubs are disengaged the pump station will not have any sort of brake capability and there is a danger of running away on grades if the towing vehicle doesn’t have the braking capacity.

- CRAWLER TRACKS ASSEMBLY-

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2.

PROCEDURE a. Equipment required; • 7/16th Spanner or Socket.

b. Operation Procedure;

Figure 72:

• Above is the normal tram condition of the Torque Hub. Use 7/16ths spanner or socket to disengage cap held in position by 2 off ¼”UNC hex head bolts.

- CRAWLER TRACKS ASSEMBLY-

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Figure73: • Loosen and remove the UNC bolt using socket or spanner.

Figure 74 • Loosen and remove the other UNC bolt using socket or spanner.

- CRAWLER TRACKS ASSEMBLY-

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Figure 75:

• The Disengage cap is now removed as shown above.

• Do not remove any other component from the Hub.

Figure 76:

• Reverse the disengaged cap as shown above and push the pin with the cap - CRAWLER TRACKS ASSEMBLY-

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Figure 77: • Position cap as shown above

Figure 78:

- CRAWLER TRACKS ASSEMBLY-

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Figure 79: • Insert and tighten the 2 UNC bolts as shown above.

Figure 80: • Repeat the same procedure with the other Torque Hub. The Brake is now disengaged and ready for towing.

- CRAWLER TRACKS ASSEMBLY-

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Figure 81: • Once the vehicle has been towed to the required location, the disengaging cap on both hubs must be reversed to tram condition as shown above so that the brakes are activated before detaching the towing vehicle.

- CRAWLER TRACKS ASSEMBLY-

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8.4

TRAMMING PUMP STATION USING THE CRAWLER TRACK UNIT

The crawler track unit has the facility to drive/tram the station using the hydraulic supply from an Eimco or similar machine.

1. SAFETY a. Personal Protective Equipment; • Safety glasses/goggles. b. Safety Checks Before Operation • Before relocating ensure that both of the hydraulic levelling cylinders are in the fully retracted position.

Refer Section 7.4.

• Before tramming, ensure that all obstacles are cleared from the direction of travel of the hydraulic pump station.

• When driving pump station using the mounted crawler tracks, the towing ‘A’ frame must be in the raised position and the safety chain connected. Refer Section 8.3.2.

• Ensure all cables or hoses laying on top of the pump station are well clear of the edges of the station.

• Ensure that there are no pinch points created during set up or transport.

• Ensure all fluid connections are plugged and leak free.

- CRAWLER TRACKS ASSEMBLY-

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2. PROCEDURES a. Operating Procedure.

• Notify all personnel in the immediate surrounding area before commencing to tram hydraulic pump station.

• Connect remote pendant control box to a connection panel on either the inbye or outbye end of the platform.

• Select the end of the pump station the remote pendant control box is connected to with the diverter switch.

• Connect all hoses from the hydraulic power source to the remote pendant control panel.

• Using remote pendant control box tram pump station into new position.

Figure 82: Photo of Remote Pendant Control

- CRAWLER TRACKS ASSEMBLY-

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Figure 83: Photo of Remote Control Connection Panel showing Quick Connectors

- CRAWLER TRACKS ASSEMBLY-

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8.5

PROCEDURE FOR REPLACING OIL FILLING OF PLANETARY HUBS

An initial oil change must be made after the first 50 hours of operation. Following this change the oil is regularly changed as follows

Every 1,000 hours or 12 Months Replace the Oil Level in the Planetary Hubs

1. SAFETY a. Personal Protective Equipment; •

Safety Glasses.

b. Safety Check; • Before filling hubs with oil ensure that the pump station is on level ground.

2. PROCEDURE; • Tram the pump station until fill plug and drain plug in the hub are vertical.

• Remove the drain plug to allow the oil to drain into a suitable container. Approximate volume is four litres.

• Replace drain plug once all the oil has drained.

• Remove fill oil plug and oil level plug located midway between top and bottom plugs.

- CRAWLER TRACKS ASSEMBLY-

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• Fill hub with oil until oil is about to flow out of oil level plug.

• Grade of oil to be used: Omala 320.

• Replace oil level plug and fill plug.

A

B

C

Figure 84: Photo of Planetary Hub showing; A)

Oil Level Plug

C)

Oil Fill Plug

- CRAWLER TRACKS ASSEMBLY-

B) Oil Drain Plug

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8.6

INSPECTION AND TENSIONING CRAWLER TRACKS

The crawler tracks will experience some slight stretching during initial operation. After four weeks of operation the tracks need to be inspected and possibly tensioned. Tensioning the tracks is achieved via grease filled cylinder which extends the idler bogie in each of the tracks. Access to the cylinder and grease nipple is via labelled plates on each of the track assemblies.

Following this the tracks are to be inspected every 6 months for slack.

8.6.1

Procedure for inspecting and Tensioning Crawler Tracks

Tension of the tracks is to be inspected after the first 4 weeks of operation and then every 6 months

1. SAFETY a. Personal Protective Equipment; • Safety Glasses.

• Safety Boots.

2. PROCEDURES a. Equipment Required; • General purpose grease in grease gun.

• 100mm square section hard wood blocks.

- CRAWLER TRACKS ASSEMBLY-

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b. Operating Procedure; • Tram pump station onto wooden blocks so that one block is beneath the idler hub and the other block is beneath the drive hub. Refer to Section 8.4 for tramming procedure

! WARNING ! – While crawler track is positioned on wooden blocks keep hands and feet well clear from beneath the crawler tracks • Place a straight edge from the bottom of the idler hub roller to the bottom of the drive hub roller.

• Measure perpendicular distance between the straight edge and the inside of the track link halfway between the hubs.

• If the distance is greater than 55mm add grease to the grease nipple mounted in the centre of the crawler track frame.

• Continue to add grease until the inside of the link is only 55mm below the straight edge.

A

Figure 85: Photo of Crawler tracks showing; A)

Measurement point midway between the hubs for determining track tension

- CRAWLER TRACKS ASSEMBLY-

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A

B

C

Figure 86: Photo of Crawler Tracks showing; A)

Grease nipple for tensioning

C)

Grease nipple access plate

- CRAWLER TRACKS ASSEMBLY-

B)

Inspection cover plate

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9. SHEARER WATER PUMP

9.1

PUMP TECHNICAL INFORMATION

PUMP TYPE: Output flow: Maximum working pressure:

HAUHINCO MODEL EHP 3K150/70 620 Litres/minute 172 Bar [17.2 MPa]

Lubricating oil capacity:

25 Litres

Lubricating oil grade:

Grade 220

Normal oil pressure:

2-to-3 Bar [200-300 kPa]

Unloading valve:

Bypass type U504

Input speed:

1500 RPM nominal

- SHEARER WATER PUMP -

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9.2

SHEARER WATER PUMP COMPONENTS

Figure 87:

Legend: 1

Pump insert with plate valves

9

Spur wheel

2

Valve cover

10

Connecting rod

3

Valve holder

11

Crankshaft

4

Plunger

12

Pump casing

5

Crosshead

13

Delivery valve plate

6

Lubrication pump

14

Delivery port

7

Pinion shaft

15

Intake valve plate

8

Gearbox

16

Intake port

- SHEARER WATER PUMP -

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9.3

GENERAL DESCRIPTION

The shearer water pump is designed to provide water at high pressure to the shearer drum for dust suppression and cooling.

The Austar Coal Mine’s shearer water pump unit is mounted on the outbye end of the pump station on the non walkway side.

This shearer water pump unit also has it’s own stainless steel tubular water storage tank.

Pressurized incoming water is supplied to the tubular tank and is then fed to the inlet ports of the pump via two (2) off hose assemblies. High pressure water then flows from the pump via an isolation valve and non-return valve into a hose assembly for delivery to the face.

The high output flow rate of this type of pump requires that the inlet water supply be boosted to a minimum of 7 Bar [700 kPa].

The tubular water tank acts as a pressurized storage tank for supplying the water to the pump and also as a receiver for the water from the bypass valve.

- SHEARER WATER PUMP -

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9.4

PUMP OPERATION

P CAUTION P – Before operating the shearer water pump ensure that there is at least 7 Bar pressure in the tubular storage tank and the suction isolation valve is FULLY OPEN. The Hauhinco shearer water pump is constructed in a similar way to the high pressure emulsion pumps, however, it uses 80mm diameter plungers and utilises a different type of unloading system. The larger diameter of the plungers mean that a larger volume of fluid is pumped every stroke at a lower pressure compared to the smaller diameter plungers in the chock and positive set pumps.

Refer to Section 2.3 for a description of the operation of the pump.

The shearer water pump is connected to a 32 litre, 400 Bar rated, accumulator to reduce the frequency of operation of the unloader valve and dampen shocks from the pump operation.

The accumulator is positioned upon a dedicated manifold located beside the shearer water pump close to the electrical receptacle stand. A DN10 pressure vent valve is located on the accumulator stand to allow for pressure venting prior to commencing maintenance upon the accumulator and/or pump.

The accumulator for the positive set pump is precharged with nitrogen to 60 Bar. A 2” check valve is connected to the inbye end of the accumulator manifold Refer Figure 96.

- SHEARER WATER PUMP -

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9.5

UNLOADING SYSTEM 9.5.1

General Description As the water is not recirculated through a circuit, but flows

to the atmosphere, it is considered an open

system.

Return Line Delivery to Shearer Drum Sprays

Supply Storage Tank

3k150/70 SW Pump

Demand for water is generally constant whenever the shearer is operating, the shearer water pump is also operating.

Output flow and pressure is constant

therefore, the control valve must be different to the control valves used on the chock pumps and positive set pump.

The pressure at which the shearer water pump delivers water to the shearer is adjustable between 30-172 Bar [0.3-17.2 MPa]. If the water pressure rises above the set pressure it is bypassed or overflows back into the tubular storage tank.

The water in the tank, which is stored

under pressure, is used as the spring medium to operate the valve and by varying the pressure of the stored water the operating pressure of the valve is varied.

The ratio of the pressure of the stored water to the operating pressure is approximately 0.5 – 1.0.

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9.5.2 Shearer Water Pump Unloader Valves

The shearer water pump, unloader Hauhinco U504 valve, is a bypass type and operates on the same principle as a simple relief valve except that the bypassed fluid is fed back into the tubular storage tank. Two (2) off of these valves are mounted on the pump with one valve painted blue acting as the working valve and the valve painted red acting as the safety valve.

The working valve has the ability to bypass full pump discharge (620 L/min) or if the requirment at the shearer is less than the full pump discharge it will split the flow and deliver what is required to the shearer and bypass the remaining unneeded water back to the storage tank.

The safety overflow valve is fitted to the pump at the drive side to act in the event of a failure of the working valve. If the safety valve operates the water is dicharged to the atmosphere.

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A

B

C

Figure 88: Photo of Shearer Water Pump showing; A)

Working Overflow Valve Pt No H6229441

C)

B) Pressure Switch Pt No H2321823

Return Line from the pump to tank Pt No 1 ½” 250 Bar Rate Hose

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9.6

LUBRICATION SYSTEM

The pump casing forms a lubricating oil reservoir to lubricate the pump components. A lubricating pump that is driven by the crankshaft via a back gear conveys the lubricating oil through the oil distributor to a port in the crankshaft, then to the connecting rod bearings. An oil cooler is fitted to the pump and uses the colder incoming water to cool the hot oil. A separate cooling circuit pump drives the oil through the oil cooler and then back through the gearbox to the pump casing. Normal oil pressure is 2-to-3 Bar [200-300 kPa] and an oil pressure switch set at 1.5 Bar [150 kPa] is fitted to protect the pump. This pressure switch will automatically cut off the electric motor, should the oil pressure drop below 1.5 Bar, to protect the pump against mechanical failure. Wicks are also used to lubricate the surface of the plungers

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A

Figure 89: Photo of Shearer Water Pump showing; A)

Sight Glass

Pt No H2440113

Note

Oil level half way up sight glass when pump is operating.

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9.7

CORRECT DIRECTION OF OPERATION

CAUTION

– The pump must only operate in the

direction as shown by the arrows on the pump crankcase and on the fan shroud of the electric motor : Failure to run the pump in the correct direction will lead to damage to the pump.

A

Figure 90: Photo of Top of Pump Case showing; A)

Correct direction to operation pump

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9.8

TRANSDUCERS FOR SHEARER WATER PUMP MONITORING

Four (4) off transducers monitor various aspects of the operation of the shearer water pump asembly. Two transducers are located on a mounting bracket on the non walkway side of the console of the pump assembly. One of these transducers monitors the pressure of the supply water.

The other

transducer monitors the pump delivery pressure. The third and fourth transducers are mounted on the non-drive end of the pump. One of these monitors the lube oil temperature and the other monitors the lube oil pressure.

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A

B

Figure 91: Photo of Shearer Water Pump showing; A)

Incoming Water Pressure Transducer Pt No CB2031-A10561-HI-S563 40 Bar

B)

Shearer Water Pump Delivery Pressure Transduces Pt No CB2031-A1065-H1-5 0 -250 Bar

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A

B

Figure 92: Photo of Shearer Water Pump showing; A) Lube Pressure Transducer Pt No CB2031-A1058-H1-S63

B) Lube Temperature Transducer Pt No PT100

0 – 10 Bar

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9.8.1

Delivery Pressure Transducer

This transducer is provided to monitor the outgoing water pressure from the shearer water pump to the face.

9.8.2 Inlet Water Pressure Transducer

This transducer is provided to monitor the incoming water pressure supplied to the shearer water storage tank. If the incoming water pressure is less than 7 Bar [700 kPa] the system will stop.

9.8.3 Lube Oil Pressure Transducer

This transducer is provided to monitor the lubricating oil pressure in the shearer water pump. Normal lube oil pressure is approximately 2-3 Bar [200-300 kPa] and a low pressure cut off switch is fitted to stop the pump if the lube oil pressure falls to 1.5 Bar [150 kPa].

9.8.4 Lube Oil Temperature Transducer Refer Section 5.4.3 for information regarding the lubricating oil temperature transducer.

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9.8.5 Transducer Pressure Dampener

Connected to the delivery valve is a pressure dampener which reduces the amplitude of pressure spikes to the shearer water pump delivery pressure transducer. This results in the transducer reading a more consistent pressure reading and also increases the life of the transducer.

A

Figure 93: Photo of Shearer Water Pump showing; A) Transducer Pressure Dampener Pt No H4477588

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9.9

SHEARER WATER PUMP INLINE INLET WATER FILTER

Fitted to the shearer water pump unit is a stainless steel inline filter to remove contaminants before the incoming fluid enters the tank. The filter contains a visual clogging indicator to show when the fliter requires cleaning.

A

B

Figure 94: Photo of Inline Water Filter showing; A)

Inline Filter Pt No OV/55 4

- SHEARER WATER PUMP -

B)

Clogging Indicator Pt No 0-DPI-1055

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9.10

SERVICE AND MAINTENANCE

9.10.1 Inspection and maintenance requirements for shearer water pump unit 9.10.1.1 Daily inspections and maintenance • Inspect oil level in the pump crankcase – it should be to the middle of the sight glass top up if needed.

• Inspect oil pressure – must be more than 1.5 Bar. • Inspect hydraulic fittings and suction hoses for leaks.

• Inspect pump insert gland packings for leaks – a small drip is acceptable.

• Check hydraulic operating pressure – compare gauges and pressure sensors.

9.10.1.2 Weekly inspections and maintenance

9.10.1.3 Every 3 months, OR 1000 hours of operation • Check oil is present in wick chambers on pumps.

• Examine pressure hoses for damage.

• Check pump insert cap screws for correct torque; M16 Æ 210 Nm M12 Æ 25 Nm • Change lubricating oil (refer Section 2.9.2.4).

• Change lubricating oil filter (refer Section 2.9.2.5).

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9.10.1.4 Every 12 months OR 5000 hours of operation Inspection to be carried out by SES Service Engineer

• Inspect plunger surface and pressure rings for scoring and wear and change gland packing.

• Inspect suction and pressure valve plates and seats for wear and replace all o-rings and backing rings in pump inserts.

• Inspect ‘big-end’ bearing shells on con-rods for scoring • Inspect oil seals for leaks and nozzle for blockages in lubricating system and clean lube oil suction strainer.

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9.10.2 Procedure for Changing the Unloader valve

If the unloader valve is faulty it must be changed. There are no serviceable components in the valve. All unloader valves are preset. If the pressure settings need to be changed contact the SES Mining Service Engineer.

1. SAFETY a. Personal Protective Equipment; • Safety Glasses. b. Safety Procedures; •

Pump Isolation Procedure

2. PROCEDURES a. Equipment Required • Personal locks • Lock out Tags • 14mm Allen key

b. Replacement Procedure • Stop pump and isolate according to shearer water pump isolation procedure • Undo hose end nut on unloader hose assembly at valve Undo hose end nut on high pressure outlet hose assembly.

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• Remove the nipples from the outlet ports on the unloader valve for fitting to the new unloader valve • Using a 14mm Allen key remove the two (2) off M16

socket

head

capscrews

holding

the

unloader valve to the pump body.

•

Mount the new unloader valve on pump body and insert the two M16 capscrews and tighten with the 14mm Allen key.

• Replace the nipples in the outlet ports of the new unloader valve.

• Connect hose end nut on overflow hose assembly to the new valve.

• Connect hose end nut on high pressure outlet hose assembly to new valve.

• Fully open delivery isolation valve mounted on top of the face delivery manifold.

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A

B

C

D

Figure 95: Photo of Shearer Water Pump showing; A)

Nipple (behind hose end)

B)

M16 Socket Head Cap Screws

D)

Low Pressure Unloader Hose

Pt No 1 ¼”x 1 ½” Nipple C) Medium Pressure Delivery Outlet Hose with whip check

1 ½”BSP f/swivel to 1 ½”Code

150Bar Max Pressure 1 ½”hose

61 SAE 250 Bar rated hose

250 Bar rated hose

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A

B

Figure 96: Photo of Face Delivery Manifold showing;

A)

32 Litre Accumulator

B)

Shearer Water Pump Face Delivery 2” Isolation ball Valve Pt No MKHG2-4423

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9.10.3

Maintenance Procedures

Procedures for the following maintenance tasks are identical to those given in Section 2.9.2.

• Adding oil to pump crank case.

• Changing pump lubricating oil.

• Changing lubricating oil filter.

• Changing oil seal in oil distributor.

• Bleeding air from the pump.

• Removing pump inserts.

• Refitting pump inserts.

• Disassembly of pump inserts.

• Pump insert inspection requirements.

• Reassembly of pump insert.

• Removal of plungers.

• Replacement of plunger packing.

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10. MISCELLANEOUS ITEMS 10.1. QUICK RELEASE ELECTRICAL RECEPTACLES All 3.3kV electrical connection points are located on the outbye end of the pump station. There are four (4) off connection points in total.

NOTE: All electrical receptacles are the quick release type

A

Figure 97: Photo of Receptacle Stand showing; A)

Quick Release Electrical Receptacles

- MISCELLANEOUS ITEMS-

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10.2. EMERGENCY STOP BUTTONS Emergency stop buttons are located on each of the pump junction boxes located beside each pump. Pressing the Emergency Stop button will cut all power to the pump station and therefore stop all pumps immediately. Stored pressure will still be present in the system. Ensure that this pressure is vented by the correct procedures if any maintenance is to be carried out after pressing the emergency stop button.

A

Figure 98: Photo of Pump Junction Box showing; A)

Emergency Stop Button

- MISCELLANEOUS ITEMS-

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10.3. START AND STOP BUTTONS

10.3.1. Chock Pump & Positive Set Pump The start and stop buttons for the chock pumps are located on the junction box for each pump.

Junction

Boxes are mounted independently beside each pump.

A

B

C

Figure 99: Photos of Pump Station showing; A)

Chock Pump No 1

C)

Positive Set Pump

- MISCELLANEOUS ITEMS-

B) Chock Pump No 2

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10.3.2. Shearer Water Pump Start & Stop Buttons

The start and stop buttons for the shearer water pump are located on the shearer water pump junction box.

The shearer water pump unit J-box, is located on the inbye end of the pump station, on the non-walkway side next to the shearer water pump unit.

A

Figure 100: Photo of Emulsion Tank showing; A)

Shearer water Junction ‘ J ‘ box with start & stop buttons

- MISCELLANEOUS ITEMS-

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10.4. EMULSION TANK JUNCTION BOX

The emulsion tank junction box is located on the inbye end of the pump station beneath the emulsion level view port.

A

Figure 101: Photo of Emulsion Tank showing; A) Junction Box

- MISCELLANEOUS ITEMS-

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10.5. LOCKABLE BALL VALVES

10.5.1. Face delivery isolation ball valves

The two (2) off high pressure face delivery isolation valves are located on the inbye face of the pump station delivery manifold.

Both isolation valves are DN50

lockable ball valves. The positive set pump delivery face isolation valve is also mounted on the inbye face of the delivery manifold and is a DN 40 lockable ball valve. The shearer water pump face isolation valve, is a 2 inch BSPP stainless steel ball valve, mounted on top of the face delivery manifold. All of these valves are lockable when in the closed position.

- MISCELLANEOUS ITEMS-

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A

B

C

Figure 102: Photo of Face Delivery Manifold showing; A)

Face Delivery Isolation Ball Valves Pt No DN50 SAE to Super Stecko

B)

Shearer Water 2” Isolation Ball Valve Pt No MKHG2-4423

C)

Positive Set Pump Face Delivery Isolation Ball Valve Pt No DN40 SAE to Super Stecko

- MISCELLANEOUS ITEMS-

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10.5.2 Chock Pump Delivery Isolation Ball Valves

Two (2) off isolation ball valves are mounted on the dual accumulator manifold. These valves are used as part of the isolation procedure as described in Section 11. These ball valves may be locked when in the closed position.

A

Figure 103: Photo of Chock Pump Dual Accumulator Manifold showing; A) Chock Pump Delivery Isolation Ball Valve Pt NoDN50 SAE to SAE

- MISCELLANEOUS ITEMS-

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10.6. LIFTING POINTS

Four (4) off lifting points have been provided on the pump station so that the entire pump station can be lifted up using a suitable heavy lifting mechanism. Each lifting point is easily accessible with one (1) off lifting point on each corner of the pump station platform close to the crawler tracks.

A

Figure 104: Photo of Pump Station showing; A) Lifting Points

- MISCELLANEOUS ITEMS-

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10.7. PUMP STATION LEVEL INDICATOR

The pump station needs be as level as possible before operating. To assist in achieving this, two level indicators have been installed on the emulsion storage tank, one on the inbye wall and the other on a support bracket for the return header pipe. Utilizing the hydraulic levelling cylinders the level of the pump station may be adjusted by raising or lowering the height of the outbye end of the pump station.

When the pump station is level the air bubbles in the indicators will be in the centre of the indicator tubes.

A

Figure 105: Photo of Emulsion Storage Tank showing: A)

Level Indicator Pt No LEV-0-GAGE SR

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Figure 106: Photo of Pump Station Level Indicator Pt No LEV-0-GAGE SR

- MISCELLANEOUS ITEMS-

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10.8.

FACE EMULSION RETURN PORTS

The single DN40 decompression return port and the two DN63 face emulsion return ports are located on the non-walkway side of the return header pipe.

A

B

Figure 107: Photo of Emulsion Tank Return Header Pipe showing; A)

Face Emulsion Ports

- MISCELLANEOUS ITEMS-

B) Decompression Return Port

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10.9.

IMPORTANT SIGNS ATTACHED TO THE PUMP STATION

All items of importance on the pump station are labelled using stainless steel labels.

- MISCELLANEOUS ITEMS-

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11. ISOLATION & PRESSURE BLEED OFF PROCEDURES

DANGER Caution must be taken when bleeding stored pressure from the pump station components as there is risk of serious injury if procedures are not followed correctly.

11.1.

HAUHINCO PUMP ISOLATION AND PRESSURE VENTING PROCEDURES

11.1.1.

Chock Pump Isolation and Pressure Vent Procedure

1. SAFETY a. Personal Protective Equipment; • Goggles/Safety glasses.

• Austar Coal Mine’s Standard PPE. b. WARNING: Ensure that care is taken when mounting and dismounting the pump station.

2. DEFINITIONS Inbye End

the end of the pump station facing towards the coalface.

Outbye End

the end of the pump station facing away from the coalface.

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Chock Pump

Hauhinco 3K200/53 pump mounted on the Inbye end of the Austar Hydraulic Pump Station. The chock pumps are painted red.

3. PROCEDURES a. Equipment Required • Personal Locks b. Operation Procedure; i. Isolate Pump Electrically • Ensure that ‘STOP’ button on electrical ‘J’ box for pump has been pressed and pump has stopped. If pump is not stopped press stop button.

• Disconnect electrical receptacle for pump and lock out using Ampcontrol’s isolation procedure. ii. Isolate Pump Hydraulically • Close and lock out emulsion pump isolation ball valve for pump being isolated located on high pressure dual accumulator manifold.

• Isolation valve for Chock Pump 1 is located on Inbye end of dual accumulator manifold. Refer Figure 108 • Isolation Valve for Chock Pump 2 is located on Outbye end of dual accumulator manifold.

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iii. Isolate Pump Mechanically from the Fluid Supply • Close the suction isolation butterfly valve for pump located on the Inbye end of the emulsion tank. The butterfly valves are labelled for ease of identification.

• See Figures 109 & 110.

iv. Bleed Stored Pressure between the Pump, Accumulator and Isolation Ball Valve.

• Slowly open DN10 vent ball valve located on pump high pressure manifold to allow pressure to dissipate. See Figure 111.

• Bleed pressure until Delivery Pressure Transducer Gauge reads zero. See Figure 112.

• Ensure that DN10 Vent ball valve is left open while maintenance is being conducted. v. After Completing Maintenance • Close all open DN10 vent ball valves.

• Open suction isolation butterfly valve located on emulsion tank.

• Open all emulsion pump isolation valves on dual accumulator manifold.

• Connect electrical receptacle.

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A

Figure 108: Photo of Dual Accumulator Manifold showing; A)

Isolation Ball Valve for Chock Pump No 1. Valve is shown in the open position DN50 SAE to SAE

Emulsion Isolation Ball Valve for Chock Pump 2 is located on opposite face of manifold shown

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Figure 109:

Figure 110:

Photos of Chock Pumps 1 & 2 showing; Butterfly Valves - in closed position

A

Figure 111: Photo of Chock Pump Showing; A) DN10 Vent Ball Valve.

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Figure 112: Photo of Delivery Pressure Transducer & Gauge Pt No CB2031-A1068-H1-S63 0-600 Bar

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11.1.2. Positive Set Pump Isolation And Pressure Vent Procedure 1.

SAFETY a. Personal Protective Equipment • Goggles/Safety glasses • Austar Coal Mine Standard PPE b.

2.

WARNING: Ensure that care is taken when mounting and dismounting the pump station.

DEFINITIONS

Inbye End

the end of the pump station facing towards the coal face

Outbye End

the end of the pump station facing away from the coalface.

Positive Set Pump Hauhinco 3K110/40 pump mounted on the outbye end of the Austar Hydraulic Pump Station. The pump is painted blue.

3.

PROCEDURES a. Equipment Required; •

Personal locks.

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b. Operation Procedure; i. Isolate Pump Electrically • Ensure that ‘STOP’ button on electrical ‘J’ box for the positive set pump has been pressed and pump has stopped.

If pump is not stopped press ‘STOP’ button.

• Disconnect electrical receptacle for pump and lock out using Ampcontrol’s isolation procedures. ii. Isolate Pump Hydraulically • Close and lock out ball valve located on the inbye face of the face delivery manifold Figure 118.

iii. Isolate Pump Mechanically from the Fluid Supply • Close the positive set suction isolation butterfly valve for pump located on the outbye end of the emulsion tank.

Figure 114.

iv. Bleed Stored Pressure Between Pump, Accumulator and Isolation Ball Valve.

• Slowly open DN10 vent ball valve located on the high pressure manifold on pump to allow pressure to dissipate.

See Figure 115 • Bleed pressure until delivery pressure gauge on positive set pressure transducer reads zero. See Figure 116.

• Ensure that DN10 Vent ball valve is left open while maintenance is being conducted.

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v. After completing maintenance • Close all open DN10 vent ball valves.

• Open suction isolation butterfly valve located on emulsion tank.

• Open ball valve on face delivery manifold.

• Connect electrical receptacle.

A

Figure 113: Photos of Positive Set Pump showing: A)

Face Delivery Isolation Valve – open position Pt No DN50 SAE to Super Stecko

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B

Figure 114: Photos of Positive Set Pump showing: B)

Suction Isolation Butterfly Valve – closed position Pt No S30 – 125 -100NB

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A

Figure 115: Photo of Positive Set Pump showing: A) DN10 Vent Ball Valve

.

A

Figure 116: Photo of Positive Set Pump showing; A) Delivery Pressure Transducer & Gauge CB2031-A1068-H1-S63 0-600 Bar

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11.1.3. Shearer Water Pump Isolation And Pressure Vent Procedure

1. SAFETY a. Personal Protective Equipment • Goggles/Safety glasses.

• Austar Coal Mine’s Standard PPE. b. WARNING: Ensure that care is taken when mounting and dismounting the pump station.

2. DEFINITIONS Inbye End

the end of the pump station facing towards the coal face

Outbye End the end of the pump station facing away from the coalface.

Shearer Water Pump Hauhinco 3K150/70 pump mounted on the outbye end of the Austar Hydraulic Pump Station. The pump is painted orange.

3.

PROCEDURES a. Equipment Required •

Personal locks

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4.

Operation Procedure; i. Isolate Pump Electrically • Ensure that ‘STOP’ button on electrical ‘J’ box for the shearer water pump has been pressed and pump has stopped. If pump is not stopped press ‘STOP’ button.

• Disconnect electrical receptacle for the shearer water pump and lock out using Ampcontrol’s isolation procedures. ii. Isolate Pump Hydraulically • Close and lock out stainless steel ball valve located on top of the face delivery manifold Figure 117.

iii. Isolate Pump Mechanically from the Fluid Supply • Close the isolation valve on the incoming water supply hose. iv. Bleed Stored Pressure Between Pump, Accumulator and Isolation Ball Valves.

• Slowly open DN10 vent ball valve located on the blue U504 unloader valve on the pump to allow pressure to dissipate. Figure 118.

• Bleed pressure until Delivery Pressure Gauge reads zero. Figure 119.

• Ensure that DN10 Vent ball valve is left open while maintenance is being conducted.

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v. After Completing Maintenance • Close the open DN10 vent ball valve on the blue U504 unloader valve.

• Open water supply isolation valve located on the water supply hose.

• Open stainless steel ball valve on face delivery manifold.

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A

Figure 117: Photo of Face Delivery Manifold showing; A) Shearer Water Pump Face Delivery Isolation Valve Pt No MKHG2”-4423

A

Figure 118: Shearer water pump showing: A)

DN10 Vent Ball Valve

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A

Figure 119: Photo of Shearer Water Pump showing: A)

Delivery Pressure Gauge Pt No 0-250 Bar Bottom Entry Gauge

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11.2. ACCUMULATOR ISOLATION AND PRESSURE VENTING 11.2.1.

1.

Dual Accumulator Manifold Isolation and Pressure Vent Procedure

SAFETY a. Personal Protective Equipment; • Safety glasses/goggles.

• Austar Coal Mine’s Standard PPE. b. Warning: Care is to be taken when mounting and dismounting pump station platform.

2.

DEFINITIONS Inbye End

the end of the pump station facing towards the coal face.

Outbye End the end of the pump station facing away from the coalface.

Dual Accumulator Manifold Block Manifold located on the Inbye end of the pump station with two (2) off high pressure 32 litre accumulator bottles mounted on the top face.

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3. PROCEDURES a. Equipment Required; • Personal locks.

b. Safety Checks Before Operation; • Check that pump station is stopped.

• Check that pump is electrically isolated (See Chock Pump Isolation Procedure and Pressure Vent Procedure, Section 11.1.1).

c. Operation Procedure; i. Isolate Dual Accumulator from Hydraulic Circuit.

• Close and lock both isolation ball valves located on dual accumulator manifold block. See Figure 120.

ii. Isolate Both Emulsion Chock Pumps from Hydraulic Fluid Supply.

• Close both suction isolation butterfly valves located on both Inbye corners of the emulsion tank to isolate the dual accumulator manifold assembly from the hydraulic fluid supply. See Figures 121 and 122.

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iii. Bleed stored hydraulic pressure in dual accumulator manifold • Slowly open DN10 bleed valve located on dual accumulator manifold stand to release pressure, until pressure gauge on accumulator stand reads zero. See Figure 123.

• Ensure that DN10 ball valve remains open while maintenance work is conducted • If removing accumulator bottle see Accumulator Lifting Procedure for Austar Coal Mine’s Hydraulic Pump. iv. Upon completion of maintenance work • Fully close DN10 bleed valve.

• Unlock and open both isolation ball valves located on dual accumulator manifold.

• Open both suction isolation butterfly valves located on Inbye end of emulsion tank.

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A

Figure 120: Photo of Dual Accumulator Manifold showing: A)

Isolation Valve - in open position Second Isolation Ball Valve is located on opposite Face

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Figure 121: Photo of Chock Pump No 1 showing; Suction Isolation Butterfly Valve located on walkway side of Inbye end of emulsion tank Pt No S30-125 100 NB

Figure 122: Photo of Chock Pump No 2 showing; Suction isolation butterfly valve located on non walkway side of inbye end of emulsion tank

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A

B

C

D

E

Figure 123: Dual Accumulator Assembly Showing; A)

Accumulator Pressure Gauge Pt No PGS-050-0600

B)

DN10 Bleed Valve

C)

Isolation Ball Valve

D)

High Pressure Fluid diffuser

E)

32 Ltr Accumulator

- ISOLATION & PRESSURE VENTING PROCEDURE-

Pt No DN40 SAE to Super Stecko

Pt No SB400-32

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11.2.2. Positive Set Accumulator Manifold Assembly Isolation and Pressure Vent Procedure

1. DEFINITIONS Inbye End

the end of the pump station facing towards the coal face.

Outbye End

the end of the pump station facing away from the coalface.

Positive Set Accumulator Manifold Block Manifold located on the Outbye end of the pump station with one (1) off high pressure 32 litre accumulator bottle mounted on the top face. The positive set accumulator manifold assembly is located closest to the emulsion tank, the single chock pump accumulator manifold stand is closer to the receptacle stand.

2. SAFETY a.

Personal Protective Equipment • Safety glasses/goggles.

• Austar Coal Mine’s Standard PPE.

Warning: Care is to be taken when mounting and dismounting pump station platform.

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3. PROCEDURES a. Equipment Required; • Personal locks. b. Safety Checks Before Operation; • Check that pump station is stopped.

• Check that pump is electrically isolated (See Positive Set Pump Isolation Procedure and Pressure Vent Procedure Section 11.1.2).

c. Operation Procedure i. Isolate positive set accumulator manifold from hydraulic circuit.

• Close and lock isolation ball valves located on face delivery manifold block on Inbye end of platform. See Figure 124.

ii. Isolate positive set pump from hydraulic fluid supply.

• Close suction isolation butterfly valve, located on Walkway side of the Outbye end of the emulsion tank, to isolate the positive set pump accumulator manifold assembly from the hydraulic fluid supply. See Figure 125.

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iii. Bleed stored hydraulic pressure in accumulator manifold.

• Slowly open DN10 bleed valve, located on positive set accumulator manifold stand, to release pressure until accumulator pressure gauge reads zero. See Figure 126.

• Ensure that DN10 ball valve remains open while maintenance work is conducted.

• If removing accumulator bottle see Accumulator Lifting Procedure for Austar Coal Mine’s Hydraulic Pump.

iv. Upon completion of maintenance work • Fully close DN10 bleed valve.

• Unlock and open isolation ball valve located on face delivery manifold.

• Open suction isolation butterfly valve on emulsion tank.

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A

Figure 124: Photo of Face Delivery Manifold showing: A)

Face Delivery Isolation Ball Valve on the inbye end of platform

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Figure 125: Photo of Positive Set Pump showing; Suction Isolation Butterfly Valve in closed position

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A

Figure 126: Photo of Positive Set Pump Showing; A)

DN10 Bleed Valve on accumulator assembly.

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11.2.3

Shearer Water Accumulator Manifold Assembly Isolation And Pressure Vent Procedure

1. SAFETY a. Personal Protective Equipment; • Safety glasses/goggles.

• Austar Coal Mine Standard PPE.

b. Warning: Care is to be taken when mounting and dismounting pump station platform.

2.

DEFINITIONS

Inbye End

the end of the pump station facing towards the coalface

Outbye End

the end of the pump station facing away from the coalface.

Shearer Water Accumulator Manifold Block Manifold located on the Outbye end of the pump station with one (1) off high pressure 32 litre accumulator bottle mounted on the top face. The shearer water accumulator manifold assembly is located closest to the receptacle stand.

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3. PROCEDURES a. Equipment Required; • Personal locks.

• Austar Coal Mine’s Standard PPE.

b. Safety Checks Before Operation; • Check that pump station is stopped.

• Check that pump is electrically isolated (See Shearer Water Pump Isolation Procedure and Pressure Vent Procedure Section 11.1.3). c. Operation Procedure i. Isolate shearer water accumulator manifold from hydraulic circuit.

• Close and lock isolation ball valve located on face delivery manifold block on Inbye end of platform.

ii. Isolate positive set pump from hydraulic fluid supply.

• Close the isolation valve on the incoming water supply hose

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iii. Bleed stored hydraulic pressure in accumulator manifold.

• Slowly open DN10 bleed valve, located on shearer water accumulator manifold stand, to release pressure until accumulator pressure gauge reads zero.

• Ensure that DN10 ball valve remains open while maintenance work is conducted.

• If removing accumulator bottle see Accumulator Lifting Procedure for Austar Coal Mine’s Hydraulic Pump.

iv. Upon Completion of Maintenance Work • Fully close DN10 bleed valve.

• Unlock and open isolation ball valve located on face delivery manifold.

• Open isolation valve on the incoming water supply hose.

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Figure 127: Photo of Face Delivery Manifold showing; A) Shearer Water Pump Face Delivery Isolation Ball Valve Located on Face Delivery Manifold on the Inbye End of Platform Pt No MKHG2-4423

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A

B

Figure 128: Photo of Shearer Water Pump showing: A)

Accumulator Pressure Gauge Pt No PGS-050-0600

B)

DN10 Bleed Valve for Positive Set Accumulator Assembly

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12. INSPECTION REQUIREMENTS NOTE: The inspection requirements stated apply to all pumps unless stated otherwise.

12.1 DAILY INSPECTIONS • Inspect oil level in hydraulic pump crankcase – it should be to the middle of the sight glass, located on the side of the crankcase, when the pump is in operation.

• Oil must be Shell Omala 220 grade or equivalent for both crankcase wicks.

• Inspect lube oil pressure on pumps – must be more than 1.5 Bar [150 kPa].

• Inspect hydraulic fittings for leaks.

• Inspect level of emulsion in storage tank.

• Check hydraulic operating pressure – compare gauges and transmitter.

• Inspect the level of emulsion in the storage tank through the viewing port. Compare reading of emulsion level with readout on PLC data screen.

• Inspect suction outlet pipes for leaks.

• Inspect emulsion hoses and fittings for leaks or damage.

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12.2 WEEKLY INSPECTIONS • Check oil is present in wick chambers on Shearer Water Pump.

12.3 EVERY THREE (3) MONTHS – OR – 1000 HOURS OF OPERATION

• Examine Pressure Hoses for damage.

• Change the lubricating oil in pumps (Refer Section 2.9.2.3).

• Change

Lubricating

Oil

Filter

(Refer

Section

2.9.2.4).

12.4 EVERY SIX (6) MONTHS • Inspect tension of crawler tracks and add grease if needed. (Refer Section 8.5).

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12.5

EVERY TWELVE (12) MONTHS – OR – 5000 HOURS OF OPERATION Inspection and Service to be Carried Out by SES Service Engineer • Inspect plunger surface for scoring or marks and change gland packing and pressure rings if necessary.

• Inspect suction and pressure valve plates and seats for indentation or pitting and replace all O-rings and backing rings in pump inserts.

• Inspect ‘big–end’ bearing shells on con rods for wear marks.

• Inspect oil seals for leaks and nozzles for blockages or wear and clean lube oil suction strainer.

• Check nitrogen precharge of all accumulator bottles.

• Inspect oil cooler tubes for leaks or cracks.

• Change air breather elements on emulsion storage tank. (Refer Section 4.9.2).

• Replace oil in Planetary Hubs of crawler tracks (or after 1000 hours of operation) (Refer Section 8.4).

- INSPECTION REQUIREMENTS -

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