DOWNLOAD PDF CAT NEWPAC COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006 BI619136

BI619136

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BUCYRUS R

Technical Manual

BI619136

NEWPAC NUMBER 1 COLLIERY 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 (November 2006) (with additions extracted from previous SES manuals written by Robin Genero) – Full Print Production - Version 1.1 (December 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

RESOURCE PACIFIC LIMITED OWNED NEWPAC NUMBER 1 COLLIERY Off New England Highway RAVENSWORTH NSW 2330 PO BOX 528 SINGLETON NSW 2330 Telephone: 02 4993 7201 Facsimile: 02 4993 7302

i

BI619136

NEWPAC NUMBER 1 COLLIERY 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

1.1

General description ……………………………………

1

1.2

General arrangement………………………………….

3

1.3

General arrangement drawing with field devices…..

5

1.4

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

7

1.5

Safety instructions ……………………………………..

8

1.5.1

Emergency stop procedure…………………..

8

1.5.2

Pump isolation steps………………………….

9

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

10

1.6

2.

ISOLATION AND PRESSURE BLEED OFF PROCEDURES.. 15 2.1

Chock pump isolation and pressure vent procedure… 15

2.2

Positive set pump isolation and pressure vent procedure………………………………………………… 21

2.3

Shearer water pump & 20L Accumulator isolation and pressure vent procedure…………………………

2.4

20L Dual accumulator manifold isolation and pressure vent procedure………………………………..

2.5

28

Single Chock accumulator manifold assembly isolation and pressure vent procedure………………..

2.6

25

31

Positive Set accumulator manifold assembly isolation and pressure vent procedure…………………………... 35 ii

BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

3.

EMULSION CHOCK PUMP……………………………………..

39

3.1

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

39

3.2

Pump components……………………………………...

40

3.3

General description …………………………………….

42

3.4

Pump operation ………………………………………...

43

3.5

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

45

3.6

Lubrication system ……………………………………..

46

3.7

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

49

3.8

Accumulators ……………………………………………

50

3.8.1

General Description………………………... 50

3.8.2

Procedure for Lifting 20L Accumulator Bottle from Pump Station………………….. 52

3.9

Servicing and maintenance of pumps……….………..

3.9.1

Inspection and maintenance requirements 54

3.9.1.1

Daily inspection and maintenance……

3.9.1.2

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

3.9.1.3

54

54

54

Every 12 months – OR – 5000 hours of operation inspection to be carried out by SES service engineer..………… 55

3.9.2

Maintenance procedures ………………….

56

3.9.2.1

Pre-maintenance……………………….. 56

3.9.2.2

Procedure for checking the pump oil level……………………………………… 57

3.9.2.3

Procedure for adding lubricating oil to the crankcase…………………………... 58 iii

BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

3.9.2.4

Procedure for changing lubricating oil.. 59

3.9.2.5

Procedure for changing oil filter………. 63

3.9.2.6

Procedure for changing oil seal and nozzle in oil distributor…………………. 67

3.9.2.7

Procedure for removing a pump insert assembly………………………………… 71

3.9.2.8

Procedure for the disassembly of a pump insert……………………………… 74

3.9.2.9

Pump insert inspection requirements... 77

3.9.2.10

Procedure for the reassembly of a pump insert……………………………… 78

3.9.2.11

Procedure for the refitting of a pump insert assembly…………………………. 80

3.9.2.12

Procedure for the removal of plungers

82

3.9.2.13

Refitting plungers………………………. 85

3.9.2.14

Replacing the plunger packing……….. 86

3.9.2.15

Removal of ADM solenoid filter block assembly………………………………... 89

3.9.2.16

Replacing ADM solenoid filter block assembly filter element………………… 91

3.9.2.17 3.9.3

Exchange of safety relief valve

93

Service tools ………………………………… 96

3.9.3.1

Set screws for valve holders of pump inserts …………………………………… 96

3.9.3.2

Set screw for oil distributor …………… 96

3.9.3.3

Withdrawing device for plungers …….. 96

iv

BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

3.9.3.4

Withdrawing device and assembly mandrel locking pin of crosshead ……. 97

3.9.4

Additional pump information ……………… 98

3.9.4.1

Bolt tightening torques ………………….. 98

3.9.4.2

Grease ….………………………………… 99

3.9.4.3

Sealant …………………………………… 99

3.9.5

Trouble shooting guide for Hauhinco pumps ……………………………………….. 100

4.

POSITIVE SET PRESSURE PUMP…………………………….

103

4.1

Pump technical information……………………………

103

4.2

General description…………………………………….

104

4.3

Pump operation…………………………………………

107

4.4

Unloading control system & 32L accumulator.………

107

4.5

Lubrication system………………………………….…..

109

4.6

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

111

4.7

Service & maintenance of pumps……………………..

112

4.7.1

Inspection and maintenance requirements 112

4.7.1.1

Daily inspections and maintenance……

4.7.1.2

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

4.7.1.3

112

112

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

4.7.2 4.7.2.1

SES service engineer……………………

113

Maintenance procedures………………….

114

Pre-maintenance procedures…………... 114

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BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

4.7.2.2

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

4.7.2.3

115

Procedure for adding oil to the crankcase…………………………………. 116

4.7.2.4

Procedure for changing lubricating oil…. 116

4.7.2.5

Procedure for changing oil filter………… 116

4.7.2.6

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

4.7.2.7

117

Procedure for removing pump intake and delivery valves………………………. 121

4.7.2.8

Procedure for removing pump insert assemblies………………………………... 122

4.7.2.9

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

124

4.7.2.10

Procedure for removal of plungers…….. 126

4.7.2.11

Procedure for fitting of plungers………... 129

4.7.2.12

Replacing the plunger packing…………. 130

4.7.2.13

Procedure for replacing safety valves…. 133

4.7.3

Additional pump information ………………. 136

4.7.3.1

Bolt tightening torques ………………….. 136

4.7.3.2

Grease ….………………………………… 137

4.7.3.3

Sealant …………………………………… 137

4.7.4

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

vi

138

BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

5.

EMULSION STORAGE TANK ………………………………….

140

5.1

Technical information ………………………………….

140

5.2

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

141

5.3

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

142

5.4

Air breathers……………………………………………..

143

5.5

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

144

5.6

Drain ports ………………………………………………

145

5.7

Emulsion temperature transducer…………………….

146

5.8

Suction Discharge Bleed point…...……………………

147

5.9

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

148

5.10

Procedure for taking sample of emulsion from tank ..

149

5.11

Service and maintenance ……………………………..

152

5.11.1

Inspection and maintenance requirements 152

5.11.1.1

Daily inspections and requirements …. 152

5.11.1.2

Twelve monthly – OR – every 5000 hours of operation inspection requirements …………………………… 152

5.12

6.

Maintenance procedures ………………………………

153

5.12.1

Suction isolation ……………......................... 153

5.12.2

Procedure changing air breather elements... 155

EMULSION BOOST PUMP……………… ……………………

157

6.1

Emulsion Boost Pump Details……………… …...……

157

6.2

General description …………………………………….

158

6.3

Operation………………… ……………………………..

159

6.4

Emulsion pressure transducer………….. ……………

161

6.5

Boost Pump Start & Stop Buttons…….. ……..………

162

vii

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

6.6

7.

Boost pump maintenance requirements…...…………

163

6.6.1 Inspections and maintenance requirements….

163

6.6.1.1 Weekly inspections…………………….

163

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

164

7.1

Pump station monitoring system components ………

164

7.2

General description …………………………………….

167

7.3

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

167

7.3.1 7.4

7.5

Emulsion temperature transducer ………….. 167

Chock and positive set pump monitoring ……………

169

7.4.1

Emulsion system pressure transducer……… 169

7.4.2

Pump lubrication oil pressure switch ……….. 170

7.4.3

Lubrication oil pressure transducer…………. 171

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

7.5.1

172

Emulsion return line filter pressure transmitter & DP switches …………………… 172

7.6

Calibration of transducer……………………………….

7.6.1

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

7.6.2

8.

173

173

Lube oil temperature transducer calibration.. 173

FILTRATION SYSTEM …………………………………………..

174

8.1

General description …………………………………….

174

8.2

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

174

8.3

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

176

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

8.4

Mineral oil filter ………………………………………….

8.4.1

177

General description …………………………... 177

8.5

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

8.6

Emulsion storage tank air breathers and filtration

178

magnets ………………………………………………...

176

8.7

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

181

8.8

Service and maintenance procedures ……………….

182

8.8.1

Procedure for changing return line filter elements and emulsion infill filter element…. 182

8.8.2

Procedure for changing shearer water inlet filter element…………………………………… 182

9.

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

186

9.1

General description …………………………………….

186

9.2

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

187

9.3

Load locks ……………………………….…………...…

188

9.4

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

188

9.5

Diverter ball valve……………………………………….

189

9.6

Remote pendant control system………………………

190

9.6.1

Remote pendant control box…………………

190

9.6.2

Remote pendant control connection panel…. 191

9.7

Crawler track units………………………………………

192

9.8

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

192

9.9

Brake valve………………………………………………

193

9.10

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

193

9.11

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

194

BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

10.

CRAWLER TRACKS ASSEMBLY …………………………….

197

10.1

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

197

10.2

General description……………………………………..

198

10.3

Towing the pump station……………………………….

200

10.3.

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

10.3.2

200

Procedure for connecting towing ‘A-frame to tow vehicle………………………………….….. 201

10.3.3

Procedure for freewheeling crawler tracks.… 213

10.4

Tramming pump station using the crawler track unit..

210

10.5

Procedure for replacing oil filling of planetary hubs…

213

10.6

Inspection and tensioning crawler tracks…………….

215

10.6.1 Procedure for inspecting and tensioning

11.

crawler tracks…………………………………..

215

SHEARER WATER PUMP ……………………………………...

219

11.1

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

219

11.2

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

220

11.3

General description…………………………………….

221

11.4

Pump operation ………………………………………...

223

11.5

Unloading system ………………………………………

224

11.5.1 General Description…………………………..

224

11.5.2 Shearer water pump unloader valves……….

225

11.6

Lubrication system……………………………………...

227

11.7

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

229

11.8

Transducers for shearer water pump monitoring……

230

x

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

9.8.1

Delivery pressure transducer…………………

235

9.8.2

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

235

9.8.3

Lube oil pressure transducer…………………

235

9.8.4

Lube oil temperature transducer……………..

235

9.8.5

Transducer pressure dampener……………..

236

11.9

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

236

11.10

Service and maintenance ……………………………..

237

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

238

11.10.1.1 Daily inspection and maintenance……

239

11.10.1.2 Weekly inspection and maintenance… 239 11.10.1.3

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

11.10.1.4

239

Every 12 months – OR – 5000 hours of operation inspection to be carried out by SES service engineer………….. 240

11.10.2 Procedure for changing the unloader valve .

12.

11.10.3 Maintenance procedures…………………….

245

MISCELLENOUS ITEMS ….…………………………………….

246

12.1

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

246

12.2

Emergency stop buttons……………………………….

248

12.3

Start and stop buttons………………………………….

249

12.3.1

Chock pump & positive set pump………….

249

12.3.2

Shearer water pump start & stop buttons…

250

Lockable ball valves…………………………………….

251

12.4.1.

251

12.4

Face delivery isolation ball valves…………. xi

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

12.4.2

13.

Chock pump delivery isolation ball valves...

253

12.5

Lifting points……………………………………………..

255

12.6

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

256

12.7

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

258

12.8

Important signs attached to the pump station……….

259

INSPECTION REQUIREMENTS ……………………………….

260

13.1

Daily inspections ……………………………………….

260

13.2

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

261

13.3

Every 6 months …………………………………………

261

13.4

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

A.

APPENDIX ‘A’ – NEWPAC SPARE PARTS SCHEDULE CRITICAL COMPONENTS

B.

262 4 PAGES

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

Emulsion Chock Pump Refer

Part No.

Description

xii

No of PAGES

BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006 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

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………………………………………….

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

xiii

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

B.2

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

Sect 3

5125359

Suction connection – blind…………………….

2

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

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

xiv

BI619136

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

C.

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 &

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

APPENDIX ‘C’ – FIELD DEVICES Sect 5

Pump station monitoring system components...

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.

3

Sect 9

Sect 5

D.

pendant switch………………………………….

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

xv

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

F.

G.

I.

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

APPENDIX ‘G’ – HYDRAULIC SCHEMATIC 4512-03C

H

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

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

3

Check on Received Merchandise ……………

xvi

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(I) 3.0

(I) 4.0

(I) 5.0

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

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 ………………………….

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J.

K.

APPENDIX ‘J’ – MATERIAL SAFETY DATA SHEETS Shell

Omala Oil 320 ……………………………………………...

7

Fuchs

RENEP K220 ………………………………………………………….

6

Fuchs

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

8

APPENDIX ‘K’ – BOOST PUMP DATA Operating instructions ……………………………………………...

1

Arrangement Drawing... ……………………………………………………….

6

xviii

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NEWPAC NUMBER 1 COLLIERY 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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NEWPAC NUMBER 1 COLLIERY 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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NEWPAC NUMBER 1 COLLIERY 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)

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1.

INTRODUCTION 1.1

GENERAL DESCRIPTION

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

The Newpac Number 1 Colliery’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.

The pump station is comprised of 3 sleds in total: • Two (2) off crawler track mounted emulsion sleds • One (1) off monorail mounted shearer water pump sled Each Emulsion Sled has the following equipment mounted on it: • Three (3) off 3K200/53 chock pump/200 kW motor sets.

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

• One (1) off 8,500L stainless steel emulsion storage tank.

• One (1) off centrifugal pump emulsion pressure boost pump /22 kW motor set • One (1) off pump platform.

- INTRODUCTION -

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• 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.

The Shearer Water Pump Sled has the following equipment mounted on it: • One (1) off 3k150/70 shearer water pump/200kW motor set • One (1) off 600 Litre stainless steel water tank • One (1) off support frame including lifting points and forklift channels • Four (4) levelling cylinders • One (1) off 400 Bar accumulator • Monitoring devices • Filtration equipment • Control valving

- INTRODUCTION -

Page 2 of 262

- 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 Emulsion Sled showing:

B

I

J

K

D) Return Filters H) Shearer Water Tank

H

1.2

A

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

GENERAL ARRANGEMENTS 1.2.1 EMULSION SLED

Figure 1 Emulsion Sled Layout

Page 3 of 262

- INTRODUCTION -

B

C D

E

F

G

H

I

J

A) Leveling Cyl;inder B) 20Litre Accumulator Stand C) Inlet Water Filter D) Tank Temper Transducer E) Tank Pressure Transducer F) 3k150/70 Shearer Water Pump G) Delivery Pressure Transducer H) Water Tank I) 200kW Toshiba Motor J) Ellectrical Junction Box Stand

Figure 2: Photo of Emulsion Sled showing:

A

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NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

1.2.2 SHEARER WATER SLED

Figure 2 Shearer Water Layout

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1.3 GENERAL ARRANGEMENT DRAWINGS 1.3.1 EMULSION SLED

Figure 3: Emulsion Sled General Arrangement Drawing - INTRODUCTION -

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1.3.2 SHEARER WATER SLED

Figure 4 Shearer Water Sled General Arrangement Drawing - 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 2 for Isolation and Venting Procedures to decay 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 following procedures in Section 2.

- 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 2 FOR DETAILED ISOLATION PROCEDURES

- INTRODUCTION -

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1.6

PUMP STATION START UP PROCEDURE

1. Safety a. Personal Protection Equipment (PPE); • Safety glasses.

• Newpac Number 1 Colliery Standard PPE

2. Procedures a. Preliminary Checks; • Pump station is positioned according to Section 9.11.

• 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.

Figure 5 Face Delivery Manifold - INTRODUCTION -

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

Figure 6 Emulsion Tank Return Ports • Connect emulsion infill hose to infill filter on the outbye end of the emulsion tank.

• Connect water hose to shearer water infill filter

Figure 7 Emulsion Tank Infill Filter and Connection Points - INTRODUCTION -

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• Check that all DN10 bleed valves on the pumps and accumulators are closed.

Figure 8 Dual Chock Accumulator Assembly

Figure 9 3k200/53 Chock Pump - INTRODUCTION -

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• Open all face isolation valves.

Figure 10. Face Delivery Manifold • Connect all electrical cables. Refer to Newpac Number 1 Colliery’s literature for procedure for connection of cables • Start emulsion boost pump by pressing Boost pump start button on Chock Pump Number 2 & boost pump junction box

Figure 11. Chock Pump Number 2 & Boost Pump Junction Box - INTRODUCTION -

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• Allow boost pump to run for at least 10 seconds • Press start button on each of the 3 chock pump junction boxes, the positive set pump junction box and the shearer water junction box

Figure 12 Chock Pump Junction Box

- INTRODUCTION -

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2.

ISOLATION & PRESSURE BLEED OFF PROCEDURES

WARNING 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.

2.1

CHOCK PUMP ISOLATION & PRESSURE VENT PROCEDURE

1.

SAFETY a.Personal Protective Equipment • Goggles/Safety glasses • Newpac Number 1 Colliery 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.

Chock Pump Hauhinco 3k200/53 pump mounted on the Emulsion Pump Sleds. The Chock Pumps are Painted Red.

-Isolation & Pressure Venting-

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3. PROCEDURES a. Equipment Required • Personal Locks b. i.

Operation Procedure; 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 Newpac number 1 Colliery’s isolation procedure.

ii.

Isolate Pump Hydraulically • Close and lock out emulsion pump isolation ball valve for pump being isolated located on high pressure accumulator manifold.

Chock Pump Isolation Valves (Open)

Figure 13 Chock Pump Isolation Valves Mounted on Dual Accumulator Manifold -Isolation & Pressure Venting-

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Chock Pump Isolation Valve (Closed)

Figure 14 Chock Pump Isolation Valve Mounted on Single Accumulator Manifold iii.

Isolate Pump Mechanically from the Fluid Supply • Close and lock the suction isolation butterfly valve for pump located on the emulsion tank. The butterfly valves are labeled for ease of identification.

Suction Isolation Valve (Closed)

Figure 15 Chock Pump Number 1 Suction Isolation Valve -Isolation & Pressure Venting-

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Suction Isolation Valve (Closed)

Figure 16 Chock Pump Number 2 Suction Isolation Valve

Suction Isolation Valve (Closed)

Figure 17 Chock Pump Number 3 Suction Isolation Valve

-Isolation & Pressure Venting-

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iv.

Bleed Stored Pressure between the Pump, Accumulator and Isolation Ball Valve.

• Slowly open DN10 vent ball valve connected to pump high pressure manifold to allow pressure to dissipate. Bleed pressure until Delivery Pressure Transducer Gauge reads zero.

• Rotate 10mm Hose or ball valve. When pressure in line has dissipated hose and ball valve will move freely.

DN10 Bleed Valve (Closed)

Figure 18 Chock Pump Showing DN10 Bleed Valve

-Isolation & Pressure Venting-

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Delivery Pressure Transducer Gauge

Figure 19 Delivery Pressure Transducer with Gauge • Ensure that DN10 Vent ball valve is left open while maintenance is being conducted.

v.

After Completing Maintenance • Close the open DN10 vent ball valve connected to the pump high pressure manifold.

• Unlock and open suction isolation butterfly valve located on emulsion tank.

• Unlock and open all emulsion pump isolation valves on dual accumulator manifold or single chock pump manifold.

• Connect electrical cables to receptacles following Newpac Number 1 Colliery procedures.

-Isolation & Pressure Venting-

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2.2

POSITIVE SET PUMP ISOLATION & PRESSURE VENT PROCEDURE

1.

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.

Positive Set Pump: Hauhinco 3k110/40 pump mounted on the inbye end of the Emulsion Pump Station. The pump is painted blue.

2.

SAFETY a. Personal Protective Equipment (PPE) • Goggles/Safety glasses • Newpac Number 1 Colliery Standard (PPE)

b. WARNING: Ensure that care is taken when mounting and dismounting the pump station.

3.

PROCEDURES a. Equipment Required • Personal Locks

b. Operation Procedure i. Isolate pump electrically • Ensure that ‘STOP’ button on electrical junction 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 -Isolation & Pressure Venting-

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ii. Isolate Pump hydraulically • Close and lock out isolation ball valve located on the positive set accumulator manifold

Isolation Ball Valve (Closed)

Figure 20 Positive Set Pump Delivery Isolation Valve iii. Isolate pump mechanically from the fluid supply • Close the positive set suction isolation butterfly valve for pump located on the inbye end of the emulsion tank.

Suction Isolation Valve (Closed)

Figure 21 Positive Set Pump Suction Isolation Valve

-Isolation & Pressure Venting-

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iv. Bleed stored pressure between pump, accumulator and isolation ball valve.

• Slowly open DN10 vent ball valve located on the H300 unloader valve on pump to allow pressure to dissipate.

DN10 Bleed Valve (Closed)

Figure 22 Positive Set Pump DN10 Bleed Valve • Bleed pressure until Delivery Pressure Gauge reads zero. Rotate 10mm Hose or ball valve.

When pressure in line has dissipated hose and ball valve will move freely.

Delivery Pressure Transducer Gauge

Figure 23. Positive Set Pump Delivery Pressure Transducer with Gauge -Isolation & Pressure Venting-

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• 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 ball valve on face delivery manifold • Connect electrical receptacle according to AMP Control Procedure

-Isolation & Pressure Venting-

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2.3

SHEARER WATER PUMP & 20L ACCUMULATOR ASSEMBLY ISOLATION & PRESSURE VENT PROCEDURE

1.

SAFETY a. Personal Protective Equipment (PPE) • Goggles/Safety glasses • Newpac Number 1 Colliery 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.

Shearer Water Pump: Hauhinco 3k150/80 pump mounted on the Shearer Water Pump Sled. The pump is painted orange.

3.

PROCEDURES a. Equipment Required • Personal Locks

b. Operation Procedure i. Isolate Pump Electrically • Ensure that ‘STOP’ button on electrical Jbox for the shearer water pump has been pressed -Isolation & Pressure Venting-

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and pump has stopped. If pump is not stopped press ‘STOP’ button • Disconnect electrical receptacle for the shearer water pump and lock out

Figure 24: Shearer Water Pump Electrical Receptacle ii. Isolate Pump Hydraulically • Close and lock out stainless steel ball valve located on the Shearer Water Pump Accumulator Manifold

Figure 25: Shearer Water Pump Delivery Isolation Valve -Isolation & Pressure Venting-

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iii. Isolate Pump Mechanically from the Fluid Supply • Close the isolation valve on the incoming water supply hose iv. Bleed Stored Pressure Between Pump, 20L Accumulator and Isolation Ball Valves.

• Slowly open DN10 vent ball valve located on the Accumulator Manifold Assembly • Bleed pressure until Delivery Pressure Gauge reads zero. Ensure that DN10 Vent ball valve is left open while maintenance is being conducted.

System Pressure Gauge

DN10 Vent Ball Valve (Open Position)

Figure 26: Shearer Water System Pressure Gauge and DN10 Vent Ball Valve v. After Completing Maintenance • Close the open DN10 vent ball valve on the 20 • Open water supply isolation valve located on the water supply hose • Open stainless steel ball valve on face delivery manifold -Isolation & Pressure Venting-

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2.4

20L DUAL ACCUMULATOR MANIFOLD ISOLATION & PRESSURE VENT PROCEDURE 1.

SAFETY a. Personal Protective Equipment (PPE) • Safety glasses/goggles • Newpac Number 1 Colliery (PPE) • 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.

Dual Accumulator Manifold Block: Manifold located on the outbye end of the pump station with two high pressure 20 litre accumulator bottles mounted on the top face.

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 Hydraulic Chock Pump Isolation Procedure and Pressure Vent Procedure 2.1). c. Operation Procedure i. Isolate dual accumulator from hydraulic circuit.

• Close and lock both isolation ball valves located dual accumulator manifold block.

-Isolation & Pressure Venting-

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Chock Pump Isolation Valves (Open)

Figure 27. Dual Chock Accumulator Manifold • Close and lock Emulsion Face Pressure Isolation Valves located on Face delivery manifold located on inbye end of pump station.

Positive Set Face Delivery Isolation Ball Valve (Closed)

Chock Pump Face Delivery Isolation Ball Valves (Closed)

Figure 28 Face Delivery Manifold ii. Bleed stored hydraulic accumulator manifold -Isolation & Pressure Venting-

pressure

in

dual

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• Slowly open DN10 bleed valve located on dual accumulator manifold stand to release pressure, until pressure gauge on accumulator stand reads zero.

Accumulator / System Pressure Gauge

DN 10 Bleed Valve (Closed)

Figure 29 Dual Accumulator Manifold Assembly • Ensure that DN10 ball valve remains open while maintenance work is conducted • If removing dual accumulator assembly refer to Section 3.8.2

iii. Upon completion of maintenance work • Fully close DN10 bleed valve • Unlock and open both isolation ball valves located on dual accumulator manifold.

• Unlock and open Emulsion Face Pressure Isolation Valves on face delivery manifold.

• Open both suction isolation butterfly valves located on Inbye end of emulsion tank.

-Isolation & Pressure Venting-

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2.5

20L SINGLE CHOCK ACCUMULATOR MANIFOLD ISOLATION & PRESSURE VENT PROCEDURE

1.

SAFETY a. Personal Protective Equipment (PPE) • Safety glasses/goggles • Newpac Number 1 Colliery Standard PPE • 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.

Single Chock Accumulator Manifold Block Manifold located on the Inbye end of the pump station with one high pressure 20 litre accumulator bottle mounted on the top face. Beside chock pump number 3 1

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 2.2).

-Isolation & Pressure Venting-

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c Operation Procedure i Isolate accumulator manifold assembly from hydraulic fluid supply.

• Close and lock isolation ball valve located on the inbye face of the single chock accumulator manifold block on Inbye end of platform.

Single Chock Pump Isolation Ball Valve (Closed)

Figure 30 Chock Pump #3 Delivery Isolation Valve

-Isolation & Pressure Venting-

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ii Isolate chock pump number 3 accumulator manifold from the hydraulic circuit • Close and lock the three (3) DN50 face isolation ball valves located on the face delivery manifold.

DN50 Face Isolation Ball Valves (Closed)

Figure 31 Face Delivery Manifold 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.

-Isolation & Pressure Venting-

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Single Chock Manifold Pressure Gauge

DN10 Bleed Ball Valve (Closed)

Figure 32 Single Chock Pump Accumulator Manifold Assembly • Ensure that DN10 ball valve remains open while maintenance work is conducted • If removing accumulator bottle see Accumulator Lifting Procedure for Newpac Number 1 Colliery Hydraulic Pump Section 3.8.2. iv Upon completion of maintenance work • Fully close DN10 bleed valve • Unlock and open isolation ball valve located on face delivery manifold.

• Unlock and open suction isolation butterfly valve on Emulsion Tank.

-Isolation & Pressure Venting-

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2.6

20L POSITIVE SET ACCUMULATOR MANIFOLD ASSEMBLY ISOLATION & PRESSURE VENT PROCEDURE

1. SAFETY a. Personal Protective Equipment (PPE) • Safety glasses/goggles • Newpac Number 1 Colliery Standard PPE • 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.

Positive Set Accumulator Manifold Block Manifold located on the Outbye end of the pump station with one high pressure 20 litre accumulator bottle mounted on the top face. Beside the Positive Set Pump 1. 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 2.2).

-Isolation & Pressure Venting-

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c Operation Procedure i. Isolate positive set pump from hydraulic fluid supply.

• Close and lock isolation ball valve located on the inbye face of the positive set pump accumulator manifold block on Inbye end of platform.

Positive Set Delivery Isolation Ball Valve (Closed)

Figure 33 Positive Set Pump Delivery Isolation Valve

-Isolation & Pressure Venting-

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ii Isolate positive set accumulator manifold from hydraulic circuit • Close and lock the face isolation ball valve located on the face delivery manifold.

Figure 34 Face Delivery Manifold

-Isolation & Pressure Venting-

Positive Set Face Delivery Isolation Ball Valve (Closed)

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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.

Positive Set Manifold Pressure Gauge

DN10 Bleed Ball Valve

Figure 35 Positive Set Pump Accumulator Manifold Assembly • Ensure that DN10 ball valve remains open while maintenance work is conducted • If removing accumulator bottle see Accumulator Lifting Procedure for Newpac Number 1 Colliery Hydraulic Pump Refer Section 3.8.2. iv Upon completion of maintenance work • Fully close DN10 bleed valve • Unlock and open isolation ball valve located on face delivery manifold.

• Unlock and open suction isolation butterfly valve on Emulsion Tank.

-Isolation & Pressure Venting-

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3.

EMULSION CHOCK PUMP

3.1

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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3.2

PUMP COMPONENTS

Figure 36: Cross section view of 3k200/53 chock 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

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A

B

C

D

E

F

G

H

Figure 37: Photo of 3k200/53 Chock Pump 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)

Lube Temperature Transducer Pt No. PT100

H)

Oil Recirculation Pump Pt No H6310133

- EMULSION CHOCK PUMP-

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3.3

GENERAL DESCRIPTION The three (3) off high pressure emulsion chock pumps (referred to as chock pumps from here on) 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 is

pumped from the tank to the pump suction inlet ports by the boost pump.. The emulsion fluid then flows from the pump under high pressure, 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 three (3) off 50mm ‘Super Stecko’ outlet connections on the inbye end of the pump station.

P CAUTION P – Before operating any of the 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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3.4

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

- EMULSION CHOCK PUMP-

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Pt No. H442064 Pt No. H151976

Pt No. H6421369

Pt No. H2112299

Pt No. H6365108

Pt No. H6448194

NEWPAC NUMBER 1 COLLIERY LONGWALL PUMP STATION SERVICE & MAINTENANCE MANUAL 2006

Figure 38: Cutaway view of Pump Insert and Plunger - EMULSION CHOCK PUMP-

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3.5

UNLOADING CONTROL SYSTEM & INDIVIDUAL CHOCK PUMP ACCUMULATOR As the pumps are positive displacement a method of unloading is required for periods when there is no demand for fluid at the face.

The chock 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

transducer monitors the system pressure and sends an analogue signal to the pump controller. The pump controller determines if the chock 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 chock 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 reciprocating action of the chock pump. 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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3.6

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 a pressure transducer is mounted on the pump to monitor the oil pressure.

This pressure transducer will automatically cut off the electric motor to protect against mechanical failure if the oil pressure should fall below 1.5 Bar.

- EMULSION CHOCK PUMP-

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A

B

C

D

E

Figure 39: Cut Away View of Chock Pump A

Lubricating Pump

B

Crankshaft

C

Connecting Rod Big End Bearings

D

Oil Reservoir

E

Oil Cooler

- EMULSION CHOCK PUMP-

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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 40: 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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3.7

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 41: Photo of Top of Pump Case showing; A)

Correct direction to operation pump

- EMULSION CHOCK PUMP-

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3.8

ACCUMULATORS 3.8.1 Description Four (4) off high pressure, twenty (20) 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 single chock pump manifold located between the positive set pump and the chock pump number 3. 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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B

A

C

D

Figure 42: Photo of Dual Accumulators showing; A) C)

32L Accumulators Pt No SB400-32 DN10 Accumulator Assembly Pressure Vent Valve

B) D)

- EMULSION CHOCK PUMP-

Nitrogen bleed points are located under hat cover Accumulator / System Pressure Gauge

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3.8.2 PROCEDURE FOR LIFTING 20L ACCUMULATOR ASSEMBLY FROM PUMP STATION 1.

SAFETY a. Personal Protective Equipment (PPE) • Safety Glasses • Newpac Number 1 Colliery Standard PPE

b. Safety Procedures • Accumulator Isolation and Pressure Venting Procedure.

Refer Sections 2.3, 2.4, 2.5 & 2.6.

2.

PROCEDURES a. Equipment Required • Two lifting slings rated to lift accumulator bottle • Overhead crane • Secondary lifting device such as a chain block

b. Safety Checks Before Operation • Ensure that there is adequate headroom to raise the accumulator away from the stand.

c. Operation Procedure • Isolate and vent stored pressure from 20 L accumulator according to Section 2.

• Totally vent the Nitrogen Precharge.

• Remove accumulator stand hat cover • Attach 1st rated lifting sling around 20L accumulator bottle and connect to overhead lifting device - EMULSION CHOCK PUMP-

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•

Affix 2nd appropriately weighted sling to the body of the vessel 180o from 1st sling and attach to a secondary lifting device mounted upon the overhead crane.

• Disconnect the fluid lines to the accumulator.

• If fitted remove the safety and isolation block.

• Release the mounting clamps • Slowly lift the accumulator out of the frame ensuring that the vessel does not pendulum or jiggle and ensure the accumulator is stabilised in the vertical position.

• Lower the vessel to the ground and stabilise vertically.

• Rotate the 20L accumulator bottle into the horizontal plain.

•

Lower the unit to the ground in a safe and controlled manner.

•

When reinstalling the 20L accumulator bottle the socket head cap screws in the SAE split clamps must be tightened to a torque of 211Nm for all 20L accumulator assemblies.

- EMULSION CHOCK PUMP-

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3.9

SERVICE & MAINTENANCE OF PUMPS

3.9.1

Inspection and Maintenance Requirements

3.9.1.1 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 3.9.2.3.).

• 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.

3.9.1.2 Every 3 Months, or 1000 hours of Operation

• Examine pressure hoses for damage.

• Change lubricating oil (refer Section 3.9.2.3).

• Change lubricating oil filter (refer Section 3.9.2.4).

- EMULSION CHOCK PUMP-

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3.9.1.3

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 20 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 280 Bar. • Inspect oil cooler tubes for leaks or cracks.

- EMULSION CHOCK PUMP-

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3.9.2

Maintenance Procedures

3.9.2.1

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 2

- EMULSION CHOCK PUMP-

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3.9.2.2 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 is located on the non-drive end of the pump crankcase .

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.

PUMP CRANKCASE

OIL LEVEL HALF WAY UP SIGHT GLASS WHEN PUMP IS OPERATING

Figure 43: Non Drive End of Chock Pump - EMULSION CHOCK PUMP-

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3.9.2.3 Procedure For Adding Lubricating Oil to the Crankcase

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

• Newpac Number 1 Colliery’s Standard PPE.

3.

PROCEDURES To add a small amount of 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 44: Photo of Pump Crankcase showing: A)

Oil filler / air breather cap Pt No H2350343

- EMULSION CHOCK PUMP-

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3.9.2.4 Procedure for Changing Lubricating Oil

! WARNING! – Risk of scalding by hot lubricating oil

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

• Heat Proof Gloves.

• Newpac Number 1 Colliery’s Standard PPE. b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure (refer Section 2.1).

• Newpac Number 1 Colliery Manual Handling Procedure.

4.

PROCEDURES a. Environmental Procedures; • Old oil to be disposed of in accordance to Newpac Number 1 Colliery’s Environmental Procedures. 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 2.1.

• Remove cap from hose labelled ‘Pump Drain Point’ connected to bottom of pump housing.

A

B

Figure 45 Chock Pump Lube Oil Drain Hose A) B)

Hose Cap

- EMULSION CHOCK PUMP-

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• Slowly, fully open yellow handle of 1-inch ball valve to drain oil into a container.

A

Figure 46 Non Drive End of Chock Pump A)

1” Ball Valve (Closed Position)

• Dispose of old oil in accordance with Newpac Number 1 Colliery’s environmental procedures.

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

- EMULSION CHOCK PUMP-

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• Remove breather/filler cap.

A

Figure 47 (A) Breather/Oil Filler Cap • Pour/Pump oil into crankcase through vent hole until oil level is slightly above midpoint of oil level sight glass.

A

Figure 48 (A) Oil Level Sight Glass • Replace breather cap.

- EMULSION CHOCK PUMP-

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3.9.2.5 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 (PPE); • Safety Glasses.

• Newpac Number 1 Colliery’s Standard PPE.

b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure (refer Section 2.1).

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 2.1.

- EMULSION CHOCK PUMP-

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• Remove coupling guard from pump console.

Figure 49 Chock Pump Console with Coupling Guard Removed

- EMULSION CHOCK PUMP-

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• Using oil filter wrench unscrew filter from mounting.

A

Figure 50: Photo of Chock Pump Mounting Flange showing; A)

Oil Filter Pt No H2350378

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

- EMULSION CHOCK PUMP-

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

A

Figure 51: Photo of Chock Non Drive End of Pump A)

Oil Level Sight Glass

• Start pump according to Section 1.5.3 and ensure there are no leaks from filter.

- EMULSION CHOCK PUMP-

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3.9.2.6 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 52: Cross Section View of Crankcase

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

• Newpac Colliery’s Standard PPE.

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

Refer to Section 2.1 - 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 3.9.4.2.

• Grease for mounting. Refer Section 3.9.4.2.

b. Operation Procedure; • Isolate pump according to Chock Pump Isolation and Pressure Venting Procedure. Refer Section 2.1 • 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 start up procedure, (Refer Section 1.5.3) ensure there are no leaks from the filter or oil distributor.

• If leakage occurs stop pump remove filter and clean gasket - EMULSION CHOCK PUMP-

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• Refit Filter and restart pump as before checking for leaks

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 53: Cross Section View of Oil Filter

- EMULSION CHOCK PUMP-

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3.9.2.7

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 (PPE); • Safety Glasses.

• Safety Boots.

• Newpac Number 1 Colliery Standard PPE.

b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure (refer Section 2.1.).

• Newpac Number 1 Colliery 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 2.1.

•

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 31] 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 Newpac Number 1 Colliery 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 54: 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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3.9.2.8 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 (PPE); • Safety Glasses.

• Newpac Number 1 Colliery Standard PPE

b. Safety Procedures; • Newpac Number 1 Colliery Manual Handling Procedure.

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 3.9.2.7).

• 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 32] taking care not to lose the five (5) off pressure springs. The pressure valve plate [4 - Fig 32] 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 32] 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 32]. Take

care when removing the valve holder [2 - Fig 32], as there are nine (9) off pressure springs between the valve holder and the suction plate [5 - Fig 32] 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 55: 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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3.9.2.9 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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3.9.2.10 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 (PPE) ; • Safety Glasses.

• Newpac Number 1 Colliery Standard PPE

b Safety Procedures; • Newpac Number 1 Colliery Manual Handling Procedure.

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

• 10mm inhex socket.

• Mallet. a. Operation Procedure; • Refer to Fig 32.

• 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.

• 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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3.9.2.11

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 (PPE); • Safety Glasses.

• Safety Boots.

• Newpac Number 1 Colliery Standard PPE.

b. Safety Procedures; • Newpac Number 1 Colliery Manual Handling Procedure.

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

• Torque wrench.

• O-ring grease. Refer to Section 3.9.4.2 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 Newpac Number 1 Colliery Manual Lifting Procedures are followed.

•

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

• Bolt coupling guard to console.

• Restart pump. Refer to Section 1.5.3

- EMULSION CHOCK PUMP-

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3.9.2.12 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 (PPE); • Safety Glasses.

• Newpac Number 1 Colliery Standard PPE.

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

Refer Section 2.1

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 2.1.

• 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 2.9.2.7 • 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 56: 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 57: 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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3.9.2.13 Refitting Plungers

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

• Newpac Number 1 Colliery Standard PPE. 2. PROCEDURE 1. 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 3.9.2.11 - EMULSION CHOCK PUMP-

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3.9.2.14 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 (PPE); • Safety Glasses.

• Newpac Number 1 Colliery 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 3.9.2.7.

- 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.

• Mount insert in pump according to Section 3.9.2.13

- EMULSION CHOCK PUMP-

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Figure 58: Pump Insert 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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3.9.2.15 Replacement 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 (PPE);

•

Safety Glasses.

•

Newpac Number 1 Colliery Standard PPE.

b.

Safety Procedures;

• Chock Pump Isolation and Pressure Venting Procedure. Refer Section 2.1 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 2.1.

•

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.

• Mount replacement 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.

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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3.9.2.16

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.

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

• Newpac Number 1 Colliery Standard PPE.

b. Safety Procedures; • Chock Pump Isolation and Pressure Venting Procedure. Refer Section 2.1

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

- 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 2.1.

• 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 59: Photo of ADM Solenoid & Filter Block Assembly

- EMULSION CHOCK PUMP-

Pt No H6256279

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2.9.2.17

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 (PPE);

•

Safety Glasses.

•

Newpac Number 1 Colliery Standard PPE.

b.

Safety Procedures

•

Chock Pump Isolation and Pressure Venting Procedure. Refer Section 2.1.

- EMULSION CHOCK PUMP-

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2.

PROCEDURES a.

Equipment required;

•

13mm Spanner.

•

O-ring grease. Refer Section 3.9.4.2

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 60:

B

Photo of Safety Relief Valves showing:

A) Safety Relief Valves

B) M8 Bolt

Pt No H1720007

- EMULSION CHOCK PUMP-

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3.9.3

SERVICE TOOLS

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

3.9.3.1

Set Screws for Valve Holders of Pump Inserts

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

3.9.3.2

Set Screw for Oil Distributor

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

3.9.3.3

Withdrawing Device for Plungers

Plunger withdrawing device Part number: H6459048

Figure 25: Plunger Withdrawal Device - EMULSION CHOCK PUMP-

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3.9.3.4

Withdrawing

Device

and

Assembly

Mandrel

Locking Pin of Crosshead.

LOCKING PIN WITHDRAWING DEVICE

LOCKING PIN ASSEMBLY MANDREL

Figure 26: Locking Pin Withdrawal Device and Mandrel 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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3.9.4

ADDITIONAL PUMP INFORMATION

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

2.9.4.1

Bolt tightening torques

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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3.9.4.2 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 3.9.4.3 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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3.9.5

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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4.

POSITIVE SET PRESSURE PUMP 4.1 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 H300

INPUT SPEED:

1500 RPM Nominal

- POSITIVE SET PRESSURE PUMP-

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4.2

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

Figure 63: Photo of Pump Station showing; A)

3K 200/53 Chock Pumps Pt No H5131162

C)

3K 110/40 Positive Set Pump Pt No H5135508

- POSITIVE SET PRESSURE PUMP-

B)

20L Positive Set Accumulator Pt No SB400-32

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A

B

C

D

E

F

G

H

I

Figure 64: 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-

Safety Valve

Lube Oil Pressure Gauge Pt No H2400146

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4.3

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.

4.4

UNLOADING CONTROL SYSTEM & 20 LITRE 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 connected to a Twenty Litre (20 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 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.

The vent valve is a 10mm ball valve located near the base of the accumulator stand.

- POSITIVE SET PRESSURE PUMP-

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Figure 65: Positive Set Pump Accumulator Manifold Assembly

- POSITIVE SET PRESSURE PUMP-

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4.5

LUBRICATION SYSTEM

Normal lube oil pressure, when pump is in operation, is between 2-and-4 Bar [200-400 kPa]. A pressure transducer is mounted on the pump to monitor the oil pressure. This pressure transducer will automatically cut off the electric motor to protect against mechanical failure if the oil pressure should fall below 1.5 Bar.

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 66: 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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4.6

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 67: Photo of Top of Pump Case showing; A)

Correct direction to operation pump

- POSITIVE SET PRESSURE PUMP-

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4.7

SERVICE & MAINTENANCE OF PUMPS

4.7.1 Inspection and Maintenance Requirements 4.7.1.1

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.

4.7.1.2 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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4.7.1.3 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 20 Litre accumulators – Pre-charge pressure is 200 Bar for the 2.5 L accumulator and 280 Bar for the 20 Litre accumulator.

- POSITIVE SET PRESSURE PUMP-

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4.7.2 Maintenance Procedures

4.7.2.1

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 2

- POSITIVE SET PRESSURE PUMP-

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4.7.2.2

Procedure for Checking the Pump Oil Level

A pump lubricating oil level sight glass is located on the non-drive end of the pump crankcase. 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 68: View of Crankcase

- POSITIVE SET PRESSURE PUMP-

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4.7.2.3

Procedure for Adding Oil to the Crankcase Refer Section 3.9.2.3

4.7.2.4

Procedure for Changing Lubricating Oil

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

4.7.2.5 Procedure for Changing Oil Filter

• Refer Section 3.9.2.5

- POSITIVE SET PRESSURE PUMP-

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

• Newpac Number 1 Colliery Standard PPE

b. Safety Procedures; • Positive Set Pump Isolation Procedure. Refer Section 2.2.

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; • Isolate positive set pump according to Section 2.2 • 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.

- POSITIVE SET PRESSURE PUMP-

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• 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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4.7.2.7

Procedure for Removing Pump Intake and Delivery Valves

1. SAFETY a.

Personal Protective Equipment; • Safety Glasses.

• Newpac Number 1 Colliery’s Standard PPE.

b.

Safety Procedures; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 2.2.

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 2.2.

• 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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4.7.2.8

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.

• Newpac Colliery’s Standard PPE.

b. Safety Procedures • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 2.2.

• Newpac Colliery’s 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 2.2.

• Dismount intake and delivery valves as per procedure 4.7.2.7.

• 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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4.7.2.9

Procedure Refitting Of Pump Insert Assemblies

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

• Newpac Number 1 Colliery’s Standard PPE.

b. Safety Procedures; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 2. 2.

• Newpac Number 1 Colliery’s Handling Procedure.

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

• Torque wrench.

• O ring grease. Refer to Section 4.7.3.2

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.

• Restart Pump According to Section 1.5.3

- POSITIVE SET PRESSURE PUMP-

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4.7.2.10

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.

• Newpac Number 1 Colliery’s Standard PPE. b. SAFETY PROCEDURES; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 2.2.

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 2.2.

• Remove pump insert assembly as according to Section 4.7.2.8.

• 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 69: 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 70: Legend: 4) Threaded bore of plunger 5) Set screw 6) Plunger withdrawal device Pt No H6640607

- POSITIVE SET PRESSURE PUMP-

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4.7.2.11

Procedure for Fitting of Plungers

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

• Newpac Number 1 Colliery’s Standard PPE b. Safety Procedures; • Pump Isolation Procedure Refer Section 2.2.

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 4.7.2.9.

- POSITIVE SET PRESSURE PUMP-

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4.7.2.12

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 (PPE); • Safety Glasses.

• Newpac Number 1 Colliery’s Standard PPE.

b. Safety Procedures; • Positive Set Pump Isolation and Pressure Venting Procedure. Refer to Section 2.2.

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 2.2.

• Remove the pump insert assembly as described in the Procedure 4.7.2.8.

• 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.

• Refit insert to pump according to Section 3.7.2.9

Figure 71: 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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4.7.2.13

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 (PPE); • Safety Glasses.

• Newpac Number 1 Colliery’s Standard PPE b. Safety Procedures; • Positive Set Pump Isolation Procedure (refer Section 2.2.

• Newpac Number 1 Colliery’s Manual Handling Procedure.

- POSITIVE SET PRESSURE PUMP-

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

b. Operation Procedure; • Isolate pump according to procedure in Section 2.2.

• 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.

B

A

Figures 72 & 73: 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 74: Photo of Positive Set Pump showing: A) Position of Safety Valve Vent

- POSITIVE SET PRESSURE PUMP-

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4.7.3 Additional Pump Information

4.7.3.1

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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4.7.3.2

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.

4.7.3.3

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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4.7.4 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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5.

EMULSION STORAGE TANK 5.1

TECHNICAL INFORMATION

Nominal Emulsion Capacity: 8,500 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.

• Three (3) return filters connected to the emulsion return header manifold • One (1) off Infill Filter and solenoid valve • Five (5) off air breathers.

• One (1) off magnetic fluid level transducer • One (1) off fluid level viewing port.

• Two (2) off drain ports.

• One (1) off emulsion temperature transducer.

• Two (2) off emulsion sample points.

• One (1) off turbulent sample point - EMULSION STORAGE TANK -

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5.2

EMULSION SUCTION OUTLET PORTS

Four emulsion outlet ports are positioned on the tank to feed each of the three chock pumps and the positive set pump.

Three of the outlets are 100mm nominal bore (NB); while the fourth outlet is 65mm NB. The three 100mm NB outlets supply the two chock pumps and the 65mm NB outlet supplies the positive set pump.

- EMULSION STORAGE TANK -

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5.3 SUCTION ISOLATION VALVES

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

A

Figure 75: Photo of Emulsion Tank showing; A)

Suction Isolation Valve (Closed Position) Pt No 530-125 65NB

Suction isolation valves, for the three 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 tank.

- EMULSION STORAGE TANK -

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5.4

AIR BREATHERS AND OVERFLOW PORT

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 76: 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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5.5

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 77: Photo of Emulsion Tank showing; A)

Fluid Level Viewing Port

- EMULSION STORAGE TANK -

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5.6

DRAIN PORTS

Two drain ports are located on the bottom of the inbye and outbye ends 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 78: Photo of Emulsion Tank showing; A)

Closed drain port

- EMULSION STORAGE TANK -

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5.7

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 79: Photo of Emulsion Tank showing; A)

Emulsion Temperature Transmitter Pt No Labom PT100

- EMULSION STORAGE TANK -

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5.8

SUCTON DISCHARGE BLEED POINT

A suction discharge bleed point has been incorporated into the tank to allow any air that has been trapped in the internal pipe work of the tank to be discharged after the tank has been filled. This bleed point is located on the outbye end of the emulsion tank. After filling the tank open the DN10 ball valve at the discharge bleed point until emulsion flows from the valve. Then close the valve.

.

Figure 80. Suction Discharge Bleed Point

- EMULSION STORAGE TANK -

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5.9

LOW PRESSURE EMULSION SAMPLE POINTS

A turbulent emulsion sample point is located on the end of the header pipe.

An emulsion sample point is located on the outbye end of the emulsion tank and a second emulsion sample point is located on the inbye end of the emulsion tank. Minimess connections have been used to allow for safe fast connection for taking samples.

A

B

Figure 81: Photo of Emulsion Tank showing; A)

Turbulent Emulsion Sample Point

B)

Emulsion Sample Point

- EMULSION STORAGE TANK -

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5.10 PROCEDURE FOR TAKING SAMPLES OF EMULSION FROM TANK 1.

2.

SAFETY a.

Personal Protective Equipment

•

Goggles/Safety glasses

•

Newpac Number 1 Colliery Standard PPE

DEFINITIONS Turbulent Emulsion Sample Point Sample point located on the return header pipe. Samples are taken of the emulsion before it flows through the return line filters and is experiencing turbulent flow conditions

A

B

Figure 82: Photo of Emulsion Tank showing: A) Turbulent Emulsion Sample Point

- EMULSION STORAGE TANK -

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Emulsion Sample Point Two emulsion sample points are provided, one on the inbye end of the tank, the other 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.

Figure 83: Photo of Emulsion Tank Showing; Emulsion Sample Point.

3.

PROCEDURES a.

Equipment Required

• •

Appropriate container for collecting emulsion sample Hose to connect to minimess sample point

b.

Operation Procedure

•

Remove Cap from Minimess Sample Point - EMULSION STORAGE TANK -

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•

Connect hose to sample point

•

Place container beneath sample point to be used

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 disconnect hose from minimess connection.

- EMULSION STORAGE TANK -

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5.11

SERVICE AND MAINTENANCE

5.11.1 Inspection and Maintenance Requirements 5.11.1.1 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.

5.11.1.2 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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5.12 MAINTENANCE PROCEDURES

5.12.1 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 2 for the Hauhinco

Pump Isolation Procedures.

- EMULSION STORAGE TANK -

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A

B

C

D

Figure 84: Photos of Emulsion Tank Isolation points showing; A)

Chock Pump No 1

B)

Pt No 530-125 100NB C)

Chock Pump No 3 Pt No 530-125 100NB

- EMULSION STORAGE TANK -

Chock Pump No 2 Pt No 530-125 100NB

D)

Positive Set pump Pt No 530-125 65NB Page 154 of 262

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5.12.2

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 85: 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 (PPE); •

Safety Glasses.

•

Newpac Number 1 Colliery Standard PPE

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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6.

EMULSION BOOST PUMP 6.1

EMULSION BOOST PUMP DETAILS

PUMP TYPE Centrifugal Close coupled pump

BRAND

MODEL

Southern Cross

ISO 80x65-160

•

Cast Iron casing, 316 Stainless Steel impeller

•

Stainless steel shaft

•

Hard faced mechanical seal with Viton elastomers

Pump connections:

Impeller Trim:

Suction

80mm

Discharge

65mm

161 mm

Figure 86. Emulsion Boost Pump Detail -Emulsion Boost Pump-

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6.2

GENERAL DESCRIPTION Due to the restricting roof height conditions underground at the Newpac Number 1 Colliery, an emulsion boost pump has been installed on the pump station to ensure that sufficient positive pressure is supplied to the three chock pumps and the positive set pump. By supplying pressurized incoming emulsion to the Hauhinco pumps, a longer service life can be expected before major service work needs to be carried out. The boost pump also eliminates the need to bleed air from the pumps after carrying out any maintenance on the wet end of the pump, as any trapped air will be forced through the system to the tank where it will dissipate to atmosphere.

-Emulsion Boost Pump-

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6.3

OPERATION

The emulsion boost pump assembly is located on the inbye end of the emulsion storage tank. The boost pump assembly is comprised of the centrifugal close-coupled pump, 22kW Toshiba motor, pump and motor mounting flange mount console and stainless steel pipe work between the emulsion storage tank and the pump. Internal pipe work has been installed in the emulsion tank to feed each of the emulsion pumps.

Emulsion fluid is drawn from the main chamber of the emulsion tank by the boost pump. The fluid exists the pump under pressure and enters the internal piping in the emulsion tank where it flows to the pipe work connected to each of the emulsion pump suction outlets and then onto the pump suction inlets.

-Emulsion Boost Pump-

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A

B

C

D

E

F

Figure 87. Emulsion Boost Pump and 22kW Motor Assembly A)

Isolation butterfly valve

B)

Wafer check valve

C)

Emulsion outlet pipe

D)

Centrifugal emulsion boost pump

E)

Mounting Console

F)

22 kW Electric Motor

-Emulsion Boost Pump-

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6.4

EMULSION PRESSURE TRANSDUCER •

A pressure transducer mounted on the outbye end of the emulsion storage tank, near the boost pump monitors the emulsion output pressure from the boost pump. If the output pressure from the boost pump falls below 2 Bar, then an alarm will be sounded, and all of the emulsion pumps will cut-out.

•

For the protection of the main emulsion pumps upon pump station start up procedures, a timer has been installed and set so that the emulsion boost pump must be in operation for at least 5-10 seconds before the main emulsion pumps will start operating.

•

Likewise, a timer is used to ensure that the emulsion boost pump continues to operate slightly after the main emulsion pumps have stopped.

ITEM

BRAND

Emulsion boost pump outlet pressure

Labom

transmitter

MODEL

RANGE

CB2021-A1058-

4-20 mA

H1-S63

(0-10 Bar)

A Figure 88.

(A) Boost Pump Pressure Transducer -Emulsion Boost Pump-

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6.5

BOOST PUMP START & STOP BUTTONS

The stop, start and emergency buttons for the emulsion boost pump are mounted on the Chock Pump Number 2 J box beside chock pump number 2.

A

B

C

Figure 89: Boost Pump Stop & Start Buttons A)

Boost Pump Start Button

B)

Emergency Stop Button

C)

Boost Pump Stop Button

-Emulsion Boost Pump-

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6.6

BOOST PUMP MAINTENANCE REQUIREMENTS

6.6.1

Inspection and maintenance requirements for emulsion charge pump unit

6.6.1.1

Weekly inspections and maintenance •

Inspect pump mechanical seal for leaks – a small drip is normal for standard operation.

•

Visual inspections can be made through the viewing ports cut into the side of the housing.

-Emulsion Boost Pump-

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7.

PUMP STATION MONITORING SYSTEM 7.1 PUMP STATION MONITORING SYSTEM COMPONENTS

DEVICE

Positive Set Pump outgoing pressure transducer Positive set pump lubricating oil pressure transducer Positive set pump lubricating oil temperature transducer Pump station overall outgoing system pressure transducer

BRAND

SET POINTS

ACTIONS

RANGE

Labom

Motor cut off

Labom

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

Motor cut off

Labom

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

Motor cut off

Labom

CB 2031-A1068-H1-S63 350 Bar – Motor cut 0-600 Bar Prod. No.: 370 Bar off 380 Bar 4-20 mA 0211292/07/001

Labom

Shearer water tank incoming water pressure transducer

Labom

50° -60°

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

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

Shearer water pump - outgoing pressure transducer

Shearer water pump - lubricating oil pressure transducer Shearer water tank fluid temperature transducer Shearer water pump - lubricating oil temperature transmitter

MODEL No.

0 - 100°

Non drive end of Positive Set Pump

Bracket mounted on Chock Pump #3

Shearer Water Pump Field Device Panel U504 safety CB 2031-A1068-H1-S63 0-250 Bar 40 Bar to mounted on non valve set Prod. No.: 4-20 mA 145 Bar walkway side of Shearer relief 0211292/03/001 Water Pump Shearer Water Pump Field Device Panel CB 2031-A1068-H1-S63 Motor cut 0-40 Bar Prod. No.: Min 6 Bar mounted on non off 4-20 mA walkway side of Shearer 0211292/02/002 Water Pump

Labom

CB 2021-A1058-H1-S63 Low 1.5 Prod. No.: Bar 0308952/02/007

Motor cut off

0-10 Bar Non drive end of Shearer 4-20mA Water Pump

Labom

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

50° -60°

Motor cut off

0° - 100°

Shearer Water Tank

Labom

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

50° -60°

Motor cut off

0 - 100°

Non drive end of Shearer Water Pump

- 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 temperature transducer

Labom

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

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

Labom

Labom

Labom

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

50° -60°

Motor cut off

0° - 100°

Non drive end of Emulsion Pump #2

CB 2031-A1068-H1Emulsion Pump #2 330 – 370 Motor cut 0-600 Bar Field Device Panel S63 Prod. No.: Bar off 4-20 mA 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.: Bar off 4-20 mA mounted on 0308952/02/003 Console of Pump PT 100 1/2 BSP 6x150/PTX/H/RTD/I S

50° -60°

Motor cut off

0° - 100°

Non drive end of Emulsion Pump #2

Emulsion Pump #3 CB 2031-A1068-H1- 330 – 370 Motor cut 0-600 Bar Field Device Panel S63 Bar off 4-20 mA mounted on Console of Pump Emulsion Pump #3 CB 2021-A1058-H1- Low: 1.5 Motor cut 0-10 Bar Field Device Panel S63 Bar off 4-20 mA mounted on Console of Pump

Labom

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

50° -60°

Motor cut off

0 - 100°

Non drive end of Emulsion Pump #3

Weka

TYPE: 31967

30% - 90%

Cut off

4-20 mA

Outbye End of Emulsion Tank

- MONITORING SYSTEM -

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DEVICE

SET ACTIONS POINTS

BRAND

MODEL No.

Emulsion face return pressure transducer

Labom

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

(In Tank) Emulsion temperature transducer

Labom

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

Ceme

8616 12V Solenoid Valve

Safety valve 1520 Bar

Boost Pump pressure transducer

Labom

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

1 Bar

Shearer Water Incoming water filter pressure transducer

Labom

CB 2031-A1068-H1S63 Prod. No.: 0211292/02/002

To be set by mine

Solenoid fill valve

6 Bar

- MONITORING SYSTEM -

RANGE

LOCATION

Alarm trip

0-10 Bar 4-20 mA

Inbye End of Emulsion Tank

Trip

4-20 mA

Outbye End of Emulsion Tank

Alarm & vent 110V through safety valve Stop Pumps if 0-10 Bar pressure 4-20 mA < set point Trip

0-40 Bar 4-20mA

Emulsion Tank

Emulsion Tank

Shearer Water Sled

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7.2

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 possible damage to the equipment.

7.3

EMULSION TANK MONITORING

7.3.1 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 90: Photo of Emulsion Tank showing; A)

Emulsion Temperature Transmitter Pt No Labom PT100

- MONITORING SYSTEM -

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7.4

CHOCK AND POSITIVE SET PUMP MONITORING

7.4.1 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 91: Photo of Face Delivery Manifold showing; A) Systems Pressure Gauge

B) Chock Pump #3

Pt No H2400006S

- MONITORING SYSTEM -

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7.4.2 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 92: Photo of pump console showing; A A)

Emulsion Pump Lubrication Oil Temperature Transducer Pt No PT100

- MONITORING SYSTEM -

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7.4.3 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 93: 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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7.5

FILTRATION SYSTEM MONITORING

7.5.1 Emulsion Return Header Pipe Pressure Transducer

Mounted above the return header pipe, this transducer monitors the pressure in the return header pipe. An increase in pressure indicates that the filters are becoming blocked and a signal will be sent to the PLC when the pressure rises above the set point to indicate that the filter requires changing.

A

Figure 94: Photo of Emulsion Tank showing; A)

Emulsion Return line Pressure Transducer

- MONITORING SYSTEM -

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7.6

CALIBRATION OF TRANSDUCER

7.6.1 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.

7.6.2 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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8.

FILTRATION SYSTEM 8.1

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.

8.2

EMULSION RETURN LINE FILTERS

On the inbye 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).

- FILTRATION SYSTEM -

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A

Figure 95: Photo of Emulsion Tank showing; A)

Return Line Hydac Filters Pt No RFBNHC1300DP005

- FILTRATION SYSTEM -

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8.3

EMULSION INLET FILTER

Located on the outbye end of the emulsion storage tank, the inlet filter is provided to filter the emulsion as it first enters the storage tank.

The filter is fitted with a 25 micron (25µm)

element.

A

B

Figure 96: 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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8.4

MINERAL OIL FILTER

8.4.1 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

Figure 97: 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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8.5

SHEARER WATER PUMP INLET FILTER

Fitted to the shearer water pump unit is a stainless steel inline, 80 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 98: A) Shearer water inlet filter

- FILTRATION SYSTEM -

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8.6

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 99: 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 100: Photo of Support Rod Spacer showing; A)

Filtration Magnets

B

Stainless Steel Spacer

Pt No Item 2610

- FILTRATION SYSTEM -

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8.7

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

ADM Solenoid Valve

B) Filter Block

Pt No H6256279

- FILTRATION SYSTEM -

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8.8

SERVICE AND MAINTENANCE PROCEDURES

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

• Newpac Number 1 Colliery Standard PPE. b. Safety Procedures; • Pump Isolation Procedures refer Section 2.

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

• Isolate pressure from all three chock pumps and the positive set pump following Isolation and Venting Procedures in Section 2.

• 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.

- FILTRATION SYSTEM -

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• Insert a new filter element into the housing.

• Replace filter housing cover and tighten bolts.

A

Figure 102: Photo of Emulsion Filter showing; A)

Cover Bolts

- FILTRATION SYSTEM -

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Figure 103: Photo of Hydac Filter Element Pt No H9000064

- FILTRATION SYSTEM -

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8.8.2 Procedure for Changing Shearer Water Inlet Filter Element

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

• Newpac Number 1 Colliery Standard PPE.

b. Safety Procedures; • Pump Isolation Procedures. Refer Section 2.3.

2. PROCEDURES

a. Operation Procedure; • Isolate and vent pressure from shearer water pump according to Shearer Water Pump Isolation and Pressure Venting Procedure. Refer 2.3.

• 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.

- FILTRATION SYSTEM -

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9.

Mineral Oil Control System

9.1

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 9.11

For information and procedures regarding the crawler tracks see Section 10.

For information regarding the mineral oil pressure filter see Section 8.4.1

- MINERAL OIL CONTROL SYSTEM -

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9.2

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 104: 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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9.3

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.

9.4

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.

A

Figure 105: Photo of Directional Control Valves showing; A)

Leveling Cylinder’s Control Levers

- MINERAL OIL CONTROL SYSTEM -

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9.5

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

Pt No 0000.008.562.01.85

- MINERAL OIL CONTROL SYSTEM -

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9.6

REMOTE PENDANT CONTROL SYSTEM

9.6.1 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 107: Photo of Remote Pendant Control showing; A) Dead Man Switch

B) Pendant Control

- MINERAL OIL CONTROL SYSTEM -

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9.6.2 Remote Pendant Control Connection Panel

Figure 108: Photo of Remote Control Panel showing; Capped 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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9.7

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 10.

9.8

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 8.4.1

- MINERAL OIL CONTROL SYSTEM -

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9.9

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.

9.10 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.

- MINERAL OIL CONTROL SYSTEM -

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9.11 NEWPAC NUMBER 1 COLLIERY HYDRAULIC PUMP STATION POSITIONING PROCEDURE 1. SAFETY a Personal Protective Equipment (PPE) •

Safety glasses/goggles

•

Safety Boots/Shoes

•

Newpac Number 1 Colliery Standard PPE

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.

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

ii.

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.

iii.

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.

iv.

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

v.

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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vi.

Connect the three (3) off DN50 and the one DN40 high pressure lines from the monorail to the delivery manifold.

vii.

Open pump isolation valves

viii.

Shearer Water Pump Operating Procedures once shearer water sled is positioned level on the ground; 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 shearer water pump delivery manifold

c.

Open shearer water pump face delivery isolation valve.

ix.

Disconnect hydraulic supply hoses from PTO Connection.

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10. CRAWLER TRACKS ASSEMBLY 10.1 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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10.2 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 maneuvering the stations into or out of a cutthrough.

- CRAWLER TRACKS ASSEMBLY-

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B

A

Figure 109: Photo of Crawler Tracks showing; A)

DBT Crawler Tracks

- CRAWLER TRACKS ASSEMBLY-

B)

Planetary Hub

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10.3 TOWING THE PUMP STATION

10.3.1 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 9.4

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

Figure 110: Photo of Towing Unit showing; A)

5 Tonne hook Pt No WLSH 130-G-BLK

C)

B)

Cylinder Pt No M3000

Hand Pump Pt No P80

- CRAWLER TRACKS ASSEMBLY-

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10.3.2 PROCEDURE FOR CONNECTING TOWING ‘AFRAME’ TO TOW VEHICLE

1.

SAFETY

a. Personal Protective Equipment; • Safety Glasses.

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

Refer Section 9.4.

• 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.

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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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10.3.3

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 10.3.2.

• 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 112:

• 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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Figure 113: • Loosen and remove the UNC bolt using socket or spanner.

Figure 114 • Loosen and remove the other UNC bolt using socket or spanner.

- CRAWLER TRACKS ASSEMBLY-

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Figure 115:

• The Disengage cap is now removed as shown above.

• Do not remove any other component from the Hub.

Figure 116:

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

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Figure 117: • Position cap as shown above

Figure 118:

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Figure 119: • Insert and tighten the 2 UNC bolts as shown above.

Figure 120: • 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 121: • 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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10.4 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 8.4.

• 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 10.3.2.

• 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 122: Photo of Remote Pendant Control

- CRAWLER TRACKS ASSEMBLY-

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Figure 123: Photo of Remote Control Connection Panel showing Capped Quick Connectors

- CRAWLER TRACKS ASSEMBLY-

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10.5 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 124: Photo of Planetary Hub showing; A)

Oil Level Plug

C)

Oil Fill Plug

- CRAWLER TRACKS ASSEMBLY-

B) Oil Drain Plug

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10.6 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.

10.6.1 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 10.4 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.

- CRAWLER TRACKS ASSEMBLY-

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Figure 125: 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 126: 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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11.

SHEARER WATER PUMP SLED

11.1

PUMP TECHNICAL INFORMATION

PUMP TYPE: Output flow: Maximum working pressure:

HAUHINCO MODEL EHP 3K150/70 474 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

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11.2 SHEARER WATER PUMP COMPONENTS

Figure 127:

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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11.3 GENERAL DESCRIPTION

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

The Newpac Number 1 Colliery shearer water pump sled has been

constructed

for

mounting

on

the

monorail

for

transportation. The sled must be lowered to the ground and leveled with the four leveling cylinders positioned on the sled before operating. The sled is comprised of • One (1) off 3k150/70 shearer water pump/200kW motor set • One (1) off 600 Litre stainless steel water tank • One (1) off support frame including lifting points and forklift channels • Four (4) levelling cylinders • One (1) off 400 Bar accumulator • Monitoring devices • Filtration equipment • Control valving Pressurised 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.

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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.

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11.4 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 70mm 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 3.3 for a description of the operation of the pump.

The shearer water pump is connected to a 20 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 inlet filter. 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 shearer water pump is precharged with nitrogen to 60 Bar.

- SHEARER WATER PUMP -

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11.5 UNLOADING SYSTEM 11.5.1

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

3k150/80 SW Pump

U504

Demand for water is generally constant whenever the shearer is operating, therefore the shearer water pump is also operating. Output flow and pressure is constant therefore, thus 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 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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11.5.2

Shearer Water Pump Unloader Valves

The shearer water pump, unloader Hauhinco U504 valve, is a bypass type valve that 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 (474 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

D

Figure 128: Photo of Shearer Water Pump showing; A)

Delivery Hose to 20 L B)

Return Line from the pump

Accumulator

to the tank Pt No 1 ½ “ 250 Bar Rated Hose

C)

Working Overflow

D)

Shearer Water Tank

Valve Pt No H6229441

- SHEARER WATER PUMP -

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11.6 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 transducer set at 1.5 Bar [150 kPa] is fitted to protect the pump.

This transducer will automatically cut off the electric motor, should the oil pressure drop below 1.5 Bar, to protect the pump against mechanical failure.

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A

Figure 129: Photo of Shearer Water Pump showing; A)

Sight Glass

Pt No H2440113

Note

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

- SHEARER WATER PUMP -

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11.7

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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11.8 TRANSDUCERS FOR SHEARER WATER PUMP MONITORING

Transducers have been installed to monitor various aspects of the operation of the shearer water pump asembly. Aspects of the sled monitored are the temperature and pressure of the water stored in the shearer water tank, temperature and pressure of the pump lubricating oil, outgoing pump delivery pressure and upstream pressure of the shearer water inlet filter to monitor the condition of the filter element .

- SHEARER WATER PUMP -

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A

Figure 131: Photo of Shearer Water Pump showing; A)

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

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A

B

Figure 132: Photo of Shearer Water Tank showing; A) Shearer Water Tank Pressure

B) Shearer Water Tank

Transducer

Temperature Transducer

Pt No CB2031-A1068-H1-S63

Pt No PT100

0 –10 Bar

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A

B

Figure 133: 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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Figure 134:

Photo of Shearer Water Pump Sled

showing; A) Water Inlet Filter Pressure Transducer Pt No. CB2031-A1061-H1-S63 0 – 40 Bar

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11.8.1 Delivery Pressure Transducer

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

11.8.2 Inlet Water Pressure Transducer

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

11.8.3 Inlet Water Temperature Transducer

Provided to monitor the temperature of the water stored in the shearer water tank. An alarm is sent to the PLC if the temperature in the tank reaches 50oC and the pump will trip out if the temperature reaches 60oC.

11.8.4 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].

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11.8.5 Lube Oil Temperature Transducer Refer Section 7.4.3 for information regarding the lubricating oil temperature transducer.

11.8.6 Water Inlet Filter Pressure Transducer Installed on the upstream side of the filter the transducer monitors the pressure of the water flowing into the filter.

An increase in pressure indicates a blockage in the filter element and a signal will be sent to the PLC that the filter requires changing.

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11.8.7 Transducer Delivery 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 135: Photo of Shearer Water Pump showing; A) Transducer Pressure Dampener Pt No H4477588

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11.9 SHEARER WATER PUMP INLINE WATER INLET 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

Figure 136: Photo of Inline Water Filter showing; A)

Inline Filter Pt No OV/55 4

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11.10

SERVICE AND MAINTENANCE

11.10.1

Inspection and maintenance requirements for

shearer water pump unit 11.10.1.1 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.

11.10.1.2Weekly inspections and maintenance • Check oil is present in wick chambers on pumps.

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

• Check pump insert cap screws for correct torque; M16 Æ 210 Nm • Change lubricating oil (refer Section 3.9.2.4).

• Change lubricating oil filter (refer Section 3.9.2.5).

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11.10.1.4 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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11.10.2 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 (PPE); • Safety Glasses.

• Newpac Number 1 Colliery Standard PPE b. Safety Procedures; •

Pump Isolation Procedure Refer Section 2.3

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 2.3 • Undo hose end nut on unloader hose assembly at valve

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• Undo SAE split clamps on hose end on high pressure delivery hose assembly to disconnect hose.

• Remove the SAE fitting and 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 replacement unloader valve on the pump body and insert the two M16 capscrews and tighten with 14mm Allen Key • Replace the nipples in the outlet ports of the new unloader valve.

• Replace the SAE Fitting on the nipple on the face delivery outlet • Connect

hose

end

on

unloader

hose

assembly to the new valve.

• Connect hose end on high pressure delivery hose assembly to new valve and replace split clamps.

• Fully open delivery isolation valve mounted on the shearer water accumulator manifold.

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A

B

C

D

Figure 137: Photo of Shearer Water Pump showing; A)

M16 Socket Head Capscrews

B)

Medium Outlet

Pressure Delivery Hose

150Bar

Max

Pressure 1 ½”hose 250 Bar rated hose C) Nipple (behind hose end) Pt No 1 ¼ ” x 1 ½ “ Nipple

D)

Low Pressure Unloader Hose 1 ½”BSP f/swivel to 1 ½”Code 61 SAE 250 Bar rated hose

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A

B

Figure 138: Photo of Face Delivery Manifold showing;

A)

Shearer Water Accumulator Manifold

B)

Shearer Water Pump Face Delivery 2” Isolation ball Valve Pt No MKHG2-4423 (Closed Position)

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11.10.3

Maintenance Procedures

Procedures for the following maintenance tasks are identical to those given in Section 3.9.2.

• Adding oil to pump crank case.

• Changing pump lubricating oil.

• Changing lubricating oil filter.

• Changing oil seal in oil distributor.

• 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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12. MISCELLANEOUS ITEMS 12.1. 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 139: Photo of Receptacle Stand showing; A)

Quick Release Electrical Receptacles Chock Pumps

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Figure 140: Photo of Receptacle Stand showing; A)

Quick Release Electrical Receptacles Positive Set Pump

Figure 141: Photo of Receptacle Stand showing; A)

Quick Release Electrical Receptacles Positive Set Pump

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12.2. 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 142: Photo of Chock Pump Junction Box showing; A)

Emergency Stop Button

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12.3. START AND STOP BUTTONS

12.3.1. Chock Pump & Positive Set Pump Stop Start Buttons 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

D

Figure 143: Photos of Pump Station Start and Stop Buttons A)

Chock Pump No 1

B)

Chock Pump No 2 & Boost Pump

C)

Positive Set Pump

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12.3.2. 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 shearer water pump sled behind the shearer water.

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12.4. LOCKABLE BALL VALVES

12.4.1. Face delivery isolation ball valves

The four (4) off high pressure face delivery isolation valves are located on the inbye face of the pump station delivery manifold. Three of the isolation valves are DN50 lockable ball valves for the chock pump emulsion delivery and the fourth is a DN40 lockable ball vale for the positive set pump. All of these valves are lockable when in the closed position.

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A

B

Figure 144: Photo of Face Delivery Manifold showing; A)

Chock Pump Face Delivery Isolation Ball Valves Pt No DN50 SAE to Super Stecko

B)

Positive Set Pump Face Delivery Isolation Ball Valve Pt No DN40 SAE to Super Stecko

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12.4.2 Emulsion Pump Delivery Isolation Ball Valves

Two (2) off isolation ball valves are mounted on the dual accumulator manifold with a third isolation ball valve is mounted on the single chock pump accumulator manifold.

The positive set pump has an isolation ball valve mounted on the positive set pump accumulator manifold. These valves are used as part of the isolation procedures as described in Section 2. These ball valves may be locked when in the closed position

A

Figure 145: Photo of Chock Pump Dual Accumulator Manifold showing; A) Chock Pump Delivery Isolation Ball Valve Pt NoDN50 SAE to SAE

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A

Figure 146: Photo of Chock Pump Single Accumulator Manifold showing; A) Chock Pump Delivery Isolation Ball Valve (Closed Position) Pt NoDN50 SAE to SAE

A

Figure 147: Photo of Positive Set Pump Accumulator Manifold showing; A) Chock Pump Delivery Isolation Ball Valve (Closed Position) Pt NoDN50 SAE to SAE

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12.5 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 148: Photo of Pump Station showing; A) Lifting Points

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12.6 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 149: Photo of Emulsion Storage Tank showing: A)

Level Indicator Pt No LEV-0-GAGE SR

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Figure 108: Photo of Pump Station Level Indicator Pt No LEV-0-GAGE SR

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12.7 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 151: Photo of Emulsion Tank Return Header Pipe showing; A)

Face Emulsion Ports

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B) Decompression Return Port

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12.8

IMPORTANT SIGNS ATTACHED TO THE PUMP STATION

All items of importance on the pump station are labelled using stainless steel labels.

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13. INSPECTION REQUIREMENTS NOTE: The inspection requirements stated apply to all pumps unless stated otherwise.

13.1 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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13.2 EVERY THREE (3) MONTHS – OR – 1000 HOURS OF OPERATION

• Examine Pressure Hoses for damage.

• Change the lubricating oil in pumps (Refer Section 3.9.2.4).

• Change

Lubricating

Oil

Filter

(Refer

Section

3.9.2.5).

13.3 EVERY SIX (6) MONTHS • Inspect tension of crawler tracks and add grease if needed. (Refer Section 10.6).

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13.4

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 5.12.2).

• Replace oil in Planetary Hubs of crawler tracks (or after 1000 hours of operation) (Refer Section 10.5).

- INSPECTION REQUIREMENTS -

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