Bsi bs en 01804 1 2001 + a1 2010

Unknown BRITISH STANDARD BS EN 1804 1 2001 +A1 2010 Machines for underground mines — Safety requirements for hydraulic powered roof supports — Part 1 Support units and general requirements ICS 73 100[.]

Machines for

underground mines —

Safety requirements for

hydraulic powered roof

supports —

Part 1: Support units and general

requirements

ICS 73.100.10

National foreword

This British Standard is the UK implementation of

EN 1804-1:2001+A1:2010 It supersedes BS EN 1804-1:2001 which is withdrawn

The start and finish of text introduced or altered by amendment is indicated in the text by tags Tags indicating changes to CEN text carry the number of the CEN amendment For example, text altered by CEN amendment A1 is indicated by !"

The UK participation in its preparation was entrusted to Technical Committee MRE/1, Mining mechanical equipment and machinery

A list of organizations represented on this committee can be obtained

on request to its secretary

This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application

Compliance with a British Standard cannot confer immunity from legal obligations.

This British Standard, having

been prepared under the

direction of the Engineering

Sector Policy and Strategy

Committee, was published

under the authority of the

Standards Policy and Strategy

Machines pour mines souterraines - Exigences de sécurité

relatives aux soutènements marchants applicables aux

piles - Partie 1: Unités de soutènement et exigences

générales

Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen für hydraulischen Schreitausbau

- Teil 1: Ausbaugestelle und allgemeine Anforderungen

This European Standard was approved by CEN on 21 September 2001 and includes Amendment 1 approved by CEN on 21 December

2009

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN Management Centre or to any CEN member

This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the official versions

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom

EUROPEAN COMMITTEE FOR STANDARDIZATION

C O M I T É E U R O P É E N D E N O R M A L I S A T I O N

E U R O P Ä I S C H E S K O M I T E E FÜ R N O R M U N G

Management Centre: Avenue Marnix 17, B-1000 Brussels

Contents Page

Foreword 3

Introduction 4

1 Scope 4

2 Normative references 5

3 Terms and definitions 6

4 List of hazards 7

5 Safety requirements 8

6 Verification of the safety requirements 13

7 User information 14

Annex A (normative) Tests for verification of the safety requirements and calculation 19

Annex ZA (informative) !!Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC"" 37

Bibliography 38

Foreword

This document (EN 1804-1:2001+A1:2010) has been prepared by Technical Committee CEN/TC 196

"Machines for underground mines - Safety", the secretariat of which is held by DIN

This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by July 2010, and conflicting national standards shall be withdrawn at the latest by July 2010

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights This document includes Amendment 1, approved by CEN on 2009-12-21

This document supersedes EN 1804-1:2001

The start and finish of text introduced or altered by amendment is indicated in the text by tags ! "

!This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s)

For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document." This standard is Part 1 of a European Standard specifying the safety requirements for hydraulic powered roof supports

Other parts are:

Part 2: Power set legs and rams

Part 3: Hydraulic control systems

Part 41): Electro-hydraulic control systems

Annex A is normative

This standard includes a Bibliography

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom

Introduction

This European Standard is a Type C-standard as stated in EN 1070

The extent to which hazards are covered is indicated in the scope of the standard

While producing (or when compiling) this standard it was assumed that:

 only trained and competent persons operate the machine;

 components without specific requirements are:

a) designed in accordance with the usual engineering practice and calculation codes;

b) of sound mechanical construction;

c) free of defects

 components are kept in good working order;

 a negotiation took place between the user and the manufacturer concerning the use of the machinery

1 Scope

This standard specifies the safety requirements for support units when used as specified by the manufacturer

or his authorised representative Examples of support units are frame supports, chock supports, shield supports, paired frames and push-pull support systems including the components of advancing and anchoring devices which provide support functions This part of the standard excludes fixing elements on the conveyor, coal-winning equipment, power set legs and rams, valves, hydraulic and electro-hydraulic control units, lighting and signalling facilities and other ancillary equipment

NOTE Some components are dealt with in other parts of this standard

This standard applies to support units used at temperatures from -10° C to 60° C

This standard also applies to support components and support accessories which are provided if the support unit is fitted with stowing equipment This standard identifies and takes account of:

 Possible hazards which may be caused by the operation of support units;

 Areas and operating conditions which may create such hazards;

 Hazardous situations which may cause injury or may be damaging to health;

This standard describes methods for the reduction of these hazards

A list of hazards covered appears in clause 4

This European standard does not establish the additional requirements for:

 Specially corrosive environments;

 Hazards occurring during construction, transportation, decommissioning;

EN 287-1, Approval testing of welders - Fusion welding – Part 1: Steels

EN 288-1, Specification and approval of welding procedures for metallic materials – Part 1: General rules for

fusion welding

EN 288-2, Specification and approval of welding procedures for metallic materials – Part 2: Welding procedure

specification for arc welding

EN 288-3, Specification and approval of welding procedures for metallic materials – Part 3: Welding procedure

tests for the arc welding of steels

EN 292-1:1991, Safety of machinery - Basic concepts - General principles for design – Part 1: Basic

terminology, methodology

EN 292-2:1991+A1:1995, Safety of machinery - Basic concepts - General principles for design – Part 2:

Technical principles and specification

EN 1050:1996, Safety of machinery – Principles for risk assessment

EN 1070, Safety of machinery – Terminology

EN 1804-2, Machines for underground mines - Safety requirements for hydraulic powered roof supports – Part

2: Power set legs and rams

!EN 1804-3", Machines for underground mines - Safety requirements for hydraulic powered roof supports

– Part 3: Hydraulic control systems

ENV 1993-1-1:1992, Eurocode 2: Design of steel structures - General rules and rules for buildings - General

rules and rules for buildings

EN 10002-1, Metallic material - Tensile testing – Part 1: Method of test

EN 10025:1990 + A1:1993, Hot rolled products of non-alloy structural steels - Technical delivery conditions

EN 10045-1, Metallic materials - Charpy impact test – Part 1: test method

prEN 13463-1:1999, Non-electrical equipment for potentially explosive atmospheres – Part 1: Basic

methodology and requirements

EURONORM 103:1971, Microscopic determination of the ferrite or austenitic grain size of steels

3 Terms and definitions

For the purposes of this standard the following terms and definitions apply

support unit in which the canopy and the base are connected to legs arranged one behind the other and side

by side to form one support unit

3.3

all components which do not lie within the flow of the support bearing force but which are necessary for the functioning of the powered roof support

support bearing force

force borne by a support unit normal to the strata, which is a function of the support height and which occurs

at the yield force

3.5.4

test force

measured force required to be applied to the support unit or support component to ensure that it is subjected

to the rated force

Table 1 — List of hazards with cross references to safety requirements

No EN 1050:1996 Safety requirements (clause) Hazards

1 1.1; 1.2; 1.3 5.1.1 Crushing, shearing and cutting

9 8.1; 8.2 5.1.1 Neglecting ergonomic principles leading

to unhealthy postures or excessive strain

11 18; 30.1 5.2.1; 5.2.2; 5.3.7 Tipping over, unexpected loss of stability

12 5.1.4 Absence or incorrect installation of

safety (protective) devices

13 5.1.5 Absence or incorrect installation or

important devices and auxiliaries for erection and repair

14 1.C 5.1.5; 5.1.7; 5.1.8; 5.2.1 Potential energy of support unit parts

which may move under the effect of gravity

5.1.3 Protection against ejected fluids

Support units shall be so designed that no hydraulic elements are damaged when used as intended

5.1.4 Protection against face material spalling

Support units having a maximum extended height of 2,5 m or more shall be fitted with devices to which sprags can be attached

The sprags shall be positively lockable when in the retracted position

5.1.5 Lifting and pulling points

Support units shall have lifting and pulling points

Lifting and pulling points shall be suitable for their intended purpose They shall be designed to have a calculated minimum factor of safety of 4 on ultimate breaking load in relation to their intended load carrying capacity They shall be clearly and permanently marked with their load carrying capacity, e.g by welding

With support units for use in inclined seams with gradients of more than 30°, the alignment force (push or pull)

of a support unit which is set shall be greater than the lateral weight component of three adjacent support units which are not set if these support units are no longer stable in the free-standing state

5.3.2 Behaviour when overloaded

Support components including face sprags shall be designed so that no failure occurs by bending, tension and compression when they are loaded up to 1,2 times the yield force of their respective actuators

5.3.3 Eccentric loading

Support units shall be designed in such a way that their ability to function is not impaired in the presence of eccentric loading e.g if the canopy is in contact with the roof on one side only

5.3.4 Loading resulting from caving or stowing

Support units shall be capable of withstanding the caving or stowing forces resulting from over tipping when operated on a gradient when working an over tipped face The forces and the gradients to be expected are normally be provided by the user (see clause 0 last indent)

5.3.5 Horizontal loading

Support units shall be designed to accommodate horizontal loads

Shield supports shall withstand a horizontal force corresponding to 0,3 times the support bearing force without any damage to the support components

All other support units shall either withstand the forces induced by the advancing mechanism or allow relative movement between canopy and base:

a) towards the waste, of at least 80 mm per metre of supported height and

b) in the coal face direction and to both sides, of at least 40 mm per metre of support height

5.3.6 Operational performance

The operational performance of the support unit shall remain unimpaired when subjected to a total of at least

26 000 load cycles with various load configurations (see A.1.3)

5.3.7 Force introduction points of legs and rams

The force introduction points of actuators shall be capable of withstanding 1,5 times the maximum tensile force and the compression force which can be generated by the support hydraulics without their function being adversely affected

5.4 Materials

5.4.1 Steel

5.4.1.1 General

The manufacturer shall specify the steel grades and characteristics to be used

The tensile strength of the steel grades used shall be at least 1,08 times the measured yield point or 0,2 % proof stress if the calculated stresses are more than 90 % of the permissible stresses (see 5.5)

The elongation prior to fracture A of the steel grades used shall not be less than 10 %, with the exception of steel grades used for pins where the elongation shall not be less than 9 %

For thermal cutting of the steels, the steel manufacturer's processing specifications shall be observed

5.4.1.2 Steel for welded support components

The steels shall be fully killed and either

a) conform to EN 10025:1990 + A1:1993, De-oxidation type FF or

b)

1) be of grain size 6 or finer as described in EURONORM 103:1971; and

2) shall have the following minimum impact values at a temperature of –20 °C :

20 J for steels with a 0,2 % proof stress of < 620 N/mm²

25 J for steels with a 0,2 % proof stress of > 620 N/mm²

The values given shall be obtained regardless of the sample position, transverse or longitudinal to the direction of rolling

The steels shall be weld able

5.4.1.3 Steel for non-welded support components

The steels shall be killed

The impact values of the steel grades shall be at least 25 J at room temperature (20 °C)

Static load calculations shall be carried out for all support components

Additional forces which stress a support component shall be taken into account

The stresses in the support components determined by calculation either shall not exceed the permissible stresses given in 5.5.2 to 5.5.5 or the manufacturer shall demonstrate by theoretical or experimental methods that the support component performs in a safe manner

5.5.2 Calculated axial stresses

For canopies, bases and footplates the calculated axial stresses shall not exceed the guaranteed minimum yield point or 0,2 % proof stress values of the materials For other support components, the calculated axial stresses shall not exceed 85 % of these values

5.5.3 Calculated shear stresses

The calculated shear stresses shall not exceed 80 % of the calculated axial stresses allowed for each support unit and load case

5.5.4 Calculated combined stresses

The calculated combined stresses shall not exceed the guaranteed minimum yield points or 0,2 % proof stress

of the materials

5.5.5 Calculated weld stresses

The calculated weld stresses shall not exceed the following values of the permitted stresses of the adjacent materials The welded joints and combined stresses shall be calculated in accordance with ENV 1993-1-1:1992 or an equivalent method

Table 2 — Weld stresses

Weld type axial stresses Shear stresses Combined stresses Fillet welds 65 % 65 % 100 % Butt welds 100 % 65 % 100 %

5.6 Articulated joints

Articulated joints which lie in the flow of the support bearing force shall be designed so that the permissible stresses as specified in 5.5 are not exceeded when subjected to:

a) central loading at 1,5 times the rated force;

b) horizontal loading at the rated force (see Figure A.6);

c) eccentric and central loading when combined at the rated force (see Figures A.1, A.2 and A.5)

5.7 Welding

All welding shall be carried out in accordance with EN 288-1, EN 288-2 and EN 288-3 The manufacturer shall make use of competent welding shops and welders This can be reached by either:

a) operating a certified quality system according to EN ISO 9001; or

b) a certificate issued by an accredited body confirming compliance with EN 729-3

The welding shall be done by competent welders approved in accordance with EN 287-1

6 Verification of the safety requirements

6.1 Type testing

One specimen of the support unit shall be type tested in accordance with Annex A The test requirements given in Annex A shall be met The following documents shall be made available to the laboratory running the type test:

 User information;

 Results of a static calculation in accordance with A.8;

 Manufacturing drawings;

 Welding drawings;

 Data relating to the material characteristics;

 Evidence of the competence of the welding workshop

NOTE The specimen which has been tested according to Annex A should not be placed on the market

If no provision has been made in Annex A for verification of the requirements in clause 5 by specified tests, they shall be verified by means of visual inspection, function test or reference to documents

Verification of the safety requirements is shown in Table 3

Table 3 — Tests for verification of the safety requirements Safety requirements Verification

5.1.7 *Visual inspection of manufacturer’s test documentation

5.1.8 *Visual inspection/comparison with the manufacturers assembly drawings 5.2.1 *Function tests or calculation

5.3.1 *See A.1.1 and A.1.2.4

5.3.2 *See A.1.1, A.1.2.1 and A.1.2.2

5.3.3 *See A.1.1 and A.1.3.4

5.3.5 *See A.1.1, A.1.2.5 and A.1.3.5

5.3.6 *See A.1.1 and A.1.3

5.3.7 *See A.1.1 and A.1.2.3

5.7 **Visual inspection of accredited body certificate

*type test; **series test

The user information shall be the primary source of information on a complete hydraulic powered roof support and shall contain all the information relating to its safe application and this shall be produced as an instruction handbook as specified in 5.5 of EN 292-2:1991 + A1:1995

Care shall be taken to ensure that the user information is available to the user on receipt of the hydraulic powered roof support The content and structure of the user information shall comply with 5.1.3 of EN 292-2:1991 + A1:1995

7.2 Technical and application data

7.2.1 Introduction

The user information shall describe the intended use of the hydraulic powered roof support

The operating instruction shall include all design and performance data necessary for the user to make an assessment of suitability for use in particular applications and environments, and for the identification of any energy supply requirements and other ancillary facilities that may be needed The information provided shall comply with 7.2.2 to 7.2.4

7.2.2 General description

This description shall explain in clear, easily understandable language of the user and in logical sequence the overall function of the hydraulic powered roof support with all special features, characteristics and markings General arrangement drawings and function block diagrams shall be provided as appropriate

7.2.3 Performance data

The principal dimensions, weights, centres of gravity and performance capabilities of the complete support unit and, where applicable, of its main component parts shall be given

In particular, information shall be provided on:

a) performance capability (e.g support bearing force and height adjustment range);

b) working conditions and limitations (e.g by giving details of minimum and maximum effective seam thickness, minimum and maximum seam pitch in the direction of and at right angles to the advancing mechanism, minimum and maximum over tip angle of the working and stowing face in relation to natural seam pitch, measured at the seam level) It shall also be stated for which working method the support units are to be used, e.g long wall method with caving, short wall method using pneumatic solid stowing etc.;

c) operating and control methods (e.g immediate forward support system, conventional support advance system, adjacent control and sequential control);

d) hazards and corresponding safety precautions for each type of support operating mode (e.g automatic control mode) and for combined use with other operating devices

7.2.4 List of additional drawings and documents

A complete list of all drawings, illustrations and other documents including e.g information about welding qualification, which are part of the information for use but provided separately from the user information, but which form part of the information required by this standard shall be provided The list shall include appropriate cross-references to the text, of the user information

7.3 Handling, transport and storage

7.3.1 Introduction

This section of the user information shall include information and instructions for the safe handling, transport and storage of the hydraulic powered roof support or its components

7.3.2 Handling and transport

The details shall include:

a) instructions for dismantling and for protection of parts during transport to their place of work;

b) list of individual components and assemblies which may be required to be lifted and transported separately, together with location of lifting points and centre of gravity;

c) weights and outline dimensions of the complete hydraulic powered roof support and individual components and assemblies listed in b) above;

d) details of any particular precautions to be taken during handling and transportation In addition, indications of possible damage to the hydraulic powered roof support during handling and transport; e) information on the number and rated load of any ancillary lifting equipment (e.g shackles, eye bolts) not supplied but necessary in order to enable safe lifting/installation of the various equipment or assemblies

7.3.3 Storage

Instructions shall be given for the storage of the hydraulic powered roof support and its main components on the surface and, where appropriate, underground as follows:

a) methods of preservation and

b) instructions for preparing the hydraulic powered roof support for commissioning after storage

7.4 Installation and commissioning

Details shall include:

a) checking the correct installation prior to connection to the hydraulic pressure supply and information on the necessary cleaning and purging procedures;

b) connection of the hydraulic pressure supply;

c) commissioning the hydraulic powered roof support and testing individual functions

7.5 Operation

This section of the user information shall include the information and instructions necessary for the safe operation of the hydraulic powered roof support

Details shall include:

a) correct use, with information on the operating range and prohibited applications;

b) mode of control;

c) location, purpose and function of each control available to the operator; and

d) location, purpose and method of use of monitoring and control facilities

7.6 Maintenance

7.6.1 Introduction

This section of the user information shall contain the necessary information and instructions to enable the hydraulic powered roof support to be maintained in, or restored to, safe working order The information provided shall be according to 7.6.2 to 7.6.5

7.6.3 Maintenance instructions

Maintenance instructions shall be provided, with illustrations where necessary, detailing the methods and procedures appropriate to the more complex preventative and corrective maintenance tasks to be carried out

in the working environment The instructions shall include reference to the following:

a) dismantling and reassembly;

b) replacement, adjustment, calibration and testing;

c) reference to parts identification lists;

d) special tools, test equipment and additional equipment; and

e) hazards which may arise and precautions to be taken

7.6.4 Fault diagnosis and correction

Information and instructions shall be included on fault diagnosis and correction

7.6.5 Maintenance schedules

Maintenance schedules shall include information provided by the manufacturer on the nature and frequency of

support in safe working order Guidance shall be given on the nature of deterioration and defects to be looked for when carrying out tests and inspections Where appropriate, limits of deterioration shall be stated which, if exceeded, could prejudice continued safe working

7.7 Parts identification lists

Parts identification lists shall be provided which include the manufacturer's part numbers and descriptions sufficient for positive identification to be made of all assemblies, sub-assemblies and components of the hydraulic powered roof support which are designed as replaceable items The list shall identify:

a) those parts which the manufacturer envisages being changed in the working environment; and

b) those parts which the manufacturer recommends should be held as spares

Parts identification lists shall be illustrated by drawings, photographs etc as appropriate, so that each component listed may be readily identified and located The list shall be presented logically in a hierarchical manner to facilitate identification of a part number by reference, first to the support unit, then to the appropriate assembly and sub-assembly and hence to the component or replaceable item

For commercially available parts of hydraulic powered roof supports, permissible values and dimensions shall

be stated or the original manufacturer's name and part number and/or a full technical description shall be given

 designation of the machinery;"

 serial number, if any;

 total leg yield force

All support components shall be clearly marked to show identification with their associated support unit type

7.9 Residual hazards

The user information shall inform the user of the residual hazards caused e.g by strata movement, when using the hydraulic powered roof support

Annex A

(normative)

Tests for verification of the safety requirements and calculation

A.1 Load tests

A.1.1 General

A.1.1.1 Introduction

The tests will take place on a complete support unit The may also take place on an individual component or a combination of components as long as this reflects the intended use

The load tests are explained by Figures A.1 to A.10

On completion of the test there shall be no cracks in the parent metal of any support component Neither cracks in welds nor permanent deformations which adversely affect the support performance shall be acceptable

All measured values and results from the tests shall be recorded

A.1.1.2 Loading conditions

Loading pads which are positioned to induce symmetrical bending stresses shall be 150 mm wide up to a bearing stress of 2,2 kN/cm2 and reach across the full width of the support component

During the test, if the bearing stress exceeds 2,2 kN/cm2, the size of the loading pad shall be increased accordingly

Loading pads which are positioned to induce torsional stresses shall be 200 mm wide and have a length of

25 % of the width of the support component In the case of the base components with separate skid sections, one of the pad dimensions shall be large enough to cover the total skid width Loading pads shall be positioned at the centres of loading as shown in Figure A.1 to A.10 Loading pads shall be positioned to the edges of the support component being tested unless it is necessary to move them away from the edge to achieve a stable loading condition

Loading pads shall be designed to accommodate flexure of the component being tested to prevent edge loading Loading pads shall be of sufficient height to accommodate flexure of the support components during test If forces are transmitted to the ends of a support components through articulated joints, they shall be introduced via the hinge (see e.g Figure A.1.2a)

Canopies and bases that are curved at the ends shall be tested in the same way as straight components for a curvature up to 30° With a curvature greater than 30°, the curved end shall not be included in the test

A.1.2 Single loading tests

A.1.2.1 Bending test

All support components subject to bending stress shall be tested for bending The bending test shall be carried out with 1,2 times the test force