Bsi bs en 01804 2 2001 + a1 2010

Unknown BRITISH STANDARD BS EN 1804 2 2001 +A1 2010 Machines for underground mines — Safety requirements for hydraulic powered roof supports — Part 2 Power set legs and rams ICS 73 100 10 NO COPYING W[.]

Machines for

underground mines —

Safety requirements for

hydraulic powered roof

supports —

Part 2: Power set legs and rams

ICS 73.100.10

National foreword

This British Standard is the UK implementation of

EN 1804-2:2001+A1:2010 It supersedes BS EN 1804-2:2001 which is withdrawn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

NORME EUROPÉENNE

English Version Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 2: Power set legs and

rams

Machines pour mines souterraines - Exigences de sécurité

relatives aux soutènements marchants applicables aux

piles - Partie 2: Etançons et vérins à pose mécanisée

Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen für hydraulischen Schreitausbau

- Teil 2: Stempel und Zylinder

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 5

4 List of hazards 7

5 Safety requirements 7

6 Verification of the safety requirements 11

7 User information 12

Annex A (normative) Tests for verification of the safety requirements 17

Annex B (normative) List of tests 30

Annex ZA (informative) !!Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC"" 36

Bibliography 37

Foreword

This document (EN 1804-2:2001+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 1804-2:2001

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 1: Support units and general requirements

Part 3: Hydraulic control systems

Part 41): Electro-hydraulic control systems

Annexes A and B are 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

1) in preparation

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;

 negotiations have taken place between the user and the manufacturer of the legs and rams (manufacturer of the roof support unit or final user in case of replacement parts) concerning the use of the machinery

1 Scope

This standard specifies the safety requirements for legs and rams when used as specified by the manufacturer or his authorised representative Examples covered by the standard include legs, support rams and rams with their mechanical extensions, internal valves and safety devices, seals, hydraulic connections (up to the first hose or Type B valve, see Part 3) and their lifting points but excluding protective pipes and gaiters, external valves and hydraulic and electrohydraulic control systems

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

This standard applies to legs, support rams and rams used at ambient temperatures from –10 °C to 60 °C This standard identifies and takes account of:

 Possible hazards which may be caused by the operation of legs, support rams and rams;

 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 standard is applicable to all legs, support rams and rams placed on the market for the first time and which are manufactured after the date on which this standard was published

This European standard does not establish the additional requirements for:

 Specially corrosive environments;

 Hazards occurring during construction, transportation, decommissioning;

 Earthquake

2 Normative references

This European Standard incorporates by dated or undated reference, provisions from other publications These normative references are cited at the appropriate places in the text, and the publications are listed hereafter For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision For undated references the latest edition of the publication referred to applies (including amendments)

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 292-2:1991 + A1:1995, Safety of machinery - Basic concepts, general principles for design – Part 2: Technical principles and specifications

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

EN 1804-1:2001, Machines for underground mines - Safety requirements for hydraulic powered roof supports – Part 1: Support units and general requirements

!EN 1804-3", Machines for underground mines - Safety requirements for hydraulic powered roof supports – Part 3: Hydraulic control systems

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

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

ISO 7745:1989, Hydraulic fluid power - Fire-resistant (FR) fluids - Guidelines for use

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

3.1

support unit

type of hydraulic powered roof support e.g frame support, chock support, shield support, consisting of support components and support accessories [EN 1804-1:2001]

legs and support rams

hydraulic actuators for producing the support bearing force of the support unit

3.2.3

single telescopic legs and support rams

hydraulic legs and support rams with one extension stage

3.2.4

multi telescopic legs and support rams

hydraulic legs and support rams with several extension stages

yield pressure of an actuator

Hydraulic pressure in an actuator when the relevant pressure limiting valve is opened This pressure in the actuator is induced by external forces (yield forces; see 3.5.2 of EN 1804-1:2001)

3.5.3

maximum permissible working pressure of an actuator

maximum hydraulic pressure at which a hydraulic component is intended be operated and/or yielded

3.6

rated actuator force

Maximum force to which an actuator is designed It is a calculated value which is determined from the actuator geometry and the maximum permissible working pressure, neglecting friction

to eliminate or reduce risk

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

No EN 1050:1996 Safety requirements (clause) Hazards

4 1e; 1.8 5.2; 5.5; 5.6; 5.7; 5.8; 5.10 to 5.13 Fatigue, overload; friction or wear

devices and accessories for assembly and maintenance

which may move under the effect of gravity

5 Safety requirements

5.1 Lifting points

Where lifting points are fitted to actuators they 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

5.2 Internal valves and safety devices

Actuators, that can be externally overloaded, shall be protected against excessive pressure

This can be by means of

internal valves

external valves (see !EN 1804-3")

safety devices such as bursting blanks

The pressure in the piston compartment of hydraulic legs shall be capable of being monitored so that leakages are recognised in good time and hazards from inadequate strata control as a result of a pressure drop in the legs are avoided

As a result of the type of fluid used and the small number of pressure cycles per day, actuators of hydraulic powered roof supports need neither to be self-bleeding nor shall they have external air bleeds

In addition, internal valves, excluding constant yield valves, are covered by !EN 1804-3" of the standard

5.3 Hydraulic fluids

Actuators shall be designed such that they may be used with:

a) fire-resistant fluids category HFA (ISO 7745:1989) specified by the support unit manufacturer in according

to 6.2.1 of ISO 7745:1989

or

b) water without additives

NOTE Hydraulic systems of roof supports, designed for coal mines and other mines with potentially explosive atmospheres, should be designed for use with non-toxic and fire-resistant fluids in accordance with SHCMOEI 7th Report (see Bibliography)

5.4 Protection against ejecting fluids

Actuators that intentionally eject fluid in to the atmosphere shall be designed to prevent any hazard due to the releasing fluid (e.g by means of a guard)

5.5 Yield capability

Legs and support rams shall be designed such that at yield pressure they are capable of supporting the forces and the movements of attached components, see annex A (see 5.3.1 of EN 1804-1:2001)

5.6 Behaviour under axial overload

Legs and support rams, including their mechanical extensions, shall be designed so that their function is not affected it they are subjected statically to 1,5 times the rated compressive or tensile force and dynamically to a mechanical impact load resulting in 1,5 times the maximum permissible working pressure (See annex A) Where dynamic load testing is not practicable legs and support rams shall be subjected statically to 2 times the rated compressive or tensile force

Rams, including their mechanical extension pieces, shall be designed so that their function is not affected it subjected statically to 1,5 times the rated compressive or tensile force (See annex A)

In the fully retracted condition legs and support rams shall be capable of withstanding 2 times the rated compressive force

Rams shall withstand 1,5 times the maximum permissible working pressure when the piston is in fully extended in contact with the internal stop

Support rams that are subjected to tensile load in operation shall not be damaged when they are fully extended in contact with the internal stop and loaded with 1,5 times the rated tensile force

5.11 Force introduction points of actuators

The force introduction points of actuators and their extension pieces shall be capable of withstanding 1,5 times the rated actuator force without their function being affected

The elongation at fracture (A) of the steel grades used shall be not less than 10 %

5.12.1.2 Steel for welded actuator components

The steel shall be of fine grain, (ferrite grain size 6 or finer as described in EURONORM 103: 1971) and shall have an impact value of at least 27 J at a temperature of -20 °C

5.12.1.3 Steel for non-welded actuator components

The steel used for the non-welded tubes of actuators shall have properties as described in 5.12.1.1 and 5.12.1.2

The steel used for the other components shall have an impact value of at least 25 J at a temperature of 20 °C

5.12.4 Seals

Actuator seals shall full fill the test requirements given in annex A

5.13 Calculated permissible stresses

5.13.1 Permissible stresses under axial central rated force conditions

The axial stresses in the individual parts of the actuators shall not exceed 70 % of the guaranteed yield point, 0,2 % proof stress or compressive limit of the materials (also valid for annular stresses as a result of fluid pressure)

The axial stresses in the bases of actuators shall not exceed 80 % of the guaranteed yield point, 0,2 % proof stress or compressive limit of the materials

The shear stresses shall not exceed 65 % of the guaranteed yield point, 0,2 % proof stress or compressive limit of the materials

5.13.2 Permissible stresses under double axial central rated force conditions

In the case of twice the central rated force in the fully retracted state of legs and support rams, the stresses shall not exceed the guaranteed yield point or 0,2 % proof stress of the materials

NOTE This requirement only involves mechanical loading There are no hydraulic pressures

5.13.3 Permissible stresses under eccentric rated force conditions

In the case of the eccentric rated force as described in A.1.3.1 the axial stresses of the leg and support ram components involved in bending shall not exceed the guaranteed yield point or 0,2 % proof stress or compressive limit of the materials The deflections determined by means of a test as specified in A.1.3.2 shall

be used as a basis for calculating the stresses

In the case of an eccentric rated force and simultaneous lateral loading (e.g to stabilize the support unit), the axial stresses of the leg and support ram components involved in bending shall not exceed the guaranteed yield point or 0,2 % proof stress or compressive limit of the materials

5.13.4 Permissible weld stresses

The weld stresses shall not exceed the permissible stresses of the adjacent materials given in Table 2, if the welds are not subjected to any non-destructive testing

Table 2 — Permissible weld stresses (5.13.1 to 5.13.3) Weld types Axial stresses Shear stresses Combined stresses

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

b) a certificate issued by an accredited body confirming compliance with the quality requirements of

EN 729-3

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

5.15 Correct assembly and installation

It shall be possible to assemble and install the actuator correctly in accordance with the assembly instructions

or other documents provided by the manufacturer

6 Verification of the safety requirements

6.1 Type testing

One specimen of the actuator 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.2;

 Manufacturing drawings;

 Drawing of welded parts;

 Evidence of the competence of the welding workshop;

 Data relating to the material characteristics;

 Data relating to the seals used

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

*type test; **series test

Clause 7 User information of EN 1804-1:2001 also applies to !EN 1804-3" and !prEN 1804-4") and

is complemented, as appropriate, by corresponding clauses in those parts

Care shall be taken to ensure that the user information is available to the user on receipt of the actuator

7.2 Technical and application data

7.2.1 Introduction

The user information shall describe the intended use of the actuator

The operating instruction shall include all design and performance data necessary, either for the user or for the manufacturer of the hydraulic powered roof support, 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 7.2.5

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 actuator with all special features and characteristics General arrangement drawings shall be provided as appropriate

7.2.5 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-reference 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 actuator

7.3.2 Handling and transport

The details shall include:

a) Weights and outline dimensions of all the supplied actuators

b) Precautions to be taken during handling and transportation In addition, indications of possible damage to the actuators during handling and transport

c) 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 actuators

7.3.3 Storage

The following information shall be given for the storage of the actuator on the surface and underground:

a) methods of preservation; and

b) instructions for preparing the actuator for use after storage

7.4 Installation, commissioning and operation

Details shall include:

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

b) connection of hydraulic pressure supply;

c) commissioning the actuator and testing individual functions

7.5.2 Maintenance instructions

Instructions shall be provided, with illustrations where necessary, detailing the methods and procedures for preventative and corrective maintenance The instructions shall include reference to the following:

a) dismantling and re-assembly;

b) replacement and adjustment;

c) a parts identification list;

d) special tools and additional equipment;

e) hazards which may arise and precautions to be taken

7.5.3 Fault diagnosis and correction

Information and instructions shall be included on fault diagnosis and correction

7.5.4 Preventative maintenance schedules

Schedules shall be provided and include information on the nature and frequency of inspections, tests, maintenance and discard criteria required to keep the actuator in safe working order

7.5.5 Technical Description

This shall be in the form of a comprehensive functional description of the actuator and its main components with appropriate illustrations designed to enable the text to be kept concise and easily understandable The description shall include details of the safety devices and measures for preventing hazards that may arise from malfunction of the equipment

7.6 Parts identification lists

A parts identification list shall be provided which shall include the part numbers and sufficiently full descriptions for positive identification of all assemblies, sub-assemblies and components of the actuator The list shall also 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

c) designation of the machinery;"

d) serial number, if any;

e) maximum permissible working pressures;

f) rated forces (tensile and compressive)

For marking of lifting points see 5.1

7.8 Residual risks

The user information shall inform the user of the residual risks when using the actuator

Annex A

(normative)

Tests for verification of the safety requirements

The tests described below and acceptance criteria are listed in Annex B

A.1 Load tests

A.1.1 General

The tests shall be carried out on actuators including the extensions, the internal valves and safety devices, the seals and the hydraulic connections During the load tests, no damage shall occur which impairs the load carrying capacity However, impairment of the load carrying capacity is permissible in the case of double overload test No cracks shall occur in the parent metal or in the welds

All measured values and results from the tests shall be recorded

A.1.2 Testing with a central axial load

A.1.2.1 Testing the extension limit

Actuators shall be extended once without encountering any external resistance against the internal stop at the maximum permissible working pressure according to 5.10 The actuator shall be left in this position for at least

3 min Support rams that are subjected to tensile loads in operation shall be extended once, by an external force, against the internal stop at 1,5 times the rated tensile force and shall be left in this position for at least 3 min

A.1.2.2 Yield test

The legs and support rams shall be loaded with an initial load of approximately 10 % of the rated leg or support ram force The connected pressure limitation valves shall be adjusted to the maximum permissible working pressure of the legs or support rams Then 2 yield tests shall be carried out for each condition, beginning at the fully extended condition, with the following travels and yield rates:

A.1.2.3 Overload tests

A.1.2.3.1 Static overload

The test may be carried out using one of the following alternative methods:

a) Actuators with possible mechanical extensions shall be fully extended at 80 % of their maximum permissible working pressure Next, the pressure compartments shall be isolated The actuators shall then be subjected to an external force of 2 or 1,5 times the rated force (see 5.6) This force shall be maintained whilst the leakage test as described in A.1.2.4 is carried out

The force applied shall be recorded and plotted against time

b) Actuators with possible mechanical extensions shall be extended against an abutment at (95 3) % of their maximum length Next the pressure compartments shall be loaded with 2 or 1,5 times the maximum permissible working pressure (see 5.6) Then the pressure compartments shall be isolated whilst the leakage test as described in A.1.2.4 is carried out

The pressure shall be recorded and plotted against time

In the tests described in a) and b) at 1,5 times the rated force or maximum permissible working pressure, the dilation of the cylinders shall be measured The permanent dilation of the cylinder diameter shall not exceed 0,02 %

In the case of actuators that will be subjected to tensile loads during operation, tests shall be carried out as in a) and b) but starting at the fully retracted position and with the annular compartments subjected to load

In addition, a test shall be carried out with legs and support rams fully retracted They shall be subjected to an external load of 2 times the rated force This force shall be maintained for at least 3 min

A.1.2.3.2 Dynamic overload

The test shall be carried out with legs and support rams at 70 to 80 % of their extended length but with a residual travel of at least 100 mm per stage in the case of legs and at least 30 mm per stage in the case of support rams The legs and support rams shall be set with 60 % of the maximum permissible working pressure and the pressure compartments shall be isolated Then the legs and support rams shall be subjected twice in succession to a sudden impact by means of a free-falling mass of at least 10000 kg for legs and at least 1000 kg for support rams This axial loading shall be applied centrally A pressure of 1,5 times (± 5 %) the value of the maximum permissible working pressure shall be attained The pressure increase from its initial value to the required pressure shall be measured with an adequate measuring device (e.g oscillograph) and be attained within a period of 30 ms The internal pressure shall be recorded and plotted against time For multi-stage legs and support rams the recorded pressure shall be the pressure in the largest stage

The functioning of the legs or support rams shall then be checked as described in A.1.2.2

A.1.2.4 Leakage test

The following requirements apply to all leakage tests within the standard Supplementary test parameters are given in specific clauses

During the leakage test the pressure compartments of the actuators to which the load is applied shall be isolated The pressure or the travel of the actuator shall be recorded and plotted against time During the first minute of test, the pressure shall not drop by more than 10 % or the actuator shall not change its length by more than 1 % For a further 5 minute period, the pressure or actuator length shall remain constant For a further 5 minute period, the pressure shall not change by more than 0,5 % and the actuator length shall not change by more than 0,05 %