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

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

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

Language : English
Pages : 276
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

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

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 4
1 4 Icons used throughout this manual 5
1 5 Safety instructions 6
1 5 1 Emergency stop procedure 6
1 5 2 Pump isolation steps 7
1 6 Pump station start up procedures 8
2 EMULSION CHOCK PUMP 9
2 1 Pump technical information 9
2 2 Pump components 10
2 3 General description 12
2 4 Pump operation 13
2 5 Unloading control system 15
2 6 Lubrication system 16
2 7 Correction direction of operation 19
2 8 Accumulators 20
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LONGWALL PUMP STATION
SERVICE & MAINTENANCE MANUAL 2006
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2 9 Servicing and maintenance of pumps 22
2 9 1 Inspection and maintenance requirements 22
2 9 1 1 Daily inspection and maintenance 22
2 9 1 2 Every 3 months – OR – 1000 hours of
operation 22
2 9 1 3 Every 12 months – OR – 5000 hours
of operation inspection to be carried
out by SES service engineer 23
2 9 2 Maintenance procedures 24
2 9 2 1 Pre-maintenance 24
2 9 2 2 Procedure for checking the pump oil
level 25
2 9 2 3 Procedure for adding lubricating oil to
the crankcase 26
2 9 2 4 Procedure for changing lubricating oil 27
2 9 2 5 Procedure for changing oil filter 30
2 9 2 6 Procedure for changing oil seal and
nozzle in oil distributor 32
2 9 2 7 Procedure for bleeding air from the
pump 36
2 9 2 8 Procedure for removing a pump insert
assembly 39
2 9 2 9 Procedure for the disassembly of a
pump insert 42
2 9 2 10 Pump insert inspection requirements 45
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AUSTAR COAL MINE PTY LTD
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SERVICE & MAINTENANCE MANUAL 2006
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2 9 2 11 Procedure for the reassembly of a
pump insert 46
2 9 2 12 Procedure for the refitting of a pump
insert assembly 49
2 9 2 13 Procedure for the removal of plungers 51
2 9 2 14 Refitting plungers 54
2 9 2 15 Replacing the plunger packing 55
2 9 2 16 Removal of ADM solenoid filter block
assembly 58
2 9 2 17 Replacing ADM solenoid filter block
assembly filter element 60
2 9 2 18 Replacing ADM solenoid filter block
assembly filter element 61
2 9 2 19 Exchange of safety relief valve 63
2 9 3 Service tools 66
2 9 3 1 Set screws for valve holders of pump
inserts 66
2 9 3 2 Set screw for oil distributor 66
2 9 3 3 Withdrawing device for plungers 66
2 9 3 4 Withdrawing device and assembly
mandrel locking pin of crosshead 67
2 9 4 Additional pump information 68
2 9 4 1 Bolt tightening torques 68
2 9 4 2 Grease 69
2 9 4 3 Sealant 69
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LONGWALL PUMP STATION
SERVICE & MAINTENANCE MANUAL 2006
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2 9 5 Trouble shooting guide for Hauhinco
pumps 70
3 POSITIVE SET PRESSURE PUMP 73
3 1 Pump technical information 73
3 2 General description 74
3 3 Pump operation 77
3 4 Unloading control system & 32L accumulator 77
3 5 Lubrication system 78
3 6 Correct direction of operation 80
3 7 Service & maintenance of pumps 81
3 7 1 Inspection and maintenance requirements 81
3 7 1 1 Daily inspections and maintenance 81
3 7 1 2 Every 3 months or 1000 hours of
operation 81
3 7 1 3 Every 12 months or 5000 hours of
operation Inspection to be carried out by
SES service engineer 82
3 7 2 Maintenance procedures 83
3 7 2 1 Pre-maintenance procedures 83
3 7 2 2 Procedure for checking the pump oil
level 84
3 7 2 3 Procedure for adding oil to the
crankcase 85
3 7 2 4 Procedure for changing lubricating oil 85
3 7 2 5 Procedure for changing oil filter 85
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SERVICE & MAINTENANCE MANUAL 2006
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3 7 2 6 Procedure for changing nozzle and oil
seal in the oil distributor 85
3 7 2 7 Procedure for bleeding air from the
pump 89
3 7 2 8 Procedure for removing pump intake
and delivery valves 92
3 7 2 9 Procedure for removing pump insert
assemblies 93
3 7 2 10 Procedure for refitting of pump insert
assemblies 95
3 7 2 11 Procedure for removal of plungers 97
3 7 2 12 Procedure for fitting of plungers 100
3 7 2 13 Replacing the plunger packing 101
3 7 2 14 Procedure for replacing safety valves 104
3 7 3 Additional pump information 107
3 7 3 1 Bolt tightening torques 107
3 7 3 2 Grease 108
3 7 3 3 Sealant 108
3 7 4 Trouble shooting guide for Hauhinco
pumps 109
4 EMULSION STORAGE TANK 111
4 1 Technical information 111
4 2 Emulsion suction outlet ports 112
4 3 Suction Isolation valves 113
4 4 Air breathers 114
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LONGWALL PUMP STATION
SERVICE & MAINTENANCE MANUAL 2006
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4 5 Emulsion tank fluid level viewing port 115
4 6 Drain ports 116
4 7 Emulsion temperature transducer 117
4 8 Low pressure emulsion sample point 118
4 9 Procedure for taking sample of emulsion from tank 119
4 10 Service and maintenance 122
4 10 1 Inspection and maintenance requirements 122
4 10 1 1 Daily inspections and requirements 122
4 10 1 2 Twelve monthly – OR – every 5000
hours of operation inspection
requirements 122
4 11 Maintenance procedures 123
4 11 1 Suction isolation 123
4 11 2 Procedure changing air breather elements 125
5 PUMP STATION MONITORING SYSTEM 127
5 1 Pump station monitoring system components 127
5 2 General description 130
5 3 Emulsion tank monitoring 130
5 3 1 Emulsion temperature transducer 130
5 4 Chock and positive set pump monitoring 132
5 4 1 Emulsion system pressure transducer 132
5 4 2 Pump lubrication oil pressure switch 133
5 4 3 Emulsion and shearer water pumps
lubricating oil temperature transducer 134
5 4 4 Lubrication oil pressure transducer 135
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SERVICE & MAINTENANCE MANUAL 2006
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5 5 Filtration system monitoring 136
5 5 1 Emulsion return line filter pressure
transmitter & DP switches 136
5 6 Calibration of transducer 138
5 6 1 Lubricating oil pressure transducer
calibration 138
5 6 2 Lube oil temperature transducer calibration 138
6 FILTRATION SYSTEM 139
6 1 General description 139
6 2 Emulsion return line filters 139
6 3 Emulsion inlet filter 141
6 4 Mineral oil filter 142
6 4 1 General description 142
6 5 Shearer water pump inlet filters 143
6 6 Emulsion storage tank air breathers and filtration
magnets 144
6 7 Solenoid pre-control valve filter 146
6 8 Service and maintenance procedures 147
6 8 1 Procedure for changing return line filter
elements and emulsion infill filter element 147
6 8 2 Procedure for changing shearer water inlet
filter element 149
7 MINERAL OIL CONTROL SYSTEM 150
7 1 General description 150
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SERVICE & MAINTENANCE MANUAL 2006
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7 2 Levelling cylinders 151
7 3 Load locks 152
7 4 Directional control valves 152
7 5 Diverter ball valve 153
7 6 Remote pendant control system 154
7 6 1 Remote pendant control box 154
7 6 2 Remote pendant control connection panel 155
7 7 Crawler track units 156
7 8 Mineral oil pressure filter 156
7 9 Brake valve 157
7 10 Brake valve hydraulic gauge 157
7 11 Austar Coal Mine hydraulic pump station positioning
procedure 158
8 CRAWLER TRACKS ASSEMBLY 161
8 1 Crawler tracks unit specifications 161
8 2 General description 162
8 3 Towing the pump station 164
8 3 1 Connecting towing unit to the ‘A-frame’ tow
bar 164
8 3 2 Procedure for connecting towing ‘A-frame to
tow vehicle 165
8 3 3 Procedure for freewheeling crawler tracks 167
8 4 Tramming pump station using the crawler track unit 174
8 5 Procedure for replacing oil filling of planetary hubs 177
8 6 Inspection and tensioning crawler tracks 179
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SERVICE & MAINTENANCE MANUAL 2006
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8 6 1 Procedure for inspecting and tensioning
crawler tracks 179
9 SHEARER WATER PUMP 182
9 1 Pump technical information 182
9 2 Shearer water pump components 183
9 3 General description 184
9 4 Pump operation 185
9 5 Unloading system 186
9 5 1 General Description 186
9 5 2 Shearer water pump unloader valves 187
9 6 Lubrication system 189
9 7 Correct direction of operation 191
9 8 Transducers for shearer water pump monitoring 192
9 8 1 Delivery pressure transducer 195
9 8 2 Inlet water Pressure transducer 195
9 8 3 Lube oil pressure transducer 195
9 8 4 Lube oil temperature transducer 195
9 8 5 Transducer pressure dampener 196
9 9 Shearer water pump inline inlet water filter 197
9 10 Service and maintenance 198
910 1 Inspection and maintenance requirements
for shearer water pump unit 198
9 10 1 1 Daily inspection and maintenance 198
9 10 1 2 Weekly inspection and maintenance 198
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AUSTAR COAL MINE PTY LTD
LONGWALL PUMP STATION
SERVICE & MAINTENANCE MANUAL 2006
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9 10 1 3 Every 3 months – OR – 1000 hours of
operation 198
9 10 1 4 Every 12 months – OR – 5000 hours
of operation inspection to be carried
out by SES service engineer 199
9 10 2 Procedure for changing the unloader valve 200
9 10 3 Maintenance procedures 204
10 MISCELLENOUS ITEMS 205
10 1 Quick release electrical receptacles 205
10 2 Emergency stop buttons 206
10 3 Start and stop buttons 207
10 3 1 Chock pump & positive set pump 207
10 3 2 Shearer water pump start & stop buttons 208
10 4 Emulsion tank junction box 209
10 5 Lockable ball valves 210
10 5 1 Face delivery isolation ball valves 210
10 5 2 Chock pump delivery isolation ball valves 212
10 6 Lifting points 213
10 7 Pump station level indicator 214
10 8 Face emulsion return ports 216
10 9 Important signs attached to the pump station 217
11 ISOLATION AND PRESSURE BLEED OFF PROCEDURES 218
11 1 Hauhinco pump isolation and pressure venting
procedures 218
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SERVICE & MAINTENANCE MANUAL 2006
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11 1 1 Chock pump isolation and pressure vent
procedure 218
11 1 2 Positive set pump isolation and pressure
vent procedure 224
11 1 3 Shearer water pump isolation and pressure
vent procedure 229
11 2 Accumulator isolation and pressure venting 234
11 2 1 Dual accumulator manifold isolation and
pressure vent procedure 234
11 2 2 Positive set accumulator manifold
assembly isolation and pressure vent
procedure 240
11 2 3 Shearer water accumulator manifold
assembly isolation and pressure vent
procedure 246
12 INSPECTION REQUIREMENTS 251
12 1 Daily inspections 251
12 2 Weekly inspections 252
12 3 Every 3 months – OR – 1000 hours of operation 252
12 4 Every 6 months 252
12 5 Every 12 months – OR – 5000 hours of operation
Inspection and service to be carried out by SES
service engineer 253
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SERVICE & MAINTENANCE MANUAL 2006
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A APPENDIX ‘A’ – AUSTAR SPARE PARTS SCHEDULE
CRITICAL COMPONENTS
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
B APPENDIX ‘B’ – HAUHINCO PUMPS SPARE PARTS LIST No of
PAGES
B 1 Emulsion Chock Pump
Refer Part No Description
Sect 2 5131162 EHP-3K 200/53 FL (50Hz) 1
Sect 2 5133556 EHP-3K 200 Flange 4
Sect 2 6042600 Spare parts drawing 1
Sect 2 6310176 Oil distributor including filter 2
Sect 2 5132797 Oil pressure control device 2
Sect 2 2321823 Oil pressure control device Condor FF-4 series 1
Sect 2 6208770 Lubrication pump 2
Sect 2 6136249 Bearing cover with flange pump 2
Sect 2 6424287 Complete oil suction filter 1
Sect 2 6426840 Suction pipe for oil pump 1
Sect 2 6343821 Feeding pipe for oil cooler 1
Sect 2 6499155 Return line from oil cooler 1
Sect 2 6230660 Oil cooler 2
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SERVICE & MAINTENANCE MANUAL 2006
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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
Sect 2 6536352 Pressure connection cover 1
Sect 2 4571657 Coupling half pkd 30 – D 60 – pump side 1
B 2 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
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SERVICE & MAINTENANCE MANUAL 2006
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Sect 3 5125359 Suction connection – blind 2
Sect 3 6136508 3/2 way-seat valve DN3 positive intrinsically
safe 12V
3
Sect 3 6217486 Oil pressure controller with armatures &
pendant switch
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
B 3 Shearer Water Pump Assembly
Sect 9 5133602 EHP-3K 150/70 flange 1
Sect 9 5133599 EHP 3K 150/70 flange (50Hz) 6
Sect 9 3762254 Lubrication pump 2
Sect 9 5118603 Lubrication pump without spur gear 2
Sect 9 6513360 Pump insert with plunger 70 D 3
Sect 9 5118913 Valve cover with spring guide 2
Sect 9 5118883 Valve Holder with Spring guide 2
Sect 9 5108101 Suction connection with hole G2 2
Sect 9 6518109 Suction connection plate G 2 2
Sect 9 6225748 Intermediate plate 1
Sect 9 6217486 Oil pressure controller with armatures &
pendant switch 3
Sect 9 2321823 Oil pressure control device – Condor ff-4 series 1
Sect 9 6479545 Overflow valve U 504/400 1
Sect 9 6229441 Overflow valve U 540/400 3
Sect 9 6480071 Overflow valve U 504/400 1
Sect 9 4571657 Coupling half pkd 30 D 60 pump side 1
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AUSTAR COAL MINE PTY LTD
LONGWALL PUMP STATION
SERVICE & MAINTENANCE MANUAL 2006
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C APPENDIX ‘C’ – FIELD DEVICES
Sect 5 Pump station monitoring system components 3
Sect 5 4152-21B Drawing- pump station field devices 1
D 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
187000603 Crawler track #9 assembly LH-00 & bill of
materials
5
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
E APPENDIX ‘E’ PIRTEK HOSE & FITTINGS SCHEDULE
Emulsion hosing circuit 1
Pump accumulator circuit 1
Pressure and return circuit – mineral oil 1
Tram Motor Circuit 2
Levelling Cylinder Circuit 1
Split flange & ball valve spare parts list 1
F APPENDIX ‘F’ – AMPCONTROL ELECTRICAL CIRCUIT
Pump 1 2181-1021 Local J/Box wiring diagram 1
Pump 2 2181-1031 Local J/Box wiring diagram 1
Pump 3 2181-1041 Local J/Box wiring diagram 1
2181-1061 Emulsion tank marshalling J/Box 1
2181-1071 Pump cart marshalling box 1
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AUSTAR COAL MINE PTY LTD
LONGWALL PUMP STATION
SERVICE & MAINTENANCE MANUAL 2006
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G APPENDIX ‘G’ – HYDRAULIC SCHEMATIC
4512-03C Pump station hydraulic schematic 1
H 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
I APPENDIX ‘I’ – TOSHIBA 200kW ELECTRIC MOTOR
INSTRUCTION MANUAL
* The Toshiba 200kW electrical motor instruction manual is included in
the form ‘as is’ as supplied by Toshiba The index and contents of the
motor section a separate page numbering, not continuing on from the rest
of the SES Group service manual
(I) 1 0 Instruction Manual No : TMAN000-SCIM-R06 1
(I) 1 0 Receiving Checks 3
I) 1 1 Check on Received Merchandise 3
I) 1 2 Storage 3
(I) 2 0 Installation 4
I) 2 1 Environment 4
I) 2 2 Foundation 6
I) 2 3 Alignment Procedures 6
(I) 3 0 Start-Up 8
I) 3 1 Check before Start-Up 8
I) 3 2 Checking point during Start-Up 9
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LONGWALL PUMP STATION
SERVICE & MAINTENANCE MANUAL 2006
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(I) 4 0 Disassembly & Reassembly of Motor 11
I) 4 1 Disassembly of Motor 11
I) 4 2 Reassembly of Motor 11
I) 4 3 Grease Requirement 11
(I) 5 0 Maintenance 13
I) 5 1 Routine Maintenance 13
I) 5 2 Knock-Down Examination 14
I) 5 3 Useful Information regarding Operation and
Maintenance
15
(I) 6 0 Troubleshooting and repair 21
(I) 7 0 Storage 25
I) 7 1 Introduction 25
I) 7 2 Storage Area 25
I) 7 3 Storage Maintenance 25
I) 7 4 Storage Inspection Record 27
(I) 8 0 Appendix
Motor Construction Drawing
Bearing Construction Drawing
K APPENDIX ‘K’ – MATERIAL SAFETY DATA SHEETS
Shell Omala Oil 320
Fuchs RENEP K220
Fuchs Solcenic 2020 4% V/V Emulsion

DESCRIPTION:

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

INTRODUCTION:
1.1 GENERAL DESCRIPTION:

• This service and maintenance manual provides an overview ofthe equipment installed and general information pertaining to the operation and maintenance of the mobile pump station and other equipment as supplied by Southern Engineering ServicesPty Ltd, in April 2006.
• The Austar Coal Mine’s mobile longwall hydraulic pump station has been designed to provide the necessary hydraulic power to efficiently operate the roof supports within a longwall mine and provide cooling water for the shearer drum and dust suppression at the coalface.

S.V 24/03/2025