SIST EN 1804-3:2006
(Main)Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 3: Hydraulic control systems
Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 3: Hydraulic control systems
This document specifies the safety requirements for hydraulic control devices, including hydraulic valves and
their control elements, valve combinations, control systems, pipes and hose assemblies, fittings, shut-off
devices, measuring devices, filters, built-in pressure limiting and check valves in legs and rams and water
spraying and dust suppression valves when used as specified by the manufacturer or his authorized
representative. Excluded are electronic control devices, pressure generators, and internal valves of legs and
rams (e.g. constant yield valves, see EN1804-2).
Some components are dealt with in other parts of this standard.
NOTE prEN1804-4 also applies to electro-hydraulic control devices. Part 4 also contains requirements for electrical
control elements of valves.
This document applies to hydraulic control devices at ambient temperatures from –10 °C to 60 °C.
This document identifies and takes into account:
- possible hazards which may be caused by the operation of hydraulic control devices;
- areas and operating conditions which may create such hazards;
- hazardous situations which may cause injury or may be damaging to health;
- hazards which may be caused by firedamp and/or combustible dusts.
This document describes methods for the reduction of these hazards.
A list of significant hazards covered appears in clause 4.
This document is applicable to all hydraulic control devices placed on the market for the first time after the
date of issue of this standard.
This document does not specify any additional requirements for:
- use in particularly corrosive environments;
- hazards occurring during construction, transportation, decommissioning;
- earthquakes.
Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen an hydraulischen Schreitausbau - Teil 3: Hydraulische Steuerungen
Dieses Dokument legt die Sicherheitsanforderungen für die vom Hersteller oder seinem bevollmächtigten Vertreter vorgesehene bestimmungsgemäße Verwendung von hydraulischen Steuerungen fest. Hierzu gehören hydraulische Ventile mit ihren Betätigungseinrichtungen, Ventilkombinationen, Steuerungen, starre und flexible Leitungen, Armaturen, Absperreinrichtungen, Messeinrichtungen, Filter, in Stempel und Zylinder fest eingebaute Druckbegrenzungs- und Rückschlagventile sowie die Bedüsungsventile zur Staubbekämpfung. Ausgenommen sind die elektronischen Steuerungen, die Druckerzeuger und die inneren Ventile von Stempeln und Zylindern (z. B. Bodenventile, siehe EN 1804-2).
Einige Komponenten werden in anderen Teilen dieser Normenreihe behandelt.
ANMERKUNG Für elektrohydraulische Steuerungen gelten zusätzlich die Anforderungen nach prEN 1804-4. Der Teil 4 beinhaltet auch die Anforderungen an elektrische Betätigungseinrichtungen von Ventilen.
Dieses Dokument gilt für hydraulische Steuerungen, die bei Umgebungstemperaturen von -10 °C bis 60 °C eingesetzt werden.
Dieses Dokument identifiziert und berücksichtigt:
- die Gefährdungen, die durch hydraulische Steuerungen hervorgerufen werden können;
- die Gefahrenbereiche und die Betriebsbedingungen, die irgendeine Gefährdung verursachen können;
- die Situationen, die zu Gefährdungen führen können, die eine Verletzung oder Gesundheitsschädigung verursachen, und
- Gefahren, die durch Grubengas und/oder brennbare Stäube verursacht werden können.
Dieses Dokument beschreibt Methoden zur Reduzierung dieser Gefährdungen.
Abschnitt 4 enthält eine Liste der behandelten signifikanten Gefährdungen.
Dieses Dokument gilt für alle hydraulischen Steuerungen, die nach dem Ausgabedatum dieser Norm erstmalig in Verkehr gebracht werden.
Dieses Dokument spezifiziert keine zusätzlichen Anforderungen für:
- den Gebrauch in besonders korrosiver Umgebung;
- Risiken bei Herstellung, Transport und Außerbetriebnahme;
für den Fall von Erdbeben
Machines pour mines souterraines - Exigences de sécurité concernant les soutenements marchants applicables aux piles - Partie 3: Systemes de commande hydrauliques
Le présent document spécifie les exigences de sécurité concernant les systemes de commande hydrauliques lorsqu’ils sont utilisés tel que spécifié par le fabricant ou son mandataire. Les systemes de commande hydrauliques comprennent les soupapes hydrauliques et leurs organes de commande, les combinaisons de soupapes, systemes de commande, tuyaux et ensembles flexibles, raccords, dispositifs d’arret et de mesure, filtres, soupapes de limitation de pression et clapets de non-retour intégrés aux étançons et vérins, soupapes de pulvérisation d’eau pour l’élimination des poussieres. Sont exclus les systemes de commande électroniques, les générateurs de pression ainsi que les soupapes internes des étançons et vérins (par exemple soupapes a coulissement constant, voir l’EN 1804-2).
Certains éléments sont traités dans d’autres parties de cette série de normes.
NOTE Les exigences du prEN 1804-4 s’appliquent également aux systemes de commande électro-hydrauliques en complément des exigences du présent document. La Partie 4 comporte aussi des exigences relatives aux organes de commande électriques des soupapes.
Le présent document s’applique aux systemes de commande hydrauliques a des températures ambiantes comprises entre -10 °C et 60 °C.
Le présent document identifie et tient compte :
- des phénomenes dangereux potentiels pouvant résulter de l’utilisation des systemes de commande hydrauliques ;
- des zones dangereuses et des conditions d’utilisation susceptibles de créer un phénomene dangereux ;
- des situations potentiellement dangereuses et susceptibles d’entraîner des blessures ou de porter atteinte a la santé ; et
- des risques dus au grisou et/ou a des poussieres inflammables.
Le présent document décrit des méthodes de réduction de ces phénomenes dangereux.
Une liste des phénomenes dangereux significatifs couverts est donnée a l’Article 4.
Le présent document est applicable a tous les systemes de commande hydrauliques commercialisés pour la premiere fois apres
Stroji za podzemne rudnike – Varnostne zahteve za hidravlično podporje – 3. del: Hidravlični krmilni sistemi
General Information
Relations
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 3: Hydraulic control systemsMachines pour mines souterraines - Exigences de sécurité concernant les soutenements marchants applicables aux piles - Partie 3: Systemes de commande hydrauliquesMaschinen für den Bergbau unter Tage - Sicherheitsanforderungen an hydraulischen Schreitausbau - Teil 3: Hydraulische SteuerungenTa slovenski standard je istoveten z:EN 1804-3:2006SIST EN 1804-3:2006en73.100.10Oprema za gradnjo predorov in podzemnih železnicTunnelling and tubbing equipmentICS:SLOVENSKI
STANDARDSIST EN 1804-3:200601-oktober-2006
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 1804-3April 2006ICS 73.100.10 English VersionMachines for underground mines - Safety requirements forhydraulic powered roof supports - Part 3: Hydraulic controlsystemsMachines pour mines soterraines - Exigences de sécuritéconcernant les soutènements applicables aux piles - Partie3: Systèmes de commande hydrauliquesMaschinen für den Bergbau unter Tage -Sicherheitsanforderungen an hydraulischen Schreitausbau- Teil 3: Hydraulische SteuerungenThis European Standard was approved by CEN on 23 August 2004.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Central Secretariat or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, 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 STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2006 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 1804-3:2006: E
EN 1804-3:2006 (E) 2 Contents Page Foreword.4 Introduction.5 2 Normative references.6 3 Terms and definitions.7 4
List of hazards.9 5 Safety requirements.11 5.1 General requirements.11 5.1.1 General.11 5.1.2 Hazard areas.11 5.1.3 Arrangement of the control devices.11 5.1.4 Dead man's control.11 5.1.5 Automatic hydraulic control system.11 5.1.6 Automatic guaranteed setting control.11 5.1.7 Shut-off devices.11 5.1.8 Pressure indicator.12 5.1.9 Pipe and hose assemblies.12 5.1.10 Hydraulic fluids.12 5.1.11 Lifting points.13 5.2 Design requirements.13 5.2.1 Protection against ejected fluids.13 5.2.2 Roof contact advance.13 5.2.3 Pressure limiting.13 5.2.4 Interruption of the operating pressure.13 5.2.5 Travel speeds.13 5.2.6 Actuating forces.13 5.2.7 Resistance to back pressure.13 5.2.8 Adjustable valves.14 5.3 Requirements of type A valves.14 5.3.1 General.14 5.3.2 Leaktightness.14 5.3.3 Yield pressure.14 5.3.4 Opening pressure.14 5.3.5 Closing pressure.14 5.3.6 Pressure pulses.14 5.3.7 Impact resistance.14 5.3.8 Pressure flow behaviour.14 5.3.9 Operating reliability.15 5.3.10 Temperature effects.15 5.3.11 Resistance to back pressure.15 5.4 Requirements for type B and C valves.15 5.4.1 General.15 5.4.2 Leaktightness.15 5.4.3 Resistance to pressure.15 5.4.4 Switching behaviour.15 5.4.5 Operating reliability.15 5.4.6 Resistance to back pressure.16 5.5 Requirements for type D valves.16 5.6 Materials.16 5.6.1 Metallic materials.16
EN 1804-3:2006 (E) 3 5.6.2 Light metal.16 5.6.3 Other materials.16 5.6.4 Seals.16 6 Verification of the safety requirements.16 6.1 Type testing.16 6.2 Additional tests.17 7 User Information.18 7.1 General requirements.18 7.2 Technical and application data.18 7.2.1 Introduction.18 7.2.2 General description.18 7.2.3 Performance data.18 7.2.4 Hydraulic data.18 7.2.5 List of additional drawings and documents.19 7.3 Handling, transport and storage.19 7.3.1 Introduction.19 7.3.2 Handling and transport.19 7.3.3 Storage.19 7.4 Installation and commissioning.19 7.4.1 Installation.19 7.4.2 Commissioning.19 7.5 Operation.20 7.6 Maintenance.20 7.6.1 Introduction.20 7.6.2 Technical description.20 7.6.3 Maintenance instructions.20 7.6.4 Fault diagnosis and correction.20 7.6.5 Preventative maintenance schedules.20 7.7 Parts identification lists.21 7.8 Marking.21 7.9 Residual risks.21 Annex A (normative)
Tests for verification of the safety requirements.22 A.1 Load tests.22 A.1.1 General.22 A.1.2 Lifting points.22 A.1.3 Testing of type A valves.22 A.1.4 Testing of type B valves.27 A.1.5 Testing of type C valves.30 A.1.6 Testing of type D valves.31 Annex B (normative)
Deviations from EN 982:1996.32 B.1 General.32 B.2 5.1.7 (EN 982:1996).32 B.3 5.3.4.1.3 Contamination control (EN 982:1996).33 B.4 5.3.4.3.2 Failure (EN 982:1996).33 B.5 5.3.6 Sequence control (EN 982:1996).33 B.6 7.3.4.1 Non-electrical control mechanisms (EN 982:1996).33 Annex ZA (informative)
Relationship between this
European
Standard and the Essential Requirements
of the EU Machinery Directive 98/37/EC.34 Bibliography.35
EN 1804-3:2006 (E) 4 Foreword This document (EN 1804-3:2006) 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 October 2006, and conflicting national standards shall be withdrawn at the latest by October 2006. This document 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 document is Part 3 of a European Standard specifying the safety requirements for hydraulic control systems. The other parts are: Part 1: Support units and general requirements Part 2: Power set legs and rams Part 41: Electro-hydraulic control systems
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, 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 the United Kingdom.
1 In preparation
EN 1804-3:2006 (E) 5 Introduction This document is a type C standard as stated in EN ISO 12100-1.
The machinery concerned and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of this document. When provisions of this type C standard are different from those which are stated in type A or B standards, the provisions of this type C standard take precedence over the provisions of the other standards for machines that have been designed and built according to the provisions of this type C standard.
The extent to which hazards are covered is indicated in the scope of this document.
While preparing this document, it was assumed that:
only trained and competent persons operate the machine; ¾ components without specific requirements are; a) designed in accordance with the usual engineering practice and calculation code; b) of sound mechanical construction; c) free of defects; ¾ components are kept in good working order; ¾ a negotiation took place between the user and the manufacturer concerning the use of the machinery.
EN 1804-3:2006 (E) 6 1 Scope This document specifies the safety requirements for hydraulic control devices, including hydraulic valves and their control elements, valve combinations, control systems, pipes and hose assemblies, fittings, shut-off devices, measuring devices, filters, built-in pressure limiting and check valves in legs and rams and water spraying and dust suppression valves when used as specified by the manufacturer or his authorized representative. Excluded are electronic control devices, pressure generators, and internal valves of legs and rams (e.g. constant yield valves, see EN1804-2). Some components are dealt with in other parts of this standard.
NOTE prEN1804-4 also applies to electro-hydraulic control devices. Part 4 also contains requirements for electrical control elements of valves. This document applies to hydraulic control devices at ambient temperatures from –10 °C to 60 °C. This document identifies and takes into account:
possible hazards which may be caused by the operation of hydraulic control devices; ¾ areas and operating conditions which may create such hazards; ¾ hazardous situations which may cause injury or may be damaging to health; ¾ hazards which may be caused by firedamp and/or combustible dusts. This document describes methods for the reduction of these hazards. A list of significant hazards covered appears in clause 4. This document is applicable to all hydraulic control devices placed on the market for the first time after the date of issue of this standard. This document does not specify any additional requirements for:
use in particularly corrosive environments; ¾ hazards occurring during construction, transportation, decommissioning; ¾ earthquakes. 2 Normative references The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies.
For undated references, the latest edition of the referenced document (including any amendments) applies. EN 853, Rubber hoses and hose assemblies — Wire braid reinforced hydraulic type — Specification EN 854, Rubber hoses and hose assemblies — Textile reinforced hydraulic type — Specification EN 855, Plastic hoses and hose assemblies — Thermoplastics textile reinforced hydraulic type —Specification EN 856, Rubber hoses and hose assemblies — Rubber-covered spiral wire reinforced hydraulic type — Specification
EN 1804-3:2006 (E) 7 EN 857, Rubber hoses and hose assemblies — Wire braid reinforced compact type for hydraulic applications — Specification EN 982:1996, Safety of machinery — Safety requirements for fluid power systems and their components —Hydraulics 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 1804-2:2001, Machines for underground mines — Safety requirements for hydraulic powered roof supports — Part 2: Power set legs and rams prEN 1804-4:2004,
Machines for underground mines — Safety requirements for hydraulic powered roof supports — Part 4: Electro-hydraulic control systems EN 13463-1:2001, Non-electrical equipment for potentially explosive atmospheres — Part 1: Basic method and requirements EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic terminology, methodology (ISO 12100-1:2003) EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2: Technical principles (ISO 12100-2:2003) EN ISO 6743-4:2001, Lubricants, industrial oils and related
products (class L) — Classification — Part
4: Family H (Hydraulic systems) (ISO
6743-4:1999). ISO 1219-1 Fluid power systems and components — Graphic symbols and circuit diagrams — Part 1: Graphic symbols ISO 6805:1994, Rubber hoses and hose assemblies for underground mining — Wire-reinforced hydraulic types for coal mining — Specification ISO 7745:1989 Hydraulic fluid power — Fire-resistant (FR) fluids — Guidelines for use
3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 1804-1:2001, EN 1804-2:2001,
prEN 1804-4:2004 and the following apply: 3.1 hydraulic control devices system required to control all the functions of the hydraulic powered roof supports 3.2 pressures 3.2.1 maximum permissible working pressure maximum hydraulic pressure at which a hydraulic component may be operated (see EN 1804-2:2001)
3.2.2 setting pressure hydraulic pressure in the legs and support rams on completion of the setting procedure. This pressure is supplied by the hydraulic system (see EN 1804-2:2001)
EN 1804-3:2006 (E) 8 3.2.3 yield pressure of a pressure limiting valve nominal hydraulic pressure to which a pressure limiting valve is adjusted and at which it should operate (see Figure A.2 and 5.3.3) 3.2.4
opening pressure of a pressure limiting valve hydraulic pressure at which a valve begins to open and hydraulic fluid is passing through it (see Figure A.2 and 5.3.4) 3.2.5 closing pressure pressure at which the valve is closed and the flow of hydraulic fluid is shut off (see Figure A.2 and 5.3.5)
3.3
valves devices for controlling the hydraulic functions (see EN 1804-2:2001)
3.3.1
type A valves (pressure limiting valves) limit the internal hydraulic pressure of actuators
3.3.2 type B valves (e.g. check valves) shut off the hydraulic fluid directly from the actuators
3.3.3 type C valves (e.g. directional control valves) in their neutral position, block off the supply pressure to the actuators . When these valves are operated, the hydraulic fluid is switched to the actuators or is used to control other valves
3.3.4 type D valves all those valves that cannot be classified specifically in one of the types A to C. These may be special types of valves or integrated types (e.g. valve combinations and control systems)
3.4 types of control systems 3.4.1 adjacent control system type of control system in which the individual functions of
one support unit are manually operated from an adjacent support unit 3.4.2 unit sequence control system control system in which a functional sequence, (e.g. lowering - advancing - setting) operates in one single support unit 3.4.3 automatic guaranteed setting control type of control system where the setting function of legs and/or support rams is operated automatically, at least until the rated value of the setting pressure of legs and/or support rams in the support unit has been attained
EN 1804-3:2006 (E) 9 3.5 pushbutton override control (dead man's control)
function that remains active for as long a pushbutton is pressed
3.6 intended roof support yield parameters parameter of the valves that is maintained at the intended yield of the hydraulic roof support
4
List of hazards The following list of hazards relates in all points to continuous operation and to installation and maintenance. This list contains the hazards and hazardous situations, as far as they are dealt with in this document, identified by risk assessment significant for this type of machinery and which require action to eliminate or reduce risk.
EN 1804-3:2006 (E) 10 Table 1 — List of significant hazards with cross-references to corresponding requirements No. acc. to EN 1050:1996 Hazards Essential requirements of Directive 98/37/EC Annex 1 Relevant clause/subclause of this document 1 Mechanical hazards due to:
- machine parts or work pieces, e.g. - accumulation of energy inside the machinery, e.g.:
1.1 Crushing hazard 1.3 5.1.2, 5.2.5, 5.4, 5.5 1.2 Shearing hazard
5.1.2, 5.2.5, 5.4, 5.5 1.3 Cutting or severing hazard
5.1.2, 5.2.5, 5.4, 5.5 1.9 High pressure fluid injection or ejection hazard 1.3.2 5.1.3, 5.1.9, 5.2.1, 5.3, 5.4, 5.5 2 Electrical hazards due to:
2.4 Electrostatic phenomena 1.5.2 5.6 7 Hazards generated by materials and substances (and their constituent elements) processed or used by the machinery
7.1 Hazards from contact with or inhalation of harmful fluids, gases, mists, fumes, and dusts 1.1.3, 1.5.13, 1.6.5 5.2.2 7.2 Fire or explosion hazard 1.5.6, 1.5.7 5.1.10, 5.6 8 Hazards generated by neglecting ergonomic principles in machinery design, e.g. hazards from:
8.1 Unhealthy postures or excessive effort 1.1.2d, 1.1.5, 1.6.2, 1.6.4 5.1.3, 5.2.6 8.2 Inadequate consideration of hand-arm or foot-leg anatomy 1.1.2d, 2.2 5.1.3, 5.2.6 8.3 Neglected use of personal protection equipment 1.1.2e 5.2.1, 5.2.8, 5.3, 5.4, 5.5 10 Unexpected start-up, unexpected overrun/overspeed (or any similar malfunction) from:
5.1.4, 5.1.6, 5.2.7, 5.2.8, 5.3, 5.4, 5.5, 5.6 13 Failure of the power supply 1.2.6 5.2.4 17 Falling or ejected objects or fluids 1.3.3 5.1.9, 5.2.3, 5.3, 5.4, 5.5, 5.6 26 Insufficient instructions for the driver/operator 3.6 5.1.3, 5.1.6, 5.1.8, 5.2.5 27 Mechanical hazards and hazardous events
27.4 From insufficient mechanical strength of parts 4.1.2.3 5.2.3, 5.3, 5.4, 5.5, 5.6 27.8 From abnormal conditions of assembly/testing/use/maintenance 4.4.1, 4.4.2d 5.1.11 34 Mechanical hazards and hazardous events due to:
34.1 Inadequate mechanical strength – inadequate working coefficients 6.1.2 5.2.3, 5.3, 5.4, 5.5, 5.6
Absence or incorrect installation of starting and stopping devices
5.1.4, 5.1.5
Absence or incorrect installation of power supply shut-off devices
5.1.7
EN 1804-3:2006 (E) 11 5 Safety requirements 5.1 General requirements 5.1.1 General Hydraulic control systems of hydraulic roof supports shall comply with the safety requirements of
EN 982 except for the deviations listed in normative Annex B. Hydraulic control systems of hydraulic powered roof supports which are designed according to this part of EN 1804 shall also meet the requirements of the other parts of EN 1804, if relevant. Hydraulic control systems of hydraulic powered roof supports should comply as appropriate with
EN ISO 12100-1:2003 and EN ISO 12100-2:2003 for hazards which are not covered in this document.
5.1.2 Hazard areas Hydraulic control devices shall be designed and positioned so that it is not necessary for per
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