SIST EN 1804-3:2006+A1:2010
(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. Some components are dealt with in other parts of this standard.
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 der 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;
EN 1804-3:2006+A1:2010 (D)
5
- 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;
Machines pour mines souterraines - Exigences de sécurité concernant les soutènements marchants applicables aux piles - Partie 3: Systèmes de commande hydrauliques
Le présent document spécifie les exigences de sécurité concernant les systèmes de commande hydrauliques lorsqu’ils sont utilisés tel que spécifié par le fabricant ou son mandataire. Les systèmes de commande hydrauliques comprennent les soupapes hydrauliques et leurs organes de commande, les combinaisons de soupapes, systèmes de commande, tuyaux et ensembles flexibles, raccords, dispositifs d’arrêt 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 poussières. Sont exclus les systèmes de commande électroniques, les générateurs de pression ainsi que les soupapes internes des étançons et vérins (par exemple soupapes à coulissement constant, voir le prEN 1804-2).
Certains éléments sont traités dans d’autres parties de cette série de normes.
NOTE Les exigences du prEN 1804-4 (actuellement en cours d’élaboration par le CEN/TC 196/GT 3) s’appliquent également aux systèmes 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 systèmes de commande hydrauliques à des températures ambiantes comprises entre – 10 °C et 60 °C.
Le présent document identifie et tient compte :
— des phénomènes dangereux potentiels pouvant résulter de l’utilisation des systèmes de commande hydrauliques ;
— des zones dangereuses et des conditions d’utilisation susceptibles de créer un phénomène dangereux ;
— des situations potentiellement dangereuses et susceptibles d’entraîner des blessures ou de porter atteinte à la santé ; et
— des risques dus au grisou et/ou à des poussières inflammables.
Le présent document décrit des méthodes de réduction de ces phénomènes dangereux.
Une liste des phénomènes dangereux significatifs couverts est donnée à l’Article 4.
Stroji za podzemne rudnike - Varnostne zahteve za hidravlično podporje - 3. del: Hidravlični krmilni sistemi
Ta dokument določa varnostne zahteve za hidravlične krmilne naprave, vključno s hidravličnimi ventili in njihovimi krmilnimi elementi, kombinacijami ventilov, krmilnimi sistemi, cevkami in cevnimi sklopi, pritrdilnimi elementi, zapornimi pripomočki, merilnimi napravami, filtri, vgrajenimi ventili za omejevanje tlaka in nepovratnimi ventili pri stojkah in potisnih cilindrih ter ventili za razprševanje vode in omejevanje prahu, ko se uporabljajo po navodilih proizvajalca ali pooblaščenega predstavnika. Izključeni so elektronski krmilni pripomočki, generatorji tlaka in notranji ventili stojk in potisnih cilindrov (npr. ventili s stalnim izkoristkom). Nekatere komponente obravnavajo drugi deli tega standarda.
General Information
Relations
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen an hydraulischen Schreitausbau - Teil 3: Hydraulische SteuerungenMachines pour mines souterraines - Exigences de sécurité concernant les soutènements marchants applicables aux piles - Partie 3: Systèmes de commande hydrauliquesMachines for underground mines - Safety requirements for hydraulic powered roof supports - Part 3: Hydraulic control systems73.100.10Oprema za gradnjo predorov in podzemnih železnicTunnelling and tubbing equipmentICS:Ta slovenski standard je istoveten z:EN 1804-3:2006+A1:2010SIST EN 1804-3:2006+A1:2010en,fr,de01-marec-2010SIST EN 1804-3:2006+A1:2010SLOVENSKI
STANDARD
SIST EN 1804-3:2006+A1:2010
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 1804-3:2006+A1
January 2010 ICS 73.100.10 Supersedes EN 1804-3:2006English Version
Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 3: Hydraulic control systems
Machines pour mines souterraines - Exigences de sécurité concernant les soutènements marchants applicables aux piles - Partie 3: Systèmes de commande hydrauliques
Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen an hydraulischen Schreitausbau - Teil 3: Hydraulische Steuerungen This European Standard was approved by CEN on 21 September 2004 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
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2010 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 1804-3:2006+A1:2010: ESIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E) 2 Contents Page Foreword .4Introduction .51Scope .62Normative references .63Terms and definitions .74List of hazards .85Safety requirements . 105.1General requirements . 105.1.1General . 105.1.2Hazard areas . 105.1.3Arrangement of the control devices . 105.1.4Dead man's control . 105.1.5Automatic hydraulic control system. 105.1.6Automatic guaranteed setting control . 105.1.7Shut-off devices . 105.1.8Pressure indicator . 105.1.9Pipe and hose assemblies . 105.1.10Hydraulic fluids . 115.1.11Lifting points . 115.2Design requirements . 125.2.1Protection against ejected fluids . 125.2.2Roof contact advance . 125.2.3Pressure limiting . 125.2.4Interruption of the operating pressure . 125.2.5Travel speeds . 125.2.6Actuating forces. 125.2.7Resistance to back pressure . 125.2.8Adjustable valves. 125.3Requirements of type A valves . 125.3.1General . 125.3.2Leaktightness . 125.3.3Yield pressure . 135.3.4Opening pressure . 135.3.5Closing pressure. 135.3.6Pressure pulses . 135.3.7Impact resistance. 135.3.8Pressure flow behaviour . 135.3.9Operating reliability . 135.3.10Temperature effects . 135.3.11Resistance to back pressure . 135.4Requirements for type B and C valves . 135.4.1General . 135.4.2Leaktightness . 135.4.3Resistance to pressure . 145.4.4Switching behaviour . 145.4.5Operating reliability . 145.4.6Resistance to back pressure . 145.5Requirements for type D valves . 145.6Materials . 14SIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E) 3 5.6.1Metallic materials . 145.6.2Light metal . 145.6.3Other materials . 145.6.4Seals . 146Verification of the safety requirements . 156.1Type testing . 156.2Additional tests . 157User Information . 177.1General requirements . 177.2Technical and application data . 177.2.1Introduction . 177.2.2General description . 177.2.3Performance data . 177.2.4Hydraulic data . 177.2.5List of additional drawings and documents . 177.3Handling, transport and storage . 187.3.1Introduction . 187.3.2Handling and transport . 187.3.3Storage . 187.4Installation and commissioning . 187.4.1Installation . 187.4.2Commissioning . 187.5Operation . 187.6Maintenance . 197.6.1Introduction . 197.6.2Technical description . 197.6.3Maintenance instructions . 197.6.4Fault diagnosis and correction . 197.6.5Preventative maintenance schedules . 197.7Parts identification lists . 197.8Marking . 197.9Residual risks . 20Annex A (normative)
Tests for verification of the safety requirements . 21A.1Load tests . 21A.1.1General . 21A.1.2Lifting points . 21A.1.3Testing of type A valves . 21A.1.4Testing of type B valves . 26A.1.5Testing of type C valves . 29A.1.6Testing of type D valves . 30Annex B (normative)
Deviations from EN 982:1996 . 31B.1General . 31B.25.1.7 (EN 982:1996) . 31B.35.3.4.1.3 Contamination control (EN 982:1996) . 32B.45.3.4.3.2 Failure (EN 982:1996) . 32B.55.3.6 Sequence control (EN 982:1996) . 32B.67.3.4.1 Non-electrical control mechanisms (EN 982:1996) . 32Annex ZA (informative)
!!!!Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC"""" . 33Bibliography . 34 SIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E) 4 Foreword This document (EN 1804-3:2006+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 1804-3:2006. The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ". 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, 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 SIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (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; 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; components are kept in good working order; a negotiation took place between the user and the manufacturer concerning the use of the machinery.
SIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (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; 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. 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 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 SIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E) 7 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)
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)
SIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E) 8 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
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. SIST EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E) 9 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.
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
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