FprEN 1804-2
(Main)This document stipulates the safety requirements for use of legs and rams as intended by the manufacturer or the manufacturer's authorized representative. These include legs, support rams and rams, including the mechanical extensions, the inner valves and safety devices, seals, the hydraulic connections, (up to the 1st hose line or to the valve of design B, 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 discussed in other parts of this standard series.
This document applies for legs, support rams, and cylinders that are used at ambient temperatures between –10 °C and 60 °C.
This document identifies and takes account of:
- possible hazards which may be caused by the operation of legs, support rams and rams;
- the hazardous areas and the operating conditions that can cause any type of hazard;
- the situations that can result in hazards that cause an injury or impair health;
- dangers that can be caused through mine gas and/or flammable dusts.
This document describes methods for reducing these hazards.
Clause 4 contains a list of the hazards discussed.
This document does not specify any additional requirements for:
- specially corrosive environments;
- risks associated with manufacturing, transport, and decommissioning;
- earthquake.
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.
Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen für hydraulischen Schreitausbau - Teil 2: Stempel und Zylinder
Dieses Dokument legt die Sicherheitsanforderungen für die vom Hersteller vorgesehene bestimmungsgemäße Verwendung von Stempeln und Zylindern fest. Hierzu gehören Stempel, Stützzylinder und Zylinder einschließlich der mechanischen Verlängerungen, der inneren Ventile und Sicherheitseinrichtungen, der Dichtungselemente, der hydraulischen Anschlüsse (bis zur 1. Schlauchleitung oder zum Ventil der Bauart B, siehe EN 1804 3:2020) und der Hebepunkte, jedoch ausschließlich der Schutzrohre und -hüllen, der externen Ventile, der hydraulischen und elektrohydraulischen Steuerungseinrichtungen.
ANMERKUNG Einige Komponenten werden in anderen Teilen dieser Normenreihe behandelt.
Dieses Dokument gilt für Stempel, Stützzylinder und Zylinder, die bei Umgebungstemperaturen zwischen −10 °C und 60 °C eingesetzt werden.
Diese Norm identifiziert und berücksichtigt:
- Gefährdungen, die womöglich durch Stempel, Stützzylinder und Zylinder hervorgerufen werden;
- die Gefahrenbereiche und die Betriebsbedingungen, die irgendeine Art von Gefährdung verursachen können, und
- die Situationen, die zu Gefährdungen führen können, die eine Verletzung oder Gesundheitsschädigung verursachen;
- Gefahren, die durch Grubengas und/oder brennbare Stäube verursacht werden können.
Diese Norm beschreibt Verfahren zur Reduzierung dieser Gefährdungen.
Abschnitt 4 enthält eine Liste der behandelten Gefährdungen.
Dieses Dokument spezifiziert keine zusätzlichen Anforderungen für:
- besonders korrosive Umgebungen;
- Risiken bei Herstellung und Außerbetriebnahme;
- Erdbeben.
Ein kompletter hydraulischer Schreitausbau besteht aus den Ausbaugestellen (FprEN 1804 1:2020), Stempeln und Stützzylindern (FprEN 1804 2:2020) sowie den hydraulischen und elektrohydraulischen Steuerungseinrichtungen (FprEN 1804 3:2020). Die einzelnen Teile dieses mehrteiligen Dokuments befassen sich mit den Sicherheitsanforderungen der Komponenten, die in den Anwendungsbereichen der jeweiligen Teile dieser mehrteiligen Normenreihe genannt werden.
Dieses Dokument gilt nicht für Stempel und Zylinder, die vor dem Datum der Veröffentlichung dieses Dokuments hergestellt wurden.
Machines pour mines souterraines - Exigences de sécurité relatives aux soutènements marchants applicables aux piles - Partie 2 : Étançons et vérins à pose mécanisée
Le présent document stipule les exigences de sécurité relatives à l’utilisation des étançons et des vérins, telle que prévue par le fabricant. Ceux-ci comprennent les étançons, les vérins de soutènement et les vérins, y compris les rallonges mécaniques, les soupapes internes et les dispositifs de protection, les joints d’étanchéité, les raccords hydrauliques (y compris le 1er tuyau flexible ou la soupape de type B, voir l’EN 1804 3:2020) et leurs points de levage, mais à l’exclusion des tuyaux et gaines à cuir de protection, les soupapes externes, ainsi que les unités de commande hydrauliques et électro hydrauliques.
NOTE Certains composants sont traités dans d’autres parties de la présente série de normes.
Le présent document s’applique aux étançons, vérins de soutènement et vérins qui sont utilisés 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 étançons, vérins de soutènement et vérins ;
- des zones dangereuses et des conditions de fonctionnement susceptibles d’engendrer tout type de phénomène dangereux ;
- des situations susceptibles d’engendrer des phénomènes dangereux pouvant entraîner des blessures ou porter atteinte à la santé ;
- des dangers pouvant être causés par le gaz de mine (grisou) et/ou les poussières inflammables.
Le présent document décrit des méthodes permettant de réduire ces phénomènes dangereux.
L’Article 4 contient une liste des phénomènes dangereux traités.
Le présent document ne définit pas d’exigences supplémentaires concernant :
- les milieux environnants particulièrement corrosifs ;
- les risques associés à la fabrication et à la mise hors service ;
- les tremblements de terre.
Un soutènement marchant complet est constitué des unités de soutènement (FprEN 1804 1:2020), des étançons et des vérins de soutènement (FprEN 1804 2:2020) et des systèmes de commande hydrauliques et électro-hydrauliques (FprEN 1804 3:2020). Chaque partie du présent document multipartie traite des exigences de sécurité des composants mentionnés dans le domaine d’application de la partie concernée.
Le présent document ne s’applique pas à tous les étançons et vérins fabriqués avant sa date de publication.
Stroji za podzemne rudnike - Varnostne zahteve za hidravlično podporje - 2. del: Deli hidravličnih stojk in potisnih cilindrov
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 für hydraulischen Schreitausbau - Teil 2: Stempel und ZylinderMachines pour mines souterraines - Exigences de sécurité relatives aux soutènements marchants applicables aux piles - Partie 2 : Etançons et vérins à pose mécaniséeMachines for underground mines - Safety requirements for hydraulic powered roof supports - Part 2: Power set legs and rams73.100.10Oprema za gradnjo predorov in podzemnih železnicTunnelling and tubbing equipmentICS:Ta slovenski standard je istoveten z:prEN 1804-2oSIST prEN 1804-2:2019en,fr,de01-april-2019oSIST prEN 1804-2:2019SLOVENSKI
STANDARDoSIST prEN 1804-2:2019
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
DRAFT prEN 1804-2
February
t r s { ICS
y uä s r rä s r Will supersede EN
s z r væ tã t r r s ªA sã t r s rEnglish Version
Machines for underground mines æ Safety requirements for hydraulic powered roof supports æ Part
tã Power set legs and rams Machines pour mines souterraines æ Exigences de sécurité relatives aux soutènements marchants applicables aux piles æ Partie
t ã Etançons et vérins à pose mécaniséeMaschinen für den Bergbau unter Tage æ Sicherheitsanforderungen für hydraulischen Schreitausbau æ Teil
tã Stempel und Zylinder This draft European Standard is submitted to CEN members for enquiryä It has been drawn up by the Technical Committee
If this draft becomes a European Standardá CEN members are bounwhich stipulate the conditions for giving this European Standard the status of a national standard without any alterationä
This draft European Standard was established by CEN in three ofer language made by translation under the responsibility of a CEN member into its own language and notified to the CENæCENELEC Management Centre has the same status as the official versionsä
CEN members are the national standards bodies of Austriaá Belgiumá Bulgariaá Croatiaá Cyprusá Czech Republicá Denmarká Estoniaá Finlandá Former Yugoslav Republic of Macedoniaá Franceá Germanyá Greeceá Hungaryá Icelandá Irelandá Italyá Latviaá Lithuaniaá Luxembourgá Maltaá Netherlandsá Norwayá Polandá Portugalá Romaniaá Serbiaá Slovakiaá Sloveniaá Spainá Swedená Switzerlandá Turkey and United Kingdomä
Recipients of this draft are invited to submitá with their commentsá notification of any relevant patent rights of which they are aware and to provide supporting documentationä
Warning ã This document is not a European Standardä It is distributed for review and commentsä It is subject to change without notice and shall not be referred to as a European Standardä
EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre:Rue de la Science 23,
B-1040 Brussels
t r s { CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Membersä Refä Noä prEN
s z r væ tã t r s { EoSIST prEN 1804-2:2019prEN 1804-2:2019 (E) 2 Contents Page European foreword ....................................................................................................................................................... 5 Introduction .................................................................................................................................................................... 6 1 Scope .................................................................................................................................................................... 7 2 Normative references .................................................................................................................................... 7 3 Terms and definitions ................................................................................................................................... 8 4 List of significant hazards ......................................................................................................................... 10 5 Safety requirements .................................................................................................................................... 12 5.1 Lifting points .................................................................................................................................................. 12 5.2 Internal valves and safety devices ......................................................................................................... 12 5.3 Pressurized fluids ........................................................................................................................................ 12 5.4 Protection against ejecting fluids ........................................................................................................... 12 5.5 Yield capability ............................................................................................................................................. 12 5.6 Behaviour under axial overload ............................................................................................................. 12 5.7 Eccentric loading .......................................................................................................................................... 13 5.8 Functional reliability .................................................................................................................................. 13 5.9 Leak tightness ................................................................................................................................................ 13 5.10 Extension limit .............................................................................................................................................. 13 5.11 Force introduction points of actuators ................................................................................................ 13 5.12 Materials .......................................................................................................................................................... 13 5.12.1 Steel ................................................................................................................................................................... 13 5.12.2 Light metal ...................................................................................................................................................... 14 5.12.3 Other materials ............................................................................................................................................. 14 5.12.4 Seals .................................................................................................................................................................. 14 5.13 Calculated permissible stresses .............................................................................................................. 14 5.13.1 Permissible stresses under axial central rated force conditions ............................................... 14 5.13.2 Permissible stresses under double axial central rated force conditions ................................ 14 5.13.3 Permissible stresses under eccentric rated force conditions ...................................................... 14 5.13.4 Permissible weld stresses ......................................................................................................................... 15 5.14 Welding ............................................................................................................................................................ 15 5.15 Correct assembly and installation ......................................................................................................... 15 6 Verification of the safety requirements ............................................................................................... 15 6.1 Type testing .................................................................................................................................................... 15 6.2 Series verification ........................................................................................................................................ 16 7 User information .......................................................................................................................................... 16 7.1 General requirements ................................................................................................................................ 16 7.2 Technical and application data ............................................................................................................... 17 7.2.1 Introduction ................................................................................................................................................... 17 7.2.2 General description ..................................................................................................................................... 17 7.2.3 Performance data ......................................................................................................................................... 17 7.2.4 Hydraulic data ............................................................................................................................................... 17 7.2.5 List of additional drawings and documents ....................................................................................... 17 7.3 Handling, transport and storage ............................................................................................................ 17 7.3.1 Introduction ................................................................................................................................................... 17 7.3.2 Handling and transport ............................................................................................................................. 17 oSIST prEN 1804-2:2019
prEN 1804-2:2019 (E) 3 7.3.3 Storage .............................................................................................................................................................. 18 7.4 Installation, commissioning, and operation ....................................................................................... 18 7.4.1 Installation ...................................................................................................................................................... 18 7.4.2 Commissioning .............................................................................................................................................. 18 7.4.3 Operation ......................................................................................................................................................... 18 7.5 Maintenance ................................................................................................................................................... 18 7.5.1 Introduction.................................................................................................................................................... 18 7.5.2 Maintenance instructions .......................................................................................................................... 18 7.5.3 Fault diagnosis and correction ................................................................................................................ 19 7.5.4 Preventative maintenance schedules ................................................................................................... 19 7.5.5 Technical description .................................................................................................................................. 19 7.6 Parts identification lists ............................................................................................................................. 19 7.7 Marking / Identification ............................................................................................................................. 19 7.8 Residual risk ................................................................................................................................................... 19 Annex A (normative)
Tests for verification of the safety requirements .................................................. 20 A.1 Load tests ......................................................................................................................................................... 20 A.1.1 General ............................................................................................................................................................. 20 A.1.2 Testing with a central axial load ............................................................................................................. 20 A.1.2.1 Testing the extension limit........................................................................................................................ 20 A.1.2.2 Yield test .......................................................................................................................................................... 20 A.1.2.3 Overload tests ................................................................................................................................................ 21 A.1.2.3.1 Static overload ....................................................................................................................................... 21 A.1.2.3.2 Dynamic overload ................................................................................................................................ 21 A.1.2.4 Leakage test .................................................................................................................................................... 21 A.1.3 Testing with eccentric force ...................................................................................................................... 22 A.1.3.1 General ............................................................................................................................................................. 22 A.1.3.2 Bending test .................................................................................................................................................... 22 A.1.3.3 Yield test .......................................................................................................................................................... 22 A.1.4 Life test ............................................................................................................................................................. 22 A.1.4.1 Application of eccentric load .................................................................................................................... 23 A.1.4.2 Application of central axial load ............................................................................................................. 23 A.1.4.3 Application of pressure in the fully extended condition ................................................................ 23 A.1.4.4 Application of tensile load ......................................................................................................................... 23 A.1.4.5 Function test ................................................................................................................................................... 24 A.1.5 Testing of lifting points ............................................................................................................................... 24 A.2 Static calculation of actuators .................................................................................................................. 26 A.2.1 General ............................................................................................................................................................. 26 A.2.2 Axial stresses .................................................................................................................................................. 26 A.2.2.1 Actuator under central axial rated force.............................................................................................. 26 A.2.2.2 Actuator under double central rated force ......................................................................................... 27 oSIST prEN 1804-2:2019
prEN 1804-2:2019 (E) 4 A.2.2.3 Actuator under eccentric rated force.................................................................................................... 27 A.2.2.4 Actuator with additional lateral force .................................................................................................. 28 A.2.2.5 Superimposition of the axial stresses ................................................................................................... 30 A.2.3 Tangential stresses ...................................................................................................................................... 30 A.2.4 Radial stresses............................................................................................................................................... 31 A.2.5 Combined stresses ....................................................................................................................................... 31 A.2.6 Individual components .............................................................................................................................. 32 A.2.6.1 Connecting parts inside leg ...................................................................................................................... 32 A.2.6.1.1 Parts under no hydraulic pressure................................................................................................ 32 A.2.6.1.2 Parts under hydraulic pressure ...................................................................................................... 32 A.2.6.2 Extension pieces ........................................................................................................................................... 32 A.2.7 Symbols and units ........................................................................................................................................ 32 A.3 Testing the material properties .............................................................................................................. 33 A.3.1 General ............................................................................................................................................................. 33 A.3.2 Weldability ..................................................................................................................................................... 33 A.3.3 Mechanical properties ................................................................................................................................ 33 A.3.4 Impact value ................................................................................................................................................... 33 Annex B (normative)
List of tests .......................................................................................................................... 34 Annex ZA (informative)
Relationship between this European Standard and the essential requirements of Directive 2006/42/EC aimed to be covered ..................................................... 40 Bibliography ................................................................................................................................................................. 41
oSIST prEN 1804-2:2019prEN 1804-2:2019 (E) 5 European foreword This document (prEN 1804-2:2019) has been prepared by Technical Committee CEN/TC 196 “Mining machinery and equipment - Safety”, the secretariat of which is held by DIN. This document is currently submitted to the CEN Enquiry. This document will supersede EN 1804-2:2001+A1:2010. 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 (are) an integral part of this document. The main differences between this document and EN 1804-2:2001+A1:2010 are as follows: a) Normative references (updated); b) Terms and definitions (modified); c) List of significant hazards (revised); d) Requirements for Steel (updated/modified); e) Requirements for static and dynamic overload (revised/modified); f) Requirements for overload fully retracted (deleted); g) List of tests (updated).
oSIST prEN 1804-2:2019prEN 1804-2:2019 (E) 6 Introduction This European standard is a type C standard, as specified in EN ISO 12100:2010. The machinery concerned and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of this document. This document is of relevance, in particular, for the following stakeholder groups representing the market players with regard to machinery safety: — machine manufacturers (small, medium and large enterprises); — health and safety bodies (regulators, accident prevention organizations, market surveillance, etc.). Others can be affected by the level of machinery safety achieved with the means of the document by the above-mentioned stakeholder groups: machine users/employers (small, medium and large enterprises); — machine users/employees (e.g. trade unions, organizations for people with special needs); — service providers, e.g. for maintenance (small, medium and large enterprises); — consumers (in the case of machinery intended for use by consumers). The above-mentioned stakeholder groups have been given the possibility to participate at the drafting process of this document. The machinery concerned and the extent to which hazards, hazardous situations or hazardous events are covered are indicated in the Scope of this document. When requirements of this type-C standard are different from those which are stated in type-A or type-B standards, the requirements of this type-C standard take precedence over the requirements of the other standards for machines that have been designed and built according to the requirements of this type-C standard. The extent to which hazards are covered is indicated in the scope of this document. When drawing up this standard, the underlying assumptions were that: — only trained and qualified personnel 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) are free of defects; — components are kept in good working order; — the implementation conditions and requirements imposed on the machine have been agreed between manufacturer of the legs and cylinders and their user (manufacturers of the support unit or users in the case of spare parts). oSIST prEN 1804-2:2019
prEN 1804-2:2019 (E) 7 1 Scope This document stipulates the safety requirements for use of legs and rams as intended by the manufacturer or the manufacturer's authorized representative. These include legs, support rams and rams, including the mechanical extensions, the inner valves and safety devices, seals, the hydraulic connections, (up to the 1st hose line or to the valve of design B, 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 discussed in other parts of this standard series. This document applies for legs, support rams, and cylinders that are used at ambient temperatures between –10 °C and 60 °C. This document identifies and takes account of: — possible hazards which may be caused by the operation of legs, support rams and rams; — the hazardous areas and the operating conditions that can cause any type of hazard; — the situations that can result in hazards that cause an injury or impair health; — dangers that can be caused through mine gas and/or flammable dusts. This document describes methods for reducing these hazards. Clause 4 contains a list of the hazards discussed. This document does not specify any additional requirements for: — specially corrosive environments; — risks associated with manufacturing, transport, and decommissioning; — earthquake. 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. 2 Normative references The following documents are referred to in the text in such a way that some or all of their content constitutes requirements 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 1804-1, 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 and electro hydraulic control systems EN 10204:2004, Metallic products — Types of inspection documents EN ISO 80079-36:2016, Explosive atmospheres — Part 36: Non-electrical equipment for explosive atmospheres — Basic method and requirements (ISO 80079-36:2016) EN ISO 148-1:2016, Metallic materials — Charpy pendulum impact test — Part 1: Test method (ISO 148-1:2016) oSIST prEN 1804-2:2019
prEN 1804-2:2019 (E) 8 prEN ISO 643:2017, Steel — Micrographic determination of the apparent grain size (ISO/DIS 643:2017) EN ISO 3834-3:2005, Quality requirements for fusion welding of metallic materials — Part 3: Standard quality requirements (ISO 3834-3:2005) EN ISO 6892-1:2016, Metallic materials — Tensile testing — Part 1: Method of test at room temperature (ISO 6892-1:2016) EN ISO 9606-1:2017, Qualification testing of welders — Fusion welding — Part 1: Steels (ISO 9606-1:2012 including Cor 1:2012 and Cor 2:2013) EN ISO 12100:2010, Safety of machinery — General principles for design — Risk assessment and risk reduction (ISO 12100:2010) EN ISO 15607, Specification and qualification of welding procedures for metallic materials — General rules (ISO 15607:2003) EN ISO 15609-1, Specification and qualification of welding procedures for metallic materials — Welding procedure specification — Part 1: Electron beam welding (ISO 15609-3:2004) Note: new version Specification and qualification of welding procedures for metallic materials — Welding procedure specification — Part 1: Arc welding (ISO/DIS 15609-1:2018) EN ISO 15614-1:2017, Specification and qualification of welding procedures for metallic materials — Welding procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys (ISO 15614-1:2017, Corrected version 2017-10-01) EN ISO 14732:2013, Welding personnel — Qualification testing of welding operators and weld setters for mechanized and automatic welding of metallic materials (ISO 14732:2013) ISO 7745:2010, Hydraulic fluid power — Fire-resistant (FR) fluids — Requirements and guidelines for use 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN ISO 12100:2010 and EN 1804-1, EN 1804-3 and the following apply. ISO and IEC maintain terminological databases for use in standardization at the following addresses: — IEC Electropedia: available at http://www.electropedia.org/
— ISO Online browsing platform: available at http://www.iso.org/obp3.1 support unit type of hydraulic powered roof support e.g. frame support, chock support, shield support, consisting of support components and support accessories [Source: prEN 1804-1:2019] 3.2 support components all components which lie within the flow of the support bearing force oSIST prEN 1804-2:2019
prEN 1804-2:2019 (E) 9 3.2.1 actuator any type of hydraulic linear reciprocating device referred to in this standard 3.2.2 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 3.3 rams all actuators which do not lie within the flow of the support bearing force but which are necessary for the functioning of the powered roof support 3.4 control devices
3.4.1 valve device for controlling the flow of hydraulic fluid 3.4.2 bursting blank singleacting hydraulic fuse 3.4.3 internal valve valve inside actuator without access from outside 3.4.4 external valve valve attached outside of the actuator 3.4.5 safety devices Type A valves according to EN 1804-3 3.5 pressures
3.5.1 setting pressure hydraulic pressure in the legs and support rams on completion of the setting procedure Note 1 to entry: This pressure is supplied by the hydraulic system. oSIST prEN 1804-2:2019
prEN 1804-2:2019 (E) 10 3.5.2 yield pressure of an actuator Hydraulic pressure in an actuator when the relevant pressure limiting valve is opened Note 1 to entry: This pressure in the actuator is induced by external forces (yield forces; see prEN 1804-1:2019, 3.5.1). 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 3.7 fun
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