DIN EN 1804-1-2010 Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 1 Support units and general requirements German version EN 1804-1.pdf

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1、May 2010 Translation by DIN-Sprachendienst.English price group 16No part of this translation may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 73

2、.100.10!$b 620 N/mm The values given shall be obtained regardless of the sample position, transverse or longitudinal to the direction of rolling. The steels shall be weld able. 5.4.1.3 Steel for non-welded support components The steels shall be killed. The impact values of the steel grades shall be

3、at least 25 J at room temperature (20 C). DIN EN 1804-1:2010-05 EN 1804-1:2001+A1:2010 (E) 12 5.4.2 Light metal Surfaces consisting of light metal or light metal alloys (including paints and coatings containing light metal) of actuators intended by the manufacturer to be used in potentially gaseous

4、mines shall meet the requirements of clause 8 of prEN 13463-1:1999. 5.4.3 Other materials Other materials shall conform to the material specification laid down by the support unit manufacturer. When such materials are used for the manufacture of support components, equivalent performance characteris

5、tics to those specified for steel in 5.4.1 shall be proven. Non-metallic materials shall meet the requirements of clause 7 of prEN13463-1:1999. 5.5 Permissible stresses 5.5.1 General Static load calculations shall be carried out for all support components. Additional forces which stress a support co

6、mponent shall be taken into account. The stresses in the support components determined by calculation either shall not exceed the permissible stresses given in 5.5.2 to 5.5.5 or the manufacturer shall demonstrate by theoretical or experimental methods that the support component performs in a safe ma

7、nner. 5.5.2 Calculated axial stresses For canopies, bases and footplates the calculated axial stresses shall not exceed the guaranteed minimum yield point or 0,2 % proof stress values of the materials. For other support components, the calculated axial stresses shall not exceed 85 % of these values.

8、 5.5.3 Calculated shear stresses The calculated shear stresses shall not exceed 80 % of the calculated axial stresses allowed for each support unit and load case. 5.5.4 Calculated combined stresses The calculated combined stresses shall not exceed the guaranteed minimum yield points or 0,2 % proof s

9、tress of the materials. 5.5.5 Calculated weld stresses The calculated weld stresses shall not exceed the following values of the permitted stresses of the adjacent materials. The welded joints and combined stresses shall be calculated in accordance with ENV 1993-1-1:1992 or an equivalent method. DIN

10、 EN 1804-1:2010-05 EN 1804-1:2001+A1:2010 (E) 13 Table 2 Weld stresses Weld type axial stresses Shear stresses Combined stresses Fillet welds 65 % 65 % 100 % Butt welds 100 % 65 % 100 % 5.6 Articulated joints Articulated joints which lie in the flow of the support bearing force shall be designed so

11、that the permissible stresses as specified in 5.5 are not exceeded when subjected to: a) central loading at 1,5 times the rated force; b) horizontal loading at the rated force (see Figure A.6); c) eccentric and central loading when combined at the rated force (see Figures A.1, A.2 and A.5). 5.7 Weld

12、ing All welding shall be carried out in accordance with EN 288-1, EN 288-2 and EN 288-3. The manufacturer shall make use of competent welding shops and welders. This can be reached by either: a) operating a certified quality system according to EN ISO 9001; or b) a certificate issued by an accredite

13、d body confirming compliance with EN 729-3. The welding shall be done by competent welders approved in accordance with EN 287-1. 6 Verification of the safety requirements 6.1 Type testing One specimen of the support unit shall be type tested in accordance with Annex A. The test requirements given in

14、 Annex A shall be met. The following documents shall be made available to the laboratory running the type test: User information; Results of a static calculation in accordance with A.8; Manufacturing drawings; Welding drawings; Data relating to the material characteristics; Evidence of the competenc

15、e of the welding workshop. NOTE The specimen which has been tested according to Annex A should not be placed on the market. DIN EN 1804-1:2010-05 EN 1804-1:2001+A1:2010 (E) 14 If no provision has been made in Annex A for verification of the requirements in clause 5 by specified tests, they shall be

16、verified by means of visual inspection, function test or reference to documents. Verification of the safety requirements is shown in Table 3. Table 3 Tests for verification of the safety requirements Safety requirements Verification 5.1.1 *Measurements5.1.2 *Visual inspection/comparison with the man

17、ufacturers drawing 5.1.3 *See A.6 5.1.4 *Visual inspection/comparison with the manufacturers drawing 5.1.5 *See A.4 5.1.6 *See A.5 5.1.7 *Visual inspection of manufacturers test documentation 5.1.8 *Visual inspection/comparison with the manufacturers assembly drawings 5.2.1 *Function tests or calcul

18、ation 5.2.2 *See A.3 5.3.1 *See A.1.1 and A.1.2.4 5.3.2 *See A.1.1, A.1.2.1 and A.1.2.2 5.3.3 *See A.1.1 and A.1.3.4 5.3.4 *See A.2 5.3.5 *See A.1.1, A.1.2.5 and A.1.3.5 5.3.6 *See A.1.1 and A.1.3 5.3.7 *See A.1.1 and A.1.2.3 5.4.1 *See A.7 5.4.2 *Visual inspection of manufacturers material specific

19、ation and see A.7.1 5.4.3 *Visual inspection of manufacturers material specification and see A.7.1 5.5 *See A.8 5.6 *See A.5.7 *Visual inspection of accredited body certificate *type test; *series test 6.2 Series verification See Table 3, clauses signed with * 7 User information 7.1 General requirem

20、ents The hydraulic powered roof support manufacturer shall provide user information meeting the requirements of clause 5 of EN 292-2:1991 + A1:1995 and clause 7. DIN EN 1804-1:2010-05 EN 1804-1:2001+A1:2010 (E) 15 The user information shall be the primary source of information on a complete hydrauli

21、c powered roof support and shall contain all the information relating to its safe application and this shall be produced as an instruction handbook as specified in 5.5 of EN 292-2:1991 + A1:1995. Care shall be taken to ensure that the user information is available to the user on receipt of the hydra

22、ulic powered roof support. The content and structure of the user information shall comply with 5.1.3 of EN 292-2:1991 + A1:1995. 7.2 Technical and application data 7.2.1 Introduction The user information shall describe the intended use of the hydraulic powered roof support. The operating instruction

23、 shall include all design and performance data necessary for the user to make an assessment of suitability for use in particular applications and environments, and for the identification of any energy supply requirements and other ancillary facilities that may be needed. The information provided sha

24、ll comply with 7.2.2 to 7.2.4. 7.2.2 General description This description shall explain in clear, easily understandable language of the user and in logical sequence the overall function of the hydraulic powered roof support with all special features, characteristics and markings. General arrangement

25、 drawings and function block diagrams shall be provided as appropriate. 7.2.3 Performance data The principal dimensions, weights, centres of gravity and performance capabilities of the complete support unit and, where applicable, of its main component parts shall be given. In particular, information

26、 shall be provided on: a) performance capability (e.g. support bearing force and height adjustment range); b) working conditions and limitations (e.g. by giving details of minimum and maximum effective seam thickness, minimum and maximum seam pitch in the direction of and at right angles to the adva

27、ncing mechanism, minimum and maximum over tip angle of the working and stowing face in relation to natural seam pitch, measured at the seam level). It shall also be stated for which working method the support units are to be used, e.g. long wall method with caving, short wall method using pneumatic

28、solid stowing etc.; c) operating and control methods (e.g. immediate forward support system, conventional support advance system, adjacent control and sequential control); d) hazards and corresponding safety precautions for each type of support operating mode (e.g. automatic control mode) and for co

29、mbined use with other operating devices. 7.2.4 List of additional drawings and documents A complete list of all drawings, illustrations and other documents including e.g. information about welding qualification, which are part of the information for use but provided separately from the user informat

30、ion, but which form part of the information required by this standard shall be provided. The list shall include appropriate cross-references to the text, of the user information. DIN EN 1804-1:2010-05 EN 1804-1:2001+A1:2010 (E) 16 7.3 Handling, transport and storage 7.3.1 Introduction This section o

31、f the user information shall include information and instructions for the safe handling, transport and storage of the hydraulic powered roof support or its components. 7.3.2 Handling and transport The details shall include: a) instructions for dismantling and for protection of parts during transport

32、 to their place of work; b) list of individual components and assemblies which may be required to be lifted and transported separately, together with location of lifting points and centre of gravity; c) weights and outline dimensions of the complete hydraulic powered roof support and individual comp

33、onents and assemblies listed in b) above; d) details of any particular precautions to be taken during handling and transportation. In addition, indications of possible damage to the hydraulic powered roof support during handling and transport; e) information on the number and rated load of any ancil

34、lary lifting equipment (e.g. shackles, eye bolts) not supplied but necessary in order to enable safe lifting/installation of the various equipment or assemblies. 7.3.3 Storage Instructions shall be given for the storage of the hydraulic powered roof support and its main components on the surface and

35、, where appropriate, underground as follows: a) methods of preservation and b) instructions for preparing the hydraulic powered roof support for commissioning after storage. 7.4 Installation and commissioning 7.4.1 General The primary objective of this clause is to minimize the hazards to personnel

36、during installation and commissioning. 7.4.2 Installation The installation of the support units shall be described together with details of any special tools which may be required. 7.4.3 Commissioning Details shall include: a) checking the correct installation prior to connection to the hydraulic pr

37、essure supply and information on the necessary cleaning and purging procedures; b) connection of the hydraulic pressure supply; c) commissioning the hydraulic powered roof support and testing individual functions. DIN EN 1804-1:2010-05 EN 1804-1:2001+A1:2010 (E) 17 7.5 Operation This section of the

38、user information shall include the information and instructions necessary for the safe operation of the hydraulic powered roof support. Details shall include: a) correct use, with information on the operating range and prohibited applications; b) mode of control; c) location, purpose and function of

39、 each control available to the operator; and d) location, purpose and method of use of monitoring and control facilities. 7.6 Maintenance 7.6.1 Introduction This section of the user information shall contain the necessary information and instructions to enable the hydraulic powered roof support to b

40、e maintained in, or restored to, safe working order. The information provided shall be according to 7.6.2 to 7.6.5. 7.6.2 Technical description This shall be in the form of a comprehensive functional description of the hydraulic powered roof support and its main components. NOTE Appropriate illustra

41、tions designed to enable the text to be kept concise. The description is built around a function block diagram or diagrams showing the logical interconnection and interaction of the various parts of the equipment. These may be augmented by drawings, illustrations, further block diagrams and circuit

42、diagrams. Also, where necessary, details of construction and test facilities should be given. 7.6.3 Maintenance instructions Maintenance instructions shall be provided, with illustrations where necessary, detailing the methods and procedures appropriate to the more complex preventative and correctiv

43、e maintenance tasks to be carried out in the working environment. The instructions shall include reference to the following: a) dismantling and reassembly; b) replacement, adjustment, calibration and testing; c) reference to parts identification lists; d) special tools, test equipment and additional

44、 equipment; and e) hazards which may arise and precautions to be taken. 7.6.4 Fault diagnosis and correction Information and instructions shall be included on fault diagnosis and correction. 7.6.5 Maintenance schedules Maintenance schedules shall include information provided by the manufacturer on t

45、he nature and frequency of inspections, tests and maintenance required to be carried out in order to keep the hydraulic powered roof DIN EN 1804-1:2010-05 EN 1804-1:2001+A1:2010 (E) 18 support in safe working order. Guidance shall be given on the nature of deterioration and defects to be looked for

46、when carrying out tests and inspections. Where appropriate, limits of deterioration shall be stated which, if exceeded, could prejudice continued safe working. 7.7 Parts identification lists Parts identification lists shall be provided which include the manufacturers part numbers and descriptions su

47、fficient for positive identification to be made of all assemblies, sub-assemblies and components of the hydraulic powered roof support which are designed as replaceable items. The list shall identify: a) those parts which the manufacturer envisages being changed in the working environment; and b) th

48、ose parts which the manufacturer recommends should be held as spares. Parts identification lists shall be illustrated by drawings, photographs etc. as appropriate, so that each component listed may be readily identified and located. The list shall be presented logically in a hierarchical manner to f

49、acilitate identification of a part number by reference, first to the support unit, then to the appropriate assembly and sub-assembly and hence to the component or replaceable item. For commercially available parts of hydraulic powered roof supports, permissible values and dimensions shall be stated or the original manufacturers name and part number and/or a full technical description shall be given. 7.8 Marking Each support unit shall be permanently and legibly marked (e.g. by the use of metal plates, engraving, etc.) with at least the following: ! the business