Solutions For Mining

Transcript

Solutions for mining Safety Programs Hydraulink and Gates offer hydraulic safety and preventive maintenance programs that can help you cut costs andprevent injuries from hydraulic assembly failures. It’s free information for maintenance managers, repair technicians and machine operators – in-fact anyone else working with high power fluid pressure systems. Simply contact us to arrange this hands-on, two hour seminar. Topics include inspection procedures, troubleshooting, hose and coupling selection, hose assembly, and crimper preventivemaintenance. In addition, you’ll receive a 72-page Safe Hydraulics Manual, with detailed information and step-by-step procedures. We also offer additional training programs that can be tailored to suit your specific requirements. Hydraulink On-Site Container Through our well equipped and fully stocked on-site containers, we offer mine operators a readily available resource that would otherwise demand capital investment and workshop space. • Professional layout • User-friendly system • Colour-coded storage system • Colour matching crimping system Hydraulink Australia Pty Limited 25 Davis Road | PO Box 6387 Wetherill Park NSW 2164 Sydney Australia P +61 2 8785 4600 | F +61 2 8785 4626 ACT NEW SOUTH WALES NORTHERN TERRITORY QUEENSLAND SOUTH AUSTRALIA • Better inventory management TASMANIA • On-site training provided VICTORIA WESTERN AUSTRALIA www.hydraulink.com.au hydraulink.com.au Changing the game A proven combination Hydraulink solutions support the complex and demanding operations of today’s global mining companies while meeting regulations and market requirements. From exploration to extraction, we offer mine operators the proven combination of Hydraulink and Gates – the industry’s supplier of choice – in helping your equipment provide peak performance at all times. We provide a full range of Gates MSHA-approved one-half SAE bend radius hoses, from low pressure return lines to extremely high pressure impulse lines. Designed and tested to deliver quality and uncompromising performance, Hydraulink couplings complement Gates specialist technology. With over 30 years experience in various conditions and across a wide array of minerals, we’ve developed a reputation for product quality as well as timely and reliable response. Both our on-site remote service and 24/7 mobile support ensure you keep going efficiently and profitably. Hydraulink Couplings Competitor Gates Couplings Competitor HYDRAULINK Competitor Competitor Hydraulink couplings show no rust formation. The white patches are salt residue, not corrosion. Hydraulink Universal Crimp Coupling System HCR Trivalent Plating The Hydraulink Universal Crimp Coupling System is unique in the industry. Featuring one stem and wire-lok non-skive ferrule for both braided and spiral hose types, the system is cost effective and easy to use. Hydraulink HCR Trivalent Plating provides in excess of 400 hours of red dust (rust) corrosion resistance when subjected to ISO 9227 salt-spray conditions. It is eco-friendly because all hexavalent chromium has been removed from the plating process. • Quick and easy hose assembly fabrication – reduced downtime • Wide application – covers all major threads and flange configurations; reduced inventory • Tested in excess of industry standards – extended coupling life, • Performance plus in all field applications – high load coupling retention; high pressure capability • All swept bend products are one-piece, no welded joints • HCR trivalent plating – rust resistant; eco-friendly GlobalSpiral™Couplings Gates Global Spiral couplings have a reputation for being the best in the industry boasting a no-skive solution to extreme pressure applications, “bite-thewire” crimp, TuffCoat plating and premium non-leaded steel. Gates Global Spiral couplings also feature machined fullback FJX and FFORX nuts. This design improves torque and sealing capability and is the reason why Gates fittings have a full 4:1 burst performance up to 24,000 psi. • No skive – fast, tailor-made assemblies; eliminates skiving equipment, odor and dust • Tested to 1,000,000 impulse cycles – extended coupling life hydraulink.com.au www.hydraulink.com.au • Coupling to 6,000 psi working pressure in all sizes* – easy-to-manage inventory • One stem used for all spiral hoses – less inventory; easy to use • Wide range of thread/ flange configuration * Except as noted in couplings tables • “Bite-the-wire” crimp – improved coupling retention TuffCoat™ Plating • Premium non-leaded steel – maximum strength • +121°C temperature capability – full performance at high temperatures; longer life • Machined full-back FJX and FFORX nuts – 4:1 burst performance up to 24,000psi; improved torque/sealing capability • Meets worldwide DIN, EN, SAE, ISO and Gates EFG6K standards and requirements – world-class performance Tested under SAE J516 and ASTMB117 salt-spray conditions, TuffCoat plating provides more than 400 hours of protection against the formation of red dust – a 500-plus percent improvement over the 72-hour SAE standard. TuffCoat plating is setting the green standard thanks to the elimination of hexavalent chrome from the manufacturing process. Hexavalent chromium, a material common in industrial plating, can be hazardous to the environment. Changing the game Gates Hoses EFG6K Spiral Wire Hose G2XH 2-Wire Braid Extreme Heat Hose—SAE 100R2 • • • • • • • • • • • • • • • For extremely high pressure applications Meets SAE 100R15 specifications Abrasion-resistant synthetic rubber cover increases service life 6,000 psi constant working pressure across all sizes Development tested at 120% of maximum working pressure up to 1,000,000 impulse cycles Abrasion-resistant MegaTuff® cover available Meets MSHA specifications for flame resistance and tested to AS1180.13A for anti static properties (FRAS) EFG4K MegaSpiral® Hose • • • • • • One-half SAE 100R12 bend radius Abrasion-resistant synthetic rubber cover increases service life 3,000 to 4,000 psi working pressure Development tested at 133% of maximum working pressure up to 1,000,000 impulse cycles Abrasion-resistant MegaTuff® cover available Meets MSHA specifications for flame resistance and tested to AS1180.13A for anti static properties (FRAS) Terminator • • • • • • M4K+ Mega4OOO® Hose • • • • • • • • • + indicates development testing at 150% of maximum working pressure up to 600,000 impulse cycles One-half SAE 100R1, 100R2 and 100R9 bend radius SAE 100R9 performance on 1/2” sizes SAE 100R12 pressure on 3/8” to 3/4” sizes All sizes have 4,000 psi working pressure Replaces spiral hose under certain conditions Abrasion-resistant XtraTuff™ and MegaTuff® cover available Meets new SAE 100R19 Meets MSHA specifications for flame resistance and tested to AS1180.13A for anti static properties (FRAS) Coal Power/Longwall Mine Hose – MCPB Plus Mine • • • • • • • High pressure hydraulic lines in longwall mining equipment and roof-support systems Working pressure per BCS174 means frequent pressure surges Tested to 100,000 impulse cycles at 133% of the dynamic working pressure Two-wire braid hose with 2,500 to 6,525 psi operating pressure Meets MSHA specifications for flame resistance and tested to AS1180.13A for anti static properties (FRAS) Abrasion-resistant MegaTuff® cover available Will handle petroleum-base fluids from -40° C to +100° C M2T® MegaFlex® • • • • • • • One-half SAE 100R2 bend radius Meets SAE 100R16 in all sizes Smaller O.D., low profile and lightweight Superior flex impulse performance Development tested at 133% of maximum working pressure up to 600,000 impulse cycles Abrasion-resistant MegaTuff® cover available Meets MSHA specifications for flame resistance and tested to AS1180.13A for anti static properties (FRAS) Has a blue CSM (Hypalon) cover that improves hose performance in high temperature applications. For high-pressure hydraulic applications where pressure or temperature requirements exceed SAE 100R2/EN 853 This two-wire braid hose has a 2,500 to 6,000 psi operating pressure Interior black tube that is specifically compounded for temperature and chemical resistance Meets MSHA specifications for flame resistance and tested to AS1180.13A for anti static properties (FRAS) Will handle petroleum-base fluids from -40° C to +149° C Will handle phosphate ester fluids within a range of -40° C to +100° C Multi-purpose hose Rated to 501 PSI in all sizes Meets MSHA specifications for flame resistance Resilient polyester reinforcement that resists flex fatigue Non-conductive at 1000 volts, DC Extremely tough Carboxylated Nitrile cover provides the ultimate in abrasion resistance MegaSys® Gates meets the needs of today’s high-powered, high-pressure hydraulic equipment with its MegaSys® hose line, a range of constant pressure spiral-wire and wire-braid hoses that can be bent up to one-third SAE specifications. The fully integrated solution is designed to provide maximum flexibility and performance in a wide range of highpressure hydraulic applications while simplifying hose selection and assembly fabrication. • Saves overall hose assembly length up to 47% • Facilitates easier plumbing and routing in tight applications • Plumbs and bends easier than conventional hose • Eases installation with higher flexibility; requires fewer bent tube fittings • 300 times the abrasion resistance of standard hose covers • Lowers inventory requirements • Tested to 1,000,000 cycles without failure • Longer life in applications where equipment movement causes sharp bends in hydraulic hose • Available with abrasion-resistant XtraTuff™ or MegaTuff® covers • Reduces costs by as much as 64% • Distinctive design and pressure colour coding system make the hoses easy to identify in stock and in service MegaTuff® Hose Cover • Super-tough cover solves abrasion and wear problems • Replaces spring guard and protective sleeves in high-wear applications. • Resistant to oil, ozone and UV rays • Outperforms any other abrasionresistant hose cover on the market today XtraTuff™ Hose Cover • Mid-range abrasion-resistant cover • Replaces spring guard and protective sleeves in high-wear applications. • 25 times the abrasion resistance of standard hose covers • Excellent cut resistance against falling rocks and when dragged across abrasive surfaces • Resistant to oil, ozone and UV ray MegaTech™ II Hot Oil/Air Pressure Line (ACP) • • • • • • 1,700 psi in 1-1/4”, 1,500 psi in 1-½” and 1,300 psi in 2” Specifically designed for air compressor to drill rig connections Can be crimped with no-skive PowerCrimp® couplings Temperature range of -40°C to +149°C Tough abrasion resistant polyester braided outer cover that does not need to be pin-pricked Blue cover GMV MegaVac® • • • • • hydraulink.com.au One-half SAE 100R4 bend radius Flexible and lightweight Available in 30m lengths Suitable for return, suction and vacuum lines Meets MSHA specifications for flame resistance & tested to AS1180.13A for anti static properties (FRAS) Changing the game Gates Hose Protection A proven quality system Hydraulink Qualification Process Lifeguard™ First sleeving system designed to protect operators, equipment and the environment from the hazards of catastrophic hydraulic hose failure. • Contains hose bursts of up to 6,000 psi reduced. Meets MSHA specifications for flame resistance. The perfect solution to neatly clamp nylon sleeve to couplings, PowerGrip SB Clamps shrink to seal nylon sleeve couplings forming a smooth, obstruction free seal. • Protects against 3,000 psi pinhole leaks up to 100ºC for up to 5 minutes • Available in sizes 6mm to 79mm • Handles hydraulic fluids and biodiesel fuel • Conform to any shape of hose and housing, even out-of-round fittings • Allows fluid to safely escape down the length of the assembly • Creates noticeable spill for hose failure detection • Correlates to ISO 3457 and EN474-1 • Meets MSHA’s flame-resistance requirements Nylon Protective Sleeve & PowerGrip SB Clamps Gates Nylon Sleeves provide excellent abrasion resistance to protect individual hoses as well as bundle hose assemblies together for maximum protection. Downtime and maintenance costs are • Easy to install with an ordinary heat gun • Made from a heat-sensitive thermoplastic with a memory to prevent over or under-tightening • Unique indicator tells when the clamp has shrunk to seal. HeatGuard provides superior protection in work environments that can reach high temperatures. Its special silicone coating withstands a broad range of solvents and fuels. Goes on easily over most hose and couplings. Temperature rating: -54°C to +260°C Packaging: 15.24mtrs per carton Plastic Hose Guard Spiral-wrapped designed to protect or bundle hoses. An easy and economical way to protect hydraulic and pneumatic lines, reduce down time, improve sighting and overall appearance. Hydraulink hose assemblies are impulse tested in excess of International Standards requirements at pressures up to 510 bar, temperatures to 121°C and 1Hz frequency Static Testing Hydraulink hose assemblies are static tested to minimum hose burst pressures, qualifying the holding power of the coupling and ensuring a minimum 4:1 safety factor. Field Testing • Packaging: 10 per carton • Easy to install before or after assembly fabrication or installation HeatGuard™ Protective Sheathing • Guards against chaffing, rubbing, crushing and harsh environmental conditions Exhaustive testing in the field subjects the couplings to stresses unmatched in any laboratory. • Temperature rating: -40°C to +150°C Constructed of tightly woven fibreglass on the inside and a specially compounded, heat resistant, silicone rubber cover on the outside; completely non-asbestos. Quick-PIC® (Quick Part Number Interchange) No waiting, no guessing, no hassles. Just the right replacement – fast! Quick-PIC cuts the job of identifying replacement assemblies down to size. • Covers over 75,000 part numbers hydraulink.com.au www.hydraulink.com.au Impulse Testing • FRAS rated range available • Comes with rounded edges both inside and out for added safety • Effective temperature range: -40°C to 138°C Gates Inventory Support Systems This one-of-a kind computerised system interchanges manufacturer part numbers with the Gates replacement. Just provide the part number of the failed assembly and within seconds Quick-Pic will interchange the part to the Gates hose assembly, including fittings, protectors and hose length. Hydraulink quality is underpinned by a rigorous testing regime undertaken in our own quality assurance facilities to ensure the retention and performance integrity of all coupling/ferrule/hose combinations. • Reduces downtime with fast, accurate service • Easier inventory management • Improves quality and reliability Gates AIM® (Accurate Inventory Management) Also unique to Gates, AIM automatically lists all the hydraulic hose and coupling Gates Testing Dedicated to leading the industry in customer-focused product research, and development, Gates testing is hard to match. Boasting the most advanced testing facilities in the industry, Gates can put any and every hose assembly or product to prototype to the test. Developmental Testing requirements for your equipment to ensure you will always have the right parts, at the right time. • Wire braid hoses – hose and coupling product development assemblies are validated at 450,000 impulse cycles, or three times the SAE industry standard • Wire Spiral Hoses – hose and coupling product development assemblies are validated at 1,000,000 impulse cycles, or TWO times the SAE industry standard Hose/Connector Testing • Lot control testing – burst, adhesion and tube properties • Frequency testing – impulse tests conducted on every 3,000m to 15,000m of hose • Quarterly testing – lot control and frequency testing, plus cold flex, ozone and aging tests • Annual testing – lot control and frequency testing, cold flex, ozone and aging tests • plus an extended level of impulse cycle testing for re-validation International Standards Gates hydraulic hoses meet and exceed various agency specifications and standards including: DIN Mining Design Guideline (MDG) 41 Compliance Hydraulink products meet, if not exceed, the specifications defined in the MDG 41 guideline and the requirement for a “matched system”. Assembly testing is carried out using a computerised data recorder which provides a tamper proof data base for all tested assemblies. Hose labeling is produced in accordance with the MDG 41 guideline requirements and can be tailored individually to suit our customer’s requirements. All tested hose assemblies are uniquely numbered and recorded for the lifespan of the hose. Through our online training and in the field instruction training, we meet the competency requirements defined by MDG 41, both as assemblers and installers of hydraulic hose and fittings. Deutsch Industry Norm, German DOT/FMVSS U.S. Department of Transportation/Federal Motor Vehicle Safety Standard EN European Norm/Standard FRAS Fire Resistant and Anti Static ISO International Standards Organisation MSHA U.S. Mine Safety and Health Administration SAE Society of Automotive Engineers With AIM computerised program matching inventory to exact needs – what to stock and how many – inventory management has never been more efficient. • Improves accuracy • Offers complete coverage • Reduces inventory costs • Saves time and money Changing the game Solutions for mining Safety Programs Hydraulink and Gates offer hydraulic safety and preventive maintenance programs that can help you cut costs andprevent injuries from hydraulic assembly failures. It’s free information for maintenance managers, repair technicians and machine operators – in-fact anyone else working with high power fluid pressure systems. Simply contact us to arrange this hands-on, two hour seminar. Topics include inspection procedures, troubleshooting, hose and coupling selection, hose assembly, and crimper preventivemaintenance. In addition, you’ll receive a 72-page Safe Hydraulics Manual, with detailed information and step-by-step procedures. We also offer additional training programs that can be tailored to suit your specific requirements. Hydraulink On-Site Container Through our well equipped and fully stocked on-site containers, we offer mine operators a readily available resource that would otherwise demand capital investment and workshop space. • Professional layout • User-friendly system • Colour-coded storage system • Colour matching crimping system Hydraulink Australia Pty Limited 25 Davis Road | PO Box 6387 Wetherill Park NSW 2164 Sydney Australia P +61 2 8785 4600 | F +61 2 8785 4626 ACT NEW SOUTH WALES NORTHERN TERRITORY QUEENSLAND SOUTH AUSTRALIA • Better inventory management TASMANIA • On-site training provided VICTORIA WESTERN AUSTRALIA www.hydraulink.com.au hydraulink.com.au Changing the game