ASD Installation On A P&H 4100 Electric Rope Shovel

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Tamsin Lorin Reynolds
6 years ago
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1 ASD Installation On A P&H 4100 Electric Rope Shovel 1

2 Installation Driver 2 An international mining company conducted a company wide review of the fire protection systems on their Ultra- Class mobile mining equipment. As a result of this review, it was decided to evaluate an ASD system on one their electric rope shovels. The ASD system was deployed as an early warning detector and not a replacement for the current heat/flame detection system to release the suppression.

3 Situational Risks & Threats 3 The 2 main fire threats on an electric rope shovel are high voltage electricity and hydrocarbon based lubricants and fluids. The feed voltage can be as high 13,800v AC and it is then converted to DC The mechanical operation of the shovel requires lubricants and hydraulic fluids that are under high pressures.

4 Installation Specifics 4 Due to the inability to get the engineering drawings of the shovel, the system was designed by site visits. The system was designed with two zones to protect both the electrical & hydraulic areas of the shovel. Vibration & jolting are an issue with this application and a special anti-vibration mounting plate was designed.

5 Actual Field Installation & Challenges 5 The installation was scheduled for the week of June 20 th to coincide with a major maintenance down. The installation team had to work around the activities of the mine s maintenance staff, which created periods of down time for the team. Mining Safety & Health Administration (MSHA) federal regulations along with the mine s site specific safety policies also created delays in the installation.

6 Installation Specifics 6 For open area detection 3 mm sampling holes were field drilled into the pipe and labeled. For electrical in-cabinet sampling, ½ flexible tube coming from the main pipe and connected to bulkhead sampling points that are penetrated into the individual cabinets. For air cooled electrical cabinets, ¾ pipe with 3 mm sampling holes were run over the cabinet s exhaust venting.

7 Actual Field Installation & Challenges 7 Accessing the under floor cable tray to run the sampling pipe was much more time consuming then initially thought. Zone layout was not installed not as originally designed. The detector/power supply anti-vibration mounting plate location needed to be re-located due to objections from a member of the operational staff.

8 4100 Machinery Deck Layout 8

9 ASD Layout Zone #1 9 Electronic Control Room Sampling hole In Pipe Lube Room Under Beaver Slide In Cabinet Sampling

10 Zone #1 - Obscuration Graph to

11 Zone #1 Alarm Events to Date Alarm Type Total Event Duration Cause Time Highest % Obscuration Friday, July 29, 2011 Fire 2 Arc-over Event 10 Saturday, August 20, 2011 Action 30 minutes 9:28:46 PM to 9:59:40 PM Sunday, August 21, 2011 Alert 18 seconds Saturday, October 01, 2011 Fire 1 4 minutes 30 seconds Unknown 7:24:32 PM to 7:29:06 PM Sunday, October 02, 2011 Fire 1 3 minutes 30 seconds Unknown 2:46:38 AM to 2:50:12 AM Sunday, October 02, 2011 Fire 1 1 hour 30 minutes Unknown 6:53:56 AM to 8:36:04 AM Saturday, October 15, 2011 Alert 6 seconds Thursday, November 03, 2011 Alert 8 seconds Thursday, November 10, 2011 Action 45 seconds Sunday, November 20, 2011 Action 4 seconds Friday, December 09, 2011 Alert 4 seconds Friday, December 16, 2011 Action 1 minute 15 seconds Unknown 1:20:34 PM to 1:21:48 PM Friday, January 27, 2012 Action 4 seconds Monday, January 30, 2012 Action 35 seconds

12 ASD Layout Zone #2 12 Transformer In Cabinet Protection Swing Motor Protection Hoist Motor Protection Inverter Cabinet Vent Protection

13 Zone #2 - Obscuration Graph to

14 Zone #2 Alarm Events to Date Highest Alarm Type Total Event Duration Cause Time Highest Percent Obscuration Monday, July 18, 2011 Alert 60 seconds Thursday, July 28, 2011 Alert 60 seconds Friday, July 29, 2011 Fire 2 Arc-over event 10% Thursday, August 04, 2011 Alert 4 seconds Saturday, August 20, 2011 Action 1 hour 45 minutes Unknown 8:13:32 PM to 9:59:52 PM Friday, August 26, 2011 Alert 2 seconds Wednesday, September 21, 2011 Alert 45 seconds Saturday, October 01, 2011 Action 2 minutes 10 seconds Unknown 7:26:42 PM to 7:28:56 PM Sunday, October 02, 2011 Action 36 seconds 2:49:16 AM to 2:49:52 AM Sunday, October 02, 2011 Fire 1 1 hour 37 minutes Unknown 6:53:40 AM to 8:30:40 AM Wednesday, October 05, 2011 Alert 6 minutes 30 seconds Unknown 10:59:20 AM to 11:05:50 AM Monday, October 10, 2011 Alert 4 seconds Thursday, October 13, 2011 Alert 6 minutes Unknown 8:20:56 AM to 8:26:44 AM Thursday, October 13, 2011 Action 1 hour 26 minutes Unknown 1:52:26 PM to 3:18:08 PM Thursday, November 17, 2011 Alert 6 seconds Wednesday, November 23, 2011 Alert 4 seconds Wednesday, November 30, 2011 Action 3 minutes Unknown 3:21:04 PM to 3:24:06 PM Sunday, December 11, 2011 Alert 4 seconds Saturday, December 24, 2011 Action 34 minutes Unknown 2:56:40 PM to 3:30:04 PM Wednesday, January 04, 2012 Alert 2 seconds Wednesday, January 18, 2012 Fire 2 18 minutes Unknown 7:17:32 PM to 7:35:20 PM

15 Anti Vibration Mounting Plate 15

16 Displays in Operator s Cab 16

17 Electronics Room 17

18 Hoist Motor Sampling Pipe 18

19 Swing Motor Sampling Point 19

20 Lube Room Sampling 20

21 Conclusion 21 In industrial applications ASD will usually not be driven by codes, but by risk management considerations. The early detection capabilities of ASD can provide value to industrial customers by protecting mission critical equipment & processes. ASD systems can be successfully deployed in harsh industrial conditions if a good plan is developed and all the stakeholders have input.

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SMOKE ALARMS. Improving the lives of those affected by burn injury January SMOKE ALARMS Working smoke alarms save lives. The most dangerous fires occur in homes without working smoke alarms. People killed in house fires die from carbon monoxide and smoke inhalation, not