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BRAKE TESTING OF TRACKLESS MOBILE MINING …

1 Safety in Mines Research Advisory CommitteeFinal Project ReportBRAKE TESTING OF TRACKLESS MOBILEMINING MACHINERYRW OttermannNDL BurgerAJ von WiellighResearch AgencyBE@UP, University of PretoriaProject numberSIM 04-05-02 Date of reportJanuary 2005 2 EXECUTIVE SUMMARYThe aim of this project is to develop an in-service BRAKE TESTING specificationfor TRACKLESS MOBILE MINING machinery of less than 50 ton. The primary outputof this project is an in-service BRAKE TESTING specification for TRACKLESS mobilemining machinery. Mines with TRACKLESS MOBILE MINING machinery will use thisspecification for the TESTING and in-service verification of brakes as an input tomaintenance to minimize the risk of BRAKE system related accidents,preventing runaways of vehicles, thereby saving status of BRAKE TESTING of TRACKLESS MOBILE MINING machinery in theplatinum, iron ore and coal sectors was established by visiting different investigation into what exists worldwide was done focusing on BRAKE testspecifications as w

1 Safety in Mines Research Advisory Committee Final Project Report BRAKE TESTING OF TRACKLESS MOBILE MINING MACHINERY RW Ottermann NDL Burger AJ …

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Transcription of BRAKE TESTING OF TRACKLESS MOBILE MINING …

1 1 Safety in Mines Research Advisory CommitteeFinal Project ReportBRAKE TESTING OF TRACKLESS MOBILEMINING MACHINERYRW OttermannNDL BurgerAJ von WiellighResearch AgencyBE@UP, University of PretoriaProject numberSIM 04-05-02 Date of reportJanuary 2005 2 EXECUTIVE SUMMARYThe aim of this project is to develop an in-service BRAKE TESTING specificationfor TRACKLESS MOBILE MINING machinery of less than 50 ton. The primary outputof this project is an in-service BRAKE TESTING specification for TRACKLESS mobilemining machinery. Mines with TRACKLESS MOBILE MINING machinery will use thisspecification for the TESTING and in-service verification of brakes as an input tomaintenance to minimize the risk of BRAKE system related accidents,preventing runaways of vehicles, thereby saving status of BRAKE TESTING of TRACKLESS MOBILE MINING machinery in theplatinum, iron ore and coal sectors was established by visiting different investigation into what exists worldwide was done focusing on BRAKE testspecifications as well as in-service verification of brakes.

2 From theinvestigation, electronic BRAKE TESTING equipment was recommended for the in-service TESTING of brakes. Different electronic BRAKE TESTING equipment wasevaluated on different vehicles to determine the usefulness of this type ofequipment. These tests were conducted at Leeupan Collieries, Kumba. Abrake TESTING specification for TRACKLESS MOBILE MINING machinery a workshop attended by interested parties from MINING houses, originalequipment manufacturers (OEM s), DME and SIMRAC the findings of theproject were presented. The workshop accepted the proposed draft braketest specification with some minor modifications.

3 The workshoprecommended that the following should be included in the follow-up project(phase 2 of project SIM 040502): Evaluate the accuracy, repeatability and limitations of available electronicbrake TESTING equipment. Include a risk assessment on the equipment. Determine the parameters of the proposed specification. Evaluate and modify the proposed following recommendations were also made during the workshop: The DME will request the SABS to compile a part 2 of SABS 1589specification to include hydrostatic drives. The BRAKE TESTING specification should be included in the code of practice(COP) of MINING operations. The DME should consider the inclusion of the BRAKE TESTING specification inthe mandatory code of practice of the DME.

4 As a large percentage of vehicle accidents are caused by the operator(human factor) and not mechanical failure, SIMRAC should consider aproject to address this authors would like to express their gratitude to the Safety in MinesResearch Advisory Committee (SIMRAC) for financial support of project SIM040502 and also for the interest and technical input of the SIMRAC TechnicalCommittee. The team would also like to thank the personnel of LeeupanColleries for their assistance during the evaluation of the electronic OF CONTENTS Page1 STATUS IN SOUTH AFRICAN VISITS TO SAMRASS BRAKING SYSTEMS REQUIREMENTS FOR BRAKE TEST INVESTIGATION INTO WHAT 3450 South Wales: Guideline on braking from specification TEST road Plate Performance-Based BRAKE Tester.

5 BRAKE test BRAKE TESTING from test equipment EVALUATION OF AVAILABLE ELECTRONIC TESTING DRAFT WORKSHOP WITH :.. of BRAKE TESTING :.. :.. :..266 CONCLUSION AND C:..32 APPENDIX D:..33 APPENDIX E:..34 APPENDIX F:..35 APPENDIX G:..365 TABLE OF FIGURESPAGESF igure 4-1:Service and secondary BRAKE system stopping 4-2: Service- and secondary BRAKE system stopping 4-3 BRAKE efficiencies on level gravel road for the 40 ton 4-4 Photo of test equipment in 5-1 Example of an information of Tables PageTable Proposed BRAKE TESTING Recommended information to be recorded on test INTRODUCTIONMost accidents due to BRAKE failure can be attributed to an inadequate brakesystem on the vehicle, inadequate maintenance or overloading of the brakesystem when driving downhill or downdip at too high a speed or gear.

6 Toreduce these accidents vehicles have to be fitted with BRAKE systems that canhandle the operational requirements and have efficient maintenance with in-service TESTING of the BRAKE system. No definitive procedure and supportingequipment exist in the South African MINING industry to evaluate the efficiencyof braking systems on TRACKLESS MOBILE MINING different levels of BRAKE TESTING that exist are daily checks by the operator,intermediate tests and system verification TESTING . The intermediate TESTING isthe in-service verification of the brakes as an input to maintenance. Thisproject focuses on the intermediate tests that are performed at is the final report on phase 1 of project SIM 040502 on BRAKE TESTING oftrackless MOBILE MINING METHODOLOGYThe following methodology was followed during this project: The status of BRAKE TESTING of TRACKLESS MOBILE MINING machinery inthe platinum, iron ore and coal sectors was established.

7 Differentmines where visited to establish what TESTING and in-serviceverification is done. The operational condition and the type ofbrake equipment on the different vehicles was also established. An investigation into what exists worldwide was done. Theinvestigation focused on BRAKE test specifications as well as in-service verification of brakes. Land Mobility Technologies (LMT)was responsible for this part of the study. Different BRAKE TESTING equipment was evaluated on differentvehicles and at varying operating conditions to determine theusefulness of this type of equipment. These tests were conductedat Leeupan Collieries, Kumba.

8 A BRAKE TESTING specification for TRACKLESS MOBILE MINING machinerywas drawn up taking the results of the studies into BRAKE testingspecifications and the TESTING of BRAKE TESTING equipment intoaccount. The emphasis of the specification was on practicality andcost effectiveness on the tests. A workshop was held with industry and manufacturers of tracklessmobile MINING machinery. Representatives of the DME andSIMRAC were also present at this workshop. During this workshopthe findings of the project were presented and the proposed draftbrake TESTING specification was discussed. The draft BRAKE testingspecification was accepted with some minor modifications. The draft BRAKE TESTING specification as accepted by the workshopwas circulated to all interested parties for comments.

9 Nocomments were received. The final project report was STATUS IN SOUTH AFRICAN Visits to QuestionerA questioner was circulated to mines to determine the type, size and numberof vehicles used in industry. This questioner was circulated through thetechnical committee of SIMRAC. No feedback was however VisitsDifferent mines were visited to determine the different TRACKLESS MOBILE miningmachinery and BRAKE systems used in South African mines, to assess whatbrake TESTING is being done and to determine how big the problem of brakefailures is. Appendix A summarises the information gathered during thesevisits. The different mines were selected from different sectors using largenumbers of TRACKLESS MOBILE MINING machines.

10 The following mines werevisited:NameTownMining sector Waterval Business Unit UG2 Rustenburg Anglo Platinum Kumba ResourcesThabazimbiIron Kumba BRAKE testingBrake TESTING of varying degrees and quality is being done on all mines. Thefollowing tests are performed:Daily check: Application and release of BRAKE system to test functionality. Test the brakes on a at certain intervals (weekly or after certain engine hours): Visual checks for wear of BRAKE parts and system tests are performed on BRAKE systems. It is accepted that thevehicles are equipped with adequate braking managers at the mines expressed the need for a test or testprocedure to test braking systems at intermediate intervals to determinemaintenance requirements.


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