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Technical Bulletin

1. FREQUENGY 7 3 9 ESIIMATE SEVERITY aa aa ever 8 3 10 ESTABLISH RISK FROM RISK MATRIX eese 8 3 11 RECOMMEND POTENTIAL NEW BARRIERS eene eene neret etr r retten 8 3 12 IMPLEMENT NEW BARRIERS ccccceeeeececeeececeeeeecececececeeesecanaeaeauanauananauaeananananananananaes 9 3 19 PREPARE REPORT ies rete oe pare E EEDR EET xa ced ch lacceauhdddendeat car 9 4 RISK IDENTIFICATION AND HAZARD MANAGEMENT eene rnnt 10 Sandvik Mining amp RA0023 Non conformance Risk Assessment page 2 of 19 Construction Tomago Pty CAT3126 DES doc Limited SANDVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT 1 EXECUTIVE SUMMARY 1 1 In order to minimise risk due to partial and non compliances of the CAT3126DES to AS NZS3584 2 2008 Sandvik and End Users should perform the following actions Refer to Section 4 for hazard identifications and specific actions required for each risk 1 2 Sandvik Actions as an outcome of the Risk Assessment These actions are nominally due for completion January 2009 1 2 1 Design revised DES nameplate not related to any non compliance but required due to new registration numbers 1 2 2 Engineer retrofit for radiator cap and issue technical bulletin 1 2 8 Issue t
2. Do Not b only single reading below nexinum torque taken Note test report identifies max torque poirt No associated risk Sandvik Mining amp RA0023 Non conformance Risk Assessment Construction Tomago Pty Ltd CAT3126 DES doc page 16 of 19 SANDVIK Sandvik Mining amp Construction Tomago Rev dase dase Conply Conmments ustification Hazard amp Effect Existing Barriers Suggested new Barriers Risk Notes Sandvik Action End User Action Required to Required to Implement New Inplerent New lt Eg E E Fal Barrier Banier E S 5 8 q 9 S pos g os e 2 9 a o a Oo 2 F63 6 Particulate filter Do Not Downstreamsensor not tested in Undetected filter fire 2 shutdown floats 1 11 End user to T Ibe Conply location shown However sensor is the ensure nominated by sane as fitted for exhaust gas Terp sensor fitted to filter elerrents are For each of the tests the 4 ine shall bef Rated ten perature of filter meda 29 C Filter derert nets and the ofthe above shutdown tenperature Refer does not caich fire ops Appendix i iately before the Rating of filter element filter hes the meda is 25 C above the of 50 C belowthe auo nma immalovabe icritiont ture of exhaust gas terrperature the filter elerrert or when nofilter f
3. MDA DES 030043 1 Superseded MDA DES 030043 Superseded COIN oy AJOJN 4 2 2 The modifications in Table 3 are not mandatory for registration however they are recommended as an outcome of risk assessment RA0023 4 2 3 Asatthe time of writing this Technical Statement a number of the recommendations were being engineered When these are available Sandvik will issue Technical Bulletins providing details Table 2 Recommended Loader Modifications Item Reference Design Change 1 RA0023 Fit fuel shutoff valve label and move valve to downstream of fuel water separator 2 RA0023 Fit mesh to ED7 LS170 as TB0719 3 RA0023 Fit belt tensioner and use of tension indicator tool 4 RA0023 Fit retrofit radiator cap 5 RA0023 Fit of radiator expansion tank where possible 4 3 Changes to Testing or Procedures 4 3 1 Owners and operators of existing loaders are required to implement or change testing or procedures listed below in Table 2 4 3 2 Additional End User requirements to comply with conditions of registration are in Appendix A Table 3 Required Changes to Testing or Procedures and End User Actions Change From Previous Design End User Action Required For Existing Loaders In service testing requirements have been revised Update mechanical engineering management plan in accordance with requirements in MDR 089003 DES Sandvik Mining and Construction
4. SANDVIK m Rubber Tyred Vehicles Technical Bulletin Bulletin Number TBO903 Date 17 06 2009 Subject Cat3126 DES Design Registration Purpose To inform the industry of the New South Wales registration and exemption of the Transport Braking System for the Sandvik Cat3126 Diesel Engine System Applicable to Sandvik Loaders and Haulers LS160 former name ED6 LS170 former name ED7 LS170L former name ED7LP LS190 former name ED10 220 TS350 former name ED25 TS355 former name ED30 TS490 former name ED40 Description New South Wales design registration and design registration exemption has been granted for the Sandvik Mining and Construction Tomago Pty Ltd Caterpillar 3126 DITA Diesel Engine System The registration MDR 089003 DES applies to all Sandvik Cat3126 Diesel Engine Systems manufactured after 14 January 2009 and used within New South Wales The Exemption Order No 090264 applies to all Sandvik Cat3126 Diesel Engine Systems manufactured prior to 14 January 2009 and used within New South Wales Note that the exemption order expires 30 June 2009 Before this time End Users in New South Wales will be required to upgrade their DES s to comply with the registration requirements In the majority of cases the only required modification will be a new nameplate BD00003888 Note that additional non mandatory changes are recommended as an outcome of the risk assessment and information on these will be released vi
5. ar TECHNICAL INFORMATION Please Check For Latest Revision 4 5 6 7 8 9 10 11 12 P es ee 7 i r 7 EXHAUST EXHAUST BYPASS VALVE OPTION EXHAUST FILTER r BYPASS HORN A2U900 259017 BYPASS WASTEGATE A2U900 697003 BYPASS 1mm ORIFICE IN FITTING REQUIRED ONLY ON ENGINE OIL pd n A2U900 690025 DO NOT REMOVE MACES ON ENGINE H Q y EXHAUST 2 RESTRICTOR 2 O gt DIAPHRAGM o aypassprorvaive MAY A2U900 694105 EE ENGINE WATER SUPPLY qp A P R ee ee R2 R1 P NP 1d og m MEME RESET VALVE COOLANT LOSS 20900 694103 M oe TIERS hp MEN z ENGINE OIL MEM P SUPPLY ENGINE COOLANT E AR SERERE 4 ON ENGINE SENTINELS 103 C E MEM LLLI occ s c cc cc c m ON OFF lt y X ue Renae i a A POSITION NEAR C ij WATER TRAP amp li E EISE LUBRICATOR H s E a 54 oot OR IVA VALVE d EXHAUST OVERTEMP START BUTTON SENTINELS OVERRIDE VALVE 70 C IN WATER OPTIONAL 1st REQUIRED 2nd 5 OPTIONAL y CHECK VALVE X VALVE EXHAUST OVERTEMP STARTER MOTOR SENTINEL FOR WHEN PARTICULATE FILTER COMPRESSOR GOVERNOR FITTED
6. 12091096 Vacuum Under Emergency Shutdown MDR 089003 DES Sandvik doc Page 3 of 6 OCCUPATIONAL HEALTH AND Registration No MDR 089003 DES SAFETY ACT 2000 i File 08 9003 Date 14 January 2009 23041 original 23 7 02 Report Testing Caterpillar 3126A diesel engine 5 system with wet exhaust system by TestSafe Australia 0056 0 05 04 06 Test Report 100 000 Cycle Test of Prototype Engine Strangler 0057 0 05 04 06 Test Report Measure of Strangler Valve Cylinder Extension Vs Air Pressure CRO184 1 08 12 06 Strangler Valve Compliance with AS4024 1 1501 2 Document Diesel Engine Emergency Shutdown System for Eimco Diesel Engine Systems A2U220 257008 Sheet 8 05 02 Purifier Water Cooled 220 LHD 1 to 5 inclusive AROFAT 4 9 10 06 Catalytic Purifier Water Cooled 220 LHD Sheets 1 to 2 inclusive RC A2U900 860004 2 13 06 06 i Compliance Statement by Designer RE0082 1 23 7 03 Verification Statement by Verifier Compliance report development of Caterpillar 3126 CR0037 2 26 7 03 Diesel Engine System with Wet Scrubber by VA Eimco i Australia Pty Ltd Report Testing of caterpillar 3126 DITA Diesel Original 13 01 03 Engine System with Wet Scrubber Exhaust System by TestSafe Australia Test Report Testing amp Certific
7. SHUT DOWN CYLINDER and override the internal compression apang If any of these valves are in the dump mode the shutdown cylinder will not build up oil pressure and a signal will not be sent to the SAFE START valve which will not engage the STARTER MOTOR Whilst the engine is running the safety system will dump the oil from the SHUT DOWN CYLINDER and stop the engine for the following reasons 1 Low engine coolant pressure less than 2 PSI 2 Engine coolant over temperature Ae sensors set at 103 deg Celsius 3 Low engine oil pressure below 10 PSI 4 Low scrubber water level two sensors 5 Engine exhaust over temperature one sensor set at 70 C in water 6 Engine shutdown by the operator SAFETY ENGINE SHUTDOWN It is important to note that this system cannot be overridden for any function other than coolant loss and this function will only override for a maximum of 30 seconds To move a malfunctioning machine the shutdown fault must be rectified i e fill the exhaust cond with water or a fitter is required to bypass any faulty valve or subsystem NOTES CONDITION TECHNICAL INFORMATION Please Check For Latest Revision STOP CONDITION ENGINE OIL ON OFF RETURN PILOT 1 THE ABOVE CIRCUIT IS FOR THE SHUTDOWN START SYSTEM ONLY THERE MAY BE OTHER AIR FUNCTIONS NOT SHOWN ON THIS SCHEMATIC FOR FULL INFORMATION REFER TO THE FULL AIR SCHEMATIC OR PARTS MANUAL FOR THE PARTICULAR MACHINE 2 CYLINDER
8. 2 of the Regulation This registration 1s issued pursuant to the provisions of Clause 109 1 a of the Regulation This registration 1s 1ssued to Address of supplier Registration number Date of expiry Description of plant Make Model OHS Registration Clause Specific Registration Category Sandvik Mining and Construction Tomago Pty Ltd ABN 38 070 973 330 Old Punt Road TOMAGO NSW 2322 PO BOX 595 RAYMOND TERRACE NSW 2324 MDR 089003 DES January 2014 5 Years Sandvik Mining and Construction Tomago Pty Ltd modified 150 kW Caterpillar 3126 DITA explosion protected diesel engine system with wet exhaust system comprising exhaust catalytic converter water based conditioner particulate filter assembly an pneumatic hydraulic shutdown system as identified by registration number MDR 089003 DES and listed documents herein Caterpillar 3126 Part 2 of the table to clause 107 of the Regulation Mining Specific Plant Diesel engine systems used in underground mines at a coal workplace This registration is issued subject to compliance with the requirements of the Act The registration has appended to it for the purposes of the Act a schedule and a list of conditions including drawings documents etc that are applicable to this registered plant design as identified during test and or assessment to assist the designer manufacturer supplier and user to comply with the obligations of the Act These co
9. 8 BSP OR CLAMP CONNECTION GAS PEON F EXHAUST PARTICULATE FILTER HOUSING A2U220 252038 END VIEW MANDATORY FOR NSW OPTIONAL FOR QLD AND OUTSIDE AUSTRALIA PART VIEW DETAIL B DETAIL C A2U220 254091 A2U220 254092 TYPICAL FOR TYPICAL FOR GASKET PURIFIER DOWNPIPE TO GASKET TURBO TO A2U220 257008 amp A2U220 257008 amp EXHAUST CONDITIONER PURIFIER DOWNPIPE A2U220 257011 A2U220 257011 WATER LEVELS FOR WATER IN SCALE 1 5 SCALE 1 5 798 EXHAUST PARTICULATE FILTER ELEMENT A2U900 292008 SPECIFICATIONS 1 MAX OPERATING TEMPERATURE 175 C 2 FILTER MEDIA FILTRETE GRD SP4055F 2 1 APPROX IGNITION TEMP NEW FILTER 960 C 2 2 APPROX IGNITION TEMP DIRTY FILTER 650 C DRAIN VALVE LO co eies WITH REMOVAL PLUG e ec 5 EXHAUST CONDITIONER A2U220 251089 TECHNICAL INFORMATION Please Check For Latest Revision EN 8823 EN 9113 REVISIONS LOW WATER TEST VALVE La 15 FORE amp AFT 15 SIDE TO SIDE ITEM PART No DESCRIPTION MATERIAL SAN DVI K Sandvik Mining and This drawing and all information thereon is the property of a Construction Tomago Pty Ltd Sandvik Miining and Construction Tomago Pty Limited and is confidential and must not be public or copied This drawing is ABN 38 070 973 330 loaned subject to return upon demand and is not to be used DRAWN DC TOLERANCES O N O directly or indirectly in any
10. HOUSING A SMALL AMOUNT OF ADDITIONAL FLOW IS ALSO DIRECTED TO TURBO COMPRESSOR HSG amp AIR INLET FLAMETRAP COVER HOUSING FOR SURFACE TEMPERATURE COOLING VENT LINES ARE LOCATED AT TOP OF EXHAUST PURIFIER DOWNPIPE amp RADIATOR amp ARE DIRECTED TO SURGE TANK 18 3 2005 20 11 06 co ce N co N TECHNICAL INFORMATION Please Check For Latest Revision REVISIONS FUEL SYSTEM SCHEMATIC PRESSURE CHECK REGULATING VALVE VALVE SECONDARY PRIMING FUEL INJECTOR FUEL FILTER PUMP PUMP CHECK C TRANSFER VALVE BUMP PRESSURE RELIEF VALVE PRIMARY FUEL FILTER EMERGENCY FUEL SHUTOFF VALVE FUEL TANK NOTES 1 FUEL SETTING amp FUEL TIMING ADJUSTMENT POINTS FACTORY SET amp LOCATED UNDER ROCKER COVER ARE TAMPER PROOF SEALED 2 HIGH IDLE ADJUSTMENT POINT TO BE TAMPER PROOF SEALED BEFORE SHIPMENT TO CUSTOMER ITEM PART No DESCRIPTION MATERIAL Sandvik Mining amp SAN DVI K Construction Pty Ltd 301097330 DRAWN DC D C TOLERANCES ON O N O DATE 24 12 02 DECIMAL x CHECKED PN o t ec t SIGNATURE P Nelthorpe P SIGNATURE P Nelthorpe DO NOT SCALE IF IN OS _ a ee me S T E This drawing and all information thereon is the property of Sandvik Miining amp Construction Pty Limited and is confidential and must not be public or copied This drawing is loaned subject to return upon demand and is not to be used directly or i
11. NECESSARY CONTROLS AND BARRIERS Risk may or may not have barriers set but in the interest of the manufacturer end user those barriers that are relatively easy or cost effective to implement should be implemented Controls or barriers should be implemented Identified risks in this category shall have barriers or controls in place 3 12 4 Hard barriers or mechanical forms of protection should be used in preference to soft barriers training and procedures where practical This is especially true when implementing barriers and controls for High risk ranked hazards 3 13 PREPARE REPORT 3 13 1 Step 10 is to prepare the report this report should have included the following as a minimum 3 13 1 1 A list of the risk assessment team including the person s name company position 3 13 1 2 Alist of the new or revised items being assessed on the equipment 3 13 1 3 Clear drawings diagrams and photos where available to validate the affected equipment 3 13 1 4 available injury and safety statistics should be documented in the appendix 3 13 1 5 All processes hazards probabilities consequences risks and barriers nominated in the exercise are to be listed 3 13 1 6 A final recommendation list of selected barriers and the hazards they minimise or eliminate must be listed 3 13 1 7 Statements as to the reasons why potential new barriers have not been implemented must be supplied by the manufacturer end user Sandvik Mining amp RA0023
12. ON ENGINE ___ SET 125 PSI 70 C IN WATER ENGINE SUMP ONLY NEEDED IF Van INTAKE LINE IS Sox FLAME SUCTION TUBE E RSP ARRESTOR BETWEEN FLAME XY OIL SUPPLY FROM FIRST EXH CONDITIONER TRAP amp CYL HEAD LOW WATER SHUTDOWN AS3584 1991 cl 2 14 1 SHOWN IN SHUTDOWN MODE ENGINE AIR FILTER Ap VALVES 4 SECOND EXH CONDITIONER ey LOW WATER SHUTDOWN Nd SHOWN IN SHUTDOWN MODE START PUMP CYLINDER is 2 SPECIAL 3 GAUGE ENGINE OIL spud RETURN SHUTDOWN naan cyunper PPP SAFETY ENGINE SHUTDOWN GENERAL AIR AND SUPPLY START SYSTEM AIRLINES ENGINE OIL LINES NOTE THE ABOVE CIRCUIT IS FOR THE SHUTDOWN START SYSTEM ONLY THERE MAY BE OTHER AIR FUNCTIONS NOT SHOWN ON THIS SCHEMATIC FOR FULL INFORMATION REFER TO THE FULL AIR SCHEMATIC OR PARTS MANUAL FOR THE PARTICULAR MACHINE ee Wo ITEM PART No DESCRIPTION MATERIAL Sandvik Mining amp Construction Pty Ltd ABN 38 070 973 330 DATE 14 11 02 CAT 3126DITA DES CHECKED FRACTIONAL x ANGULAR 220 LHD DWG No A2U220 830855 DO NOT SCALE IF IN DOUBT ASK SHEET 10F 1 SCALE NTS 11 This drawing and all information thereon is the property of Sandvik Miining amp Construction Pty Limited and is confidential and must not be public or copied This drawing is loaned subject to return upon demand and is not to be used directly or indirectly in any way detrimental to our interests TITLE SAFETY
13. RATED MAX TORQUE 30 1 kg hr FUEL SETTING 7 79mm FUEL TIMING 65 34mm GOVERNOR GRP UNIT INJECTOR C2A1333062 FUEL INJECTOR C2A1278218 COOLING SYSTEM SYSTEM IS DESIGNED FOR CONTINUOUS OPERATION IN 40 C AMBIENT CONDITIONS MAX COOLANT OPERATING TEMPERATURE 99 C FAN AIR FLOW 7 m 3 s SURGE TANK RELIEF PRESSURE 48 kPa COOLANT BOILING POINT RELIEF PRESSURE 113 C ENGINE AUXILLARIES GEAR PUMP HYDRAULIC FAN DRIVE OPTIONAL MECHANICAL DRIVE FAN COMPRESSOR REFERENCE DRAWINGS GENERAL SAFETY SHUTDOWN SYSTEM GENERAL AIR SCHEMATIC A2U220 830555 DIESEL ENGINE SYSTEM MASS APPROX MASS 1100 kg APPROX MASS 1200 kg WITH PARTICULATE FILT HSG COMPONENT SPECIFICATIONS ENGINE AIR SYSTEM AIR CLEANER ASSEMBLY MINIMUM RATING 18 5 m43 min AT 10 W G PRESSURE DROP PRIMARY AND SAFETY ELEMENTS REQUIRED TURBO ASSEMBLY MODIFIED SANDVIK P N A2U220 259009 AFTERCOOLER FLAMETRAP ASSEMBLY SANDVIK P N A2U220 241041 FLAMETRAP ELEMENT SANDVIK P N A2U900 241033 FLAMETRAP APPROVAL No M77 3636 ENGINE EXHAUST SYSTEM EXHAUST CONDITIONER SANDVIK P N A2U220 251089 EXHAUST CONDITIONER MATERIAL 316 SAF 2205 STAINLESS STEEL EXHAUST CONDITIONER MAX OPERATING ANGLE 15 FORE AFT amp SIDE TO SIDE EXHAUST PURIFIER DOWNPIPE SANDVIK P N A2U220 257008 EXHAUST PURIFIER DOWNPIPE SANDVIK P N A2U220 257011 TURBO ASSEMBLY MODIFIED SANDVIK P N A2U220 259009 EXHAUST PARTICULATE FILTER HOUSING S
14. TO PURIFIER WATER COOLED DOWNPIPE COMPRESSOR HSG COOLING WATER A2U220 259009 WER COOLED TEST PORTS IN OUT TEST PORTS MOUNTING FENCE TURBO ASSEMBLY MODIFIED TURBO HSG EXHAUST EXHAUST THICKNESS WATER IN SCALE 1 5 PURIFIER DOWNPIPE 1 8 BSP PURIFIER DOWNPIPE 1 8 BSP MATERIAL SPECS TO EXHAUST COND PURIFIER DOWNPIPE TO EXHAUST COND PURIFIER DOWNPIPE MILD STEEL CAST IRON ALUMINIUM CONNECTION TO TURBO ASS Y CONNECTION TO TURBO ASS Y 3mm PL FIXED JOINT 4 CONNECTION FIXED JOINT 4 FILTER BYPASS FILTER HSG amp FASTENER DETAILS FIXED JOINT 3 ru WASTEGATE FILTER ELEMENT FIXED JOINT 2 M10 STUD CAT P N 8T 7044 SPECIFICATIONS BACKPRESSURE NAMEPLATE SHUTDOWN 20220 257008 20220 257011 DIAPHRAGM FLOAT VALVE ASS Y PURIFIER DOWNPIPE WATER COOLED PURIFIER DOWNPIPE WATER COOLED SCALE 1 5 SCALE 1 5 WATER MAKE UP MATERIAL SPECS MATERIAL SPECS VALVE MILD STAINLESS STEEL MILD STAINLESS STEEL EXHAUST GAS PIPE CONE SECT 3mm PL PIPE CONE SECT 3mm PL E NLET FASTENER DETAILS FASTENER DETAILS FIXED JOINT 3 M10 x 45LG BOLT M10 STUD GRD 8 8 FIXED JOINT 3 M10 x 45LG BOLT M10 STUD GRD 8 8 FIXED JOINT 4 M12 x 45LG BOLT GRD 8 8 FIXED JOINT 4 M12 x 45LG BOLT GRD 8 8 EXHAUST TEMP WATER ISOLATION SENTINEL j VALVE CLOSED FOR A2U936 694046 SHUTDOWN LOW WATER TESTING FLOAT VALVE ASS Y WATER CONNECTED TO EXHAUST GAS TEST PORTS STRAINER EXHAUST OUTLET OUTLET EXHAUST WATER SUPPLY PIPE VIA FLANGE SIDE VIEW 1
15. Tomago Pty Ltd Page 3 of 7 ABN 38 070 973 330 Old Punt Road Telephone Tomago NSW 2322 61 2 4985 2625 Australia Facsimile 61 2 4985 2626 SANAS DOCUMENT No A2U900 860132 Rev A 5 General Requirements for End Users Regarding Diesel Engine Systems 5 1 These recommendations are additional to those provided in the loader Operator and Service Manuals including addendums and relevant alerts and bulletins issued by Sandvik or the industry 5 2 Engine system specifications stated on nameplates and in documentation are valid only for adequately maintained engine systems Inadequate maintenance may reduce performance levels and increase levels of particulates and gases 5 3 All vehicle operators are to be suitably trained and qualified especially with regard to isolation air and fuel performing pre start checks on the DES and emergency shutdown procedures 5 4 For the determination of required Category and or SIL levels for safety related parts of control systems Sandvik assume the operating environment is maintained as specified by the regulatory authority with regard to coal dust suppression mine ventilation and explosion barriers 5 5 Sandvik FMEA s on vehicle systems may exclude generic faults from the analyses in accordance with AS4024 1502 Section 4 The generic faults that may be excluded and conditions for exclusion are in listed in AS4024 1502 Appendices A B C and D End Users should note that if the vehicle system
16. WATER BATH 2 15 6 2 EXHAUST TEMPERATURE SENSOR 2 15 7 2e ii OPTIONAL SEE NOTE 2 amp 3 V EXPLOSION PROTECTED JOINTS AIR INLET SYSTEM FIXED JOINTS A CYLINDER HEAD TO AIR INLET MANIFOLD PORTS 3 OFF AT TOP OF AIR INLET MANIFOLD AIR INLET MANIFOLD TO AFTERCOOLER FLAMETRAP HSG OPEN JOINT A AFTERCOOLER FLAMETRAP HSG EXPLOSION PROTECTED JOINTS EXHAUST SYSTEM FIXED JOINTS B CYLINDER HEAD TO EXHAUST MANIFOLD EXHAUST MANIFOLD TO TURBO C TURBO TO EXHAUST PURIFIER DOWNPIPE EXHAUST PURIFIER DOWNPIPE TO EXHAUST CONDITIONER ATMOSPHERE NOTE EXHAUST FILTER ASSEMBLY MANDATORY IN NSW OPTIONAL IN QUEENSLAND AND OUTSIDE AUSTRALIA ITEM PART No DESCRIPTION MATERIAL Construction Tomago Pty Ltd AB DRAWN D C DATE 24 12 02 CHECKED PN SIGNATURE P Nelthorpe SIGNATURE P Nelthorpe DATE 24 12 2002 SAN DVI K Sandvik Mining and N 38 070 973 330 DECIMAL ec DO NOT SCALE IF IN OS This drawing and all information thereon is the property of Sandvik Miining and Construction Tomago Pty Limited and is confidential and must not be public or copied This drawing is loaned subject to return upon demand and is not to be used TOLERANCES directly or indirectly in any way detrimental to our interests TITLE GENERAL ARRANGEMENT DIESEL ENGINE SYSTEM CAT 3126DITA A2U220 830553 SHEET 4OF 4 SCALE 1 10 11 SIZE REV
17. able to be shutdown label Tech Bulletin of vehicle Consider fitting narreplate A 2 14 4 Explosion due to delayed 11 Recommend movement of fuel 11 Issue Tech Bulletin regarding End user to mowe valve shutdown cownstreai rroverrent iud et venues End User ensure ball valve is shut off routinely to Dague ensure it does not sieze shut down time is reduced but access to valve is easy A F636 Undetected filter fire 11 End user to ensure norrinated filter elements are used A 2 13 d Pinch points and impact 13 Recommend belt tensioner 17 White TB recontrending belt Fit nesh to ED7 L S170 mies due to rotating Sere and belt tension tensioner and tension indicator Erste Pd e eor equiprrent indicator tool tool rd arc all ice andi Fe Consider fitment of belt tensioner and use of tension indicator tool A 2 13 b Scalding due to uncontrolled 13 Recorrrrend retrofit of fill point 20 Engineer retrofit for radiator Fit retrofit release of hot fluids with safety cap and fastened cap Ensure se reor cover Write technical bulletin hazard Consider fitment of expansion tank Sandvik Mining amp Construction Tomago Pty Ltd RA0023 Non conformance Risk Assessment CAT3126 DES doc page 11 of 19 Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT Table 2 Listing of all hazards requiring Sandvik action and delega
18. clause 136 5 of the Regulation in relation to the specified plant in clause 2 and b Hirers from complying with the requirements of clause 127 2Xc of the Regulation in relation to the specified plant in clause 2 2 Application conditions and duration of exemptions 2 1 This exemption only applies to Sandvik Mining and Construction Tomago Pty Ltd modified Caterpillar 3126 DITA explosion protected diesel engine systems used in an underground mine at a coal workplace in compliance with previous approvals MDA DES 030043 file C03 0043 as amended 2 2 Each diesel engine system must comply with all applicable conditions of approval as specified in MDA DES 030043 as amended 2 3 Each diesel engine system must hold a current item registration issued under Subdivision 2 of Division 3 of Part 5 2 of the Regulation before the plant is used 2 4 Each diesel engine system must be inspected tested and maintained 2 4 1 competent people with appropriate training qualifications experience and knowledge of risk controls on the diesel engine system and 24 2 in accordance with AS3584 2 2008 AS3584 3 2005 and MDG 29 and 2 43 accordance with the designer manufacturer s recommendations or as otherwise recommended and documented in writing by a competent person in accordance with clauses 136 and 137 of the Regulation 2 5 Without limiting the requirements of clause 2 4 each diesel engine system must be maintained in accordanc
19. identified hazards from occurring 3 8 ESTIMATE FREQUENCY Determine the probability of a hazard as identified in step 3 occurring The rating of the probability is decided by team consensus or statistics where available The basis of the rating is shown on the table below for a WRAC SYSTEM TO MDG 1010 APPENDIX AT FREQUENCY OF THE EVENT A Almost certain to happen more once per month B Likely to happen at some point more than once per year C Possible it might happen more than once per 5 years D Not likely to happen less than once per 5 years E Practically impossible unlikely to ever occur Sandvik Mining amp RA0023 Non conformance Risk Assessment page 7 of 19 Construction Tomago Pty CAT3126 DES doc Limited SANDVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT 3 9 ESTIMATE SEVERITY Determine the severity of the identified failure should they occur The consequence rating is determined by team consensus or statistical information where available The basis of the severity rating is shown on the following table SEVERITY OF THE EVENT PERSONNEL INJURY FINANCIAL COST LOSS OF PRODUCTION 1 FATALITY OR PERMANENT gt 500K gt 1 DAY DISABILITY 2 SERIOUS LOST TIME INJURY 100K 500K gt 1 SHIFT OR ILLNESS 3 MODERATE LOST TIME 50K 100K gt 1 HOUR INJURY OR ILLNESS 4 MINOR LOST TIME INJURY 5K 50
20. is modified outside the scope of the registration or design intention or has not been tested or maintained as specified the conditions upon which a generic fault may have been excluded will no longer be valid and the likelihood of this fault occurring will increase 5 6 Sandvik FMEA s and risk assessments assume that the assessed design has not been modified and has been adequately maintained End Users should note that modification or poor maintenance practices will invalidate assessment of some risks 5 7 Mine Transport Rules should consider the following issues e Prevention of operation of DES in prohibited areas e Rated grades for mobile plant are not exceeded Sandvik Mining and Construction Tomago Pty Ltd Page 4 of 7 ABN 38 070 973 330 Old Punt Road Telephone Tomago NSW 2322 61 2 4985 2625 Australia Facsimile 61 2 4985 2626 ANUS DOCUMENT No A2U900 860132 Rev 6 Appendix A Conditions of Use Compliance Details 6 1 The following table details the compliance to conditions of use nominated in 0889003 DES Table A1 Clause By Clause Conditions of Use Compliance Details Item Requirement Sandvik Compliance End User Statement for New Requirements Supply Cat3126 DES 3 Conditions for Supply and Use Heading 3 1 General Conditions for Supply Heading 1 The plant design registration number must Comply when nameplate Install nameplate to appear in a conspicuous place in a legible BD00003
21. of the safety system by preventing the accidental or purposeful override of important safety functions such as engine over temperature exhaust over temperature low engine oil low exhaust conditioner water and coolant loss Features of the system include Inability to start the engine for any of the following functions LOW ENGINE WATER OVERRIDE ENGINE OIL SUPPLY RESTRICTOR Or KCN ENGINE WATER SUPPLY 1 Low engine oil below bottom level of dipstick 2 Over temperature 103 Celsius 3 Low scrubber water double float type 4 Machine not in neutral 5 Park brake not applied 6 Emergency shut down valve closed cylinder retracted Engine coolant is overridden at start up but the engine will shut down after starting within 6 30 secs depending on the engine oil temperature This will not allow the operator to start more than 3 5 times before the air receiver losses its charge There is an additional Start Button Override Valve which is fitted to prevent the engine low water valve being overriden by holding in the start button Only a single start button is used which will only engage the starter if all of the safety functions are correct A single direct mounted oil operated shutdown cylinder is mounted into the governor fuel control unit which cannot be externally manually operated An emergency shut down that cuts off airflow to stop the engine when shutting off the fuel supply doesn
22. system and failures of the normal reported as required shutdown system must be documented and reported to the Department Inspectorate 9 After activation of the emergency shutdown End User responsibility Ensure failures are system there must be a risk assessment to reported as required determine the issues of resetting and the continued safe operation of the diesel engine system 10 Each diesel engine system must be Refer Notice of Inspection Ensure failures are inspected and maintained by people with in Plant Safety File reported as required appropriate training qualifications experience and knowledge of the explosion protection characteristics of the diesel engine system Sandvik Mining and Construction Tomago Pty Ltd ABN 38 070 973 330 Old Punt Road Telephone Tomago NSW 2322 Australia Facsimile 61 2 4985 2625 61 2 4985 2626 Page 7 of 7 1 2 A2U220 830553 AIR FILTER ASS Y AIR FILTER 3 BLOCKAGE INDICATOR E AIR INTAKE PIPE ASS Y B PLUGGED PORTS GOVERNOR CONTROL UN UNO THREAD UNIT INJECTOR N FUEL SHUTDOWN ENGINE COOLANT GROUP SURGE TANK A2U220 220037 COOLANT SYSTEM RELIEF VALVE RADIATOR EXHAUST OUTLET TEST PORT EXHAUST 1 8 BSP ENGINE COOLANT EXHAUST TEMP Pee ENGINE COOLANT SENTINEL U913 694007 SENTINELS TRIGGERED A2U936 694046 A2U900 694090 APPROX 103 C CLEANING PORT EXHAUST CONDITIONER COVER PLATE WATER SUPPLY OR OPTIONAL W
23. t stop the engine An optional strangler interlock valve will prevent the DES from being started when the strangler valve has no air supply i e closed position and applies shutdown cylinder in safety circuit when strangler is activated SYSTEM DESCRIPTION COOLANT LOSS ENGINE COOLANT SENTINELS 103 C AIR SYSTEM Air is supplied from the air receiver and passes through to the Emergency Stop Valve and ON OFF valve The Emergency Shut Down Valve controls 1 The air supply to the Emergency Shut Down Cylinder If the Emergency Shut Down button is depressed air vents from the cylinder and airflow to the engine is blocked If the Emergency Shut Down button is released the cylinder extends and the airflow path to the engine is open EXHAUST OVERTEMP SENTINELS 70 C IN WATER 1st REQUIRED 2nd OPTIONAL Air then passes through the ON OFF valve which controls both 1 The air supply to the start system 2 The piot pressure to the ON OFF PILOT valve which dumps the oil to the shutdown cylinder and thereby shutdown the engine Further down the system the air passes through the START valve which controls the following functions 1 The air supply to the start system 2 A pilot signal is sent to the LOW ENGINE WATER OVERRIDE valve which by passes the COOLANT LOSS valve at start this is necessary as there is no engine water pressure at start 3 Air is supplied to the START PUMP CYLINDER to allow for the pres
24. way detrimental to our interests EMERGENCY SHUT DOWN DATE _ 23 03 06 DECIMAL FRACTIONAL TITLE CHECKED PN PN ANGULAR SIGNATURE NELTHORPE DWG N DATE 12 04 2006 DO NOT SCALE IF IN DOUBT ASK SAFE START VALVE POSITION NEAR STARTER RELAY VALVE This drawing and all information thereon is the property of Construction Tomago Pty Ltd Sandvik Miining and Construction Tomago Pty Limited and is confidential and must not be public or copied This drawing is loaned subject to return upon demand and is not to be used DIESEL ENGINE SYSTEM CAT 3126DITA A2U900 830750 SHEET 3 SCALE NTS OO ee eS SIZE SAN DVIK Sandvik Mining amp Construction Pty Ltd RISK ASSESSMENT REPORT RISK ASSESSMENT REPORT REPORT NO RA0023 JOB NO EN 9105 MACHINE Sandvik CAT3126 DITA Diesel Engine System PROJECT Non conformance Risk Assessment for Cat3126DITA Diesel Engine System against AS NZS3584 2 2008 ASSESSMENT DATE 25 11 08 PREPARED FOR NSW Department of Primary Industries REVISION DATE REVISIONS 25 11 08 Initial Release H uM 5 id Design Engineer Sandvik Mining amp Construction Tomago Pty Ltd Sandvik Mining amp RA0023 Non conformance Risk Assessment page 1 of 19 Construction Tomago Pty CAT3126 DES doc Limited SAN DVIK Sandvik Mining amp Construction Pty
25. way detrimental to our interests MINIMUM LOW WATER SHUTDOWN LEVEL DATE 24 12 02 DECIMAL FRACTIONAL TITLE CHECKED PN 2 SIGNATURE ee P Nelthorpe Om DWG N INO DATE 24 12 2002 A2U220 830553 DO NOT SCALE IF IN DOUBT ASK SHEET 30F 4 SCALE 1 10 GENERAL ARRANGEMENT DIESEL ENGINE SYSTEM CAT 3126DITA LOW WATER TEST LEVEL SECTION A A STATIC WATER LEVEL SIZE 1 A2U220 830553 24 12 02 18 3 2005 20 11 06 co N co N EN 8001 EN 8380 EN 8823 EN 9113 REVISIONS 3 NENNEN E a E a TECHNICAL INFORMATION Please Check For Latest Revision 3 4 5 6 7 8 9 10 DES BLOCK DIAGRAM AIR FILTER ASSEMBLY WITH VACUUM INDICATOR 2 11 AFTER COOLER ASSEMBLY amp AIR INLET ATMOSPHERE D gt gt NE gt e gt ASSEMBLY EXHAUST PURIFIER DOWNPIPE ASSEMBLY EXHAUST 2 11 CONDITIONER WATER gt gt MAKE UP TANK ENGINE COOLANT V LOSS SENSOR ASSEMBLY 2 14 3a2 ENGINE ASSEMBLY EXHAUST 4 TEMPERATURE ENGINE COOLANT SENSOR TEMPERATURE 2 15 7 26 SENSORS 2 14 3a1 i WASTEGATE PRIMARY amp SECONDARY Oc LOW WATER SENSORS 2 15 4 3a amp b RUBROS ENGINE COOLING SYSTEM 2 13 2 15 71 COOLING FAN EXHAUST CONDITIONER WATER BASED FLAMETRAP PARTICULATE oe FILTER SPARK ARRESTOR ASSEMBLY os 2 15 7 EXHAUST COOLING
26. 3 Non conformance Risk Assessment page 6 of 19 Construction Tomago Pty CAT3126 DES doc Limited SAN DVIK Sandvik Mining amp Construction Pty Ltd RISK ASSESSMENT REPORT 3 8 RISK ASSESSMENT FLOWCHART 3 3 1 SET ASSESSMENT OBJECTIVES 3 3 2 DEVELOP OPERATIONAL PROCESS 3 8 8 IDENTIFY HAZARDS 3 3 4 NOMINATE EXISTING BARRIERS 3 8 5 ESTIMATE PROBABILITY 3 3 6 ESTIMATE CONSEQUENCES 3 3 7 ESTIMATE RISK USING MATRIX 3 3 8 RECOMMEND POTENTIAL NEW BARRIERS 3 3 9 IMPLEMENT NEW BARRIERS 3 3 10 PREPARE REPORT 34 SET ASSESSMENT OBJECTIVES Set an objective to aim at throughout the process It is important that all parties agree on the objective of the process and that it is strictly adhered to throughout the discussions 3 5 DEVELOP OPERATIONAL PROCESS Analyse the operation of the equipment and to lay it out in a flow chart form so that a step by step approach to the use of the equipment can be evaluated 3 6 IDENTIFY HAZARDS Examine each operation along the flow chart created in step 2 to identify hazards or loss scenarios associated with those operations In line with the previously decided limitations of the exercise only the operations relating to the objectives and scope were examined for possible hazards and loss scenarios 3 7 NOMINATE EXISTING BARRIERS Nominate where possible any existing barriers presently in the design of the machine system or procedure which may prevent
27. 800 60 50 600 NO NO 7 400 ppm 30 ppm 200 ITEM PART No DESCRIPTION MATERIAL 0 0 S AN DVI K Sandvik Mining and This drawing and all information thereon is the property of 500 1000 1500 2000 2500 3000 Construction Tomago Pty Ltd Sandvik Miining and Construction Tomago Pty Limited and is DO ABN 38 070 973 330 confidential and must not be public or copied This drawing is loaned subject to return upon demand and is not to be used ENGINE SPEED dis DRAWN DC TOLERANCES O N O directly or indirectly in any way detrimental to our interests DECIMAL TE GENERAL ARRANGEMENT DIESEL ENGINE SYSTEM SIGNATURE Pepe RM DO NOT SCALE IF IN DOUBT ASK SHEET 10F 4 SCALE 1 10 pq _ A2U220 830553 SZ 1 2 5 4 20220 830553 VENT LINE ENGINE COOLANT SENTINELS ENGINE COOLANT SURGE TANK THERMOSTAT HSG RADIATOR COOLANT PUMP RAD TOP RAD BOT VENT LINE ENGINE COOLANT FLOW CIRCUIT COOLING CIRCUIT DESCRIPTION MAIN COOLANT FLOW FROM PUMP IS DIRECTED INTO ENGINE OIL COOLER amp ENGINE BLOCK CYLINDER HEAD SOME FLOW THEN PASSES THROUGH EXHAUST MANIFOLD amp THEN RETURNS TO REGULATOR HOUSING ADDITIONAL FLOW IS ALSO DIRECTED THROUGH TURBO amp EXHAUST PURIFIER DOWNPIPE BEFORE RETURNING TO REGULATOR HOUSING ADDITIONAL FLOW DIRECTLY FROM WATER PUMP IS DIRECTED THROUGH THE AFTERCOOLER amp THEN RETURNED TO REGULATOR
28. 888 installed existing vehicles manner on each item of registered plant Remove old approval unless specifically excluded nameplate 2 The designer manufacturer and or supplier Comply for new loaders Ensure the required must provide any person who owns the plant supplied by Sandvik refer documentation is or who has control of the plant or the end use to supplied when selling or all information as required by clauses 96 Operator Manual hiring out the Loader 105 and 122 of the Regulation and all Service Manual documents listed in section 2 1 of this Plant Safety File or registration previous approval documentation Training Manuals Service Schedules JSEA s 3 A copy of the registration of plant design Comply for new DES Ensure the required documentation must be supplied to any supplied from Sandvik documentation is person who owns or who has control of the supplied when selling or registered plant The documentation must hiring out the Loader comprise the number of pages listed in the footer block together with all documentation and drawings as listed in the Schedule specifically nominated for the purposes of installation inspection and maintenance of the plant design 4 The manufacturer is to certify in writing that Refer to Section 1 2 of the particular plant design supplied is in this Technical Statement accordance with the requirements of this 5 There must be no variation in the materials Refer Notice of Ins
29. ANDVIK P N A2U220 252038 NOTE FILTER HOUSING OPTIONAL IN QLD AND OUTSIDE AUSTRALIA ENGINE COOLING SYSTEM RADIATOR SANDVIK P N A2U220 261073 FAN SANDVIK P N A2U220 267111 FAN HUB MATERIAL ZINC OR STEEL FAN BLADE ANTI STATIC VEE BELT MECHANICAL FAN DRIVE SANDVIK P N TBA VEE BELT WATER PUMP DRIVE SANDVIK P N A2U220 267109 VEE BELT APPROVAL No MDA 860144 AS 2784 FRAS MISCELLANEOUS AIR COMPRESSOR HOSE CONSTRUCTION PTFE STEEL WIRE REINFORCED BRAIDED TURBO COMPRESSOR OUTLET HOSE SILICON HOSE TEMP RATING 230 C ALUMINIUM ALLOY COMPONENTS ROCKER COVER AIR INLET MANIFOLD TURBO COMPRESSOR ENGINE TIMING CASE FIXED JOINTS GASKET MATERIAL GRAFOIL GHE GHR NOVATEC PREMIUM GENUINE CATEPILLAR GASKETS AIR INLET SYSTEM 1 CYLINDER HEAD TO AIR INLET MANIFOLD CAT CYLINDER HEAD GRP P N C2A1407370 CAT INLET MANIFOLD GRP P N C2A1323527 CAT GASKET P N C2A1136250 2 PORTS 3 OFF TOP OF AIR INLET MANIFOLD 3 AIR INLET MANIFOLD TO AFTERCOOLER FLAMETRAP HSG CAT GASKET P N C2A7C1152 EXHAUST SYSTEM 1 CYLINDER HEAD TO EXHAUST MANIFOLD CAT CYLINDER HEAD GRP P N C2A1407370 CAT EXHAUST MANIFOLD GRP P N C2A7C6373 CAT GASKET P N C2A1136200 2 EXHAUST MANIFOLD TO TURBO CAT GASKET P N C2A4P7704 3 TURBO TO EXHAUST PURIFIER DOWNPIPE 4 EXHAUST PURIFIER DOWNPIPE TO EXH CONDITIONER OPEN JOINTS AFTERCOOLER FLAMETRAP HSG REFER TO DETAIL FUEL PUMP GOVERNOR CONTROL OIL COOLER COVER
30. CIRCUIT 1 2 3 4 A2U900 830750 AIR FILTER ASS Y AIR FILTER BLOCKAGE INDICATOR AIR INTAKE PIPE ASS Y H i PLUGGED PORTS GOVERNOR CONTROL A UNO THREAD UNIT INJECTOR NEM C CES NE FUEL SHUTDOWN ENGINE COOLANT GROUP SURGE TANK A2U220 220037 COOLANT SYSTEM RELIEF VALVE ea un e 9 gt lt 5 Q A lt Q e lt ac EXHAUST OUTLET TEST PORT EXHAUST 1 8 BSP A ENGINE COOLANT LOSS VALVE A2U913 694007 EXHAUST TEMP SENTINEL A2U936 694046 CLEANING PORT EXHAUST CONDITIONER COVER PLATE WATER SUPPLY OR OPTIONAL WITH FILTER amp SCREW ON COVER WATER ISOLATION EXHAUST COND VALVE LOW WATER LEVEL EXHAUST COND EXHAUST CONDITIONER TEST TAP WATER MAKE UP SHUTDOWN VALVE FLOAT ASS Y VALVE UNDERCOVER 2U220 256034 NOTE DIESEL PARTICULATE FILTER HOUSING NOT SHOWN 1980 E ija AFTERCOOLER FLAMETRAP HOUSING A2U220 241041 WITH FLAMETRAP ELEMENT FLAMETRAP COVER WATER COOLED TURBO ASS Y SILICON HOSE CONNECTION MODIFIED BETWEEN TURBO OUTLET amp FLAMETRAP WATER COOLED COVER INLET A2U220 259009 EXHAUST PURIFIER DOWNPIPE A2U220 257008 A2U220 257011 EXHAUST CONDITIONER A2U220 251089 TURBO COMPRESSOR WATER COOLED ENGINE OIL START PUMP CYLINDER SUCTION PIPE ENGINE SAFETY CIRCUIT EXHAUST COND WATER DRAIN VALVE WITH REMOVABLE PLUG NOTE DIESEL PARTICULATE FILTER HOUSING NOT SHOWN TECHNICAL INFORMATION Please Check For Latest Revis
31. DES Applicable Sandvik Technical Bulletins 2 8 The Mechanical Engineering Management Plan under the Coal Mine Health and Safety Regulation 2006 must provide systems for the safe use of each diesel engine system when in use at a underground mine at a coal workplace 2 9 This exemption only applies to diesel engine systems manufactured before the date of the order 2 10 A copy of this exemption order must be held at the coal workplace where the specified diesel engine system is being used and must be 2101 given to all persons employed at the coal workplace in accordance with any consultation arrangements and 2 402 displayed on an employee notice board for a period of 28 days NEW SOUTH WALES GOVERNMENT GAZETTE No 20 x MTM Silah IS a T RORE ORIA a tata ge Ee EAE lo a VUE MER 438 OFFICIAL NOTICES 23 January 2009 This Order has effect from the date of publication in the Government Gazette until and including 30 June 2010 Dated this 13th day of December 2009 PETER ALSINA SUNOL Acting Senior Inspector of Mechanical Engineering NSW Department of Primary Industries NEW SOUTH WALES GOVERNMENT GAZETTE No 20 DOCUMENT No A2U900 860132 Rev A TECHNICAL STATEMENT DOCUMENT No A2U900 860132 TITLE COMPLIANCE STATEMENT CONDITIONS OF USE MDR 089003 DES JOB No EN9105 PROJECT PRODUCT LINE RUBBER TYRED VEHICLES MACHINE MODEL S CAT3126 DITA DIESEL ENGINE SYSTEM SERIA
32. EXTENDED EMERGENCY SHUT DOWN VALVE OPEN ENGINE RUN CYLINDER RETRACTED EMERGENCY SHUT DOWN VALVE CLOSED ENGINE EMERGENCY SHUT DOWN EMERGENCY SHUT DOWN POSITION INDICATOR CONTROL VALVE A2U936 690001 A2U900 594615 Q A2U900 594079 SUPERSEDED PUSH ACTIVATE TWIST RELEASE BUTTON UUUUUUUVN EMERGENCY SHUT DOWN CYLINDER A2U900 651010 ENGINE OIL SUPPLY ON ENGINE EMERGENCY SHUT DOWN ASSEMBLY A2U900 241058 CHECK VALVE A2U900 694015 RELIEF VALVE 150PSI LL a e WATER TRAP amp LUBRICATOR RUN AN START BUTTON OVERRIDE VALVE OPTIONAL OPTIONAL STRANGLER VALVE INTERLOCK VALVE A2U913 694052 CHECK VALVE O SZ ua aS VALVE GOVERNOR SET 125 PSI COMPRESSOR ON ENGINE ONLYNEEDEDIF INTAKE LINEIS FLAME TRAP amp CYL HEAD ENGINE AIR FILTER STARTER MOTOR OIL SUPPLY FROM ENGINE SUMP AS3584 1991 cl 2 14 1 SUCTION TUBE 2 VALVES gt START PUMP CYLINDER SPECIAL GAUGE ENGINE OIL PRESSURE SHUTDOWN CYLINDER GENERAL AIR AND SUPPLY START SYSTEM ITEM PART No DESCRIPTION MATERIAL AIRLINES ENGINE OIL LINES SAN DVI K Sandvik Mining and pe ABN 38 070 973 330 DRAWN MP TOLERANCES directly or indirectly in any
33. End User Action Required to Required to 5 9 9 Implement New Implement New 3 2 285 c al os e o 9 e a O 23 07 03 2 14 3 Engine oil pressure Do Not Shutdown pressure at 10 psi Explosion due to Eirrco have always had E D 4 21 b Corrply failure of safety the shutdown pressure system on their 3306 and 3304 engine systems lower than the Caterpillar recomended rrinimumoil pressure This is to ensure that nuisance shutdowns don t occur when the oil pump is wom No incidents have been reported that were considered to have occurred because the shutdown pressure is below the recomended rrinimum Note that there are at least 350 installations of this type of shutdown system with the systembeing in Operation for at least 12 years 23 07 0 5 2 d The location and Partial For details of the catalytic None 3 principal converter refer Eimco drawings dimensions of the specified as reference only in exhaust system approval application Compliance Report CROO37 2 2 2 Suitable sampling points Do Not No point available on engine Refer 2 2 above shall be provided to allow monitoring of the following b engine speed 2 2 14 3 Engine oil pressure A Do Not Shutdown cylinder operates on low Refer 2 14 3 b above b sensor to measure low engine oil pressure shutdown 70 kPa engine oil pressure 10 psi but nin recontmended pressure which shall be set to i
34. HEALTH AND Registration No 089003 DES SAFETY ACT 2000 File 08 9003 Date 14 January 2009 3 2 The designer manufacturer and or supplier must provide to any person who owns the plant or who has control of the plant or the end user all information as required by clauses 96 105 and 122 of the Regulation and all documents listed in section 2 1 of this registration A copy of the registration of plant design documentation must be supplied to any person who owns or who has control of the registered plant The documentation must comprise the number of pages listed in the footer block together with all documentation and drawings as listed in the Schedule specifically nominated for the purposes of installation inspection and maintenance of the plant design The manufacturer is to certify in writing that the particular plant design supplied is in accordance with the requirements of this design registration There must be no variation in the materials design or construction of the plant associated with this registration Unauthorised alteration or substitution of registered plant will render this registration void New plant must not be manufactured or supplied to this design registration after the specified date of expiry If no date is specified after 10 years from the date of registration This does not prevent ongoing use of existing plant manufactured prior to the specified date of expiry General Conditions for Use The co
35. ISIONS 1 A2U220 830555 17 7 2003 EN 8380 SAFETY SYSTEM DESCRIPTION The safety system was developed to preserve the integrity of the safety system by preventing the accidental or purposeful override of important safety functions such as engine over temperature exhaust over temperature low engine oil low exhaust conditioner water and coolant loss Features of the system include Inability to start the engine for any of the following functions 1 Low engine oil below bottom level of dipstick 2 Over temperature 103 3 Low scrubber water double float type 4 Machine not in neutral 5 Park brake not applied Engine coolant is overridden at start up but the engine will shut down after starting within 6 30 secs depending on the engine oil temperature This will not allow the operator to start more than 3 5 times before the air receiver losses its charge There is an additional Start Button Override Valve which is fitted to prevent the engine low water valve being overriden by holding in the start button Only a single start button is used which will only engage the starter if all of the safety functions are correct A single direct mounted oil operated shutdown cylinder is mounted into the governor fuel control unit which cannot be externally manually operated SYSTEM DESCRIPTION AIR SYSTEM Air is supplied from the air receiver and passes through the ON OFF valve which contr
36. IT CAT 3126 DITA DES 220 LHD A2U900 830750 EMERGENCY SHUT DOWN DIESEL ENGINE Sheets 1 to 3 inclusive SYSTEM CAT 3126 DITA 2 2 Other Documents Submitted for DPI Reference and Assessment The following documents are listed for DPI assessment only and need not be supplied to the end user DOCUMENT No ISSUE DATE TITLE i Non conformance Risk Assessment for Cat 3126 DITA A 27105 diesel Engine System against AS NZS 3584 2 2008 4 1 Compliance of the Sandvik Cat 3126 DES to AS NZS CR0326 26 11 08 3584 2 2008 CR0207 0 16 11 06 Compliance Statement by Designer A2U220 860065 0 23 11 06 Verification Statement by Design Verifier 0072 0 23 11 06 Cat 3126A Blocked Filter Bypass Testing 4 Particulate Filter Attention Memo Operation Guide for all RTVs which 2 1 22 11 06 i Operation have the Particulate Filter Hom arrangement fitted A2U130 240068 204 18 12 06 Retro Fit air Intake A2U130 240070 F 10 11 08 Air Intake Line ED7 A2U220 240065 4 7 02 07 Retro Fit Kit Air Intake ED10 AU220 240072 F 12 11 08 Air Intake Line ED10 A2U900 241058 F 11 11 08 Shut Down Valve 0050 3 8 12 06 FMEA Emergency Shutdown System Engine Strangler Valve Test Report Measure Time to Stop and Exhaust ot
37. ITH FILTER amp SCREW ON COVER WATER ISOLATION EXHAUST COND VALVE LOW WATER LEVEL EXHAUST COND EXHAUST CONDITIONER TEST TAP WATER MAKE UP SHUTDOWN VALVE FLOAT ASS Y VALVE UNDER COVER 20220 256034 NOTE DIESEL PARTICULATE FILTER HOUSING NOT SHOWN 1980 E AFTERCOOLER FLAMETRAP HOUSING A2U220 241041 WITH FLAMETRAP ELEMENT FLAMETRAP COVER WATER COOLED TURBO ASS Y SILICON HOSE CONNECTION MODIFIED BETWEEN TURBO OUTLET amp FLAMETRAP WATER COOLED COVER INLET A2U220 259009 EXHAUST PURIFIER DOWNPIPE A2U220 257008 A2U220 257011 EXHAUST CONDITIONER A2U220 251089 TURBO COMPRESSOR WATER COOLED ENGINE OIL START PUMP CYLINDER SUCTION PIPE ENGINE SAFETY CIRCUIT a n EXHAUST COND WATER DRAIN VALVE E e WITH REMOVABLE PLUG Te NOTE DIESEL PARTICULATE FILTER HOUSING NOT SHOWN TECHNICAL INFORMATION EN 8823 Please Check For Latest Revision REVISIONS 1156 APPROX 2000 DIESEL ENGINE SPECIFICATIONS CATERPILLAR MODEL 3126DITA SERIAL No 922R02262 ARRANGEMENT No 139 3317 CAPACITY 7 2 LITRES BORE 110mm STROKE 127mm RATED SPEED 2300 RPM RATED POWER RATED SPEED 150 kW RATED TORQUE SPEED 1900 RPM RATED TORQUE 736 Nm HIGH IDLE 2600 RPM LOW IDLE 800 RPM MAX INLET VACUUM 6 2 kPa MAX EXHAUST PRESSURE 10 0 kPa TURBO BOOST PRESSURE 150 kPa MIN OPERATING OIL PRESSURE 100 kPa FUEL CONSUMPTION RATED MAX POWER 36 6 kg hr
38. K 1 HOUR OR ILLNESS 5 NO LOST TIME POSSIBLE lt 5K INSIGNIFICANT FIRST AID 3 10 ESTABLISH RISK FROM RISK MATRIX The risk ranking can be determined by checking the frequency and severity rating for each hazard against the Risk Matrix below The Risk Matrix has been sourced from Sandvik s Sandvik Safety Take 5 Personal Risk Assessment Handbook RISK MATRIX FREQUENCY SEVERITY A B D E 1 2 3 4 5 3 11 RECOMMEND POTENTIAL NEW BARRIERS Recommend through group discussion drawing from the team members experience means of reducing or eliminating the risk through appropriate barriers or controls Sandvik Mining amp RA0023 Non conformance Risk Assessment page 8 of 19 Construction Tomago Pty CAT3126 DES doc Limited SAN DVIK Sandvik Mining amp Construction Pty Ltd RISK ASSESSMENT REPORT 3 12 IMPLEMENT NEW BARRIERS 3 12 1 The implementation of the potential new barriers that have been selected by the manufacturer and or end user of the equipment or system of use 3 12 2 A written explanation as to the reasoning behind selection or rejection of the suggested new barriers is required for each of the identified hazards 3 12 3 Asa guide to ensure each identified hazard is sufficiently addressed the table below may be used as a guide for the minimum expected controls or barriers for each risk ranking RISK LOW MEDIUM HIGH
39. L NO s REFERENCE MDR 089003 DES Approved by Mark Peristy Design Engineer Sandvik Mining and Construction Tomago Pty Ltd REV DATE DESCRIPTION AUTHOR A 3 02 2009 Initial Release Mark Peristy Sandvik Mining and Construction Tomago Pty Ltd Page 1 of 7 ABN 38 070 973 330 Old Punt Road Telephone Tomago NSW 2322 61 2 4985 2625 Australia Facsimile 61 2 4985 2626 SANAS DOCUMENT No A2U900 860132 Rev A 1 2 3 4 5 6 1 2 1 3 Table of Contents Compliance Statement Schedule of Partial and Non Compliances Document Schedule Design Changes and End User Actions General Recommendations for End Users Regarding Diesel Engine Systems Appendix A Conditions of Use Compliance Details Compliance Statement The following compliance statement is applicable to Caterpillar 3126 DITA diesel engine system DES designed manufactured and supplied by Sandvik Mining and Construction Tomago Pty Limited hereby referred to as Sandvik into the New South Wales market The diesel engine system design and any acceptable variation to it specified in documents listed in MDR 089003 DES Section 2 1 complies with the following standard with the exceptions as listed in Section 2 of this document e AS NZS 3584 2 2008 Diesel engine systems for underground coal mines Part 2 Explosion protected This compliance statement must be read in conjunction with Sandvik Compliance
40. Ltd RISK ASSESSMENT REPORT TABLE OF CONTENTS 1 EXEGUTIVE SUMMARY icio etas 3 2 INTRODUC TION wrsccvesiin deavavedcteracesteccaccdedenteatcavvaded aderevecdev caveddcesdeateavtedadadesseataaecaccneiev a a aaa 4 2 1 BACKGROUND EM 4 22 REFERENCES nma 4 EX MEP iae cc 4 2 4 RISK ASSESSMENT 5 25 RISK ASSESSMENT SCOPE 5 2 6 RISK ASSESSMENT TEAM MEMBERG cccccccccscscsceceesceesceescesscesseeeseeeaeeeaeananenananenenaes 5 3 MEIHODOLEOQGY iessocectexet ire ever a a Crue av cated eek eren Dave epa niea Y capo 6 3 1 RISK ASSESSMENT PROCEDURE s I emen nennen nnn nnns senes sss sss s assess nasse 6 3 2 RISK ASSESSMENT PROCESS 6 3 3 RISK ASSESSMENT 7 3 4 SET ASSESSMENT 7 3 5 DEVELOP OPERATIONAL PROGCESS esses e een eerte rre etr r tree nananana 7 3 6 IDENTIFY HAZARDS uiii 7 3 7 NOMINATE EXISTING neret rrr re rre erret tenens 7 3 8
41. Non conformance Risk Assessment page 9 of 19 Construction Tomago Pty CAT3126 DES doc Limited SAN DVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT 4 RISK IDENTIFICATION AND HAZARD MANAGEMENT 4 1 The partial compliances and non compliances to the specified standard have been assessed for design risk in this section The information is contained in the following 3 tables e Table 1 Listing of all hazards requiring Sandvik or End User Action sorted highest risk to lowest risk e 2 Listing of all hazards requiring Sandvik action and delegation of responsibilities e Table 3 Listing of all risks pertaining to gap analysis between the design and nominated standard Sandvik Mining amp RA0023 Non conformance Risk Assessment page 10 of 19 Construction Tomago Pty CAT3126 DES doc Limited SANDVIK RISK ASSESSMENT REPORT Sandvik Mining amp Construction Tomago Pty Ltd Table 1 Listing of all hazards requiring Sandvik or End User Action sorted highest risk to lowest risk Rev Clause No Hazard amp Effects v Suggested new Barriers 15 Sandvik Action Required End User Action Required to Implement New S to Implement New Barrier Barrier tc tc x x E E tc tc A 2 14 4 Explosion due to DES not 11 Recorrrrend fuel shut off valve 11 Engineer narreplate and issue Ensure operators are adequately trained prior to use being
42. OIL FILTER HEAD FUEL FILTER HEAD COOLANT LOSS VALVE COMPRESSOR AIR GOVERNOR TURBO SAVIOUR HOUSING ASSEMBLY GENERAL NOTES 1 COMPLIANCE SPECIFICATION WARNING NAMEPLATES AS REQUIRED BY AS3584 2 TO BE FITTED IN CLOSE PROXIMITY TO THE DES 2 BACKPRESSURE GAUGE TO BE FITTED IN A POSITION READILY VISIBLE TO THE MACHINE OPERATOR THIS MAY BE REMOTE FROM THE DES MAXIMUM EXHAUST BACKPRESSURE IS 10 kPa FULL THROTTLE NO LOAD FILTER ELEMENTS SHOULD BE CHANGED AT THIS PRESSURE 4 ALUMINIUM ITEMS WILL BE PROTECTED BY COVERS COMPLYING WITH AS3678 2 WHEN SUPPLIED FOR USE IN UNDERGROUND COAL MINES DATE 24 12 02 NO2 ppm NO ppm DATE 24 12 2002 CERTIFICATE APPROVAL Nos NEW SOUTH WALES AUSTRALIA MDA DES 030043 CAT 3126 CO CO2 EMISSIONS 10 140 8 120 SINGLE POINT SMOKE MEASUREMENTS 100 2 6 80 SPEED 1541rpm 1656rpm 2047rpm 2300 rpm CQ 4 60 ppm BOSCH UNITS 40 20 0 0 MAXIMUM ENGINE SYSTEM SURFACE TEMPERATURES 500 1000 1500 2000 2500 3000 MEASURED DURING TYPE TESTING WITH amp WITHOUT ENGINE SPEED METHANE INJECTION rpm TEMP LOCATION TEMP C WITH METHANE TEMP C WITHOUT METHANE AFTERCOOLER HOUSING amp CO CO ppm TURBO CENTRAL BODY FLANGE DOWNPIPE TO EXH CONDITIONER NOTE ENGINE POWER WITH METHANE INJECTION WAS APPROXIMATELY 190 kW CAT 3126 NO NO2 EMISSIONS 70
43. START valve mounted in the dash and if all of the above requirements are met a charge of air is supplied _ to the oil filled START PUMP CYLINDER This then strokes and supplies a charge of oil via a CHECK valve to the safety system Oil must pass the SENTINEL valves and through the LOW WATER SHUT DOWN and the ON OFF PILOT valves to reach the SHUT DOWN CYLINDER and override the internal compression spring If any of these valves are in the dump mode the shutdown cylinder will not build up oil pressure and a signal will not be sent to the SAFE START valve which will not engage the STARTER MOTOR Whilst the engine is running the safety system will dump the oil from the SHUT DOWN CYLINDER and stop the engine for the following reasons 1 Low engine coolant pressure less than 2 PSI 2 Engine coolant over temperature ie sensors set at 103 deg Celsius 3 Low engine oil pressure below 10 P 4 Low scrubber water level two sensors 5 Engine exhaust over temperature one sensor set at 70 C in water 6 Engine shutdown by the operator It is important to note that this system cannot be overridden for any function other than coolant loss and this function will only override for a maximum of 30 seconds To move a malfunctioning machine the shutdown fault must be rectified i e fill the exhaust cond with water or a fitter is required to bypass any faulty valve or subsystem eis a 2 5 N ae 9 amp
44. Sandvik Miining and Construction Tomago Pty Limited and is DM confidential and must not be public or copied This drawing is loaned subject to return upon demand and is not to be used ABN 38 070 973 330 DRAWN MP TOLERANCES O N O directly or indirectly in any way detrimental to our interests TITLE EMERGENCY SHUT DOWN DIESEL ENGINE SYSTEM ANGULAR SIGNATURE P Nelthorpe we 3126DITA DATE 12 04 2006 A2U900 830750 SZE DO NOT SCALE IF IN DOUBT ASK SHEET 1OF 3 SCALE 1 10 A REVISIONS 1 A2U900 830750 3 4 5 6 7 8 9 EMERGENCY SHUT DOWN VALVE DES BLOCK DIAGRAM CYLINDER ACTIVATED AIR FILTER ASSEMBLY WITH VACUUM INDICATOR 2 11 y AFTER COOLER ASSEMBLY A AIR INLET FLAMETRAP ATMOSPHERE D gt gt gt ASSEMBLY EXHAUST PURIFIER DOWNPIPE ASSEMBLY 2 11 CONDITIONER WATER gt gt MAKE UP TANK ENGINE COOLANT TURBO E LOSS SENSOR ASSEMBLY 2 14 3a2 ENGINE ASSEMBLY ine 4 ENGINE COOLANT SENSOR p TEMPERATURE 2 15 7 26 STRAINER SENSORS 2 14 3a1 PRIMARY amp SECONDARY 2 4 LOW WATER SENSORS 2 15 4 3a amp b ENGINE COOLING SYSTEM 2 13 COOLING FAN EXHAUST CONDITIONER WATER BASED FLAMETRAP 2 15 4 3 SPARK ARRESTOR EXHAUST a i FILTER EXHAUST COOLING WATER BATH ASSEMBLY 2 15 6 2 2 15 7 EXHAUST TEMPERATURE SENSOR n 2 1543 ATMOSPHERE EXPLOSION PROTECTED JOINTS AIR INLET SYSTEM FIXED JOIN
45. Statement A2U900 860004 Schedule of Partial and Non Compliances Refer to Sandvik Risk Assessment RA0023 for listing of non compliances and for recommended end user actions and residual risks arising from these non compliances Document Schedule The design of the Cat3126 DES has been examined and tested as recorded in MDR 089003 DES Section 2 2 Sandvik Mining and Construction Tomago Pty Ltd Page 2 of 7 ABN 38 070 973 330 Old Punt Road Telephone Tomago NSW 2322 61 2 4985 2625 Australia Facsimile 61 2 4985 2626 SANAS DOCUMENT No A2U900 860132 Rev A 4 Design Changes and End User Actions 4 1 This registration applies to both new and existing diesel engine systems There are some changes from MDA DES 030043 4 5 6 4 2 Loader Modifications 4 2 1 Owners and operators of existing loaders are required to perform the modifications listed below in Table 1 in order to comply with the requirements of MDR 089003 DES Table 1 Required DES Modifications Item Reference Design Change 1 MDR 089003 DES Fit new compliance registration nameplate BD00003888 and remove existing DES nameplates compliance plate A2U220 171724 and specification plate A2U220 171725 MDA DES 030043 6 Installation of exhaust filter bypass wastegate MDA DES 030043 5 Addition of emergency shutdown system strangler MDA DES 030043 4 Initial current design MDA DES 030043 3 Superseded MDA DES 030043 2 Superseded
46. TS A CYLINDER HEAD TO AIR INLET MANIFOLD PORTS 3 OFF AT TOP OF AIR INLET MANIFOLD AIR INLET MANIFOLD TO AFTERCOOLER FLAMETRAP HSG OPEN JOINT A AFTERCOOLER FLAMETRAP HSG TECHNICAL INFORMATION Please Check For Latest Revision EXPLOSION PROTECTED JOINTS EXHAUST SYSTEM FIXED JOINTS B CYLINDER HEAD TO EXHAUST MANIFOLD EXHAUST MANIFOLD TO TURBO C TURBO TO EXHAUST PURIFIER DOWNPIPE D EXHAUST PURIFIER DOWNPIPE TO EXHAUST CONDITIONER NOTE EXHAUST FILTER ASSEMBLY MANDATORY IN NSW REFER APPLICABLE REGULATORY AUTHORITY REQUIREMENTS OUTSIDE NSW OO ee ee Se ITEM PART No DESCRIPTION MATERIAL SAN DVI K Sandvik Mining and This drawing and all information thereon is the property of Construction Tomago Pty Ltd Sandvik Miining and Construction Pty Limited and is confidential and must not be public or copied This drawing is loaned subject to return upon demand is not to be used DRAWN MP TOLERANCES directly or indirectly in any way detrimental to our interests DATE 23 03 06 DECIMAL TITLE EMERGENCY SHUT DOWN DIESEL ENGINE SYSTEM S126DITA NO Azu900 830750 S7 DO NOT SCALE IF IN DOUBT ASK SHEET 3 SCALE 1 10 1 2 j 4 9 6 8 9 10 11 12 20900 830750 TEE Se aT ea Lh SAFETY SYSTEM DESCRIPTION REVISIONS The safety system was developed to preserve the integrity
47. a technical bulletins when they become available The mandatory and recommended changes are nominated in A2U900 860132 attached Although the registration applies to vehicles operating in NSW coal workplaces recommendations and the attachments to this technical bulletin are applicable to all End Users Changes Required changes to existing vehicles are nominated in A2U900 860132 Contact Contact your Sandvik representative for further information or any questions you may have Sandvik Mining and Construction Tomago Pty Ltd ABN 38 070 973 330 Old Punt Road Telephone Tomago NSW 2322 61 2 4985 2625 Australia Facsimile 61 2 4985 2626 SANDVIK SW Rubber Tyred Vehicles Technical Bulletin Attachments DOCUMENT NO ISSUE DATE TITLE 1 MDR 089003 DES 14 01 09 Notice of Registration of Plant Design Diesel Engine System 2 090264 23 01 09 Exemption Order 3 A2U900 860132 A 03 02 09 Compliance Statement Conditions Of Use MDR 089003 DES 4 A2U220 830553 E 26 11 08 General Arrangement Diesel Engine System Cat 3126 DITA 5 A2U220 830555 3 20 11 06 Safety Circuit Cat3126 DITA DES 220 LHD 6 A2U900 830750 C 28 11 08 Emergency Shut Down Diesel Engine System Cat 3126 DITA 7 RA0023 A 25 11 08 Non Conformance Risk Assessment for Cat3126 Diesel Engine System against AS NZS 3584 2 2008 Sandvik Mining and Construction Tomago Pty Ltd ABN 38 070 973 330 Old Pun
48. al operator must conduct a site specific operational risk assessment in respect to the introduction of the plant items detailed in this notice and implement all barriers to risk identified in the risk assessment prior to the introduction of the plant into a coal workplace This operational risk assessment must be reviewed when operating conditions vary A copy of the design registration document must be held at the coal work place where the specified plant is being used i The coal operator must ensure that adequate information is retained at the coal workplace to enable the plant to be correctly operated tested and maintained in the registered condition Fhis information must also be made available wherever the plant is overhauled or repaired This design registration remains valid only when the plant is designed modified examined tested maintained overhauled and repaired in accordance with the registration conditions the registration documents the Coal Mines Health And Safety Act 2002 and the Coal Mine Health and Safety Regulation 2006 The Mine Safety Management System must include provision to notify the registration holder or supplier when the plant is seen not to comply with the registration notice or when safety related defects occur The owner of the plant must conduct a safety audit of the registered plant This safety audit must be carried out at intervals not exceeding five 5 years be documented and must include a an a
49. ation Australia 3M Filter Media Type Filtrete 4 05 00 Test Report Micro Fresh Filters Filter Media 00 A RB 02 28 02 00 6 08 97 Sharp amp Howells Test report on Filter Encap Adhesive ED10 fitted with caterpillar 3126 DITA with Wet 0029 0 i 23 06 03 Scrubber Exhaust System Test Scrubber Operation On Inclines of 1 4 by Eimco Australia NSH 103 11 06 02 S Test Report Exhaust Conditioner A2U220 1 4 Safe Work Procedure Testing Humphrey Valves Individually FMEA Caterpillar 3126A Diesel Engine System safety amp Shutdown System SWP 130 LHD No 34 01 Oct 2002 0028 1 16 07 03 Report Pressure Determination and Hydrostatic 25571 Original 31 08 04 Testing of Caterpillar 3126 DITA Diesel Engine by TestSafe Australia ED7 2 01 01 06 08 04 JSEA Testing Humphrey Valves Individually n n Applicable vehicle model operator manual ooo ES Applicable vehicle model service manual 1 Applicable vehicle model service schedules incorporating Cat 3126 service requirements 3 Conditions for Supply and Use 3 1 General Conditions for Supply 1 The plant design registration number must appear in a conspicuous place and in a legible manner on each item of registered plant unless specifically excluded MDR 089003 DES Sandvik doc Page 4 of 6 OCCUPATIONAL
50. checks shall include but are not limited to schedules for a Protection of exposed Aluminium or light maintenance metals requirements b Operation of the engine and emergency Refer to registration shutdown systems drawings for listing of C All checks as identified in Clause 4 4 of aluminium components AS3584 2 2003 and shutdown systems 5 Diesel fuel must comply with that specified by End user responsibility Only use compliant gazettal under Clause 73 of the Coal Mines Fuel supplied with the diesel fuel for the DES Health and Safety Regulation 2006 vehicle is standard diesel with no additives and sourced from major fuel suppliers Some standard diesel fuel may have a flash point 60 5 C 6 The exhaust gas emissions must comply with Refer Diesel Exhaust Conduct in service testing and monitor DES emission levels Page 6 of 7 NLS DOCUMENT No A2U900 860132 Rev A Item Requirement Sandvik Compliance End User Statement for New Requirements Supply Cat3126 DES 7 Routine testing of exhaust gas emissions Refer Diesel Exhaust Conduct in service must be carried out by a licensed laboratory Report in Plant Safety testing and monitor DES and must not exceed those results obtained File emission levels during type testing as specified by gazettal under Clause 74 of the Coal Mine Health and Safety Regulation 2006 8 All emergency activations of the emergency End User responsibility Ensure failures are shutdown
51. e System DES on a VA Eimco Australia 030043 4 Pty Ltd 220 LHD machine with a Caterpillar 3126 Direct Injection Turbo Assisted DITA engine rated at 150kW with wet exhaust system per the listed documents Table 1 Sandvik Caterpillar 3126 Applicable Approvals Technical Bulletin 0826 04 De Ampcontro Methane System Dec 08 Bypass Strangler Air Schematic Correction Cat3126 Turbo Studs Failures 17 Jan 08 Strangler Valve Update Water Make Up Valve Refuelling ED10 LHD s Description 0722 15 Oct 07 Cat 3126A DITA Water Pump V Belts 5 0721 14 07 Methane Monitor Air Circuit Interlock 0716 02 31 07 Electrical Protection NSW Legislation Requirements 0713 17 May 07 Amendment to TB0632 TB0633 amp TB0634 0712 03 05 07 Progress of Strangler Valve Redesign 3 0710 18 Apr 07 Blocked Purifier Restrictor 0703 05 Feb 07 Progress of Strangler Valve Redesigi 08 Dec 06 Excessive exhaust backpressure on Cat 3126A engine 22 Sep 06 Effect of Excessive exhaust backpressure on low water shutdown O1 Sep 06 Exhaust Downpipe Cooling Water Jacket Connections for LHD s 4 Engine Cooling Group 45 Degree Elbows for ED6 ED7 ED7LP 21 Sep 06 ED25 ED30 0614 28 Jun 06 Progress of Strangler Valve Redesigi 0511 12 Sep 05 Removal of transmission overtemperature sentinel 20 Jul 05 Diesel engine emergency shutdown system 1 Table 2 Caterpillar 3306
52. e stamped on each of the following components a Inlet manifold assembly b Exhaust manifold c Exhaust pipe assembly d Wet exhaust conditioner e Exhaust gas catalytic converter and oxidiser f Exhaust particulate filter assembly g Emergency shutdown valve 2 An individual item registration number must Comply when authorised Item register DES or be allocated for each diesel engine by the Department of primary Industries Mine Safety unit This number must be stamped on the by plant owner provide authorisation to Sandvik for item registration engine block in an accessible location that specified by gazettal under Clause 74 of the Coal Mines Health and Safety Regulation 2006 Sandvik Mining and Construction Tomago Pty Ltd ABN 38 070 973 330 Old Punt Road Tomago NSW 2322 Australia Telephone Facsimile Report in Plant Safety File 61 2 4985 2625 61 2 4985 2626 3 MDG32 AS3584 3 or any relevant Australian End user responsibility Comply with Standard must be considered in the requirements of Section development of the mine s mechanical 3 3 3 of MDR 087597 engineering management plans under TBS Clause 20 of the Coal Mine Health and Safety Regulation 2006 4 Each installation of this engine type must be Refer Notice of Inspection Maintain DES as per checked to ensure compliance with in Plant Safety File requirement Australian Standard AS 3584 2 2003 These Refer to Sandvik service
53. e with the current Sandvik Mining and Construction Tomago service schedule 2 6 specified diesel engine system may only be altered if the alteration is in full compliance with AS3584 2 2008 and under the direction of a suitably qualified competent person The alteration must be documented and must be kept in a plant safety file 2 7 or before 30 June 2009 each diesel engine system must comply with 2 1 1 applicable approval documents as specified in Table I and 2 7 2 applicable Sandvik Technical Bulletins as specified in Table 2 NEW SOUTH WALES GOVERNMENT GAZETTE No 20 SE ee oe LK a ek A ain aC a AAA A e 23 January 2009 OFFICIAL NOTICES Approval MDA DES 030043 6 MDA DES 030043 5 Description of Changes to Diesel Engine System Supplementary approval for MDA DES 33 to fit an exhaust filter bypass wastegate to Eimco Caterpillar 3306 Diesel Engine Systems This supplementary approval allows the installation of the VAMT exhaust filter bypass wastegate as per the listed documents on the following diesel engine systems ii MDA DES 030043 file C03 0043 Supplementary approval for the use of a VAMT emergency shutdown system as per the listed documents This supplementary approval allows the VAMT emergency shutdown systems to be used on the following Diesel Engine Systems iti MDA DES 030043 file C03 0043 MDA DES Type Approval for the Diesel Engin
54. echnical bulletin recommending belt tensioner and tension indicator tool 1 2 4 Engineer fuel shutoff label and issue technical bulletin 1 2 5 Issue technical bulletin regarding movement of fuel shutoff valve 1 3 End User Actions as an outcome of the Risk Assessment 1 3 1 Install revised DES nameplate 1 3 2 Ensure operators are adequately trained prior to use of vehicle specifically in the location of the fuel shutoff valve 1 3 3 Consider fittingfuel shutoff valve label and move valve to downstream of fuel water separator 1 9 4 Ensure fuel shut off valve is shut off routinely to ensure it does not sieze 1 8 5 Ensure nominated particulate filter elements are used 1 9 6 Ensure Operators and maintainers are aware of pinch point hazard of engine belts and pulleys and all guards and covers are fitted 1 3 7 Consider fitting mesh to ED7 LS170 as per TB0719 1 3 8 Consider fitment of belt tensioner and use of tension indicator tool 1 3 9 Ensure Operators and maintainers are aware of radiator scalding hazard 1 3 10 Consider fitting retrofit radiator cap 1 3 11 Consider fitment of radiator expansion tank Sandvik Mining amp RA0023 Non conformance Risk Assessment page 3 of 19 Construction Tomago Pty CAT3126 DES doc Limited RISK ASSESSMENT REPORT Sandvik Mining amp Ltd 2 INTRODUCTION 2 1 BACKGROUND In order to apply for Design Registration for the Cat3126 diesel engine systems a gap analysis and risk assess
55. ed itens requiring covers are fitted maintenance in fan belt Consider fitment area of belt tensioner Engine to be shut off and use of tension when tensioning belts indicator tool A 2144 The manual fuel shut Do Not Manual fuel shut off valve not labelled Explosion due to Operator training P E 1 11 Recontrend fuel shutoff E 1 11 Engineer Ensure operators Off valve shall be dearly Corrply but clearly identified in Operator s DES not being able Stranger valve valve label narreplate and are adequately identified and labelled Manual to be shutdown issue Tech trained prior to including operating Safety shutdown system Bulletin use of vehicle instructions The label Operator Manual Consider fitting shall be as close as 5 practicable to the valve Vehicle won t start if operator doesn t open fuel switch A 2144 In addtion the physical Do Not Operator s manual Clearly identifies Explosion due to Operator training P E 1 11 location of the valve Conply manual fuel isolation valve DES not being able Stranger valve shall be dearly to be shutdown indicated by a second Safety shutdown system label readily visible to Operator Manual the operator driver of any vehicle to which an Vehicle won t start if explosion protected Se cesi open engine systemis fitted fue switch Sandvik Mining amp RA0023 Non conformance Risk Assessment CAT3126 DES doc Const
56. fied events may occur and the magnitude of their likely consequences Risk Assessment The overall process of risk analysis and risk evaluation Risk Management The systematic application of management policies procedures and practices to the tasks of identifying analysing evaluating treating and monitoring risk Risk Control That part of risk management which involves the provision of polices standards and procedures to eliminate avoid or minimise adverse risks facing an enterprise Monitor To check supervise observe critically or record the progress of an activity action or system on a regular basis in order to identify change FMEA A procedure by which potential failures are analysed and each failure mode identified is ranked according to the combined influence of its likelihood of occurrence and the severity of its consequences Sandvik Mining amp Construction Tomago Pty Limited RA0023 Non conformance Risk Assessment CAT3126 DES doc Construction Tomago Pty page 4 of 19 SAN DVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT 2 4 RISK ASSESSMENT OBJECTIVE The objective of the risk assessment is to identify and then resolve or minimise any hazards which could impact on the health or safety of workers operating the equipment due to it s non conformances with the current standard for Underground Coal Mines The
57. here must be a risk assessment to determine the issues of resetting and the continued safe operation of the diesel engine system Each diesel engine system must be inspected and maintained by people with appropriate training qualifications experience and knowledge of the explosion protection characteristics of the diesel engine system P A Sunol Acting Senior Inspector Mechanical Engineering by delegation MDR 089003 DES Sandvik doc Page 6 of 6 436 OFFICIAL NOTICES 23 January 2009 OCCUPATIONAL HEALTH AND SAFETY ACT 2000 Occupational Health and Safety Regulation 2001 Use of Plant Design Registration Requirements in Coal Workplaces Exemption Order No 090264 I PETER ALSINA SUNOL Acting Senior Inspector of Mechanical Engineering under the Coal Mine Health and Safety Act 2002 with the delegated authority of the Director General pursuant to section 137A 2 of the Occupational Health and Safety Act 2000 the Act and pursuant to clause 348 of the Occupational Health and Safety Regulation 2001 the Regulation hereby make the following Exemption _ Order as specified in the Schedule Words and expressions used in this Order have the same meanings as those used in the Act and the Regulatton SCHEDULE 1 Exemptions Subject to the conditions and for the period if any as applicable to a matter specified in clause 2 this Order exempts Employers at coal workplaces from complying with the requirements of
58. iance Report CROH26 A 2 13 b Eachradiator filler and Do Not Cap may be removed whilst under Scalding due to J SEA for filling of P C 3 13 Recommend retrofit of fill E 3 20 Insorreinstances Engineer retrofit Fit retrofit radiator cap shall be so Comply pressure uncontrolled release radiator point with safety cap and uncontrolled for radiator cap arranged or interlocked of hot fluids T fastened cover release of ghigh i n Operator traini White technical and maintainers so that coolant Operator s Manual specifies safe id terrperature liquid bulletin are aware of pressure behind the fill working procedure for cap rerroval Optional expansion tank can occur up to n point cap or radiator on sorre vehicles 30 seconds after capis safely released rerroval of Consider fitment prior to the cap being radiator cap of expansion tank able to be rerroved A 2 13 d Cooling fans and Partial Cooling fan guarded pulleys are not Pinch points and Mesh guard on newer P 3 13 Recontrend belt tensioner D 3 17 White TB Fit mesh to rotating parts shall be guarded on older mode machines inpact injuries due ED7 _S170 s as per armangerrent and belt recontrending ED7 LS170 accordance utilising the CAT3126 DITA to 719 tension indicator tool belt ey and with AS 4024 1601 equipment JSEAon te tension indicator and rairtai isolation toal are aware of Vehide hazard all guards and Limit
59. ion REVISIONS ENGINE COOLANT SENTINELS TRIGGERED A2U900 694090 APPROX 103 C EMERGENCY SHUT DOWN VALVE LOCATION INSTALLED IN AIR INTAKE PIPE ASSEMBLY SHUT DOWN VALVE NOT SHOWN EXACT LOCATION IN INTAKE PIPE VARIES BETWEEN LHD MODELS EMERGENCY SHUT DOWN VALVE LOCATION INSTALLED IN AIR INTAKE PIPE ASSEMBLY SHUT DOWN VALVE NOT SHOWN EXACT LOCATION IN INTAKE PIPE VARIES BETWEEN LHD MODELS _ Ee aE ee Oe ae a eae ae aS ee ee EMERGENCY SHUT DOWN ASSEMBLY 1 TYPICAL CONNECTION TO PIPE FROM AIR FILTER CONNECTOR SLEEVE EPDM RUBBER 100 C RATING SECURED WITH BOLT T CLAMP INLET ADAPTOR OPTIONAL DEPENDING ON LHD MODEL MIN 1 6mm GRADE 304 STAINLESS STEEL GASKET NOVATEC PREMIUM GRAFOIL GHE INLET HOUSING AS3678 250 2 EMERGENCY SHUT DOWN VALVE BUTTERFLY VALVE BRASS 3 TYPICAL CONNECTION TO PIPE TO AFTER COOLER OUTLET HOUSING AS3678 250 GASKET NOVATEC PREMIUM GRAFOIL GHE OUTLET ADAPTOR OPTIONAL DEPENDING ON LHD MODEL MIN 1 6mm GRADE 304 STAINLESS STEEL CONNECTOR SLEEVE SILICONE RUBBER 230 C RATING SECURED WITH E BOLT T CLAMP REFERENCE DOCUMENTS 1 SANDVIK DRAWING A2U220 830553 GENERAL ARRANGEMENT DIESEL ENGINE SYSTEM CAT3126 DITA 2 SANDVIK DRAWING A2U220 830555 SAFETY CIRCUIT CAT3126DITA DES 220 LHD F ITEM PART No DESCRIPTION MATERIAL S AN DVI K Sandvik Mining and This drawing and all information thereon is the property of Construction Tomago Pty Ltd
60. itted 25 C belowthe rated Hence sensors fitted for tenperature exhaust gas ten perature shutdown are adequate for filter elerrenrt protection Downstreamsensor mounted in straight pipe sare insertion depth as upstreamsersor No reason to expect different performance Sandvik Mining amp RA0023 Non conformance Risk Assessment Construction Tomago Pty Ltd CAT3126 DES doc page 17 of 19 SANDVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT Rev dase dase Conply Comments ustification Hazard amp Effect Existing Barriers Suggested new Barriers Risk Notes Sandvik Action End User Action Required to Required to 5 9 9 Implement New Implement New 3 2 285 c pos el g os e o 4 9 o e a O 2 F6310 Lowengneoil pressue Do Not Oil pressure on shutdown lower than Engine darrege due Eim have always had E D 4 2 Corrply Caterpillar min recommended oil low the shutdown pressure on enin em pressue all pressure power than the Caterpillar recontrended nininum oil pressure This is to ensure that nuisance shutdowns don t occur wren the oil punpis wom No inddents have been reported that were considered to have occurred because the shutdown pressure is belowthe recorrrrended rrinimum Note that there are at least 350 insta
61. llations of this type of shutdown system with the systembaing in operation for at least 12 years 2 F63 11 Fail to safety system Do Not Failure modes nominated refer VA No associated risk tests Comply Eirrco report 0028 dated 3 1 2003 Tre manufacturer shall Testing authority hasn t confined fail to nominate all credible safety of failure nodes systemfailure nodes The testing authority shall confinrmthat each nominated single failure mode will cause the systemto fail to safety Compliance Report CRO207 There are no nor conpiiances listed in this report Sandvik Mining amp RA0023 Non conformance Risk Assessment Construction Tomago Pty Ltd CAT3126 DES doc page 18 of 19 SANDVIK Sandvik Mining amp 8 Construction Tomago Pty Ltd RISK ASSESSMENT REPORT Rev Case dase Conply Commrents ustification Hazard amp Effect Existing Barriers Suggested new Barriers Risk Notes Sandvik Action Required to Personnel or Equipment Probability Consequence Risk Rank Probability Consequence Risk Rank Compliance Statement A2U900 860004 2 F6 3 6 Particulate filter Do Not Exhaust gas ten perature sensor Refer F6 3 6 above Cowsstreamcf particulate filter dement not tested during type testing Tests shall be Conny For each of the tests the engine shall stop before the terrperatu
62. ment are required to be performed and issued to the regulating authority The gap analysis has been performed in Sandvik Compliance report CRO326 The partial and non compliances identified by this compliance report have been risk assessed in this Risk Assessment Report to identify the criticality their non compliances present to the use of the machine 2 2 REFERENCES Australian New Zealand Standard 4360 1999 Risk Management MDG 1010 Risk Management Handbook MDG 1014 Guide to Reviewing a Risk Assessment AS NZS3584 2 2008 CR0326 2 3 DEFINITIONS Hazard Diesel engine systems for underground coal mines Part 2 Explosion Protected Cat3126 DES compliance to AS NZS3584 2 2008 A source of potential harm or a situation with a potential to cause loss Principle Hazard A source of potential harm or a situation with a potential to result in multiple fatalities Likelihood Used as a qualitative description of probability and frequency Probability The likelihood of a specific outcome measured by the ratio of specific outcomes to the total number of possible outcomes Consequence The outcome of an event or situation expressed qualitatively or quantitatively being loss injury disadvantage or gain Risk The chance of something happening that will have an impact upon objectives It is measured in terms of consequences and likelihood Risk Analysis A systematic use of available information to determine how often speci
63. nature msec with filter Diesel particulate signature with no filter 1 3 Typical test results at approved power rating Torque Nm Power Turbo Boost Exhaust Pressure kPa 6 0kPa 45 mmHg Fuel Consumption kg hr Maximum surface temperature location rc 146 C Aftercooler housing Conditioner water consumption over 1 hour Carbon Dioxide 5 M MDR 089003 DES Sandvik doc Page 2 of 6 OCCUPATIONAL HEALTH AND Registration 089003 DES SAFETY ACT 2000 File 08 9003 Date 14 January 2009 before after treatment Carbon Monoxide CO before after treatment Oxides of Nitrogen NO before after treatment Nitrogen Oxide NO before after treatment Nitrogen Dioxide NO before after treatment Smoke Single point before after treatment 595 612 2 1 Documents and Drawings to be Submitted to the Owner and Person in Control ppm ppm 632 656 2 Documents Submitted for Registration The documents listed must be supplied to the owner and person in control of each item of design registered plant Refer to clauses 96 105 and 122 of the OHS regulation DOCUMENT No ISSUE DATE THLE A2U220 830553 GENERAL ARRANGEMENT DIESEL ENGINE Sheets 1 to 4 inclusive SYSTEM CAT 3126 DITA A2U220 830555 3 20 11 06 SAFETY CIRCU
64. ndirectly in any way detrimental to our interests TITLE GENERAL ARRANGEMENT DIESEL ENGINE SYSTEM CAT 3126DITA A2U220 830553 re DWG SHEET 4 SCALE 1 10 11 1 2 4 6 ENGINE AIR INLET SYSTEM A2U220 830553 TEST PORT 1 8 BSP WATER OUT TEST PORT 7 16 UNO OR 1 8 BSP AFTERCOOLER HSG TO INLET MANIFOLD A WATER JACKET CONNECTION A FIXED JOINT 3 AIR FLOW TO AIR FLOW FROM AIR FLOW INTO FLAMETRAP ELEMENT FLAMETRAP COVER ENGINE VIA INLET MANIFOLD Y A A2U220 241041 _ _ A2U900 243007 AFTERCOOLER FLAMETRAP ASSEMBLY WATER IN GASKET FLAMETRAP COVER TO SCALE 1 5 A2U220 241042 AFTERCOOLER FLAMETRAP ASSEMBLY MATERIAL SPECS FLAMETRAP COVER WATER COOLED ARFLOWFROM MILD STAINLESS STEEL SCALE 1 5 TURBO COMPRESSOR CONE SECT 3mm PL MATERIAL SPECS FASTENER DETAILS DETAIL A OPEN JOINT MILD STAINLESS STEEL FIXED JOINT 3 M8 x 40 LG BOLT GRD 8 8 CAT P N 6V5219 SCALE 1 1 ENGINE EXHAUST SYSTEM EXHAUST GAS FLOW EXHAUST GAS IN TURBO TO EXHAUST EXHAUST GAS FLOW MOUNTING FLANGE FROM EXHAUST MANIFOLD CONNECTION AIR IN FROM AIR WATER JACKET MANIFOLD FIXED JOINT 2 FILTER ASSEMBLY PURIFIER ELEMENT MOUNTING FLANGE ADDITIONAL WATER C JACKET FOR HOT SPOT C AIR OUT TO TEST PORTS WATER OUT FLAMETRAP COVER TEST PORTS EXHAUST EXHAUST 1 8 BSP 1 8 BSP EXHAUST GAS ou
65. nditions must be complied with for the registration to remain valid The designer manufacturer and or supplier must ensure that the supplied item of registered plant does not deviate in plant design and is not inferior in any way to the item tested and or assessed _ The owner the person in control of the plant and the user must ensure the supplied item is installed operated and maintained in accordance with designer manufacturer s instructions and in accordance with the registration conditions of this notice The Chief Inspector has the right to vary or revoke this registration at any time A Sunol Acting Senior Inspector Mechanical Engineering by delegation MDR 089003 DES Sandvik doc Page 1 of 6 OCCUPATIONAL HEALTH AND Registration No 089003 DES SAFETY ACT 2000 File 08 9003 3 3 10 Date 14 January 2009 Specific Conditions Design registration number MDR 089003 DES the Suppliers name or mark and the required minimum ventilation quantity of 9 1m sec must be inscribed on a durable plate fixed in a prominent position on the equipment In addition the design registration number must be stamped on each of the following components a Inlet manifold assembly b Exhaust manifold c Exhaust pipe assembly d Wet exhaust conditioner Exhaust gas catalytic converter and oxidiser f Exhaust particulate filter assembly g Emergency shutdown valve An individual item registration
66. number must be allocated for each diesel engine by the Department of Primary Industries Mine Safety unit This number must be stamped on the engine block in an accessible location MDG32 AS3584 3 or any relevant Australian Standard must be considered in the development of the mine s mechanical engineering management plans under Clause 20 of the Coal Mine Health and Safety Regulation 2006 i Each installation of this engine type must be checked to ensure compliance with Australian Standard AS 3584 2 2003 These checks shall include but are not limited to a Protection of exposed Aluminium or light metal alloys b Operation of the engine and emergency shutdown system c All checks as identified in clause 4 4 of AS3584 2 2003 Diesel fuel must comply with that specified by gazettal under Clause 73 of the Coal Mines Health and Safety Regulation 2006 The exhaust gas emissions must comply with that specified by gazettal under Clause 74 of the Coal Mines Health and Safety Regulation 2006 Routine testing of exhaust gas emissions must be carried out by a licensed laboratory and must not exceed those results obtained during type testing as specified by gazettal under Clause 74 of the Coal Mine Health and Safety Regulation 2006 All emergency activations of the emergency shutdown system and failures of the normal shutdown system must be documented and reported to the Department Inspectorate After activation of the emergency shutdown system t
67. ols both 1 The air supply to the start system 2 The piot pressure to the ON OFF PILOT valve which dumps the oil to the shutdown cylinder and thereby shutdown the engine Further down the system the air passes through the START valve which controls the following functions 1 The air supply to the start system 2 A pilot signal is sent to the LOW ENGINE WATER OVERRIDE valve which by passes the COOLANT LOSS valve at start this is necessary as there is no engine water pressure at start 3 Air is supplied to the START PUMP CYLINDER to allow for the pressurisation of the oil system If all of the above valves have been activated the air will pass onto the SAFE START valve which will not pilot across until it senses a minimum of 20 PSI in the oil SHUT DOWN CYLINDER This feature isolates the MOTOR if there is any disfunction the oil based shutdown cylinder ENGINE OIL SYSTEM The safety shutdown system is supplied by oil from two places 1 The standard oil pressure pick up at the fuel pump side of the engine block 2 suction tube mounted into the sump on the turbo side of the engine Before start a spring return START PUMP CYLINDER draws oil from the suction tube supply on the engine sump via a CHECK valve This charge of oil is ready to start the engine should there be no oil in the engine the cylinder will not charge and the engine will not start At start the operator depresses the
68. osition and 150 165 150 vake has no siezeo seconds in test position however position is difficult to access A F6 3 7 The operation of the Do Not Manual fuel shut off tested to the Explosion due to Idle is worst case fortine P E 1 11 b manual fuel shut off requirements of AS3584 2 2003 failue of ball valve to t5 shutdown valve shall be tested at Cut off fuel Lowidle is worst case in terrre of Strange vave shutdown tines Safety shutdown system b rated power and T by Test Safe Ball valve to be closed at 50 hr service to drain wetter from fuel weter separator ensures ball valve has not siezed A F6 38 The operation of the Explosion due to Safety shutdown system P E 1 11 b errergency stop system DES bane Balanced valve air flow shal pe obes does not exert a net b ard force torque on valve Tested at high free idle Rated power unlikley under rrethance conditions requires Correct fuel mix and load on engine Report REOO82 Sandvik Mining amp RA0023 Non conformance Risk Assessment page 14 of 19 Construction Tomago Pty CAT3126 DES doc Ltd SANDVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT Rev dase dase Conply Comrrerts ustification Hazard amp Effect Existing Barriers Suggested new Barriers Risk Notes Sandvik Action
69. pection Ensure loader is design or construction of the plant associated in Plant Safety File maintained as per with this registration Unauthorised alteration registration or substitution of registered plant will render requirements this registration void 6 New plant must not be manufactured or Not Applicable at this Not Applicable supplied to this design registration after the time specified date of expiry If no date is specified after 10 years for the date of registration This does not prevent ongoing use of existing plant manufactured prior to the specified date of expiry 3 2 General Conditions for Use End User Responsibility Comply with requirements of Section 3 2 of MDR 087597 TBS Sandvik Mining and Construction Tomago Pty Ltd Page 5 of 7 ABN 38 070 973 330 Old Punt Road Telephone Tomago NSW 2322 61 2 4985 2625 Australia Facsimile 61 2 4985 2626 NLS DOCUMENT No A2U900 860132 Rev A Item Requirement Sandvik Compliance End User Statement for New Requirements Supply Cat3126 DES 3 3 Specific Conditions Heading 1 Design registration number MDR 089003 Comply when nameplate Install nameplate DES the Suppliers name or mark and the BD00003888 installed BD0003888 or required minimum ventilation quantity of equivalent 9 1m sec must be inscribed on a durable Stamp components plate fixed in a prominent position on the equipment In addition the design registration number must b
70. re of the exhaust gas steamintredately before the filter reaches the lesser of 50 C belowthe auto ignition ten perature of the filter elerren or 25 C belowthe rated terrperature 2 2 14 36 Lowergireoil Do Not Shutdown pressure 10 psi is below Refer F6 3 10 above 2 15 2 pressure Comply Caterpillar nininumrecommended oil F63 10 i dd pressure 14 5 psi engine systemat rated Sandvik Mining amp RA0023 Non conformance Risk Assessment page 19 of 19 Construction Tomago Pty CAT3126 DES doc Ltd
71. resolution or minimisation of risks may be achieved via design changes additional signage or modifications to operating and maintenance procedures Engineering changes that eliminate the risk are preferred where practical 2 5 RISK ASSESSMENT SCOPE The Risk Assessment scope is limited to the the Sandvik Cat3126 DES Risk areas have been identified as areas of non conformance with the current Australian Standard AS NZS3584 2 2008 2 6 RISK ASSESSMENT TEAM MEMBERS NAME ORGANISATION POSITION Phil Nelthorpe Sandvik Mining amp Construction Engineering Manager RTV Tomago Pty Ltd Mark Peristy Sandvik Mining amp Construction Design Engineer Tomago Pty Ltd Wayne Scrivens Sandvik Mining amp Construction Product Engineer Tomago Pty Ltd Sandvik Mining amp RA0023 Non conformance Risk Assessment page 5 of 19 Construction Tomago Pty CAT3126 DES doc Limited SANDVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT 3 METHODOLOGY 3 1 RISK ASSESSMENT PROCEDURE The risk assessment was carried out by following the following four defined stages Stage 1 Determine an objective and a scope e objective was to identify non compliances with MDG39 incorporating Amendment No 1 and then perform a risk assessment on these non compliances e scope was limited to the braking systems on the 130HD LHD specifically the non compliance
72. ruction Tomago Pty Ltd page 13 of 19 SANDVIK Sandvik Mining amp 8 Construction Tomago Rev dase dase Conply Conmments ustification Hazard amp Effect Existing Barriers Suggested new Barriers Risk Notes Sandvik Action End User Action Required to Required to Implement New Implement New lt Eg E E Fal Barier Barrier EE S ES s g 5 556 29 2 esl amp 3 Fa os e o 2 2 elu e a O A 2 14 4 The manual fuel shut Do Not Manual fuel shut off valve mounted Explosion due to Strangler valve 1 11 Recontrend rroverrert of E 1 11 Issue Tech End user to nove delayed shutdown i off valve should be Conply before filter and pun p s fuel shut off valve to Bulletin regarding valve connected into the fuel downstreamof fuel weter rroverrent of End eare systemafter all supply Tests conducted at Hexhamworkshop Tested by Test Safe separator to ensure shut valve i _ on 26 11 08 ind ina fuel Me ball valve is shut PI pumps and NAS Ball valve to be dosed at off inely to to minimize the tine shutoff to j sabe aide purrp 50 hr senice to drain access to valve is easy er amp ure itd E required to shut down reduced pd beide 1de D7010 60 veter fomfuedivater ous the engine systemafter uae dnd separator ensures ball operation of the valve original p
73. s 100kPa 14 5 psi operate at a pressure of not less than the engine rranufadurers mininum recommended pressure RA0023 Non conformance Risk Assessment Sandvik Mining amp page 15 of 19 Construction Tomago Pty Ltd CAT3126 DES doc SANDVIK Sandvik Mining amp Construction Tomago Pty Ltd RISK ASSESSMENT REPORT Rev Case dase Conply Commrents ustification Hazard amp Effect Existing Barriers Suggested new Barriers Risk Notes Sandvik Action End User Action INo Required to Required to 5 9 9 Implement New Inplerent New um E SINN Barrier Banier 8 S 8 2 o c e ol 2 e a e a O 2 2 15 2 Monitoring and Do Not Refer 2 14 3 b above Refer 2 14 3 b above a shutdown devices Conply 2 5 2 GENERAL Do Not ii Overall lengths meaningless for this No associated risk ARRANGEMENT design DRAWING iii pipe sizes vary would require The ee eae arrangerrent craving specify shall be nuntbered and shall induce its curent The location and principle dirrensions of the exhaust system induding ii Overall lengths iii Pipe sizes and wall thicknesses i georretry and Overall dirensions of exhaust gas stream Pipework fromeoyinder head to exhaust flarretrap iv requires manufacturing drawing to adequately spedfy 2 7 1 2 Test procedure The following test procedure shall be followed
74. s to MDG39 incorporating Amendment No 1 Stage 2 Identification of non conformances of the 130HD LHD braking systems to MDG39 incorporating Amendment No 1 These have been recorded in Sandvik Compliance Report CR0348 Stage 3 The formal risk review was undertaken at Sandvik Mining amp Construction Tomago Pty Ltd Hexham offices on 31 10 08 This risk review nominated the expected criticality of the risks and suggested new barriers where applicable Stage 4 Following the completion of the risk assessment the report was written and a list of recommendations developed for implementation Stage 5 Additional actions are required subsequent to the risk assessment and these are as follows e Engineering and Management review of Risk Assessment recommendations to determine suitability requirements practicality and approval of each suggested new barrier e Engineering of approved suggested new barriers and recommendations e Update of vehicle training operating and maintenance documentation to reflect approved recommendations e Communication of new barriers to industry via Technical Bulletin e Ongoing audit of Risk Assessment actions until all items closed out e Re assessment of risks in response to changes to requirements or vehicle design for the life of the machines 3 2 RISK ASSESSMENT PROCESS The risk assessment process utilised is outlined on the following flowchart 2 3 to clearly define each step Sandvik Mining amp RA002
75. ssessment for compliance against these registration conditions and b an assessment for compliance against the current community standards and gazettal criteria applicable to the registered plant at the time of the audit and implementation of interim control measures to reduce risk to an acceptable level and C an assessment of the safety defects identified since the previous audit and a review of the improvements required to minimise these defects d Areview of the site specific operational risk assessment The owner and the person in control must ensure that safety related recommendations of the designer manufacturer or supplier are complied with as far as they relate to the safe use of the plant unless an appropriately documented risk assessment is used to identify alternative risk controls as providing an equivalent Jevel of safety and these risk controls being implemented MDR 089003 DES Sandvik doc Page 5 of 6 OCCUPATIONAL HEALTH AND SAFETY ACT 2000 Registration No MDR 089003 DES File 08 9003 Date 14 January 2009 PRIMARY INDUSTRIES NOTICE OF REGISTRATION OF PLANT DESIGN DIESEL ENGINE SYSTEM It is hereby notified that the plant design listed herein is registered in accordance with the Occupational Health and Safety Act 2000 the Act Subdivision I of Division 3 of Part 5 2 of the Occupational Health and Safety Regulation 2001 the Regulation and appropriate standards or gazetted requirements under Clause 107
76. surisation of the oil system EXHAUST OVERTEMP SENTINEL FOR WHEN PARTICULATE FILTER FITTED If all of the above valves have been activated the air will pass onto the TO CN WATER SAFE START valve which will not pilot across until it senses a minimum of 20 PSI in the oil SHUT DOWN CYLINDER This feature isolates the Mailaa MOTOR if there is any disfunction in the oil based shutdown cylinder ENGINE OIL SYSTEM The safety shutdown system is supplied by oil from two places FIRST EXH CONDITIONER LOW WATER SHUTDOWN 1 The standard oil pressure pick up at the fuel pump side of the SHOWN IN SHUTDOWN MODE engine block 2 suction tube mounted into the sump on the turbo side of the engine Before start a spring return START PUMP CYLINDER draws oil from the suction tube supply on the engine sump via a CHECK valve This charge of oil is ready to start the engine should there be no oil in the engine the cylinder will not charge and the engine will not start SECOND EXH CONDITIONER LOW WATER SHUTDOWN SHOWN IN SHUTDOWN MODE At start the operator depresses the START valve mounted in the dash and if all of the above requirements are met a charge of air is supplied _ to the oil filled START PUMP CYLINDER This then strokes and supplies a charge of oil via a CHECK valve to the safety system 2 Oil must pass the SENTINEL valves and through the LOW WATER SHUT OWN and the ON OFF PILOT valves to reach the
77. t Road Tomago NSW 2322 Australia Telephone Facsimile 61 2 4985 2625 61 2 4985 2626 OCCUPATIONAL HEALTH AND Registration No MDR 089003 DES SAFETY ACT 2000 File 08 9003 Date 14 January 2009 REGISTRATION SCHEDULE Detailed Description of Registered Item s and Variation s Sandvik Mining and Construction Tomago Pty Ltd modified 150 kW Caterpillar 3126 DITA explosion protected diesel engine system with wet exhaust system comprising exhaust catalytic converter water based conditioner particulate filter assembly an pneumatic hydraulic shutdown system as identified by registration number MDR 089003 DES and listed documents herein Ll Assessment Criteria Performance criteria specified in the NSW Government Gazette No 24 of 2 February 2007 page 667 Requirements for Design Registration of Diesel Engine System Designs 12 Engine specifications Description of Diesel Engine System including its major components Combustion System Piston Displacement Cylinder bore and stroke Direct injection exhaust drive turbocharged 7 24 110 x 127 1 5 3 6 2 4 15 1 150 2300 736 1900 Firing order Compression Ratio Testing Dynamometer Power Rating speed Rated Torque speed Fuel setting Fuel timing Torque stall power speed kW rpm 150 KW 2 250 rpm 800 Idle speed Minimum ventilation requirements m sec 9 1 gas Diesel particulate sig
78. tion of responsibilities Rev ITEM SUGGESTED CONTROLS ACTION RESPONSIBLE APPROVED DATE YES NO REQUIRED A 2 13 b Recommend retrofit of fill Engineer retrofit for M Peristy Yes 01 2009 point with safety cap and radiator cap W Scrivens fastened cover Write technical bulletin A 2 13 d Recommend belt tensioner Write TB recommending M Peristy Yes 01 2009 arrangement and belt tension belt tensioner and tension indicator tool indicator tool A 2 14 4 Recommend fuel shut off Engineer nameplateand M Peristy Yes 01 2009 valve label issue Tech Bulletin A 2 14 4 Recommend movement of Issue Tech Bulletin M Peristy Yes 01 2009 fuel shut off valve to regarding movement of downstream of fuel water valve separator to ensure shut down time is reduced but access to valve is easy 1 Approval may be determined subsequent to initial issue of this Risk Assessment Sandvik Mining amp Construction Tomago Pty Ltd CAT3126 DES doc RA0023 Non conformance Risk Assessment page 12 of 19 SANDVIK Sandvik Mining amp Construction Tomago Table 3 Listing of all risks pertaining to gap analysis between the Sandvik Cat3126DITA and AS NZS3584 2 2008 Required to Required to g g Implement New Inplement New E SENT E a Barrier Barrier EE IS ES s g 5 2 S 2 amp i Bp os 2 o 2 9 o a oO Compl

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