Draft for Comments Only Draft Indian Standard MAN RIDING HAULAGES (CAR) SYSTEM FOR TRANSPORTATION OF PERSONS IN MINES GENERAL REQUIREMENTS (ICS 73.100.40) Not to be reproduced without the permission of Last date for receipt of BIS or used as a STANDARD comments is: 31 Foreword (Adoption clause to be added later on). Man Haulage Car Systems are being widely used for transportation of persons on rail track in mines and queries. As a number of safety issues are involved and equipment/systems are to operate in hazardous conditions therefore the committee has decided to formulate a standard for use of stake holders. This standard has been prepared in consultation and in agreement with the regulatory authority. Manufacturers and users are expected to adhere to the rules and regulation which are applicable to mines and other regulatory requirements enforced from time to time. Use of man-riding in underground mines shall comply with specific provisions of Mines Act, 1952 and Rules and Regulations made there under. No man-riding shall be used unless it is of a type approved by the statutory authority and is maintained in its designed conditions. For the purpose of deciding whether a particular requirement of this code is complied with the final value, observed or calculated, expressing the results of a test or analysis, shall be rounded off in accordance with IS 2:1960 Rules for rounding off numerical values (revised). The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard 1
1 SCOPE 1.1 This standard covers the design and construction of man riding haulage (car) system used for transportation of persons on rail track in mines or quarries. 1.2 This standard is not intended to contravene any provisions of the statutory regulations wherever they are in force. 2. REFERENCE The Indian Standards as listed in Annex A contain provisions which through reference in the text, constitute provision of this standard. At the time of publication, the editions indicated were valid. All standards are subjected to revision, and parties to agreements based on this standard are encouraged to investigate the possibility of applying the most recent editions of the standards indicated in Annex A. 3 APPLICATION/INSPECTING AUTHORITY 3.1 Duly authorized representative of the purchaser shall inspect the Man Riding Car at the time of installation and determine its acceptability on the basis of this standard and compliance to prevailing statutory rules and regulations. 4 GENERAL REQUIREMENTS 4.1 Rules for the Construction of Installations 4.1.1 Each part of man riding car equipment shall be according to IS 9494. 4.1.2 A certificate of a recognized testing laboratory shall be supplied by the manufacture as regards the characteristics of all material used and essential to the safety of the installation. The drum shaft, brake gears, linkages shall be free from any cracks/defects or discontinuities. Nondestructive tests where applicable shall be carried out by laboratory/agency duly approved by statutory authority. 4.2 Route and Profile of the Roadway 4.2.1 As a rule, the axis of the rail line in its position shall be straight. However, horizontal deviations, if any, of the travel may be permitted such as to maintain minimum radius of 15m required to negotiate Man Riding Car. 4.2.2 The profile of the terrain chosen for constructing the installation and that of the line shall be as regular as possible and such route shall facilitate and allow persons to get down easily from cars incase of power failure or due to any other reason. 4.2.3 The Man Riding System with End less Haulage shall not run in a steeper gradient more than 1:12 4.2.4 The Cars shall be capable of passing over rail track with 610mm gauge minimum. 2
4.2.5 In order to ensure free movement of passengers, the following distances shall be provided and ensured: a) Below the roof shall not be less than 0.3m after duly considering the undulations, if any. b) Irrespective of the Man Holes that were provided, if any, the clearance from the edge of the Man Riding Car: 0.6 m c) Between two Cars that are on adjacent tracks the clearance shall be at least : 0.3m 4.2.6 The height and width of gallery shall not be less than 3.0m X 3.0m. 4.2.7 Track used for man riding shall be installed and maintained to a high standard. In particular: a. It shall be straight and leveled enough such that the travel shall be smooth without any impact transfer to the passengers. b. It should be properly ballasted and drained. c. The sleepers shall be placed at equal distances and the spacing shall be such that the sag of the rails by virtue of movement of the Car wheel is minimized and there by the effective Car movement. d. The rail used for the purpose of track shall have a weight not less than 60 lb / yd and shall be of uniform cross section throughout. e. Special attention should be paid to rail joints to ensure that no step is formed by the rail ends which might foul a track brake shoe applied to the rail particularly where there is a change in rail section and every rail joint shall be secured by suitable fish plates fitted with the full number of bolts. f. Track limiting switches should be provided at the in-bye and out-bye ends of the journey, to warn the engine driver of an impending over run and an automatic device shall be provided to stop the haulage after the warning has been given. 4.3 Design of Haulage Engine a) The haulage engine shall be located in properly built engine house; b) The haulage shall be firmly fixed to a firm foundation or anchorage; c) Every haulage shall be provided with adequate guards or fencing; and d) The design of the direct haulage engine shall be such that frame and all the components 3
can be easily dismantled without much difficulty for transportation and maintenance in the mine. 4.3.1 Mechanical Details MED 08(1200)C Besides statutory and other specific requirements the direct rope haulage for transporting persons in mines shall confirm to the following requirements: a) Drum diameter in mm minimum 80 times of rope diameter. b) Drum width in mm minimum 60 times the rope diameter. c) Flanges diameter in mm minimum 100 times the rope diameter. d) Rope capacity on drum up to 2000m. 4.3.2 Maximum Speed The normal working speed of car shall not exceed 8 km/h. The speed adjustment arrangement shall be made available at Hauler. The variation of the speed of cars during acceleration or deceleration shall not be such as to give rise to any signs of discomfort to the persons. 4.3.3 Brakes a) A service brake shall be fitted to haulage and should be capable of regulated application. The service brake shall have a braking capacity of 1.5 times the static torque. b) An emergency brake shall be fitted and the braking torque shall be three times the torque resulting from the maximum rope pull. 4.3.4 Safety Features in Haulage Engine a) A distance indicator showing the position of man riding train throughout the run shall be provided in the haulage engine. b) An automatic device shall be provided to warn the engine driver in the distance indicator at either end of the run. c) An Automatically recording speed indicator, over travel limit switch and over speed trip switch shall be provided in the haulage. The over speed trip switch shall be set at 10 percentage more than normal speed of rope. 4
d) A dead man s handle shall be fitted to the haulage in order to stop the haulage in the event of collapse or incapability of the operator e) Slack rope protection shall be provided. f) Slow banking device shall be provided so that Man Riding cars will travel at less than 1.5m/sec when it is being hauled at stations. 4.4.5 Lowering of Man Man riding car shall not be lowered without power. Declutching of Haulage drum shall not be allowed. The clutch if provided, shall be kept locked. 5 ROPE AND CAPPEL 5.1.1 The wire rope used shall confirm to IS 1855 and shall be of 6x7 stranded constructions, galvanized, lubricated with fiber core. The fiber core shall conform to IS 1804. 5.1.2 The minimum breaking load of wire rope shall not be less than ten times the maximum pulling load by haulage. This shall be ensured during service. 5.1.4 In order to facilitate periodic in service checks the carrying rope shall preferably be checked by a suitable non destructive means like magneto inductive test to ensure the requirement. 5.1.5 The lubricants incorporated in the wire rope during manufacture shall not exert any corrosive action on the material of rope. 5.1.7 Conical white metal rope cappel of an approved type shall be used with the man riding haulage rope. The cappel of the rope shall be treated as part of the suspension gear of winding system and shall confirm to IS 7587(Part II). Bent wire cappel shall not be used with man riding haulage apparatus. The rope shall be secured tightly by 16 bolt ham bone clamp and bolts shall be tightened with a minimum torque of 220 Nm. 5.1.8 Rope capping shall be done with in 6 months period. In the length of the rope which lies within the tapered part of the socket of any fiber core, 3m length rope shall be cut when the capping is made and sample rope shall be tested for break load and tensile, torsion & bend test of wires. 5.1.9 Spliced rope shall not be used on any direct rope haulage system. 5.1.10 Rope life The life of rope shall be fixed by manager in consultation with engineer and in any case it shall not be more than 2 years. Any rope found defective in a weekly or monthly examinations such rope shall not be used again for man riding. 5.1.11 Rope in all types of haulage systems shall be securely fastened to the drum. 5
5.1.12 In an endless rope haulage system employed in man riding, the point on the rope at which the man riding train is attached shall be changed not less than once in 3 months. When the position of clamps, screws, clips or other attaching devices are changed, each shall be moved along the rope to new point of attachment a distance not less than the maximum length of man riding train and all such movements shall be in the same direction. Clamp bolts shall be securely tightened to the rope. 6 MAN - RIDING CAR a) Man riding car shall be made either as per IS 9494 or as per design approved by statutory authority. b) Every man riding train shall be provided with a head lamp that provides adequate illumination of the road way and track for a minimum distance of 60 m. A red lamp at the rear of the car of similar visibility shall also be provided. The man riding train should not run until the head and tail lamps are ON. c) Every car used for man riding shall be provided with safe seats, shall be protected on sides and ends to prevent the persons from falling off the cars and shall be provide with suitable means for persons to mount and dismount. d) Provision shall be made for safety connection in between cars by D-shackle coupling. Safety chains may be centre buffer coupling (CBC). e) The automatic over speed track brakes shall be provided and shall be set to operate at not more than 20 percent above the maximum operating speed of the rope. f) Each car shall be provided with hand levers to operate track brakes by persons traveling in cars in case of emergency g) Each car shall be hydraulically connected to adjacent car by quick release coupling or any other method in order to activate all brakes in all the cars to be applied at a time h) All man riding cars while carrying men shall not be use to carry materials other than light equipment such as scientific equipment etc. i) Pressurize hydraulic system to 2000 Psi to enable brake shoes to lift clear off the rail by 25mm and Man riding train is set to operate. The brake shoe pads shall be arranged with Tungsten Carbide Nibs. j) The Man riding capacity for normal height car shall be as mentioned below: Rope Anchor Car: 24 persons Man Riding Car: 30 persons 6
k) All man riding cars shall have ambulance facility. Otherwise special ambulance cars shall be made available. When a special ambulance car is attached to the man riding train it is recommended that it be coupled between the first and second car at the out bye end of the train. Such cars shall not be used other than for carrying first aid equipments, the injured persons and their attendants. 7 D- SHACKLE, COUPLING AND SAFETY CHAIN 7.1 The coupling and safety chain material shall be any of the following. a) 20Mn2 confirming to IS 4432 b) 11Mn2 confirming to IS 1570 c) 20Ni 55 Cr 5Mo 20 to IS 4432 Any other steel not inferior to those stated above and approved by the statutory authority may be used. 7.2 The factor of safety for both coupling and safety chains shall not be less than 10. Safety attachments shall be provided between cars (chain or other suitable appliance) and shall be so fitted that they are not normally subjected to load and shall be strong enough to sustain any shock load which might be imposed on them due to failure of the main drawer. 8 SIGNALLING SYSTEM 8.1 Pantograph shall be provided in rope anchor car and leading man riding car to provide signals to Haulage driver. 8.2 Separate signaling arrangements on haulage road ways shall also be provided. 8.3 FLP/Intrinsically safe page - phones of approved type shall be provided along the road ways at a distance of every 50 m. 8.4 Care shall be taken to ensure that the telephonic and signal cables do not come in to contact either with carrying person or rope even under worst conditions of weather. These cables are connected such that to avoid interference between the cables and carrying ropes which can affect the safety and regularity of operation. 9 STATIONS 9.1 Boarding and Alighting Stations a) At every station, the road way shall be white washed for full length of boarding and alighting platforms and full length stations shall be adequately lighted. 7
b) Appropriate boarding or alighting signs shall be provided at the approach to each platform. c) All stations shall be specially secured against falls of ground and roof. d) At all stations, there shall be exhibited one or more illuminated conspicuous notices incorporating the following: No person shall pass beyond this point to board a man riding system until he has received permission from the train guard. e) A notice sign shall be posted at each station specifying the number of persons who may be carried on any man riding train and in any vehicle of such train. f) Stop sign shall be provided at each end of man riding haulage run with an electrically lighted or red reflector type. 10 ELECTRICAL DETAILS 10.1 In general the electrical equipment for haulages shall be selected in accordance with IS 9559. i) For use in underground mines, all electrical equipments and fittings on the man riding system shall be of flame proof construction / safe as per Indian Electricity Rules 10.2 The selection of electrical components shall be determined mainly on the basis of duty cycle of haulage operation and condition of installation and operation and may include consideration for the following: a) Slow speed running and its duration. b) Number of start stop and inching operation in each cycle and in each stage of operation. c) Over loading and its duration. d) Over speed running and its duration. e) Total duty cycle with acceleration and retardation time. f) Braking or plugging if required, g) Ambient and environmental condition, and h) Thermal characteristic curves of the motor. 8
10.3 Selection of drive may include the following consideration. a) Slip ring or squirrel cage motor to be determined as per the requirements of haulage installation also the type of enclosure namely TEOC or FLP may be selected as the case may be for the requirements of haulage and its installation condition. b) Output voltage speed and torque accordance to the requirements of haulage and and available power supply system. c) Duty of the drive with considerations for the parameters mentioned 3.2.1. d) The motor shall confirm to the requirements of IS 3682 and shall have class of insulation corresponding to minimum 80 C temperature rise. The motor shall also confirm to at least the following other requirements: i) 200 percent over speed for 5 minutes. ii) 15 to 20 numbers of inching operation in each cycle during acceleration and slow speed running. iii) slow speed running for one third period of duty cycle at one third of rated speed on full load iv) Duty cycle 10 min and pause of 2 to 3 min. v)) Acceleration times 1 minute and retardation times 10.3 s. vi) 50 percent overload for 1 minutes continuous operation. 10.4 The selection of rotor resistance and its numbers of steps shall be determined considering motors rotator data, the duty factor and duration of operation in each step. Further it shall confirm to at least the following requirements. (a). 30 percent speed and 35 percent torque at first notch for inspection speed. (b) 30 percent speed and 60 percent torque at second notch for slow speed running. (c) 30 percent speed and 100 percent torque at third notch slow speed running to cope with sharp bend and underselling in track. (d) 100 percent duty factor of first second and third notch. (e) 20 percent duty factor for fourth and onward notch for acceleration. (f) The maximum develop torque shall not be more than 250 percent and minimum not less than 180 percent from fourth notch and onward (g) Maximum permissible temperature rise of resistance box shall not be more than 70 C. (h) The resistance unit shall be shock proof, vibration proof and rust proof. Suitable torque speed characteristics for rotor resistance shall be adopted. (i) Maximum unbalance motor resistance if selected shall be restricted to 150 percent of normal full load current. (j) Fully enclosed or FLP construction (k) The design and construction of the enclosure shall be such that during operation resistance units heat dissipation takes place at appropriate rate 9
from its body. 10.5 If liquid rheostat is used the following additional protection shall be provided. (a). Open type liquid rheostat shall not be used. (b) Low electrolyte level protection. (c) Provision to check concentration of electrolyte. d) Provision of adjustment of electrodes at maximum position when semi master controller is in OFF position. e) Sufficient cooling arrangement for cooling the electrolyte. f) One contractor shall be provided for shorting the rotator of motor when semi master controller is in fully ON position and g) Provision for desalting arrangement shall also be made for periodic checking and prevention of sealing. 10.6 The following basic element/features shall be considered while selecting the control gear: a) Supply isolation device. b) Forward / Reverse Operating Device with the mechanical and electrical interlocking. c) Motor Protection Relays (Short / Over Load / Under Voltage Protection preferably with Starter). d) Earth leakage protection. e) Current voltage and speed indicator. f) ON OFF and earth leakage indicator. g) Earth leakage test and reset arrangement. h) OFF position mechanical and electrical interlocking of drum controller / master controller / semi master controller. i) Circuit for emergency brake. j) Emergency stop push button. k) Environmental conditions. l) Motor shall be controlled by a switch gear disconnect automatically the supply in the event of conditions of single phasing over voltage and over current. 10.7 Further the controller shall confirm to at least the following requirement: a) Operating line contactor shall be of AC-4 duty class and handling of motor in current by drum controller to be restricted as far as possible. b) Matching and minimum setting characteristic of over current relay circuit breakers and line contactors shall be provided, and c) Operation of haulage during lowering shall be made with power supply to motor. Lowering under gravity shall be prohibited during normal use. 10
ANNEX A (Clause 2) LIST OF REFERRED INDIAN STANDARDS IS No. Title 28:1985 Phospher bronze ingots and castings (fourth revision) 210:2009 Grey iron castings Specification (fifth revision) 1030:1998 Carbon steel castings for general engineering purposes (fifth revision) 2062:2011 Hot rolled medium and high tensile structural steel (seventh revision) 1570(Part 1):1978 Schedule for wrought steels Part 1 Steels specified by tensile and/or yield properties (first revision) 1804:2004 Steel wire ropes Fibre main cores Specification (fourth revision) 1855:2003 Standard steel wire ropes for winding and man riding haulages in mines Specification (second revision) 4322:1967 Specification for endosulfan dusting powers 7587(Part 2):2006 Cage suspension gear for winding in mines: Part 2 Cappels (second revision) 9494:1980 Specification for man riding cars used in mining 9559:1980 Guide for selection of electrical and electronic equipment for mines 11
ANNEX B Material specifications for Main Assemblies in Man Riding Car System Description Description of Material Specification of assly. Component Hauler Drum Assembly. Brake Rim IS 210/IS 1030 Casting Brake liner Asbestos interwoven with brass wire Drum Support IS 1030, Gr. 260-520 Casting Bush bearings Ph.Bronze, IS 28, Gr 2 Casting Gear Box out put shaft C 45(N), IS 1570 (Drum shaft) Forging Gear box assembly. Housing IS 2062 Bearing Housing IS 1030, Gr. 260-520 Casting Input shaft Material I Forging Intermediate shaft C 45(N), IS 1570 Forging Input pinion 40Ni2 Cr1 Mo28, IS 1570 Forging Intermediate gear Material II Casting Intermediate pinion Material I Forging Out put gear Material II Casting Bearing Covers IS 210 Casting Bush bearings Ph.Bronze, IS 28, Gr 2 Casting Emergency brake Brake liner Asbestos interwoven with brass wire Brake drum IS 210 Casting Caliper brake Turn buckle C45, IS 1570 Tie Rods Material IV Disc Spring Material V/50CrV4, IS 12511Part 2 Cars Brake pads Tungsten tipped Bogie wheels IS 1030, Gr 3 Castin 12
Bogie axle Material III Forging Rope guide IS 210 Casting Couplings 20 Mn2, IS 1570 Safety chains 20 Mn2, IS 1570 16 Bolt ham bone clamp Material I Forged Bracket for 16 Bolt ham bone clamp IS 2062 White metal socket 11 Mn2 of IS 4432 rope cappel / 20Mn2 of IS 1570 Bracket for white metal socket rope cappel IS 2062 13
MATERIAL SPECIFICATIONS Material I forging: Properties as below: Typical chemical composition C SI Mn S P Cr Mo Ni 0.36-0.44 0.10-0.35 0.45-0.70 0.040 max 0.035 max 1.00-1.40 0.20-0.35 1.30-1.70 Heat treatment: Hardening Quneching Tempering Brinell Rockwell Hardness Temperature Medium Temperature 830-860 oil 540-680 44-55 Mechanical Properties Size mm Tensile Strength N/mm² Yield Stress N/mm² Elongation Impact Izod J Impact KCV J Brinell Hardness HB 63 to 150 850-1000 680 Min 13% 54 50 248-302 150 to 250 850-1000 654 Min 13% 40 35 248-302 14
Material II Casting: Typical chemical composition C Mn Si S P Cr. Ni Mo.35 -.45.50 -.80.10 -.35 0.04 max 0.04 max.90-1.40 -.20 -.40 Heat treatment: Hardening Quneching Tempering Brinell Rockwell Hardness Temperature degc Medium Temperature 900-950 oil 200-225 45-55 Mechanical Properties : Heat Treatment Tensile Strength Rm N/mm² Yield Stress Re N/mm² A min on 5.665 So Impact Izod J Impact KCV J Proof Stress rp0.2 Hardness HB R 700/850 495 15 34 28 480 201/225 >100 250 S 775/925 555 13 27 22 540 223/277 >150 250 S 775/925 585 15 54 50 570 223/277 >63 150 T 850/1000 680 13 54 50 665 248/302 >29 100 U 925/1075 755 12 47 42 740 269/331 >13 63 V 1000/1150 850 12 47 42 835 293/352 >6 29 W 1075/1225 940 12 40 35 925 311/375 >6 19 Size mm 15
Material III Forging: Typical Analysis In % C Si Mn Cr W V Co Mo Ni 0.15 0.10-0.35 0.30/0.60 0.60/1.10 S&P each 0.05 (max) 3.00/3.75 Heat Treatment & Processing: Forging Annealing Hardening Quenching Tempering Hardness Temp. C Temp. C Temp. C Medium Temp. C Rockwell C 1100-850, 880-930 620-670, 850-880 760-780 - 170-210 BHN 220 16
Material IV : Typical chemical composition C Mn Si S P Cr. Ni Mo.50 -.60.50 -.80.05 -.35 0.04 0.04 - - - Heat treatment: Hardening Quneching Tempering Brinell Rockwell Hardness Temperature Medium Temperature 850-900 oil 200-250 55-60 Mechanical Properties Heat Treatment Tensile Strength Rm N/mm² Yield Stress Re N/mm² a% on 5.665 So Impact Izod J Impact KCV J Proof Stress rp0.2 Hardness HB R 700/850 495 15 34 28 480 201/225 >100 250 S 775/925 555 13 27 22 540 223/277 >150 250 S 775/925 585 15 54 50 570 223/277 >63 150 T 850/1000 680 13 54 50 665 248/302 >29 100 U 925/1075 755 12 47 42 740 269/331 >13 63 V 1000/1150 850 12 47 42 835 293/352 >6 29 W 1075/1225 940 12 40 35 925 311/375 >6 19 Size mm 17
Material V: ElementWeight % C 0.48-0.53 Mn 0.70-0.90 P 0.035 (max) S 0.04 (max) Si 0.15-0.30 Cr 0.80-1.10 V 0.15min Heat Treatment: Annealing Quenching Tempering Normalizing Q & T Mechanical Properties Quantity Young's modulus Tensile strength Elongation Fatigue Yield strength Value 200000-200000 650-880 8-25 275-275 350-550 Unit MPa MPa % MPa MPa Physical Properties Quantity Thermal expansion Thermal conductivity Specific heat Melting temperature Density Resistivity Value 10-10 25-25 460-460 1450-1510 7700-7700 0.55-0.55 Unit e-6/k W/m.K J/kg.K C kg/m 3 Ohm.mm 2 /m 18
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