SKS-W MAINTENANCE

TRAINING TOPIC 6
Agenda

1. Overview
1.1 nxonxonxo xnox
1.2 xxx
2. xxxx
3. Summary
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Topic 6

Dust Collector And Water Injection

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WATER INJECTION PIPING

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DUST CURTAIN

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DUST CURTAIN

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DUST CURTAIN

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Dust Suppression System

FOUR SYSTEMS ARE INCORPORATED TO CONTROL

DUST SUPPRESSION ON THE DRILL

1. DRY DUST COLLECTION.

2. WATER SPRAYS LOCATED AROUND THE DRILL DECK

3. WATER INJECTION INTO DRILL SERVICE AIR

4. DUST CURTAIN FOR DECK SEALING

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Dust Suppression Systems

Typical Dust
seal
arrangement

Regular inspection and maintenance of the
Deck seal will prolong the service life of the
Deck bush and minimise dirt build up from
cuttings on the Drill deck work area. The
new cassette type design allows easy
removal for replacement.
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The drill deck viewing hatch is used to view
the drill collar location and is moved in and out
by a single hydraulic cylinder operation is via a
toggle switch located on the control panel in
the cab.
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Dust Collector
All Bucyrus drills utilize the ‘Duraquip’ dry dust collection system. It is well
documented that this system can increase drill bit life by up to 100% which equates
to a considerable reduction in drill cost per metre.

The system consists of a primary drop-out box that ejects the coarse material or
fines allowing the superfines or dust to travel onto the main dust collector unit where
it is stored and ejected and the end of each drill cycle.

The dust collector system has a hydraulic driven fan that is used to create the
suction required. The fan draws the air/dust mixture from the drill skirt area, through
the primary box and into the main dust collector. Located in the main chamber are
four [4] filters that collect the dust allowing clean air to exhaust from the fan outlets.
The dust collector filters are cleaned via four [4] ‘back pulse’ valves that are
electronically timed. The length of pulse and pulse interval are fully adjustable to
suit ground conditions. Fan speed is variable by way of a hydraulic flow control
valve.

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Dust Collector - “Basic Operation”
(4) Filtered air
exits unit at
(3) Fine dust Fan exhaust
drawn into
Dust Collector
filters
(5) Purge air
cleans filters
and forces
fines to exit
unit at drop-out
shute

(2) Drawn through

Pre-cleaner drop
box (collects heavier)
(1) Dust and
particles
Cuttings forced
T Y P IC A L D U S T C O L L E C T O R O P E R A T I O N
up drill hole

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Duraquip Dust Collector - Dry Collection Unit

Timer Box
Filtered Air
Exhaust

Primary
Dust Drop Box
Collector
Unit

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Dust Control Systems

Dust collector precleaner

(Primary dropout)

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Duraquip HDE 1800 Dust Collector
Motor
Fan

Pulse Valves

Filters x 4

Drop Out Flap - Ensure Good Seal

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Dust Control Systems
Misc. Items
Duraquip Model HDE - 1800 Parts List
Pulse air hose 1.0 ID. 250 psi
Item Qty Description
Pulse air fittings 1.0 in BSP 1.0 in tail
1 1 Main housing
Manifold drain hose 0.5 in psi
2 1 Drop out hopper
Manifold drain hose fittings 0.5 in BSP 0.5 in tail
3 1 Hyd. Motor
Drop out flap rubbers 0/25 in rubber insertions
4 1 Hyd. Motor to fan housing plate
All nuts, bolts, capscrews UNC thread grade 5.
5 1 Fan housing and mounting plate
6 1 Fan wheel c/w hub
7 1 Main body top cover plate
8 1 Air manifold c/w valve pipes
9 4 Pulse valves 1.5 in 24 VDC
10 4 Filter extension tubes c/w filter bolt
11 4 Filter retaining plates
12 - Electronic timer 24 VDC NOTE: the dust collectors
13 1 Manifold drain cock
14 2 Manometer fittings
mounting bolts need to be
15 4 Filters c/w top seals checked regularly for security
16 2 Inspection plates
17 1 Inlet suction hose for 8.0 in hose
18 1 Drop out flap

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Dust Control Systems

Fan Speed

The dust trapped within the dust curtain is transferred through the pre-cleaner, to the dust
collection unit by the blower assembly, which provides the vacuum source to move the dust.
The blower assembly consists of an aluminium blower wheel or fan, an aluminium blower
housing, and a hydraulic motor. For the unit to operate effectively the fan must turn at both
the right speed and in the right direction.

The proper speed for the fan is 3000 RPM without a pre-cleaner and 3300 RPM with pre-
cleaner.

The fan speed is adjusted hydraulically by a flow control valve with a by-pass check valve.
This is plumbed into the motor, and mounted on the side of the dust collection unit. To
increase fan speed, wind flow control out, to decrease speed wind flow control in.

The by-pass check also operates as a wind down check for the fan motor to prevent
cavitation.

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Dust Control Systems

Dust collector flow

control (fan speed)

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Dust Control Systems

Direction of Rotation
All filter dust collectors have fans that rotate in a clockwise direction when viewing from the
top. It is imperative that the fan turn in the right direction. It will not always be immediately
obvious when the fan is turning backwards because the unit will still pull a vacuum of 2-3 inches
of water. (See manometer adjustment). The easiest method to determine the fans rotation is to
physically view the fan as it is either starting or stopping and note the direction it is turning.

Fan Speed Clearance

It is extremely important to ensure that there is the correct clearance between the fan housing
and the fan - 3mm. When delivered from the factory the correct clearance should already be
set. Should the hydraulic motor or the fan wheel be replaced, the clearance between the bottom
fan plate and the clearance ring in the housing MUST be set to 3mm.

With the taperlock bush loose on the motor shaft, assemble the fan as in the next slide. Tighten
the three capscrews of the taperlock bushing in succession to 192 in lbs torque to lock the fan
to the motor shaft, while maintaining the correct clearance between the fan wheel and the
clearance ring in the housing. Rotate the fan wheel by hand to ensure that the wheel is not
interfering with any part of the housing.

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Dust Collector - Motor And Fan Assembly

3mm Clearance

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Dust Control Systems
Dust collector sub-system function - fan speed adjustment

Manometer adjustment
The correct fan speed is…
3000 RPM (12-13 inches) - without pre-cleaner
3300 RPM (12-13 inches) - with pre-cleaner

Although the speed can be determined directly with a tachometer, the preferred method is to set
the speed to give the desired vacuum as measured with a water manometer. It is a very simple
device consisting of a clear plastic tube bent into a ‘U’ shape, which is partially filled with water.
Two columns of water appear side by side, and extend approximately half way up the length of
the manometer.

If both ends of the tube are open to the atmosphere, then the water level in each leg of the
manometer will be equal. However, if one leg is connected to a vacuum source, the air pressure
in the other leg will be greater and will push the water column down on the side connected to
atmosphere. At the same time, the column connected to the vacuum will rise. The distance in
inches between the two water columns is the measurement of the vacuum in inches of water.

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Dust Control Systems
Dust collection filters
The four dust filters are an important part of the effective operation of the dust collection system. They are a
‘paper’ filter, and when wet or damp dust is sent through to them they become blocked very quickly. The life
of individual filters may vary. The fact that one filter has failed does not mean all filters need to be changed.
Investigation of the filters will determine if they are damaged.

Filter life depends upon a number of variables. An indication that one or more of the dust collector filters will
need cleaning or replacing is when dust purges from the fan outlet. To identify which filter is at fault, dust
will purge from the fan outlet when the faulty filter is purged. By watching the timer firing order and noting
when the dust discharges from the fan outlet, the faulty filter can be identified. Remove the suspect filter
and check for a damaged seal or ruptured filter paper. Replace filter or seals as necessary.

Clean the dust from the filter retainer bolt threads before unscrewing the nut. Care must be taken
not to unduly over tighten the retaining bolt as the filter may be crushed. Check all filters for
tightness while the hopper is opened.

If the collector is not working because the filters have become blocked with mud, once the filters and mud
have dried out, the back pulsing may not be effective in cleaning them. The back pulse purging of the filters
will remove dry dust from the filter, but not mud. So, in such cases remove the filters and blow the dried out
mud off them with a compressed air blow pipe. Then inspect for any damage and replace or reinstall as
necessary.

Note: Filters will continually block if drill cuttings are moist or damp when using Dust Collector

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Dust Control Systems
Access to dust collection filters

To access the dust collector filters the bottom hopper needs to be removed (see the procedures
below)...

1) Check that the safety hinge bolts (1) and (2) are in position

2) Unscrew hopper bolts (3) from each side of the collector, this will lower the
hopper slightly and leave it hanging on its hinge bolts.

3) With the hopper now lowered and hanging in the hinge bolts (2), push the hopper towards the rear
and the safety bolts can be removed. The hopper is now free to swing away from the body allowing
filters to be inspected.
CAUTION: Care must be taken to ensure that the hopper is lowered in a controlled manner. It
may want to swing out quickly which could cause physical harm if it comes in contact with
somebody or something.

4) In the event that more access room is required the hopper can be raised higher using rope or
hand winch between lifting eyes (4).

5) Reverse the procedure to secure the hopper to main body.

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Dust Control Systems
Compressed Air Supply
The compressed air supply is used to back blow the filter elements
to clean the filters as previously described. The outside section of
the top of the dust collector is a compressed air reservoir. This air
tank is connected directly to the impulse valves which supply
the air pulse to clean the filter (see the schematic). The
air regulator mounted on the side of the dust collector
unit steps down the auxiliary pressure, to a pressure
that the filters can handle. The regulator MUST be
set at 40-80 psi. Lift the cap and turn to adjust,
then push the cap back down to lock. If the
pressure is too high the filter elements will
be damaged. If it is set too low, the filters
won’t be purged or cleaned. The air
regulator is fitted with a water
separator which automatically
drains the water off as it
accumulates in the bowl.

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Dust Control Systems
Timer
The electric timer is a 24 Volt controller designed to sequentially activate 24V solenoid directional
air valves. The solenoid valve, when activated, exhausts to atmosphere the air from the top of the
impulse valve. Exhausting this air causes the impulse valve to pulse. The electric timer is set up
at the factory and should need no adjustment. However, to suit your particular drilling situation
you may wish to increase or decrease the interval between pulses.

The numbers on the FIRST OUT and LAST OUT dials indicate the order in which the impulse
valves fire. Do not change these settings. The red sequence lights indicate which impulse
valve is firing. If only four filters are used, then only four lights will flash.

If there are any problems first check that the green POWER ON light is on and that the fuse is
not blown. Push the RESET BOTTON if power has been interrupted. The green power indicator
light (top left hand corner of the timer board) will be ON if power is reaching the timer. Check the
switch and wiring to the timer board. If the power light is ON check that the STEP and PULSE
control knobs are not back to the OFF position, readjust if necessary. The pulse duration should
be sharp, (indicated by the length of time the RED indicator light flashes ON). The interval
between pulses should be from 2-4 seconds, depending on drilling conditions. To check that the
filters are being cleaned connect manometer to the top and bottom ports provided while drilling, if
the reading is over 6”WG decrease the interval between the valve firing by adjusting of the pulse
knob.

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Dust Control Systems
Timer con’t

If the valves misfire in a regulator nature (one valve misfires)

in the firing sequence and the red indicator light flashes on,
the problem could be in the wiring circuit from the timer to the
pulse valve.

Check the terminals on the board and valve:

• If the circuit is in order, change out the solenoid valve coil.
• If the green power indicator light is ON, and one red flash
indicator does not light in the sequence firing order, the
circuit board is at fault…change out the board.
• If the red indicator light are miss firing in an irregular
pattern, the timer board is at fault, change out the board.

Refer to wiring diagrams to identify faulty valve.

Timer circuit board
Access to valves and solenoids is by removing the Sends signal to solenoid operated flush valves
Fully variable
suction fan assembly. Controls pulse length
Controls time between pulses

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Dust Collector Timer Unit
TIME
BETWEEN
PULSE

Timer Unit

PULSE
LENGTH

1 2 3 4

LED INDICATION Fuse

OF PULSE OF
1 2 3 4
EACH FILTER

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