Hydraulic Fluid Control System in Hard Coal Mines

In cooperation with Tiefenbach Control Systems, Germany we develloped and manufacture the TibaLyzer HFA-QCS. The TibaLyzer is an on-line measuring system for monitoring and controlling HFA fluids used for Roof Support.

The TibaLyzer HFA-QCS:

• Effectively reduces corrosion damage caused by an inadequate concentration of the face hydraulic fluid.
• Extends the life of the shield support
• Helps to reduce costs by minimizing maintenance and repair costs of the hydraulic components
• On-line monitoring of the face hydraulic both underground and at the surface via fibre optic cable or copper wire
• The focus is on production-specific activities

Thus resulting in ................... increased economic efficiency & enhanced competitiveness

The system consists out of the following components:

Analysis unit and measuring device (left part of picture):

• Process Refractometer TibaND for HFA concentration analysis
• pH-meter
• Conductivity meter
• Level gauges in the HFA concentrate tank and the tank for the HFA emulsion
• Flowmeter for measuring the flow of the make-up water (total water consumption)
• Temperature gauge
• Flowmeter to measure the flow through the sample line

 RioMaster evaluation unit (right part of picture):

• recording the measured values and calculating the concentrations
• visualizing and documenting the measured values
• activating the concentration control devices
• communication to the surface via fibre optics technolgy or copper wire

MODULES

The core components of the system are easily exchangeable modules, installed in a flame proof housing. This arrangement facilitates maintenance. Any necessary repairs can be conducted at the surface. These modules are:

• Process Refractometer Module; ProcanND, for measuring the concentration HFA
• The EMUD Module, with pH and Conductivity Measurement.
• RioMaster Module; ProcanRM, with PAC (Programmable Automation Controller) for processing the digital measuring data and out-going control signals. Process TFT screen.

The PDA which is supplied as a standard allows the measurement parameters and software settings of the RioMaster module to be changed. Furthermore it permits to change between different screen displays.

Communication between the PDA and the RioMaster module is effected via Blue Tooth^® interface without the need to open the unit. The PDA is certified for use in ATEX Zone 1/21  

All the modules are mounted on drawers for easy access to all the components. This ensures easy maintenance for the complete system. 

FLOW DIAGRAM

The measuring system is integrated in the circulation loop of the HFA emulsion supply container. The pH meter and the conductivity meter are located directly in the flame proof housing. For flushing and zero point comparison operations the measuring system can change over to water. The components required for emulsion adjustment such as filter, pressure reducers, pressure gauges, shut-off valves etc. are fitted.

Level meters are installed in the HFA tank and the HFA concentrate tank. The make-up water flow meter is installed in the water supply line. The ProcanND refractometer measures the HFA concentration in the emulsion and the RioMaster software compares the value with the target value defined for the concentration. Should the concentration value differ from the target value the concentration will be corrected immediately. If the value is too low concentrate will be added (concentrate valve opens) and if the value is too high the water valve will be activated.

In the RioMaster software all data are visualized, both digitally as trend and as bargraph. All data from the measuring mode are available on the hard disk of the  PC underground. If required, these data can be checked as trend for further processing. Fibre optics technology is used for the connection to the server PC at the surface. This technology ensures trouble free data transmission and operation of the measuring instruments from the surface control room.

Download: TibaLyzer HFA-QCS