SOLIDS PUMPING SYSTEMS

SV200-SPDK Operations Manual

U1/ 5-7 Boeing Place - Caboolture - QLD 4510 - Australia+61 456 000 665 / info@solidsvac.com / www.solidsvac.com
ISSUED DATE - 140421

V 1.3

LAST REVISED - 311223

CONTENTS
Description

Page

Safety First

3

1.

Operation Overview

3

2.

Technical Data

4

3.

Schematic

5

4.

Design Registration & Technical Standards

6

5.

Pump Set-Up

7

6.

Operation

8

7.

Maintenance

98.

Timer Cycling & Adjustments

13

9.

Accessories

14

10.

Operational Risk Assessment

15

11.

Parts Assembly

23

12.

Job Safety Analysis

24

Scan this QR Code for an electronic version of this Operations ManualSAFETY FIRSTCAUTION & GENERAL SAFETY
This manual contains important information concerning the installation, operation and maintenance of the Solidsvac Pump, Model
SV200-SPDK. To prevent injury to personnel or equipment damage, this manual MUST be read and understood by those responsible forthe installation, operation and maintenance of the equipment.
THIS OPERATION MANUAL MUST BE USED IN CONJUNCTION WITH BOTH SITE-SPECIFIC RA AND JSA’s.
-

Isolate, tag out and disconnect the air supply to the unit prior to working on any part of the system-

Lift the equipment only at the lifting points provided-

The pump should be installed in a safe level area, which provides adequate access for operating the equipment-

Ensure all hoses are in good condition, correctly rated and certified for the service in which they are to be used-

Inspect the unit regularly for damaged or worn components-

All covers MUST be fitted prior and during operation-

Air pressure should NEVER exceed rated pressure-

Tie down points (if fitted) MUST NOT be used as lifting point

CAUTION: BE AWARE OF RETAINED MATERIAL IN THE TANK INCREASING WEIGHTSOLIDSVAC PUMPS EACH HAVE SPECIFIC COMPRESSED AIR REQUIREMENTS DEPENDING ON THE JET PACK FITTED.
The operator MUST ensure that an appropriate and adequate air supply is available depending on the model and Jetpack in use.
All Solidsvac equipment require a minimum operating pressure of 689kPa and have a maximum operating pressure of 758kPa(110psi). The recommended size for the air supply hose is dependent on the Jetpack configuration, below is a guide for each.
50-230CFM – 1”
380-600CFM – 2”
900-1200CFM – 3”
Note: An 18mm (¾”) i.d. Air hose contains HALF the volume of the recommended 25mm (1”) hose.
The Discharge hose MUST be no smaller in diameter than the pumps outlet, preferably a self-supporting type and secured at regularintervals.

1. OPERATIONAL OVERVIEWThe Solidsvac range is a compressed air driven and controlled pumping system which utilises a compressed air venturi to vacuum

and convey material through a pressure vessel (AS1210). This is achieved with a range of airflows from 50 CFM (84.95m3/hr)- 1200
CFM (2038.8m3/hr) @ 100psi (6.89bar). During the suction phase the venturi creates vacuum that allows any flowable material withsolids ranging up to 75mm to be drawn into the vessel. Then during the discharge phase, compressed air is exerted into the vessel
and the material, is pressure discharged. These 2 phases are repeated to allow the pump to convey material, with the duration ofeach phase being controlled by timers.
With the Solidsvac range of Constant Vacuum/ Constant Discharge units (CVCD) a dual system unit is utilised, with one systemhaving a vacuum exerted on it whilst the second has pressure exerted on it. This results in a near continuous flow of material at both
ports.
A Solidsvac Vac-Pack uses a compressed air powered venturi system to only generate a vacuum. The Vac-Pack can turn any
appropriately rated container into a recovery vessel.

WARNING

Compressed air can be dangerous. Correctly rated hoses and piping should be used in conjunction with the appropriate fittings andsafety devices on all connections.
The unit is not designed to operate above 758kPa (114psi) and the PRV will relieve at 758 +/- 35kPa (110psi +/- 5psi).

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page 3

3. TECHNICAL DATATECHNICAL DATAMETRICUS IMPERIAL

Height1400 mm

55”

Width

1150 mm

45”

Length1650 mm65”

Weight600 kg1322 lb

Air inlet

50 mm

2” BSP

Suction inlet

100 mm4”

Discharge outlet

1000 mm

4”

Delivery

500+ m1640+ ft

Suction lift

10m+ @ 180 cfm
Up to 15m @ 230 cfm

32' ft+ @ 180 cfm Up
to 50' ft @ 230 cfm

Air consumption

5.1 m3 /Min Jet Pack
6.5 m3 /Min Jet Pack180 cfm Jet Pack
230 cfm Jet Pack

Displacement cycle

190 ltr

50 galOperating pressure

7 Bar (Required) @ 690 kPa

100 psi (Required)

Measured Water Throughput

665 lpm (230 cfm)

175 gpm (230 cfm)

Maximum solids

80 mm

3”

Air Consumption Options

76 to 88 kPa

22.5" to 26" Hg

Note: All performance statistics listed were measured on water and will require 7 bar (100 psi) operating pressure.

telephone +61 456 000 665
email info@solidsvac.com
page 4

4. SV200-SPDK SCHEMATIC

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page 5

4. DESIGN REGISTRATIONThe Solidsvac SV200-SPDK has a Certificate of Plant Design Registration from Workcover NSW, Australia. A copy of which
may be obtained by contacting Solidsvac Pumps.
DESIGN REGISTRATION # PV-6-204612/16

TECHNICAL STANDARDS-

AS2971-2007 Serially Produced Pressure Vessels-

AS4343-2005 Pressure Equipment - Hazard Levels-

AS1210-1210 Pressure Vessels-

ISO 80079-36:2016-

ISO 80079-37:2016-

ISO 80079-38:2016-

IEC 60079-0:2017

The requirements of ISO 80079-36 and IEC 60079-0 have been applied to this equipment.
Temperatures are continuously rated and deterioration of the equipment during use will not compromise the Ex properties.
An ignition hazard assessment has been performed in accordance with ISO 80079-36.

Certificate:

IECEx ExTC 24.0008X

Code:

Ex h I Ma (0 °C ≤ Tamb ≤ +50 °C)
Ex h IIB T4 Gb (0 °C ≤ Tamb ≤ +50 °C)

CONTENTS EXCLUDED FOR PUMPING

Solidsvac recommends that any contents the fall within the scope of the below class liquids should not be pumped with any Solidsvac

unit. Solidsvac also recommend that a site-specific JSA should be conducted with reference to any other type of material being
pumped.
-Class IIIA liquids with a flash point equal to or greater than 140 °F (60 °C), but less than 200 °F (93 °C) have a NFPA 704
flammability rating of 2.

-

Class IIIB liquids with a flash point equal to or greater than 200 °F (93 °C) have a NFPA 704 flammability rating of 1.

OPERATING PARAMETERS
The Solidsvac SV200-SPDK can operate within environments ranging from 0 °C to 50 °C and all humidity.
The maximum medium temperature allowable for the SV200-SPDK is 50 °C.

HOSES

Solidsvac recommends the hoses (Air Supply, Suction, Discharge) used in operation with the Solidsvac Pumps are to be made ofanti-static material to ISO 6805:2020.

EARTHING POINT

All Solidsvac models are fitted with an Earthing Point which is mandatory requirement prior to operation. Solidsvac strongly
recommends that the operator takes the necessary measures to earth the unit prior to operation.

CONDITION OF USE
It is a condition of use that the equipment is to be earthed according to the user manual prior to operation.
It is a condition of use that the equipment is to be supplied compressed air from a clean source.

WARNING:

TO AVOID POSSIBLE ELECTROSTATIC CHARGES PRODUCED BY THE MATERIAL CONVEYEDTHE OPERATOR MUST EARTH THE UNIT PRIOR TO OPERATION

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page 6

5. PUMP SET-UP
Before commencing operation, Solidsvac strongly recommends each user reads the Operation Manual supplied with each unit andavailable online or via the QR code on pump.
Note: No training is necessary to operate the SV200-SPDK however understanding the Operations Manual is essential to safe
practice.
Solidsvac also recommends that a site-specific Risk Assessment (RA) of the pumping operation is undertaken. Any recommendations
arising from the Risk Assessment would be additional to the following:-

The unit and all hoses and fittings are undamaged and in good working order.

-

All covers are fitted in place and correctly secured.

-

Clean compressed air at minimum working pressure of 690kPa (100 psi) is available.

-

A 50mm (2”) N.B air hose is available.

-

The discharge area has suitable warnings to protect personnel.

-

The correct PPE is available and worn for operating compressed air equipment-

Eye Protection-

Hearing Protection-

Gloves-Safety Boots-

Set the Solidsvac Pump in a safe level location as close to the material to be pumped as possible.

-

Attach both suction and discharge hoses along with any accessories as required and ensure safety clips are in place.

-

Ensure the main air valve is in the off position and attach the 40mm (1 1/2”) air hose to the Solidsvac Pump & fit safety clips.

-

Ensure the frame is adequately earthed.

-

The pump is now ready for use.

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page 7

6. OPERATION

Turn the air supply valve ON at the source. Turning the pump valve to ON, the pump will now commence its cycle of operation. The
LOAD and DISCHARGE cycles are controlled by adjustable pneumatic timers, these allow for adjusting the pump to varying conditions,i..e. heavy or light material or long or short distances etc. During the LOAD cycle the operator should note an audible difference (Gargle)
once the vessel has filled, adjust the LOAD timer to where the cycle completes just as or prior to this occurring. The DISCHARGE cycle
depends on both the material being transferred and the distances involved. A discharge setting of 7-10 seconds will accommodate
about 95% of most pumping jobs with the SV200-SPDK.
Once pumping is completed, remove the suction from the material and allow the pump to cycle self-clean, on completion of theoperations isolate the air supply and allow the pump to cycle until the supply in the line is exhausted, then turn the pump off at the
supply line. SOLIDSVAC recommends checking the pump discharge to ensure it remains correctly anchored at the exit. Lubrication is
not required during operation.
Note: Dry operation will not damage the pump.

CYCLE INDICATOR

The pump is fitted with an indicator to inform the operator which cycle the pump is operating in, when in the discharge cycle theindicator is yellow and when in the suction cycle the indicator is clear.
Note: If the pump is supplied with a head of pressure it is possible for the pump to siphon when the air supply is turned off. To
prevent siphoning when the pump is not in operation, turn the pump off when it is in the discharge cycle or isolate the material
supply source to the pump.

PRESSURE GAUGE
The pump is fitted with a pressure gauge to inform the operator of the supply pressure at the pump. For optimal performance, it isrecommended that supply pressure is monitored and remains at 7 bar (690 kPa).

telephone +61 456 000 665
email info@solidsvac.com
page 8

7. MAINTENANCE
In use, the Solidsvac SV200-SPDK requires little to no maintenance, however Solidsvac recommends that the following strict measures
are taken to ensure the pump remains in good working order for as long as possible.
Maintenance, repairs and the disassembling of the unit can be carried out by any qualified Fitter with a basic knowledge ofpneumatics.

SERVICE TIPS-	Clean the machine areas before removing pneumatic components.
Note: When steam cleaning or using water to clean a machine, be sure that filler openings, breather caps etc are protectedfrom possible entry of water into the system.

-

Use clean plastic plugs to cover the ends of disconnected lines or to plug openings when working on a pneumatic system.

-	A clean workbench is an absolute ‘MUST’ when servicing components. An industrial-type vacuum cleaner is a valuable aid in
removing dust, dirt and tiny metal particles from the work area.

-	Check the condition of your tools – they should be clean. Always use hammers made of plastic or leather, so there is no dangerof metal chips getting into components.

-	When removing parts for service, clean them and then store them in plastic bags or other clean containers until they are
installed again.

-

 hen cleaning pneumatic parts, use extreme care to ensure that the cleaning fluid is non-flammable and compatible with theWsystem.

MAINTENANCE SUGGESTIONS-

Set up a maintenance schedule and follow it diligently.

-Inspect filter elements that have been removed from compressors and the system for signs of failure, which may indicate thatthe service interval should be shortened or that there are impending system problems.

-

Do not run the compressor or the system unless all normally provided filtration devices are in place.

-

Use common-sense precautions to prevent dirt entering components that have been temporarily removed from the circuit

EFFECTS OF DROPS IN PRESSURE
A combined drop in flow rate and pressure will affect the power requirements of a pneumatic machine, especially in mobile
applications, where the speed of the prime mover will have to increase to meet system demand. Generally, compressors powered byelectric motors cannot increase revolution speed to provide greater flow rate. Pneumatic motor performance is affected by a drop in
power (torque and speed capabilities).
Actuators convert pneumatic energy back into mechanical energy. It is here that lack of flow and pressure instigates the faultfinding
process. Jerky cylinder and motor movements are unacceptable and the combination of these pneumatic faults results in amachine’s power performance dropping. The problem MUST be solved to ensure efficient operation.

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page 9

SYSTEM TESTING PROCEDURES
Pneumatic systems, like all machines, require routine maintenance to ensure reliability. However, there are still times when problems
occur and MUST be located quickly and efficiently, especially in production applications. A step-by-step method has been devised asa way of finding and solving pneumatic problems quickly.
These steps are as follows:

STEP 1: KNOW THE SYSTEM Study the machine’s technical specifications to obtain an understanding of how the system operates and the function of themachine’s components. Obtain a circuit drawing and check the system through. Check the machine’s maintenance records andcommissioning test results if they are available.

STEP 2: ASK THE OPERATOR Determine the symptoms of the problem by asking the operator for a detailed description of the machine’s normal operating
performance.

STEP 3: INSPECT THE MACHINE Use your senses (touch, smell, sight and hearing) to locate problems or damage such as noisy components, air leaks, malfunctioning
components and damaged air lines.

STEP 4: OPERATE THE MACHINE Operate the machine and check that the machine’s gauges are reading ‘normal’ and that there are no unusual noises. The operationof the machine’s controls should not be ‘sticky’ or ‘spongy’. The machine’s performance should not be slow, erratic – nor non-existent.

STEP 5: LIST THE POSSIBLE CAUSES Once the fault has been located and recognised, list the possible causes – starting with the simplest.

STEP 6: REACH A CONCLUSION Use a troubleshooting chart to check the list of possible causes; then decide which is the most likely.

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page 10

SYSTEM MAINTENANCE
A pneumatic system is easy to maintain. However, like any other mechanism, it MUST be operated and maintained correctly.
Pneumatic systems can be damaged by excessive pressures, fluid contamination and by high operating temperatures.
Regular maintenance will reduce your pneumatic troubles. By using a regular maintenance programme (preventative maintenance)
to care for a system, you can eliminate common problems and anticipate special ones. Problems can be corrected or averted before
a breakdown occurs.
The following are the key problems that commonly need to be addressed in pneumatic maintenance:-

Water-contaminated air-

Poor air filtration-

Incorrect pressure settings-

Incorrect lubricator settings, resulting in sticking valves-

High air temperature-

Loose supply lines-

Faulty seals

IMPORTANCE OF CLEANLINESS
Cleanliness is of supreme importance when it comes to servicing pneumatic systems. Keep dirt and other contaminants out of thesystem. Small particles can score valves, cause seizing of components and clog orifices, resulting in expensive repair jobs.
When servicing a pneumatic system, always do the following to ensure cleanliness:-

Keep the compressor and machine's lubricating oil clean-

Keep the system clean-

Keep your work area clean-

Be careful when you change or add oil-

Be careful when you change seal or components (take photos)-

Use caution with compressed air-

Ensure all pneumatic components supply lines are securewww.solidsvac.com

page 11

AIR INLET FILTER
Prior to commencing each pumping operation:-

Check that all fittings and connection are serviceable.

-

Adequate compressed air is available.

-	A general visual inspection of the unit including the suction and discharge valvesis recommended.

SAFETY FIRSTPRIOR TO COMMENCING ANY WORK ON THE UNIT, THE AIR SUPPLY VALVE MUST BE
ISOLATED AND THE CONTROL SYSTEM TESTED DEAD

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page 12

8. TIMER CYCLING & ADJUSTMENTS
Adjustment of the Load and Discharge cycles may be required depending on material being transferred and the distances
involved etc.
Turning the upper flow restrictor to negative will decrease the loading time, similarly rotating it to positive will increase the load time.
The Pressure Relief Valve can be manually operated via the lever as indicated below.
Caution: It is recommended that only small incremental adjustments are made at a time.

Pressure Relief Valve

Cycle Control Timers

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page 13

9. ACCESSORIES
Suction Wand - Attaches to the suction hose allowing the operator tostand upright and ambient air to be introduced at the material inlet.

Strainer - Available in two sizes and attaches to the suction hose toprevent the ingestion of oversize particles.

VacHead - An industrial vacuum head with squeegee brush allows theoperator to stand upright, recovering material from hard surfaces i.e. an oil
spill from a road surface.
Note: It is recommended that the suction timing cycle is set to 15 seconds
when using this accessory.

Delivery Carousel - Controlled discharge to either a conveyor or
multiple points/skips etc.

Hoses - A complete range of high quality suction and discharge hoses areavailable.

Hoover Head - Helps focus the vacuum and is ideal for recoveringheavier material such as barite, oil sludge, mud or similar from tank bottoms
and various hard surfaces.
Dropbox - Delivery of material to a skip, conveyor or specific point.
Tool Kit - Contains all you need for basic maintenance on your pump.
Service Kit - Contains all you need for basic maintenance on your pump.

telephone +61 456 000 665
email info@solidsvac.com

page 14

OPERATIONAL RISKASSESSMENT

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page 13

OBJECTIVE:
The objective of the hazard identification and risk review process is to ensure all hazards are identified and accurately assessed for risk.
Suitable and effective controls MUST be nominated and implemented to keep workplace safe.

CONTEXT:The Solidsvac Mobile Solids Pump is designed to be used for the purpose of pumping and transferring heavy slurry/media. The
Solidsvac Mobile Solids Pump will be in a stationary position on the floor. The floor conditions need to be safe and level.

SCOPE:The Scope of the risk assessment as follows:1)

Identify operational hazards associated with the use of the Solidsvac Mobile Solids Pump

2) Risk Assess each of the identified hazards3) Implement controls to minimise any hazards to an acceptable level

INVOLVED PERSONS/STAKEHOLDERS:
Risk Facilitator
Solidsvac Management/Tradespeople

ASSUMPTION:
Supplier
Competent, comply with standards and drawings.
End User (Owner/Hirer/User)
The end user has:-Competent (operators are trained, competent, authorised, etc.)-

Procedures (change management, traffic rules, risk assessed, developed, effectively implemented, etc.)-

Equipment fit for purpose (rated, designed compatible, maintained, inspected, monitored, etc.)-

Leadership (communication, directions, monitoring, etc.)-

Environmental conditions are compatible to the operational capabilities of the equipment (natural vs. man-made, etc.)

INCLUSIONS:
Only the aspects directly related to Solidsvac Mobile Solids Pump.

EXCLUSIONS:Transporting and storing the Solidsvac Mobile Solids Pump (Users operational risk assessment, training, competence);
Assessment of the environmental conditions in the operational area (Users planning and local risk control)

REFERENCE MATERIAL:QLD Coal Mining Safety & Health Act 1999
QLD Coal Mining Safety & Health Reg 2001
Recognised Standard 02 Control of Risk Management Practices

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page 16

RISK MATRIXStep 1: Establish the Consequence (1-5)
Injury / Occupational Illness
or Disease
Consequences(How to manage Work Health and Safety
Risk – Code of Practice. Safety Work
Australia 10 August 2011). The company
must ensure levels of consequence andlikelihood are relevant to the company’s
Business risk.

Business
Loss/Asset
DamageReputation/
Social/Community

Legal and
Regulatory/
Contract

Environmental
Impact(e.g. Hydrocarbon spills)

1

Insignificant

Report only<$5kComplaint/
Single project or
stakeholder

Minor noncompliance- internal report
only

Negligible pollution

2

Minor

First Aid Treatment Injury/Illness
Non-prescription medication/
treatment that can beadministered by first aider.

<$20k

Local publicconcern

Minor legal noncompliance Contractual issue

Minor pollution/
Nuisance3

Moderate

Medical Treatment Injury/Illness
Prescription medication/treatmentthat can only be administered by aregistered doctor/nurse.
Minor LTI <5 full days work lost<$50k

Regional publicconcern/Multiple
stakeholders

Serious breach of
law/Investigation
by authority/
On the spot fine.
Major breach ofcontract.

Noticeable pollution

4

Serious

Serious Lost Time Injury/Illness
Loss of 5 or more days work/
admission to hospital/serious
injury under WHSA definition<$100kNational publicconcernSignificant
penalties/
Termination ofcontract

Significant
environmental event

5

Major

Fatality
Single or multiple fatalities<$100kInternational
public concern

Law suits/
Prosecution/
Removal fromsuppliers list

Major environmental
event/Material
environmental harm

Step 2: Establish the Likelihood (A-E)
Frequency Examples

Description(How to manage Work Health and Safety Risk – Code of Practice. Safety Work Australia 10 August 2011).

A

Certain to occur

Expect to occur in most circumstances (>1 event/month)B

Very likely

Will probably occur in most circumstances (2 to 1 events/year)

C

Possible

Might occur occasionally (1 event/1 to 2 years)

D

Unlikely

Could happen at some time (1 event/2 to 3 years)

E

Rare

May happen only in exceptional circumstances (>3 to 5 years)

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page 17

RISK MATRIXStep 3 : The Hierarchy of Risk Control Model
Start at the top and only if you can’t select controls from one section, move to the next one down.
You need to use a combination of control measures to achieve the second level of risk control.
If a particular hazard can’t be removed the risk associated with the hazard can never be eliminated.
1

Elimination

Complete removal of the hazard

2

Substitution

Replacing the material of process with a less hazardous one

3

Isolation

Separate the hazard from people

4

Engineering

Guarding, ventilation, design, re-design etc

5Administration

Providing controls such as training and procedures

6

PPE

Use of PPE when other controls are not practical

7

Post

Mitigation after an event (ell Fire extinguisher)

Most effective

Least effective

Using the Matrix to Determine Risk Score
Likelihood

Consequences
1

2

3

4

5

A
Certain to occur

Low
11

Moderate
16

Moderate
20

High
23

High
25

B
Very likely

Low
7

Low
12

Moderate
17

High
21

High
24

C
Possible

Low
4

Low
8

Moderate
13

High
18

High
22

D
Unlikely

Low
2

Low
5

Moderate
9

Moderate
14

High
19

E
Rare

Low
1

Low
3

Low
6

Moderate
10

High
15

ALARP - As low as reasonably practical
Tolerable

Take action to manage ALARP

Intolerable (without specific senior management approval)

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page 18

www.solidsvac.com

page 19

Operation

1.1

1.2

MaintenanceSet up1.0

1.3

Travel position

Transport towork site

Environment

SUB ACTIVITYACTIVITYREFERENCE

Risk Assessment assumes that current
controls are adequate and working.
The Risk Scores have been achieved
using the qualitative risk analysis
matrix from the Solidsvac Risk
Management procedure and is
attached at the end of this document.

2

2

2

Rated pressure hoses
Mine Site Induction and Training
Competencies

Mine Site Induction and Training
Competencies
Operation manual and training documents
the set up procedure incorporates
barricading discharge area with caution
tapeOperation manual and training documents
unblocking procedure
Pressure relief valve at the pump relievesdischarge pump pressure
Operation manual and training documents
unblocking procedure
Isolation training and procedures
Low pressure i.e. 10psi
Strainer or nozzle fitted to suction hose

Resulting in personal
injuryFailure of thecompressed air
system resulting in:
Personal injury frombeing exposed tocompressed air due
to hose failure and/or
damageInteraction withconveyor resulting inpersonal injury
Resulting in personal
injuryResulting in personal
injuryResulting in personal
injuryResulting in personal
injury and/or process
delayHigh pressurecompressed air

Work on or around amoving belt

Discharged material(at 100psi) contacts
operators

Pinch points on Solidsvac
SV200 Mobile Solids
pump during operation

Blocked discharge hoseresulting in exposure
to stored energy while
unblocking hose

Blocked suction hoseresulting in process delay

Resulting in personal
injury and/or process
delay

2

Operation manual and training documents
setup, removal procedures
Operation manual and training documents
identify the need to drain pump before
disconnecting. Mine transport rules Line ofsight before any movements
No machine movements without positive
communications
Hi-viz clothing

Nip/crush points and“Line of Fire” issues frommobile equipment, lowroof height issues during
set up and removal
resulting in crush injuries

Incorrect maintenanceresulting in equipment
failure3

Manual handling training at Induction teamlifts where required
Most set up and removal tasks conductedfrom floor level and reasonable height

Failure of the correctmanual handlingtechnique

Manual handling

Tested to Australian Standards
OEM Maintenance scheme

Fit for purpose covers fitted to pump during
operation, MUST be in place

2

Operation manual and training documents
set up procedure on level ground or
securing pump to the rib using rated
restraining devices when operating on
uneven groundResulting in personal
injury and damage to
the Solidsvac SV200
Mobile Solids Pump
during operation

Solidsvac SV200 Mobile
Solids Pump set up on
uneven ground or pumpis inadequately secured
to rib when on unevenground resulting in
unplanned movementof pump

2

2

3

2

Wheels and handle on the Solidsvac SV200
Mobile Solids Pump
Designed well balanced
Mine transport rules

Resulting in personal
injury and damage to
the Solidsvac SV200
Mobile Solids Pump
during transport

Inadequate transport
methodCONSEQUENCE

C

C

C

C

C

C

C

C

C

C

LIKELIHOOD

L8

L8

L8

L8

L8

L8

M 13

M 13

L8

L8

L8

RISK RATINGCURRENT RISK WITH EXISTING CONTROLSEXISTING CONTROLSRISK EVENT

HAZARD

THIS IS A BASIC R.A
SOLIDSVAC STRONGLY RECOMMEND THATA SITE-SPECIFIC R.A IS CONDUCTED.

OPERATIONAL RISK ASSESSMENT

ALARA

ALARA

ALARA

ALARA

ALARA

ALARA

ALARA

ALARA

ALARA

ALARA

RISK TREATMENT(Accept, Transfer,
Avoid, or Further
Risk Review)

Open

Placement and loading of the
Solidsvac SV200 Mobile Fluids
Pump to be included in the training
and assessment document in
the Solidsvac SV200 Mobile Solids
Pump

Maintenance to be carried out as
per OEM Suppliers SV20
Operation/Maintenance ManualTraining and assessment in the
Solidsvac SV200 Mobile Solids
pump package

Training and assessment in the
Solidsvac SV200 Mobile Solids
pump package

Training and assessment in the
Solidsvac SV200 Mobile Solids
pump package

STATUS(Complete,
Incomplete,
In progress)

ADDITIONAL RECOMMENDATIONS

Reviewedby

TARGETRESIDUALRISK AFTERTREATMENTDate

RISK REGISTER ACTION PLAN
No

ITEM/ISSUEAGREED ACTION

WHO

WHEN

Operation

StorageCommunicate to end user todevelop work procedures forstorage of Solidsvac SV20 Mobile
Fluids Pump

Solidsvac

Delivery

Travel position

Communicate to end user todevelop work procedures fortravelling

Solidsvac

Delivery

Use of Solidsvac
SV20 Mobile
Fluids Pump

Supplier to develop work
procedures for operating the
Solidsvac SV20 Mobile Solids Pump

Solidsvac

Delivery

Daily

Supplier to develop daily
and/or pre-use visual inspections
procedures for using andoperating the Solidsvac SV20
Mobile Solids Pump

Solidsvac

DeliveryWeeklySupplier to develop weekly
visual, operational, maintenanceinspections for using andoperating the Solidsvac SV20
Mobile Solids Pump

Solidsvac

Delivery

Maintenance

COMP DATEREVIEW/AUDIT
DATE

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page 20

PUMP PREVENTATIVE
MAINTENANCE PROGRAM
The following is the work to be performed to a SV200-SPDK Pump during Preventative Maintenance Check.
All items, except annual checks (Tradesman), are to be carried out by a Competent Operator.
-

Lock and tag out equipment-

Record equipment data-

Check all mounting and flange bolts are secure and tight-

Check vessel support frame and wheels for soundness-

Visual inspection of pump for any damage-

Check for knife gate seal leaks-

Check condition of flange gaskets-

Check knife gate packing for excessive leakage and adjust and/or replace-

Make sure all timers are operational-

Check operation of Pressure Relief Valve-

Check in-line gauze filter (if fitted)-

Inspect condition of airlines and fittings-

Check operation of swing check valve (if fitted)-

Check condition of venturi nozzle-

Test the operation of the SV200-SPDK pump prior to returning to service-

Make note on the field report of any findings that may require additional workwww.solidsvac.com
page 21

PUMP MAINTENANCE CHECKLISTMAINTENANCE FREQUENCYDESCRIPTIONCOMMENT

Pump use andtimingCheck operation of pump prior to use.

X

Overall visualinspection

Complete overall visual inspection to be sure all
equipment is operating and safety systems are inplace.

X

Check knife gate
seals

Assure that all seals are in good condition and notworn, split or damaged.

X

Check knife gatepacking

Check packing for wear and leakage and repack asnecessary.

X

Check airlines andfittings

Inspect airlines for any deterioration, check fittings forcracks and leaking.

X

Check bolts

Check and secure all flange bolts.

X

Check in-line gauze
filterCheck in-line filter for cleanliness and obstructions.
Clean as necessary.

X

Check venturi
nozzle and PRV

Check the condition of the venturi nozzle. Check
operation of the PRV.

Pressure Vessel
Inspection

Inspect the vessel for wear, cracks and/or damage.

X

Full Service and PRV

Conduct a full service on the pump and replace the
PRV.

X

DAILY

WEEKLYMONTHLY

ANNUALLY

X

telephone +61 456 000 665
email info@solidsvac.com
page 22

JOB SAFETYANALYSIS
Note: It is recommended that a site-specific JSA is conducted prior to operation of the unit.

www.solidsvac.com

page 24JOB SAFETY ANALYSISSOLIDSVAC SV200-SPDK SLURRY PUMP
Date Of Audit – June 2016.
Equipment/Task: Set-up and operate Solidsvac Solids/Slurry Pump.
Note: Site Safety requirements MUST be adhered to at all times. Personal Protective Equipment including approved safety eyewear
and hearing protection are to be worn at all times whilst operating this equipment.

STEP #JOB STEPSHAZARDS/WHAT CANGO WRONGCONTROLS & RISK REDUCTION

1

Siting the pump.

The pump may beunstable.

Site the pump on a reasonably flat, level& stable surface, or on a suitable straddle
frame.

Connecting discharge hose range to pump.

(a) Use of inappropriate
non pressure rated
discharge hose, hoseor couplers may cause
discharge hose range
failure.

Ensure minimum 2” discharge range isused rated to 10Bar. Hose may be rubber
or poly. The pump utilises the camlock
coupling system. Use Solidsvac supplied
FRAS rubber Stainless Steel camlock ended
pressure rated hose ass’y to enable safe
connection.

(b) Sharp bends, teepieces and valves ina discharge line cancause blockages.

Ensure discharge hose range has no
sharp bends or tee pieces and is free ofrestrictions such as reductions in hosediameter or gate valves etc.

(c) Discharge hose
range may moveparticularly atdischarge exit point.

Ensure discharge hose range is secured
at appropriate points along its length andparticularly at discharge exit point.

Connecting the suction hose to the pump.

Sharp bends, teepieces and valves in asuction hose can cause
blockages.

Wear eye and hearing protection. Holdhose firmly. Ensure suction hose range has
no sharp bends or tee pieces and is free ofrestrictions. Ensure suction hose couplings
are correctly engaged and have safety
clips fitted.

Connecting the air supply hose to the pump. Air
hose should be blown clean before connection.

(a) Compressed air
can be dangerous
and may cause injury.
Blowing air supply hoseclean can cause eye,hearing or physicalinjury if not carried out
in a controlled manner.

Ensure air hose is turned off completely
and that the pump air inlet ball valve isclosed before connection.

(b) Air supply hose can‘fly off’ if not properly
connected.

Ensure air line couplings are correctly
engaged and have safety clips fitted.

2

3

4

telephone +61 456 000 665
email info@solidsvac.com

page 25JOB SAFETY ANALYSISSOLIDSVAC SV200-SPDK SLURRY PUMP
Date Of Audit – June 2016.
Equipment/Task: Set-up and operate Solidsvac Solids/Slurry Pump.
Note: Site Safety requirements MUST be adhered to at all times. Personal Protective Equipment including approved safety eyewear
and hearing protection are to be worn at all times whilst operating this equipment.

STEP #

5

6

7

8

JOB STEPSHAZARDS/WHAT CANGO WRONGCONTROLS & RISK REDUCTION

Pump Operation – Unblocking Suction Hose or
Suction Wand.

Reverse flushing ofsuction hose or suction
wand nozzle with highpressure water hose
can result in eye injury.

If disconnecting suction hose or suction
wand – stop the pump. Wear approved
eye protection.

Pump Operation – Unblocking Discharge Hose
Range Blockages.

Pressure in discharge
range has potential tocause eye and physicalinjury.

STOP THE PUMP. DO NOT DISCONNECTANY DISCHARGE HOSE RANGECOMPONENT WHILST PUMP IS
OPERATING. Depressurise the dischargehose range by operating a manualpressure relief valve on the pump orwithin the hose range (if fitted) OR, using
EXTREME CAUTION, loosen hose couplings
upstream of the estimated blockage point(i.e. between pump and blockage) to safely
vent residual pressure before attempting tofully open hose joints to clear the blockage.

Pump Operation – Discharge Hose Range Exit
Point.

Injury can be caused byhigh velocity material
ejected from discharge
point.

Do not stand in front of the discharge hose
range exit point. Minimise risk by directing
this point away from traffic zones. Use
Solidsvac supplied Dead Head/Drop Box
to reduce velocity & control material atdischarge point.

Disconnecting Pump from Air Supply.

Injury may result fromuncontrolled whippingof pressurised air hose.

Before disconnecting air hose isolate it
upstream & open the Pump Air Supply Ball
Valve to release residual pressure from theair line.

www.solidsvac.com

page 26

Model Number
Serial Number
Date of Manufacture
Inspected by

U1/ 5-7 Boeing Place - Caboolture - QLD 4510 - Australia+61 456 000 665 / info@solidsvac.com
www.solidsvac.com