SOLIDS PUMPING SYSTEMS

SV440-CVCD Operations Manual

U1/ 5-7 Boeing Place - Caboolture - QLD 4510 - Australia+61 456 000 665 / info@solidsvac.com / www.solidsvac.com
ISSUED DATE - 010124

V 1.4

LAST REVISED - 010124

CONTENTS
Description

Page

Safety First3

1. Operation Overview

3

2. Design Registration

3

3. Technical Data

4

4. Schematic

55. Pump Set-Up

7

6. Operation, Timer Cycling & Adjustments

8

7. Maintenance9

8. Accessories

13

9. Operation Risk Assessment

14

10. Spare Parts

22

11. Job Safety Analysis

30

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
SV440-CVCD. To prevent injury to personnel or equipment damage, this manual MUST be read and understood by those responsible
for the 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

Height1600 mm

63”

Width

1270 mm50”

Length2010 mm79”

Weight950 kg2094 lb

Air inlet

50 mm

2” BSP/NPT

Suction inlet

100 mm4”

Discharge outlet

100 mm4”

11.5 m @ 330 cfm
25m @ 380 cfm
35m @ 600 cfm
6.5m3/Min JetPack & 2.8 m3 /Min Discharge
10.7 m3 /Min Jetpack & 5.6 m3 /Min Discharge
16.9 m3 /Min Jetpack & 5.6 m3 /Min Discharge

37' 7" @ 330 cfm
57’ @ 380 cfm
88’ @ 600 cfm
230cfm Jetpack & 100cfm Discharge
380 cfm Jetpack & 180 cfm Discharge
600 cfm Jetpack & 180 cfm Discharge

Delivery

500+ m1640+ ft

Displacement cycle

420 ltr

34 galOperating pressure

7 bar (Required) @ 690 kPa

100 psi (Required)

Unit Requirements

15.8 m3 /Min or 22.1 m3 /Min

560 cfm or 780 cfm

Maximum solids

80 mm

3”

Water throughput

1000 lpm (380 cfm)

264 gpm (380 cfm)

Suction lift
Air consumption options

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page 4

4. SV440-CVCD SCHEMATIC

12
3 1 5

2
4
14 12
4

3 1 5

2
14 12
4

3 1 5

2
14

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page 5

SV440 CONTROL AIR AND DRAIN

4

2

5 1 3

4

2

5 1 3

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page 6

4. DESIGN REGISTRATIONThe Solidsvac SV440-CVCD has a Certificate of Plant Design Registration from Workcover NSW, Australia. A copy ofwhich 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 SV440-CVCD can operate within environments ranging from 0 °C to 50 °C and all humidity.
The maximum medium temperature allowable for the SV440-CVCD 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 7

5. PUMP SET-UP
Before commencing operation, Solidsvac strongly recommends each user reads and understands the Operation Manual suppliedwith each unit and available online or via the QR code on each pump.
Note: Minimum training is required to operate the SV440-CVCD however, it is essential for the safe operation of this equipmentthat the Operator has read and understands the SV440-CVCD Operation Manual.
Solidsvac also recommends that a site-specific Risk Assessment (RA) and Job Safety Analysis (JSA) be undertaken prior to thecommencement of any works involving the Solidsvac.
Any recommendations arising from these should be considered additional to these:-

The unit and all hoses and fittings are in good working order and fit for purpose.

-

The source of compressed air is sufficient in both volume and pressure.

-

The correctly rated compressed air supply hose is used (50mm or 2" ID)-

All equipment covers are correctly fitted and properly secured.

-

The Discharge Hose is adequately secured to prevent "hose whip".

-

The Discharge Area has both barriers and signage in place to protect personnel.

-

The Discharge Area has suitable warnings to protect personnel.

-

The correct PPE is available and worn by the operator- 2 Eye Protection- 2 Hearing Protection- 2 Gloves- 2 Safety Boots-

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

-

Attach both the suction and discharge hoses along with any accessories in use and ensure all safety clips are in place.

Note: If a flexible Discharge Hose is to be used, it MUST be secured at regular intervals to prevent "hose whip".
-Attach the compressed air supply line to the pump and fit the appropriate safety clips.

-

Ensure the Main Air Supply Valve is in the "OFF" position, turn the compressed air supply valve on at the source.

-

Ensure the frame is adequately earthed.

-

The pump is now ready for use.

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page 8

6. OPERATIONWith the Suction hose out of the material to be conveyed, turn the pumps Main Air Supply Valve "ON". The pump will commence
operation.
Note: Dry operation will not damage the pump.
With the system energized and the unit cycling, check both pneumatic gauges and ensure the correct pressure is available tocommence operations. The Primary Gauge indicates the working pressure and should indicate approximately 7 Bar, or 100psi isavailable. The smaller Secondary Gauge indicates control system pressure and MUST always remain above 5.8 Bar or 85psi, when
operating.

LOAD TIMERS
The Load and Discharge cycles are controlled by adjustable 0-30 Sec pneumatic timers located within the control box. Due to thecontinuous system of the SV440-CVCD the pneumatic timers MUST be set at an equal setting (i.e., 5/5 or 10/10 etc). The load cycle will
determine the overall setting for the timers, therefore if optimal load time is 5 seconds, then discharge time will automatically be set to
5 seconds.
Solidsvac recommend that the operator allows the pump to cycle twice prior to transferring material to ensure all aspects of thepump set-up are functioning correctly and safely. It is advisable to introduce the Suction Wand (if fitted) or Suction Hose to thematerial to be conveyed for an initial single cycle and observe that all aspects of the pump set-up are functioning correctly and safely.
If no adjustments are required, commence continuous pumping operations.
IMPORTANT: TIMERS ARE REQUIRED TO BE ADJUSTED TOGETHER EQUALLY.

PNEUMATIC GAUGE CONTROLSThe SV440-CVCD is fitted with 2 pneumatic pressure gauges to ensure the operator has a correct reading of control and operational
air pressure. A small, mounted gauge ON the control box will display the regulated air for all controls running at 586kPa (85psi).
The second pressure gauge is mounted on the exterior of the control box and displays the working pressure of the pump. This gauge
will only show the operational air pressure at the pump, this is not to be assumed as the pressure output of the compressor. Solidsvac
recommend checking the compressor's gauge to obtain a reading.

CONTROL BOX
NEUTRAL POSTIONCONTROL BOX
OFF POSITIONCONTROL BOX
ON POSITION

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page 9

7. MAINTENANCE
The Solidsvac SV440-CVCD generally require a minimum of maintenance although
Solidsvac recommend the following be adhered to as a minimum:

DAILY:-

Check that all fittings and connection are serviceable.

WEEKLY:-The unit’s auto drain filter be inspected and cleaned as required.

-

The exhaust box be inspected and cleared of any carry over material.

MONTHLY:-

Carry out both the daily and weekly maintenance requirements.

-

	Using “service air only”, and with NO HANDS WITHIN THE UNITS VALVE ARRANGEMENT cycle the unit and carry out a visualinspection of the valve linkages.

-	In very harsh environments, a spray of CRC penetrant or similar is recommended.

SERVICE AIR:-

It is recommended that only service air is used when performing maintenanceon the pump.
(That is air plugged in to the pneumatics not through the air manifold or venturi.)

A service air connector will be provided with any unit service KIT and upon request.

MAIN AIR FILTER
The main air filter is located against the control box and is self-draining, however it should be inspected weekly.

EXHAUST BOX
All CVCD variants are fitted with an exhaust box located in the front of the unit. The exhaust box can be accessed for cleaning by
removing the top lid. Hosing the exhaust box will ensure debris is free from blocking the exit vent. Blocking of the exit vent and exhaustbox in general will reduce vacuum performance.
The SV440-CVCD is fitted with 316 stainless steel deflector plates to improve pumping efficiency. Solidsvac recommends to inspect
and clean the exhaust box assembly after each job.
All CVCD variants are fitted with a drain valve located underneath the exhaust box. The drain valve can be operated on the control box(see page 8.)

EXHAUST BOX
DEFLECTOR PLATESEXHAUST BOX
DRAIN LOCATION

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page 10

MAINTENANCE CONTINUED...
In use, the Solidsvac SV440-CVCD requires little to no maintenance, however Solidsvac recommends that the following strict measures
are taken to ensure the pump remains in good working order.
Maintenance, repairs and the disassembling of the unit be carried out by any authorised personnel.

SERVICE TIPS-

Set up a maintenance schedule and follow it diligently.

-

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.

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

SYSTEM PERFORMANCE
Pneumatic problems that affect system flow and pressure are not always easy to locate. The system testing procedure described laterin this section is based on a useful step-by-step approach to troubleshooting. Troubleshooting charts make the fault-finding processeasier and faster.

EFFECTS OF A DROP IN SYSTEM FLOW RATE-A	 pressure drop will affect the speed and cycle times of a pneumatic machine; actuators will not extend, retract, or rotate at
the required speed. Actuator control will become jerky with inconsistencies in flow as cylinders and motors are supplied at
different rates. In many complex pneumatic systems, the sequencing and positioning of component operations will be affected
as cycle times become thrown out of programmed control.

- he compressor's discharge flow rate should be checked first to ensure that the drop in flow is not a problem of internalTleakage or incorrect setting of compressor controls.

EFFECTS OF DROPS IN PRESSURE
The major causes of pressure drop include:-

Pipework restrictions (for example, incorrect sizing) fitting restrictions and sharp corners-

Incorrect pressure settings-

Sudden enlargement in fluid conductors-

Long lengths of fluid conductors-

Component leakage (internal and external)-

Broken valve springs-

Blocked or crimped air lines-

Loose fittings-

Valves not sealing correctly because of contaminants-

Some combination of the above causes

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page 11

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.
Note: 99% of all issues are air supply related.

SAFETY FIRSTTHE SV440-CVCD MUST BE ISOLATED FROM ITS AIR SUPPLY AND TESTED
DEAD PRIOR TO ANY MAINTENANCE WORK BEING UNDERTAKEN.
FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

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page 12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-

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 seal or components (take photos)-

Use caution with compressed air-

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

page 13

8. 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 a wide range of sizes and attaches to the suction
hose to prevent 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 long whenusing 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.
Service Kit - Contains all you need for basic maintenance on your pump.

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page 14

OPERATIONAL RISKASSESSMENT

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page 15

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 SV440-CVCD Solids Pump is designed to be used in a coal mine for the purposes of pumping slurry/fluids. The Solidsvac
SV440-CVCD 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 SV440-CVCD 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.)As		 per the instructions in the manual all personnel responsible for the installation, operation or maintenance of theequipment MUST read and understand the manual.

-

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 SV440-CVCD Solids Pump.

EXCLUSIONS:Transporting and storing the Solidsvac SV440-CVCD 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

3

2

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 ground

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

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
tape

Resulting in personal
injury and damage to
the Solidsvac SV440CVCD Solids Pump
during operation

Failure of the correctmanual handlingtechnique

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

Solidsvac SV440-CVCD
Solids Pump set up on
uneven ground or pumpis inadequately secured
to rib when on unevenground resulting in
unplanned movementof pump

Manual handling

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

High pressurecompressed air

Work on or around amoving belt

2

2

2

Operation 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
Fras or bonded hosing used for Suction,
Discharge and Air Supply. Ear bond point
installed on equipment. Fit for purpose.

Resulting in personal
injuryResulting in personal
injury and/or process
delay

Resulting in personal
injury and/or process
delay
Resulting in personal
injury and/or process
delay

Blocked discharge hoseresulting in exposure
to stored energy while
unblocking hose

Blocked suction hoseresulting in process delay

Friction generated static
discharge

Incorrect maintenanceresulting in equipment
failureTested to Australian Standards
OEM Maintenance scheme22

Resulting in personal
injuryPinch points on Solidsvac
SV440-CVCD Solids Pump
during operation

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

Resulting in personal
injuryDischarged material(at 100psi) contacts
operators

3

2

Wheels and handle on the Solidsvac
SV440-CVCD Solids Pump
Designed well balanced
Mine transport rules

Resulting in personal
injury and damage to
the Solidsvac
SV440-CVCD Solids
Pump during transport

Inadequate transport
methodCONSEQUENCE

C

D

C

C

C

C

C

C

C

C

C

LIKELIHOOD

L8

L5

L8

L8

L8

L8

L8

M 13

M 13

L8

L8

L8

RISK RATINGCURRENT RISK WITH EXISTING CONTROLSEXISTING CONTROLSRISK EVENT

HAZARDOPERATIONAL RISK ASSESSMENT

ALARA

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 SV440-CVCD Mobile
Fluids Pump to be included in
the training and assessment
document in the Solidsvac
SV440-CVCD Solids Pump

Maintenance to be carried out as
per OEM Suppliers SV440-CVCD
Operation/Maintenance Manual

OEM recommends a specific Risk
Assessment to be conducted to
identify friction generated static
discharge.

Training and assessment in the
Solidsvac SV440-CVCD Solids
Pump package

Training and assessment in the
Solidsvac SV440-CVCD Solids
Pump package

Training and assessment in the
Solidsvac SV440-CVCD 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 SV440-CVCD
Mobile Fluids Pump

Solidsvac

Delivery

Travel position

Communicate to end user todevelop work procedures fortravelling

Solidsvac

Delivery

Use of Solidsvac
SV440-CVCD
Mobile Fluids
Pump

Supplier to develop work
procedures for operating
the Solidsvac SV440-CVCD
Solids Pump

Solidsvac

Delivery

Daily

Supplier to develop daily
and/or pre-use visual inspections
procedures for using andoperating the Solidsvac
SV440-CVCD Solids Pump

Solidsvac

DeliveryWeeklySupplier to develop weekly
visual, operational, maintenanceinspections for using andoperating the Solidsvac
SV440-CVCD Solids Pump

Solidsvac

Delivery

Maintenance

COMP DATEREVIEW/AUDIT
DATE

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

page 20

PUMP PREVENTATIVE
MAINTENANCE PROGRAM
The following is the work to be performed to a SV440-CVCD 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 bolts and clamps are secure and tight-

Check vessel support frame and wheels for soundness-

Visual inspection of pump for any damage-

Check exhaust box for cleanliness (if fitted)-

Check condition of seals-

Check 2 way ball valve for leakage-

Make sure all timers are operational-

Check operation of Pressure Relief Valve-

Check in-line gauge filter-

Inspect condition of airlines and fittings-

Check operation of swing check valve (if fitted)-

Check condition of venturi nozzle-

Test the operation of the SV440-CVCD 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 ball valve
seals

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

X

Check exhaust box

Check exhaust box for foreign material and clean asnecessary.

X

Check airlines andfittings

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

X

Check bolts

Check and secure all clamps and 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10. SPARE PARTS

www.solidsvac.com

page 23

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

page 24

www.solidsvac.com
page 25

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

page 26

www.solidsvac.com
page 27

www.solidsvac.com

page 28

www.solidsvac.com
page 29JOB SAFETYANALYSIS
Note: It is recommended that a site-specific JSA is conducted prior to operation of the unit.

telephone +61 456 000 665
email info@solidsvac.com
page 30

JOB SAFETY ANALYSISSOLIDSVAC SV440-CVCD SLURRY PUMP
Date Of Audit – June 2020.
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.

JOB STEPSHAZARDS/WHAT CANGO WRONGCONTROLS & RISK REDUCTION

1

Selecting the right pump.

Selecting the incorrect
pump/equipment totransfer media thatis either hazardous
in itself or becomeshazardous whentransferring can result
in delay of operating
and injury.

Site-specific JSA MUST be conducted prior
to operation to identify site-specific media
risks & hazards.

2

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.

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.

STEP #

3

4

Connecting the suction hose to the pump.

www.solidsvac.com
page 31JOB SAFETY ANALYSISSOLIDSVAC SV440-CVCD SLURRY PUMP
Date Of Audit – June 2020.
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.

JOB STEPSHAZARDS/WHAT CANGO WRONGCONTROLS & RISK REDUCTION

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.

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.

7

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.

8

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 thispoint away from traffic zones. Use Solidsvac
supplied Dead Head/Drop Box to reduce
velocity & control material at discharge point.

9

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.

STEP #

5

6

Pump Operation – Unblocking Suction Hose or
Suction Wand.

telephone +61 456 000 665
email info@solidsvac.com
page 32

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