Client: Big Mining Company
Project: Vault Gate Mechanism Upgrade & Automation
Provider: HWC
Key Focus: Working at Heights Safety Elimination, System Automation & Operational Efficiency
HWC successfully engineered and deployed a custom hydraulic actuation solution to upgrade a vault gate mechanism for client. By replacing manual lever mechanisms and swing arm pulley systems with hydraulic actuators, the site eliminated the need for Working at Heights permits during gate operations while enhancing precision and operator safety.
The Challenge
The existing vault gate setup relied on a manual upper pin lever mechanism and a swing arm pulley system. Operating this system presented two main issues:
Safety Risks & Permit Overhead: Operating the upper pin required personnel to work at height, requiring a Working at Heights permit for standard operations.
Manual Effort & Precision: Aligning pins manually with a pulley system was labour-intensive and lacked fluid operational control.
The HWC Solution
HWC designed and implemented a hydraulic actuation system controlled via a remote, panel-mounted two-lever manual control valve, powered by a remote Hydraulic Power Unit (HPU).
Key Technical Features
Hydraulic Actuation: Replaced the upper pin lever and swing arm pulley with dedicated hydraulic cylinders, eliminating high-access manual Labor.
Overpressure Protection: Built-in inlet pressure relief valve set at 160 bar within the control valve bank to protect the system regardless of which HPU is connected on-site.
Flexible Mounting & Custom Piping: The control valve panel can be mounted based on site supervisor requirements. Ports (A & B) feature hard-tubing to flexible soft-hose connections tailored to site geometry.
Poka-Yoke Couplers: Supplied male/female quick-coupler pairings to match host HPU connections, preventing incorrect line hook-ups (P & T).
Customizable Valve Labelling: Directional and function labels are applied on-site based on preferred operator ergonomics and piping layouts.
HWC developed a streamlined commissioning sequence to ensure zero downtime and peak reliability:
- System Flushing: Oil is circulated through P & T lines prior to valve connection to ensure fluid cleanliness.
- Pressure Optimization: Main relief valve pressure is set incrementally to 15\% above the minimum required pressure to lift the door, reducing unnecessary mechanical stress.
- Air Purging & Testing: Full operational cycles purge trapped air and verify leak-free seal integrity before handover.
- Feathered Precision Control: Micro-positioning allows operators to slightly open the pin lever, so the pin smoothly drops into alignment as the door swings into position
ROUTINE MAINTENANCE
Keep the HPU well maintained as per HPU OMM and ensure quick connect couplers are always covered with supplied dust plugs and free of any dirt before hooking up. After hooking up allow oil to circulate through the valve before operating actuators.
