Aussie ups the pressure

Australian Pump Industries is well known for their design and building of top-quality pressure cleaners for the mining industry. Their Mine Boss range is popular because of the extra effort the company’s engineers put into the design, safety and efficiency features.

Aussie Pumps, as they’re colloquially known, work hard to collect data from mine sites about the operating conditions and are always ready to listen to experienced folk who are at the cutting edge of using the equipment. Their designs have proven to be more user friendly and safer because of the extra care and attention working with operators on a direct basis.

“We get that information, not only for Australian mining customers but also from outside Australia as well. Getting feedback about our Australian designed products from South America and even as far away as Mongolia, provides us with inspiration and ideas,” Aussie Pumps Chief Engineer John Hales said.

Hales explains how the company’s market feedback, mixed with the latest knowledge of developments overseas, helps to keep them ahead of the game.

“Our job is to serve the customers and that’s where the real inspiration comes from,” Hales said.

AUSSIE’S 7,000 PSI RAPTOR MKII

Aussie’s Raptors use ‘Big Berty’ Bertolini heavy duty triplex pumps with 316 stainless steel heads.

“We chose these pumps because of their quality and care the Bertolini team put into designing and building of the product. After testing other first world brands, we found Bertolini understood that investing more into preventative failure design, extends life dramatically. The big 316 stainless steel heads on the pumps provide great strength to maximise chemical resistance in any 7,000psi application,” Hales said.

Their stainless steel check valves have undergone special thermal treatment that increases life. They are mounted in axial position to ensure the maximum volumetric efficiency. Bertolini also use the highest quality ceramic pistons, fixed without screws with their innovative ‘interference’ system.

These premium features are also contributing to the way the Aussie machines last decades of use if properly maintained.

“We’d rather spend a bit more money on the pumps to provide substantially longer pump life for the user,” Hales said.

Another classic example of the Bertolini difference is the big finned crank cases that run cooler because of their higher volume capacity and multiple fin design.

RAPTOR EVOLUTION

The first Aussie Raptors were big machines built into heavy duty hot dipped galvanised steel frames, powered by Yanmar TNV water cooled diesel engines. They used Bertolini 500 bar pumps with tooth belt drive.

“The machines are a splendid example of taking mining and quarry applications seriously. On the other hand, they are big, heavy and expensive, even though they are fitted all the standard Aussie Mine Boss features. We had the idea there would be a lot more 500 bar, 7,000 psi applications in mining, marine and commercial applications. There was a problem with what amounts to being a cost/price hurdle,” Hales said.

“Customers that bought 5,000 psi Class A pressure cleaners, Aussie’s Predator A model, had good experiences, especially if the machines were fitted with the Aussie turbo lance. That increased performance. The effective working pressure (EWP), with 5,000 psi turbo, provides the ‘whack’ of up to 8,500 psi. That’s a calculated figure, rather than a measured pressure.”

The company reasoned that there were applications where 7,000 psi (500 bar) should be applied to get the job done faster with an emphasis on safety.  The result was a Raptor Series II that are lighter and more compact while still having the ability to deliver that same ‘whack’ that Hales referred to earlier.

The new Mark II machines, instead of being built into huge cumbersome frames, come in Aussie’s stainless steel Scud design. They are fitted with air cooled petrol or diesel engine, gearbox drive from the engine, directly to the big 500 bar pump and compact, just like the end of the production run shown in the photo.

“We didn’t only reduce cost, but we also were able to deliver these 500 bar machines in a form that enables prices to come tumbling down,” Hales said.

Aussie Pumps research reveals that in a number of applications, particularly in mining and quarry chores, cleaning can be done more efficiently and substantially faster by using these lighter, more mobile machines.

“The Raptor Series II offer the same series of high pressure Bertolini pumps but by reducing the horsepower and the flow rate, we were able to deliver Hydro-blasters that provide 16 or 18 lpm at 500 bar pressure. These machines are Class B units, therefore operators need to be properly trained by a Registered RTO in line with the Australian Standards ruling,” Hales said.

Aussie has taken substantial steps to make the machines as safe as possible for the operator and to prevent any malfunction of the machine itself.

“For example, we use the very best in terms of accessories.  The heavy duty guns we use with these machines are rated to up to 7,300 psi. We even have heavy duty stainless steel German made turbo gun kit that boosts EWP to 12,000 psi. So, instead of paying $50,000 for a heavy duty machine, much the same effect can be achieved with a machine that comes in at a substantially lower price,” Hales said.

SAFETY ASPECTS

The machines all feature hose restraints, emergency stop, battery isolation and fire extinguisher. Additionally, the company has taken steps to make sure the user is well aware of the safety clothing available as part of Aussie’s TST range of overalls, jackets, boots, gloves and helmets that are part of their 500 bar protection kits.

“We’ve seen a big trend towards pressure cleaner safety over the last decade,” Hales said.

Aussie Pumps has played a major role in promoting their ‘Safe Operator’ Training Program for high pressure cleaner operators.

“It could be argued that 500 bar is more dangerous than 350 bar. In the hands of the untrained operator, both models, Aussie’s Predator and Aussie Raptors II machines, could be equally lethal,” Hales said.

GET THE JOB DONE FASTER

Efficiency equals cost reduction. Everybody in mining knows that.  Moving to higher pressure with these more versatile, smaller mobile units means the task can be carried out more promptly and efficiently and in a more convenient way.

“We’ve even heard stories about Raptors being used to clear blocked drains in mine processing functions. That makes sense but the right pressure equipment needs to be used so that rodding becomes obsolete in the future, replaced by flexible high pressure 500 bar hose assemblies, using Aussie’s pressure propelled nozzle components. We are working on that now,” Hales said.

Aussie Pumps is a member of the US Water Jet Technology Association, based in Missouri. They get a lot of good ideas from their American cousins, but at the same time, sometimes are astonished at the apparent advantage Australia appears to have in terms of safety precautions to keep both operator and machines from harm.

AUSSIE DOUBLES PRODUCTION

“Now that we have finalised the first runs of Raptor II, we will see a wider use of this level of pressure but operated by technicians that are aware of safety precautions that need to be taken, but also understanding exactly how the machine works so there is a clear understanding from a total perspective,” Hales said.

The Raptor II series adds to the major impact that Australian Pumps had on pressure cleaning for the mining industry. The Mine Boss existing range, using either petrol or diesel, matched to Bertolini pumps with slow speed gearbox drive, has had a significant impact on washdown efficiency.

“Driving the pressures up is not just about a number on a piece of paper, but rather, about the impact and the savings made, in terms of getting the job done faster. Even exploring new applications that can take advantage of this advance in Australian pressure cleaning manufacturing technology,” Hales said.

Aussie knows they’re ahead of the rest of the game in Australia but keep their eyes open from Europe and the USA. Even there, they seem to be edging ahead, mainly driven by the influence of customer feedback, as well as their desire to bring efficiency, matched with safety to the industry.

Australian mines are realising that high pressure water Jetters can play a vital role in so many different applications in the field. These range from maintaining minor accommodation sewer lines to restoring process pipes.

Further information, including details of Aussie Pumps free safety training program, Aussie Safe Operator, and a range of trailer mounted mine Jetting equipment is available from aussiepumps.com.au