Published on July 22, 2014
Martin Kime GLWPE Long Wall Conference Monday 14th of October Metropolitan Replacement Long Wall Installation and Innovation
2 Metropolitan Mine Background • Operations constrained by geography & the vintage of facilities - located in residential area • Large Central Lease (60Mt) area has remained unmined due to geological features restricting access • Central Lease Area development (Part 3 Approved), provides opportunity to continue mining & expand • Metropolitan Colliery is located in the Southern Coal fields of New South Wales, Australia • Production began in 1888 at Metropolitan Mine and has operated for 125 years
Metropolitan Mine Plan 3 ● Most of future mining under Sydney Catchment Authority ● New JOY Longwall Mining equipment will commence within the Reservoir Notification Area (LW 23a) ● Metropolitan Exports Metallurgical coal via Port Kembla ● Currently mining LW22b
Mine site 6
Proximity to township of Helensburgh 7
Southern Coal Fields – New South Wales 8
Metropolitan Project ● Metropolitan gained Peabody capital approval to undertake modernization of its infrastructure and to increase production capacity. The project focused on 7 elements to modernization. Todays presentation will focus on – the replacement of the existing Longwall with a JOY state of the art Long wall, – safety initiatives – engineering design and functionality improvements. – delay in drift completion and alternate transportation arrangements and engineering challenges 9
Replacement Long wall ● The replacement Long wall was to be transported via the new drift as part of the Metropolitan expansion project ● JOY were successful in winning the Turn Key contract to manufacture and supply – 89 1.75m roof supports (Alternate testing Protocol used) – AFC and BSL – 7LS2a Shearer (Landmark, cowl less) – Macquarie Manufacturing Monorail – Inhoxihp pump station - monorail mounted – Ampcontrol Electrics and lighting system 10
Man Down Technology ● The Metropolitan Contract was specific in relation to the man down protection in the shearer controller and required JOY to supply shearer remotes with the technology. ● During the process Metropolitan drove the compliance to Australian standards and required functionality between the remote, shearer and roof supports. ● Final product is a credit to JOY and the Project Team 12
UPS backed Lighting ● Project team wanted to improve the lighting in and around the longwall during maintenance periods and loss of power events. ● A plan was developed to utilize Led lights supplied from Uninterruptable Power supplies from the TG roof supports to MG Corner and MG Corner to the Freek Station (First Response Emergency Evacuation Kit) (CABA) ● Each UPS supplies 4 Led lights for approximately 10 hours operation. Benefits – In the event of emergency Lighting will remain on – Permanent lighting during Maintenance activities – Permanent lighting during breakdowns 13
Outbye lighting layout – 41 ups supplied lights between sub and MG, UPS backed light on every roof support 14
Roof support Testing Protocol ● Pat Solars Twenty Mile underground General Manager developed a strenuous testing protocol after dealing with significant engineering failures of Twenty mile roof support bases. ● The testing protocol was focused around the inclusion of blocks to simulate the maximum amount of transverse and longitudinal camber (manufacturing tolerances) allowed by the OEM during manufacture of the base and canopy. The testing cycles were also increased to 70105 cycles. ● The Metropolitan roof support was designed and manufactured to meet the stringent testing protocol. ● The roof support passed the testing protocol with minor issues during testing; 90k cycles were completed without a failure that would result in the roof support experiencing a catastrophic failure over its intended design life. 15
Testing Requirments 16
Roof support Tip Pressure ● Metropolitan currently run combination of 1.5m Metropolitan shields and 1.75 ex Shoeshone shields. ● The existing shields are rated at approximately 800t and Metropolitan do have significant strata issues due to the lack of support density the shields are providing ● The opportunity to increase the roof support density was a welcome relief; the roof supports were specified to provide Yield – >115t/m2 before the cut; ● During Front End Engineering it was identified that the Gate End roof support density had decreased from the 115t/m2 required. ● The project team provided guidance and instruction to add an additional Compensating cylinder on the gate end supports, this increased the tip pressure from <12t/m2 to >20tm2 and allow the gate end supports to meet the contracted rate of 115t/m2 17
Double Compensation cylinder – gate end 18
Transportation of the New Longwall ● The expansion project at Metropolitan included the excavation of a new Man, Material and belt access Drift. This was to be the transport route to the underground workings for the new longwall. ● The drift project was post poned at the 562m mark until further notice. ● A detailed analysis of the available options to transport the LW underground was conducted; identifying 7 possible opportunities ● The safest, Cost effective and least disruptive to the day to day operations was to transport the new long wall via the existing man and materials winder. ● The following slides identify safety, productivity and engineering challenges to transporting the long wall undergound via the man and materials winder. 19
Man and Material Winder ● The second hand man and material winder was installed at Metropolitan in 1954, it is currently running under and exemption from the NSW Department. ● Peabody Energy has committed to the purchase of a new winder to replace the aging plant. Challenges ● Remediation work Rail line ● Winder access dimensions 20
Current Risks LONGWALL Issue • Maintaining schedule of longwall equipment transport over and above regular operational activities Mitigation • Weekly operational transportation meeting to focus on objectives • Underground track repairs completed • Specialist transportation equipment manufactured for ease of haulage. Low loader successfully run into mine with PRS base • Just in time delivery of equipment to surface to lessen burden on yard 21
Rail Remediation work – replacement of old rail. ● Track being broken up ready to lift 22
Each old rail was lifted and replaced
Broken end found during remediation work
Track being reinstalled with new sleepers
Track being ballasted
Winder Window ● The winder portal has height, width, length and weight limitations ● Due to the limitations of the portal an analysis of the new long wall equipment was completed identifying the plant that would be required to be modified, disassembled, or built underground. ● Equipment in Orange has been modified 27
Winder Window 28
Analysis New Joy Longwall dimensions and weight QTY Description Length Width Height Weight Comments Action AFC 80 Pan 1.75 2 1.25 3OK N/A 1 M/G croner 3.7 3.6 1.55 30 Won't fit in current drift, this item does not lend itself to being cut down Re-engineered and costed 1 T/G tensioner 6.1 3.15 1.1 20 Won't fit in current drift, Base plate to be cut in half, and re attached U/G Re-engineered and costed 1 Ramp pan 4.3 3.1 1.55 12 Won't fit in current drift, could possibly be cut down, have not fully discussed with Joy this option, could be be modified to be half width and either be bolted or pinned together, extra cost Re-engineered and costed 5 Re-router pan 3.6 3.1 1.25 10 Won't fit in current drift, could possibly be cut down, have not fully discussed with Joy this option, could be be modified to be half width and either be bolted or pinned together, extra cost Re-engineered and costed 8 Chain bin 5 1.4 1.8 8 Approximate values Would need to have special bins made up, and then would need to look at handling options with longer lower bins, what machines do we have to this with. Maybe a low loader flat top Re-engineering Required 29
Analysis Cont BSL 1 Ramp pan OK 1 Crusher 4 2.8 1.9 Ok 1 Delivery OK 1 convex OK 1 concave OK 1 Straight OK 1 mini pans OK 1 Boot end 8 3.2 1.4 OK 2 Chain bin 5 1.5 1.8 8 Approximate values Would need to have special bins made up, and then would need to look at handling options with longer lower bins, what machines do we have to this with. Maybe a low loader flat top Further Revew required 30
Analysis Cont Roof supports 77 Run of Face 7.1 1.7 1.8 30 Won't fit down current drift, over weight and too high Will need a low loader flat top, and do something with the weight issue Canopy must come off special Low loader required 10 Gate end 7.5 1.75 1.8 31 Won't fit down current drift, over weight and too high Will need a low loader flat top, and do something with the weight issue Canopy must come off special Low loader required 2 Transition shields 7.9 1.7 1.8 31.5 Won't fit down current drift, over weight and too high Will need a low loader flat top, and do something with the weight issue Canopy must come off special Low loader required Electrics 1 Tx 10 3.55 2.2 45Won't fit down current drift Must be stripped, transported and assembled again underground, special low loader required 1 Pump DCB 4.5 1.1 1.35 5.5Ok 1 Face DCB 9.1 1.25 1 9.5Ok 1 CME 2.5 1 1.3 5Ok 1 AFC motor Ok Pumps 2 Pump module 4.5 1.31 1.4 5.2Ok 2 Tank Module 4.5 1.31 1.4 8Ok 1 Dump valve pod 2.5 1.31 1.4 3OK 31
Analysis Cont Shearer 1 Main body 8.5 1.8 1.4 36Too heavy to go down current drift Component Weights and sizes have been calculated will require stripping 2 Ranging arm 3.1 1.7 0.9 10.5OK Requires Jig 2 Drum 2 2 0.9 4OK Mono rail 10 mono rail pump pods 2.3 1.8 0.8 To Big Reengineered 10 Hose cassette 17.4 2.9 26.5 tare Won't fit down current drift Two cassettes in line to accommodate the length of hose required Reengineered 32
33 Roof supports ● The roof supports were manufactured with the intent to install underground as a fully assembled tested and fit for purpose plant. ● Engineering review identified – Roof support collapsed 1850mm – Canopy removed 1750mm – Frames required to ensure the canopy can be transported underground – Risk Analysis and Safe Work Procedures developed – Low Loaders engineered and manufactured for the Base – Underground crane purchased and installed
Nice New Roof supports 34
What we have to do to them 35
Trials strips completed and SWP developed 36
Procedure in fast forward 37
Procedure in fast forward 38
Procedure in fast forward 39 Position canopy on frame
Procedure in fast forward 40 Base ready for transport to site.
Canopy frame design and manufacture ● Transport frame design Considerations – Remain lower than drift access portal – Must be able to be transported by the underground battery hauler and be positioned over the body of the machine. ● Final Design – 2 Piece design – Winder frame – carries all components and is lower than 1.45m – Battery hauler transport plate, locating lugs and securing points for the winder frame – bottom of the canopy must be higher than 1.6m. – Must be able to handle the braking force in event of winder emergency stop. 41
Final Canopy frame 42
Canopy Frame includes the side shield 43
Roof support Base Transport ● Conceptual design and functional requirement agreed upon at site ● Engaged Reliance Hexham to complete final engineering and detailed design of the low loader skip ● Restrictions – Maximum radius of rail – Off camber sequential changes in rail height and angle – Drift has to locations where it flattens and then rolls over causing clearance issues to the bogie floor and roof support to roof – Weight – drift Max 22t 44
Hosing and Cylinders 47
Skip trial 48
Test silhouette of roof support 49
Touching but will only scar one shield
First trial Skip first trial on site was empty – we did not get past the first turn on surface - Derail – Jack hammer concrete 54
Second Trial ● Skip second trial – derail – Increase articulation of bogies 55
Success Third Trial – Pit Bottom reached Empty 56
First Trial entering drift loaded
Shield at lowest travelling height
Shield arrives pit bottom – Relief
Underground Crane workshop ● To enable the roof supports to be reassembled underground an underground crane workshop was built with a 25tonne crane concrete flooring. ● Process – Excavate crane workshop to 8m high and support – Secondary support installed – Installation of crane frame no ground mounted pedestals – Concreted floor level – Wall Cranes installed to assist in the handling of the 160kg pins – Ventilatation fans installed to allow for welding and other site works. 61
Underground Crane workshop 62
UG Workshop construction by mine
Assembly of Roof support ● Once the roof supports are underground they are moved into the underground crane workshop and reassembled following detailed Safe Work Procedures ● Disassembly = 4.5 hours, position canopy and secure on frame. ● Assembly = 2 roof supports on day shift, 1 on afternoon shift and setting up another 2 supports ready for day work. 64
AFC and BSL ● The AFC and BSL was identified as requiring modification post mandatory drawing signing, luckily prior to manufacture identified changes – Ramp pans separated from bed plate – TG sliding module and drive module bed frame split. – Crusher requires rotor and base plate to be split and transported seperately – MG Drive base split into 2 – Ramp pan split – Boot end will stripped into 4 discreet components 65
AFC Transport Sizes
AFC Transport Sizes
Crusher Transport Sizes
Boot End Transport Sizes
Transformer ● Ampcontrol 4.5mva transformer will be required to be fully stripped – Remove low and high tension end enclosures – Remove transformer tank – Remove tracks ● The transformer tank will be transported on a specifically manufactured low loader. 70
Transformer dimensions 71
Monorail – Concertina sections delivered straight to site in discreet components and assembled underground – The transportation sleds were designed to transport the trolleys, drives and sleds underground. – Suitable 160m heading identified and monorail hung for the assembly of the monorail underground. 72
Monorail sled base 73
Drive Transport Sled 74
Shearer ● Shearer chassis weighs 31.1tonnes without Ranging arms (to be transported separately) ● Remove – Down Drives – 4.3 t – Sloughing Plate – 1.5 t – Ranging arm cylinders - 1.6 t – Faceside beams and skid shoe – 0.5 t ● Shearer will then be approximately 23 t, we will then continue to strip until the machine weighs in at 22t. 76
“A carelessly planned project takes three times longer to complete than expected; a carefully planned project takes only twice as long 77 When presented with a challenge look at it as an opportunity to change others attitudes and expectations. Thankyou for your valuable time! Questions??
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