martin kime, metropolitan mine peabody energy
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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
Stables
Pre 1950
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
Innovations
11
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 3 OK 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 45 Won'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 5.5 Ok
1 Face DCB 9.1 1.25 1 9.5 Ok
1 CME 2.5 1 1.3 5 Ok
1 AFC motor Ok
Pumps 2 Pump module 4.5 1.31 1.4 5.2 Ok
2 Tank Module 4.5 1.31 1.4 8 Ok
1 Dump valve pod 2.5 1.31 1.4 3 OK
31
Analysis Cont
Shearer 1 Main body 8.5 1.8 1.4 36 Too 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 10.5 OK Requires Jig
2 Drum 2 2 0.9 4 OK
Mono rail 10 mono rail pump pods 2.3 1.8 0.8 To Big Reengineered
10 Hose cassette 17.4 2.9 2 6.5 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
45
Manufacture
46
Hosing and Cylinders
47
Skip trial
48
Test silhouette of roof support
49
tight
Tight
Tight
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
60
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
75
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??
78
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