Confederation of Indian “MINING SAFETY” of Indian Industry “MINING SAFETY” Longwall...

Confederation of Indian Industry

“MINING SAFETY”Longwall Technology

Date:

11.09.2015

The Singareni Collieries Company Limited(A Government Company)

B. Bhaskara Rao GM ( I &PM ), SCCL

Longwall Technology

for

Safe underground mining

Adriayla Longwall – a torch bearer

Structure

• Introduction

• Coal mining – an overview

• Safety trends in mining

• Brief on SCCL

• Adriyala Longwall Project – Significance and

experiences.

Mining

Any thing we use – If it is not grown ( agriculture ) it is

Mined

Pre historic Industry – stone age/metal age

Corporate Planning & Projects

3

A natures gift – Geo specific

Major Economic activity – globally : Direct or Indirect- Fuels

economic growth of the nation.

Impact Socio & Political International relations

Yet it is Dirty ,Hazardous & not eco friendly

Mining

•Metal Mining

•Non Metal

•Coal•Non Coal

Corporate Planning & Projects

4

•Coal mining became synonymous for mining

-for its predominant proportion

-risks and safety requirements

-global share in energy …………..

…………..

Global Energy Consumption

� Coal continues to be

Key source of global energy

� Increase from 26 % to 30 %

In 2014.

Source: http://www.euanmearns.com/wp-content/uploads/2014/06/global_energy_2013.png

5Corporate Planning & Projects

� World Coal Production: 7,823 MT

� Major Producers of Coal as on 2014-15:

� PR China 3 561 MT

� USA 904 MT

� India 612 MT

World Coal Scenario

RUSSIA

SOUTH AFRICA

3%

GERMANY

2% POLAND

2%KAZAKHSTAN

2%

India :

3rd place

8.5 % Share

� India 612 MT

� Indonesia 489 MT

� Australia 459 MT

� Russia 347 MT

� South Africa 256 MT

� Germany 191 MT

� Poland 143 MT

� Kazakhstan 120 MT

� Others 740 MT (Source IEA

2014)

RR CHINA

46%

USA

12%

INDIA

8.5%

INDONESIA

5.5%

AUSTRALIA

6%

RUSSIA

4%

6Corporate Planning & Projects

In India

In India

• Disasters in earlier years :

– Inundations

– Explosions

– Fires

27 December 1975: Chasnala Mining disaster due to

inundation, Dhanbad in Jharkand, India, 372 miners

Major Causes of accident:

inundation, Dhanbad in Jharkand, India, 372 miners

died.

• In recent past

– Roof and Side fall

– Haulage

• From the stage of major disasters, accident

trend decreases by various measures.Corporate Planning & Projects 9

Major Statutes that Govern Mines Safety

� The Mines Act – 1952

� The Mines Rules – 1955

� The Coal Mines Regulations – 1957

� Mines Vocational Training Rules – 1966

� Indian Explosives Rules - 1983

� Indian Explosives Act - 1884

� Mines Rescue Rules - 1985

� Central Electricity Regulations – 2010

10Corporate Planning & Projects

11Corporate Planning & Projects

1. To continuously review all existing Safety practices and

to improve and update them as and when the changed

circumstances demand.

2. To ensure that every one in the Organization is aware of

the safe working Methods and follow them in day-to-

SAFETY POLICY OF THE COMPANY

the safe working Methods and follow them in day-to-

day work.

3. To develop the skills of employees as a skilled worker

can only be a safe worker

4. To reduce the accident rates to the barest minimum and

to achieve zero accident potential being the ultimate

aim.

12Corporate Planning & Projects

Current Trends

- Risk Assessment

- Risk Management Plan

- Safe Operating Procedures.

- Duty Care System.

- Self Regulation.

- Inclusive Systems – even family and colleagues

involvement

- Welfare and Social well being.

- Training and Skill Development.

13Corporate Planning & Projects

Drivers of Change

- End of Colonialism

- Nationalization of Coal Industry.

- Amalgamation of Smaller mines

14Corporate Planning & Projects

- Thrust on Opencast mining.

- Militant Trade unionism.

But what is the real game changer ?

TREND OF FATAL ACCIDENTS

(Number of persons killed)

35

45

55

In SCCL

5

15

25

1981

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

2000 1 2 3 4 5 6 7 8 9

10

11

12

13

Fatalities

36

34

30

28

33

39

46

27

31

50

29

3536

27

33

44

30

40

50

60

Manpower (Number of Work Persons in Ten Thousonds)

Production (In MT)

Fatalities in SCCL

10 people died in Roof fall

&17 in Inundation in 2003

19

20 22

23

2120

28

21

26

1717

24

19

27

21

27

25

23

14

12

19

10

13

21

12

8

1212

5

0

10

20Fatalities (Number of Persons)

11

18

23

11

14 14

15

11

15

20

25

Roof fall

Side fall

Rope Haulage

Cause-wise Fatalities In SCCL

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

Roof fall 6 6 11 18 23 11 7 9 10 9 14 7 14 15 8 1 6 1 1 11 1 3 0 2

Side fall 4 4 2 1 5 0 2 7 3 5 3 3 5 1 1 1 3 1 1 0 2 1 2 0

Rope Haulage 5 4 6 8 8 2 5 6 8 3 4 8 3 3 0 3 4 1 1 3 4 1 0 0

6 6

11 11

7

9

10

9

7

8

1

6

1 1

11

1

3

0

2

4 4

2

1

5

0

2

7

3

5

3 3

5

1 1 1

3

1 1

0

2

1

2

0

5

4

6

8 8

2

5

6

8

3

4

8

3 3

0

3

4

1 1

3

4

1

0 00

5

10

- Major accidents at GDK 7 LEP and GDK 8 A in 2003 – But the companyresponded by positive aggressive changes on the core..

- Two Key Changes

- Face Machnisation – Minimise Exposure to the face

- Men Transport Systems.

-

- Mechanization increases production and Productivity.

18Corporate Planning & Projects

- Mechanization increases production and Productivity.

- Reduce number of men exposed to RISK.

- There by reduce number of accidents / fatalities.

From Here Where We go for Safe High Productive Minnig of Coal -

-----------Adriyala Longwall a Torch Bearer …………………..

COAL SCENARIO INDIA

Reserves:• Estimated Indian coalreserves 297 billion tons

• SCCL sharing 7% with22.21 billion

0-300

59%

300-600

34%

600-1200

7%

India Total Reserves:

297.42 Bt

Depth wise Coal reserves as on 01.04.2013 (Bt)

(Courtesy: infomine.com/index/pr/PB443157.pdf)

0-300

43%

300-600

40%

600-1200

17%

SCCL Total Reserves:

22.21 Bt

01.04.2013 (Bt)

0-300 300-600 600-1200 Total

INDIA 174.16 101.14 22.12 297.42

SCCL 9.65 8.79 3.77 22.21

UG mining technologies presently in vogue in

India are :

• Manual Bord & Pillar system

• Semi-mechanized Bord & Pillar System With SDLs / LHDs

• Blasting Gallary Method

• Continuous Miners : B&P liquidation &

20

• Continuous Miners : B&P liquidation & Development

– High Wall Mining

• Mechanized Longwall (PSLW) Mining System– Short wall Mining Technology

Adriyala – a Torch bearer

21

LOCATION

Godavari valley coal fields

Mines are located across 4 districts of Telangana i.e. Adilabad, Karimnagar, Warangal and Khammam

22

Telangana

22Corporate Planning & Projects

HUMAN ASSETS

58,495

as on 31.08.2015

GROSS TURNOVER

Rs. 14,078 Crs.(2014-15) Prov.

56.00 MT52.53 MT

SCCL at a glance

HUMAN ASSETS

58,495

as on 31.08.2015

GROSS TURNOVER

Rs. 14,078 Crs.(2014-15) Prov.

56.00 MT52.53 MTStarted in 1889

Regions - 3

Areas - 11

OC Mines – 16

UG Mines - 31

56.00 MT

Target (2015-16)

52.53 MT

Coal produced

(2014-15)

23Corporate Planning & Projects

Started in 1889

Regions - 3

Areas - 11

OC Mines – 16

UG Mines - 31

56.00 MT

Target (2015-16)

52.53 MT

Coal produced

(2014-15)

1948: Machine mining ( Joy loader & shuttle cars)

1951: Electric coal drills

1953: Electric cap lamps

1954: Flameproof electric equipment

1975: Opencast mining

1979: Side Discharge Loaders

1981: Load Haul Dumpers and Road Headers

SCCL Mile stones –to improve safety

2424

1981: Load Haul Dumpers and Road Headers

1983: Longwall mining

1986: Walking Dragline

1989: Blasting Gallery method

1994: In-pit crushing and conveying

2002: Surface Miner

24

SCCL Mile stones – to improve in safety

2004: Phasing out manual Coal filling launched.

2006: Continuous Miner.

2007: 3D Laser Scanner (for mine survey)

2008: ERP(SAP) (first Govt. Coal producing

Company)

2008: Diesel operated UG machinery

2009: LED Cap Lamps2009: LED Cap Lamps

2010: High Wall Mining

2012: Air Conditioning in Underground

2014: High Capacity Longwall : Adriyala

25

“State of Art Technology

In Underground Mechanization”

In the eve of Reduction in

Accidents and Improve in Safety

SCCL introduces

High Level Mining method.

In Underground Mechanization”

“A Case Study of Adriyala Longwall

Project”

FBL-55

• Availability of shallow reserves for immediate requirement.

• Need of immediate bulk production.

• Requirement of huge capital and long gestation –limiting entrepreneurs

Reasons for decline of U/g mining

27

• High risk investments.

• Increases in manpower costs and low OMS in U/g method.

• High risks of strata control, fires, subsidence, gas problems etc.

• Non availability of indegenous equipments & limited markets

Challenges in U/G mining - ALP

• Ventilation

• Strata control

• Men transport

• Material transport• Material transport

• Coal transport system

• Pumping and water management

• Automation systems

Future of Underground mining

Longwall Technology

HISTORY OF LONGWALL IN INDIA• First Longwall face in India: August 1978 at Moonidih, CIL

• First Longwall face in SCCL: GDK 7 Incline in September 1983 in SCCL

• Production from LW

in India & SCCL:

CIL achieved highest

production In the year

1999-00 where as

SCCL achieved highest

LONGWALL PRODUCTION (LT)

10

15

20

25

PRODUCTION (LT)

CIL

SCCL

SCCL achieved highest

production In the year

1996-97.

• The experience from the first generation Longwall faces was not

encouraging.

0

5

1983-84

1984-85

1985-86

1986-87

1987-88

1988-89

1989-90

1990-91

1991-92

1992-93

1993-94

1994-95

1995-96

1996-97

1997-98

1998-99

1999-00

2000-01

20001-02

� Poor Utilisation of Man and Machine � Problems with caveability of the roof

� Strata control problems � Downtime of equipments by improper

matching of the sub systems.

GLOBAL LONGWALL SCENARIO

The world’s most productive longwalls are located in the USA, Australiaand the Shenhua coalfield of China.

Experience of LW world wide

• USA

– 49 operating Longwalls

– producing over 175 million tonnes per year

– best achieving over 7 million tonnes per year.

– average production is over 3.8 million tonnes per longwall face per year

• Australia– 9 operating Longwalls

– Producing over 47.5 million tonnes per year

– Best achieving over 7 million tonnes per year

• China– Shenhua operating 07 major Longwalls

– producing over 200 million tonnes per year

– Producing between 5 and 10 million tonnes per longwall face per year.

LONGWALL MINING IN AUSTRALIA

• 28 faces produced 100Mt (only LW 92MT, Excluding Development)

• Average for all LW face > 3MT

• 10 faces produced over 4MT (Most of the new faces)

• High production mines 5 to 7MT from one face

– Beltana, Ulan, Newlands, Kestrel, Oaky, Creek..etc.

• Ulan Produced 6.3MT

• Trend is towards wider and longer faces (most of the new LW faces towards300m. Ex: Ulan mine- 400m face length).

• One LW face per mine (moved away from 2 faces per mine)

32

Description Capacities

Low Medium High

Production 2 – 2.5MT 3-5MT 7-10MT

Face width 150-200m 250m 300-400m

Support capacities in T 700-1000 1000-1200 >1700

Support type, Width 4leg, 1.5m 2leg, 1.75m 2leg, 2.0m

Shearer Kw 600-100 1200-2400 Up to 3000

AFC TPH 1500-2000 Up to 3000 Up to 5000

State of the art in yrs. Early / mid 1990’s Early / mid 2000’s Current

Analysis of

the

problem

Improper selection

Geo-Mining conditions

Management of

Face

Longwall support

selection deficiencies

Large expansion in

opencast mining

Faulty planning

Research needs

Standardization of

equipment

Present

actions and

future needs

Planning

equipment

Monitoring of

performance

Workshops and

overhauling facilities

Man power

deployment

Spare parts

management

Indigenization

(Source:

http://www.slideshare.net/shanz2u/longwall-

mining-14602171)

ALP MINE PLAN

• FR approved on: 29.09.2006.

• Production capacity: 2.144 MTPA.

• Capital outlay: Rs 438.24 Crores.

STUDIES AND CONSULTANCIES

• Required studies was carried out by various scientific institutes like CIMFR,

NIT(Warangal), BHU, ISM(Dhanbad).

• Other Consultancy services:

Andy Rutherford Pty. Ltd, Australia.

M/s Mine Advice Pty. Ltd, AustraliaM/s Mine Advice Pty. Ltd, Australia

Awarded value: Rs 5,87,84,318.00

List of Scientific studies awarded

� As per the guidelines of CSIRO, the FR proposals have been modified.

� Entries to the property were made through ‘Punch Entries’ on OC-II side for Adriyala property.

Activities in Construction

• Development

• Strata control ( cable bolts pictures can be in this head )

• Equipment procurement.

• Ventilation ( Pictures of shaft – fans etc. can be here )

• Men transport

• Material transport system– Floor concreting. –

• Conveying system

• Dewatering

• Inbye water supply system..

• Face installation : ( transport of equipment )

( Like this list activities in proper order – susbsequent slides be in that order – highlight key point in the activity with photographs where ever available )

Development

• Four DOSCO’s with twin bolters arrangement.

• One WIRTH Road header with twin bolters arrangement.

• TWO Refurbished AM 50.

Overall length 11.18m

Height (canopy) 2.25m

Width 3.56m

Machine weight 63T

maximum working gradient 18°

Total power 362 kW

Overall length 10.29m

Height 2.57m

Width 3.6m

Machine weight 65T

maximum working gradient 18°

Total power 360 kW

Strata control• Gate roadways development

– Problem with working section

– 2 major falls in TG1 gate roadway etc.

– Guttering along the galleries ( Horizontal stress)

– Roof deformation

– Water seepage

• Change of working section• Change of working sectiono Roof section was lowered by leaving 0.3m coal against 0.75m

shale+0.25mclay+0.1m shale.

o Sand stone floor was exposed by cutting the stone floor for

FSVs movement.

o But roof Guttering problem found to be continuing.

o Hence, a decision was taken lower the roof section further to

reduce the effect of roof guttering.

Major recommendations by Russel Firth:

• Change in the cut troughs

direction in view of the Major

Horizontal Stress.

• Rigid Wire mesh

Stable roof conditions

Roadway with rigid wire

mesh and single bolts

without w strap

Rigid wire

mesh

Single bolts

in mesh

overlap area

Stable roof

conditions

• Pre Tensioning Cable

bolts introduction for

eliminating the vertical

supports

(OC Props).

• Face dip Supporting / • Face dip Supporting /

preparation of the installation

roadway with 8m width.

Equipment procured

• Major equipment (LW face equipment, Gate belt, 11 KV

electricals, Wirth Road header) : Germany

• 11 KV electricals, Cables for 11 KV system, DOSCO

Road header : UK

• Crane : US

• Ventilation Fans : Spain

• Over land and Trunk conveyors : China• Over land and Trunk conveyors : China

• Free steered Vehicles, Spares for Free steered

vehicles, Cable bolts and its accessories : Australia

�Total value: 594.15 crores

Details of equipment procured

Ventilation

Construction of Return Air shaft:

• Return air shaft of finished diameter of 7.50m. & approximate depth of

468 m sunk at Adriyala for the purpose of ventilation.

Type of Lining:

• Reinforced Cement Concreting of 300mm thick Grade M-20, Containing

coarse aggregate of 20mm down gauge.

Ventilation arrangements• Main Mechanical Ventilators :

– 400KW , Zitron make MMV.

– 15000m3 / min

43

Air Conditioning in UG mine

• Average surface temperatures in Coal fields of SCCL varyfrom 12 deg (Winter) to >50 deg (Summer).

• To create comfortable working conditions in the mines, highcapacity fans are being installed in the mines.

• Air-conditioning system installed at VK-7 incline mine of KGMarea and envisaged to install Air conditioning/spot coolers inits future deep mines.

44

Men and Material Transport system

• Man riding chair car system

was provided in PE5.

Floor concreting for

movement of Diesel

equipment

• Total length - 1.8 km

• Width - 5.2m

• Grade - M 40

System of Men Transportation By

Mine Cruisers

Coal conveyance System

• Total number of Gear heads – 11 nos

• Capacities varying from - 1 X315KW to 4 X 500KW

• Speed - 4 m / sec

• Type of Drive - VFD

• Belt capacity - 3500 TPH

• Belt Type - Steel cord (ST 800 to ST2500)

• Total Length – 9km• Total Length – 9km

• Total power - 12765 KW

Conveyor installationCivil works:

� Construction of Foundation beds:

• Templates fixing:

Overland belt conveyors

A2 Discharge

A1 Conveyor

A3 Conveyor

Overland belt conveyors

A1 Conveyor – Stock pile arrangement

Overland belt conveyors

A4 Conveyor

Overland belt conveyors

B3 Conveyor Discharge

Overland belt conveyors

B1 Conveyor Discharge

B0 Conveyor

B0 Conveyor Discharge

Overland belt conveyors

Walk way

Electrical System• 11 kV transmission to UG

– First time in India.

• Existing installed power of the mine – 6MVA

• Proposal for longwall

– Longwall - 7530 Kw (including GB)

– Trunk belts - 12765 Kw ( UG-6300Kw + SF 6465 Kw)– Trunk belts - 12765 Kw ( UG-6300Kw + SF 6465 Kw)

– Ventilation - 2 X 400Kw + 75Kw

– Pumps - 5 X 350HP and 4 X 190HP

– MRS / haulers - 500 Kw

– Air cooling plant - appox 300Kw

– Air compressor plant - 3 X 250 KW

SUPPORTS LOADING AT GERMANY

PRS & MATERIAL UNLOADING AT GDK10A

Total tonnage:

7354 T

Local transport –

surface:

Total equipment

transportation from GDKtransportation from GDK

10A longwall shed to

Punch Entry surface

was done by 60 T trailer,

10 T Lorries and loading

with 120 T groove, 10 T

escort cranes.

Material Handling

Different type of tools used:

For Roof Supports:– 25T ‘D’ Links – front side – 2nos

– 10T ‘D’ Links – rear side – 2nos

– GLVD Sling 6x37 32mm, 40T, 10.0 mtr length – 2nos

– GLVD Sling 6x37 24mm, 10T, 4.0mtr length-4nos

– Changed the above set of ‘D’ Links and slings for every 30 Supports.

For other material:– 5T ‘D’ Links – 8 nos

– 10T ‘D’ Links – 6 nos– 10T ‘D’ Links – 6 nos

– GLVD Sling 6x19 24mm, 10T, 6.0 mtr length - 6 nos

– GLVD Sling 6x19 12mm, 5T, 5.0 mtr length - 8 nos

– GLVD Sling 6x37 32mm, 30T, 6.0 mtr length - 4 nos

– POLYSTER Round sling 5T, 12mtr length – 8 nos

– POLYSTER Round sling 10T, 6mtr length – 8 nos

– Changed the above set of ‘D’ Links and slings for every 10 days.

Types of methods adopted:

Cranes:– 120T Grove Crane – 1no

– Escorts Crane – 1no

Longwall Installation:

Underground transport and installation:

• Total equipment transportation and installation was done by FBL

diesel equipments from surface to Longwall face which was imported from

Caterpillar - Australia. Approx. 9000 T of equipment was transported by

these vehicles.

Machines used are:

• FBL- 55 - 2No.s• FBL- 55 - 2No.s

• FBL-10 - 2No.s

• FBL-15 - 2No.s

• CHT-50 - 4No.s

Tools used:

Chain binders:

‘D’ links: 10 T, 05 T

Supports Transportation

Supports Transportation

Supports Transportation

Shearer Loading & transportation

Shearer Loading & transportation

Shearer Loading & transportation

DGMS permissions

Field trial permissions:

• Total 16 no of equipment approvals obtained.

Permissions obtained:

• Total 23 permissions have been obtained from inspectorate.

Specific New Permissions:

• 8 m roadway without vertical supports.• 8 m roadway without vertical supports.

• Extraction of 250m length Longwall face.

• Long development drivages and Gate road dimensions.

Over View of Adriyala Longwall Project

Punch EntriesPunch Entries Stock pile arrangement Stock pile arrangement

–– contingency contingency

9km Trunk belts from Face to SILO9km Trunk belts from Face to SILO Mine Control CenterMine Control Center

Adriyala Longwall Project

* Standard Operating Procedures for

every operation have been laid down and

are strictly implemented.

Face operation

Challenges for Growth

• High Cost : UG mining to be subsidized / cross

subsidy

• High cost Imported equipment : Tax reliefs on

capital equipment for infrastructure.

• DGMS approvals : Liberal frame work to use

globally proved equipment

• Need of more players for shaft sinking ,

development etc.

• Business partnerships – Risk gain share /

MDOs

Thank You for your Attention