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

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Proximity to township of Helensburgh

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Southern Coal Fields – New South Wales

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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

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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

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Innovations

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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

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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

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Outbye lighting layout – 41 ups supplied lights between sub and MG, UPS backed light on every roof support

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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.

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Testing Requirments

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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

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Double Compensation cylinder – gate end

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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.

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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

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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

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Rail Remediation work – replacement of old rail.

● Track being broken up ready to lift

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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

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Winder Window

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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

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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

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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

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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

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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

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What we have to do to them

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Trials strips completed and SWP developed

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Procedure in fast forward

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Procedure in fast forward

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Procedure in fast forward

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Position canopy on

frame

Procedure in fast forward

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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.

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Final Canopy frame

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Canopy Frame includes the side shield

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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

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Manufacture

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Hosing and Cylinders

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Skip trial

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Test silhouette of roof support

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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

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Second Trial

● Skip second trial – derail

– Increase articulation of bogies

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Success Third Trial – Pit Bottom reached Empty

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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.

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Underground Crane workshop

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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.

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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

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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.

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Transformer dimensions

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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.

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Monorail sled base

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Drive Transport Sled

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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.

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“A carelessly planned project takes three times longer to complete than

expected; a carefully planned project takes only twice as long

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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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