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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