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PRESENTATION ON SUMMER INTERNSHIP AT
SARPI COAL MINE PROJECT, JMS INDIA
BY: MINING MACHINERY ENGINEERING ISM DHANBAD
AN OVERVIEW OF THE PRESENTATION
AN INTRODUCTION TO SARPI PROJECT. VARIOUS MACHINERIES DEPLOYED IN THE
MINE. DEVELOPMENT AND DEPILLARING PATTERN
FOLLOWED IN THE MINE. COST OF THE CONTINUOUS MINER
PACKAGE. SHUTTLE CAR: a) SPECIFICATIONS b) VARIOUS MECHANICAL AND HYDRAULIC
SYSTEMS IN A SHUTTLE CAR. c) SAFETY FEATURES.
INTRODUCTION TO THE SARPI CONTINUOUS MINER PROJECT.
BORD AND PILLAR TYPE OF MINING IS FOLLOWED. MINE IS STILL IS IN DEVELOPMENT PHASE. CONTINUOUS MINER IS USED FOR CUTTING THE COAL
INSTEAD OF CONVENTIONAL DRILLING BLASTING METHOD.
DAILY PRODUCTION OF THE CONTINUOUS MINER PANEL IS ABOUT 1500 TONNES.
THE DEPTH OF THE SHAFT IS 159m. 5 HEADING DEVELOPMENT IS DONE. THE WIDTH AND HEIGHT OF THE GALLERIES IS 6mX4.6m. THE DIMENSIONS OF THE PILLAR IS 32mX32mX4.6m. DEGREE OF GASSINESS-II
Actually Continuous Miner is a package of machinery including-Coal Cutting Machine :- Continuous MinerCoal Hauling Machine :- Shuttle CarCoal Lump Breaking & Feeding Machine to Conveyors :- Feeder BreakerFace Supporting Machine :- Quadbolter Face & Road Cleaning Machine :- LHDPower Distribution :- Load Centre As Continuous Miner is large underground machinery, so lowering the package of CM machinery can only be done through incline of proper cross section & gradient – not through any shaft / pit.
OPERATING MACHINERIES
Typical Development Layout
The standard layout consists of a five road development, with the main conveyor and feeder breaker positioned in the central roadway. This provides working areas to carry out all the main development functions:
One heading for the CM to be cuttingOne heading ready for cuttingOne heading for ventilation rearrangement and survey workOne heading for cleaning by LHDOne heading for supporting by Quadbolter
Typical De-pillaring layout
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
Breaker lines installed for 3 rows before extraction commences6
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
3
4
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
3
4
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
4
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
4
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
4
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213
4
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
17
18
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
17
18
19
20
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
17
18
19
20
21
22
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
17
18
19
20
21
22
23
24
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
17
18
19
20
21
22
23
2425
27
26
28
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
17
18
19
20
21
22
23
2425
27
26
28
29
30
31
32
16154
Breaker lines installed for 3 rows before extraction commences6Extraction sequence
Breaker lines installed during pillar split
Remote Reading Telltale (3m + 10m) 2 x 2.4m SG bolts (breaker line) Pillar stress cells (5m + 10m)
Auto warning telltale (single height 10m – trigger 5mm)Remote Rib Exto. (3m + 10m)
BA
RR
IER
PIL
LA
R
Proposed Monitoring Scheme CM1 Panel
1
Auto warning telltale installed during pillar split
2
35
6
7
8
9
10
11
1213 14
17
18
19
20
21
22
23
2425
27
26
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30
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32
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36
PRICE LIST OF DIFFERENT MACHINERIES IN THE CM PANEL
Sl. No.
Equipment Quantity
Country of Origin
Unit Price US $
Total Price US $
1 Continuous Miner 12CM15-10D
1 no. USA 2,791,265.00 2,791,265.00
2 Shuttle Car10SC32B
2 no. RSA 934,617.00 1,869,234.00
3 Feeder BreakerBF14B-3-7C
1 no. USA 743,312.00 743,312.00
4 Quad Bolter 1 no. Australia 1,183,225.00 1,183,225.00
5 Electrical Equipment
1 no. UK 971,115.00 971,115.00
TOTAL PACKAGE VALUE – US DOLLARS 7,558,151.00(US Dollars Seven million Five hundred Fifty Eight thousand one hundred Fifty One only)
SHUTTLE CAR 10SC32
ROLE OF SHUTTLE CAR IN THE OVERALL PROCESS.
The function of shuttle car is to transport the coal that is sheared by continuous miner from the face to the place where feeder breaker is installed.
Capacity of a 10SC32 shuttle is 10.19 tons and the fill
factor is about 0.85.
Joy Shuttle Car Model 10SC32B Specifications
General•Type : JOY 10SC32•Operating voltage: 1050 V•Voltage Rating: ±10%•Total Rated Power: 202.6kW
2 × 85 kW Traction Motors1 × 18.6 kW Conveyor Motor1 × 14 kW Pump Motor
•Weight 20,500kg (approximately) empty•Cubic Capacity : 10.19cu meters•Dimensions (l × w × h): 8.99m × 3.05m × 1.31m •Ground clearance: 290mm (Nominal)•Ground Bearing Pressure: 520 kPa empty; 830 kPa loaded•Gradient (in line of advance): Below 6 degrees. If greater than 6 degrees, a new gear with reduction of 66.56: 1 could be used.•Cross gradient: not greater than 5 degrees •Total Service Life: 1.5 million tones
VARIOUS PARTS IN A SHUTTLE CARSHEAVE WHEELS
CABLE REEL COMPARTMENTCHAIN CONVEYOR
TRACTION MOTOROPERATOR’S CABINCONVEYOR DRIVE MOTOR
TYRESHYDRULIC PUMP MOTOR COMPARTMENT
Conveyor boom
headlights
MAIN MECHANISMS IN A SHUTTLE CAR
CABLE REEL MECHANISM.
BOOM LIFTING MECHANISM.
STEERING MECHANISM.
DUMPING MECHANISM.
OPERATION OF SERVICE JACKS.
NEED FOR CABLE REELING
Pump motor compartment
Cable reel compartment
Traction motorControllerConveyor motor
Conveyor reducer
Operatorcompartment
Design
CABLE REEL SYSTEM
HYDRAULIC MOTOR
SHEAVE WHEELS
SPOOLING MECHANISM
SHEEVE WHEEL
BOOM LIFTING MECHANISM
Boom lifting mechanism is present so to adjust with variable discharge heights.
Telescopic type of cylinder is used. Atmospheric vent is provided in the cylinder to prevent the
cylinder from damage during roof fall condition. extend pressure: 120.6-127.5 bar. atmosphere relief pressure: 227.7 bar. Dual output pump is used 46 lpm and 34lpm.
The high volume stage of pump delivers (46LPM) fluid to cable reel valve(Since here, shuttle car is in stationary mode, cable reel motor will be in stalled position) & conveyor elevating cylinder.
The Low volume Stage delivers (34LPM) fluid to hydraulic cylinders in steering mechanism and Brake circuits (emergency/ park & service).
POSITION OF BOOM ELEVATING AND LOWERING CYLINDER
BOOM ELEVATE CIRCUIT
BOOM LOWERING CIRCUIT
STEERING MECHANISM
FOUR WHEEL STEERING MECHANISM IS USED IN JOY SHUTTLE CARS TO NEGOTIATE TIGHTER TURNS.
Steering Arrangement
HYDRAULIC CIRCUIT FOR LEFT TURN
HYDRAULIC CIRCUIT FOR RIGHT TURN
LOADING AND DISCHARGE END OF SHUTTLE CAR
LOADING END
DISCHARGE END
CONVEYOR
DISCHARGE BOOM.
DUMPING MECHANISM
DUMPING MECHANISM
SERVICE JACKS
Four floor jack cylinders are provided at four corners of the shuttle car so that the machine can be lifted from the ground for maintenance.
SAFETY FEATURES OF SHUTTLE CAR AT A GLANCE
Drum limit switch Emergency stops Oil temperature Oil level Brake pressure switch E/Leakage Relays off load and on load Overloads Pre-start Alarm Emergency and Service Brakes
NOTE:- All the machine have DANGER,WARNING,CAUTION, SIGNS mounted on them.
FireExtinguisher
Safety Features of SC
Boom SafetyPins
Low CableCut-Out
Poly RearBumpers
EmergencyStops
BrakePressureSwitch
Oil TemperatureLevel Sensor
Load LocksConveyor & Floor Jack
Cylinders
AudibleAlarm
EmergencyStop
EmergencyStop
BrakeHead Light
Head Light
Head Light
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