Transcript Document

ACARP Roadway Development Operators Workshop March 2008
Roadway Development at Crinum Mine
Gregory Crinum
Introduction
 Development at Crinum Mine has undergone massive
changes over the last 2 years.
 Changed from panel development off mains to punch
longwall system.
 After 13 years of utilising Joy continuous miners
introduced an ABM 25S continuous miner.
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Crinum Mine - Technical Data
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Roof strength UCS 6 to 22 MPa
Floor strength UCS 6 MPa
Roadway width 4.8m
Pillar dimensions 30m wide x 130m centres
Coal Seam height 3.2m
Cutting height 3.2 to 3.3m leaving 0.3m coal on the floor
Stone cut 0.2 to 0.3m
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Crinum Mine - Equipment
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Joy 12CM32 continuous miner
Joy 15SC32 shuttle car
Joy Mobile boot end
Track mounted auxiliary fan (18m3) with 720mm
diameter ventilation tubes
Panel belts 1400 belt and structure with 2 x 375kw
drivehead and 300m loop take up
Coal cleared via mains belts
Pipes installed utilising pipe pods on MPV’s
Stone dusting utilised stone dust pods on MPV’s
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Crinum Mine - Development Rates
 Averaged 140m per week in MG15
MG15 Weekly Development Metres
250
206
200
185
Metres
164
186
181
212
177
166
159
150
120
107
159
128
136
136
109
107
103
92
100
156
147
125
115
100
145 142
143
136
118
184
221
213
205 201
105 106
80
74
70
65
40
50
08 Oct
24 Sep
10 Sep
27 Aug
13 Aug
30 Jul
16 Jul
02 Jul
18 Jun
04 Jun
21 May
07 May
23 Apr
09 Apr
26 Mar
12 Mar
26 Feb
12 Feb
29 Jan
15 Jan
01 Jan
0
Week Ending (Date)
01.01.01
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Crinum Mine - Development Rates
 Averaged 3.0m per op hr for 46.6 op hrs per week in
MG15
MG15 Weekly Metres per Hour
4.50
3.91
Matres per Hour
4.00 3.69
3.49
3.09 3.003.23
2.882.96
2.84
3.50
3.00
3.43
3.33
2.67
2.40
2.19
2.50
3.223.09
2.68
3.82
3.47 3.38
3.44
3.24
3.20
3.03
2.953.01
2.86 2.96 2.862.902.97
2.66
3.69
2.842.76
2.84
2.50
2.36
2.31
1.91
1.79
2.00
1.50
1.00
0.50
08 Oct
24 Sep
10 Sep
27 Aug
13 Aug
30 Jul
16 Jul
02 Jul
18 Jun
04 Jun
21 May
07 May
23 Apr
09 Apr
26 Mar
12 Mar
26 Feb
12 Feb
29 Jan
15 Jan
01 Jan
0.00
Week Ending (Date)
01.01.01
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Decision Behind Crinum East
Moved from Crinum to Crinum East in October 2006.
Change from mains drivage to punch longwall system.
Increase in productivity due to U/G panel belts only.
No outbye mains areas to maintain.
Trench conveyors simpler because they do not require
gas monitoring and surface conveyors easier to
maintain.
 Quicker travel time from surface to U/G – have Toyotas
that can go from surface to crib room.
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Decision Behind Crinum East
 Less infrastructure to maintain – no complex gas
monitoring system, u/g dewatering system, road
maintenance.
 Longwall moves easier as there is no mains to deal with.
 Ventilation of panels simple.
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Crinum East Mine Plan
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Crinum East Trench
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Crinum East - Changes to Development
 Panel belts changed to 1050 belt with 1400 structure and
2 x 75 kw combi drives with a 7m loop take up.
 Coal stockpiled outside portal and trucked out of trench
to surface stockpile.
 No MPV’s used at Crinum East as part of the BHPB
FRCP’s.
 Pipe trailer and Eimco utilised for installing pipes.
 Quick duster utilised for stone dusting.
 Seam height 3.1m at Crinum East requiring additional
stone to be cut
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Crinum East - Production with Joy CM
 Initially commenced development at Crinum East with
Joy continuous miner.
 Small decrease in weekly development metres due to
reduced operating hours.
 Mineworkers unfamiliar with pipe trailer.
 Lost time with stone dusting due to issues with the
quick duster.
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Crinum East - Production with Joy CM
 Averaged 135m per week in MG17 with Joy miner.
MG17 Weekly Development Metres - Joy Continuous Miner
300
244
Metres
250
200
169
157
186
171
167
119
114
119
158
100
62
52
40
50
119
111
104
91
202
200
179
141
134 131
150
191
188
52
31
29 Apr
22 Apr
15 Apr
08 Apr
01 Apr
25 Mar
18 Mar
11 Mar
04 Mar
25 Feb
18 Feb
11 Feb
04 Feb
28 Jan
21 Jan
14 Jan
07 Jan
31 Dec
24 Dec
17 Dec
10 Dec
03 Dec
26 Nov
19 Nov
12 Nov
05 Nov
29 Oct
0
Week Ending (Date)
01.01.01
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Crinum East - Production with Joy CM
 Averaged 3.2m per op hr for 42.4 op hrs per week in
MG17 with Joy miner.
MG17 Weekly Metres per Hour - Joy Continuous Miner
Metres per Hour
4.50
3.85
3.70
4.00 3.74 3.44
3.50
2.96
3.00
2.50
3.24
2.67
2.592.61
2.84 2.77
3.72
3.40
3.13
3.35
3.03
3.11 3.25
3.25
3.44
3.13 3.29 3.11
3.00
2.38
3.50
2.38
2.00
1.50
1.00
0.50
29 Apr
22 Apr
15 Apr
08 Apr
01 Apr
25 Mar
18 Mar
11 Mar
04 Mar
25 Feb
18 Feb
11 Feb
04 Feb
28 Jan
21 Jan
14 Jan
07 Jan
31 Dec
24 Dec
17 Dec
10 Dec
03 Dec
26 Nov
19 Nov
12 Nov
05 Nov
29 Oct
0.00
Week Ending (Date)
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Introduction of the ABM
 The ABM continuous miner was introduced to Crinum
due to a number of key factors:
 Continuous bolting and cutting cycle.
 The canopy suits poor ground conditions.
 The ABM was justified on a 15% productivity increase over
the Joy miners. Expectation was 183m per week.
 Improved ergonomics at the bolter controls and elevating
working platform for mineworkers and improved ergonomics
for tradespersons.
 Roof mesh holder on the tail.
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Introduction of the ABM
 Monorail and flexiduct ventilation system to improve cutting
rate and reduce manual handling of ventilation tubes.
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Introduction of the ABM
 The introduction of the ABM introduced significant
changes to the mining cycle:
 The monorail and flexiduct ventilation system needed to be
developed to suit Crinum.
 Supplies for the ABM required smaller cassettes and rackers.
The cassettes for the Joy held 35m on 6 bolt pattern where
the ABM cassettes could only hold 25m.
 Joy CM requires 5 person crews, ABM requires 6 person
crews for continuous bolting and cutting.
 The majority of mineworkers in the department had not
previously worked with ABM’s before.
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Crinum East - Production with ABM CM
 Drastic reduction in cutting time and rate leading to
overall reduced metres per week.
 Identified a number of issues within the ABM system.
 The positive indicator is that cutting rate was improving
toward the end of the panel.
 We know the system can produce metres with one shift
achieving 38m.
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Crinum East - Production with ABM CM
 Averaged 84m per week in MG17 with ABM miner.
MG17 Weekly Development Metres - ABM Continuous Miner
171
180
Metres
140
120
100
156
148
160
119
95
87
66
80
60
40
96
54 52
121
110
109
107
93
81
60 57
50
38
91
89
100
85
70
62 64
54
47
44
38
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02-Dec
18-Nov
04-Nov
21-Oct
07-Oct
23-Sep
09-Sep
26-Aug
12-Aug
29-Jul
15-Jul
01-Jul
17-Jun
03-Jun
20-May
06-May
0
Week Ending (Date)
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Crinum East - Production with ABM CM
 Averaged 2.45m per op hr for 35 op hrs per week in
MG17 with ABM miner.
MG17 Weekly Metres per Hour - ABM Continuous Miner
4.00
3.56
3.13
3.13
Metres
3.50
3.38
2.85
2.58
2.53
2.22
3.00 2.562.642.70
2.36
2.50
2.00
2.71
2.692.812.682.74
2.38
2.25
2.17
2.82
2.61
2.202.25
2.19
2.00
3.27
2.7
2.56
1.46
1.50
1.09
1.00
0.50
02-Dec
18-Nov
04-Nov
21-Oct
07-Oct
23-Sep
09-Sep
26-Aug
12-Aug
29-Jul
15-Jul
01-Jul
17-Jun
03-Jun
20-May
06-May
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Week Ending (Date)
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Crinum East - Issues with the ABM System
 There were a number of issues associated with the ABM
and the system supporting it:
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Issues with the ABM.
Issues with shuttle car haulage.
Issues with the flexiduct ventilation system.
Issues associated with the conveyor system.
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Crinum East - Issues with the ABM System
 Issues associated with the ABM:
 Cutting height had to be increased from 3.3m to 3.5m to
allow flitting underneath the flexiduct in A heading.
 The cutting cycle was shuttle car constrained – gone from 2
cars per metre to 2.5 cars per metre. The tail on the ABM was
shorter than the Joy miner.
 Large amount of road works required prior to flitting the
miner.
 Issues with the pick lacing causing an arched profile.
 Excessive water usage creating a face water issue.
 Number of electrical faults.
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Crinum East - Issues with the ABM System
 Issues associated with the shuttle car:
 Shuttle car constrained - stubs had increased from 20m to
30m in A heading and 40m in B heading to accommodate
monorail and flexiduct.
 Slow loading onto belts due to 1050 belt and jiffy drives.
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Crinum East - Issues with the ABM System
 Issues associated with the monorail and flexiduct:
 Flexiduct smaller in diameter by 20mm with higher resistance
resulting in reduced quantity at face.
 Build up of fines in the throat.
 Flexiduct twists and collapses reducing ventilation to face
near fan.
 Has added an additional shift to the panel extensions.
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Crinum East - Issues with the ABM System
 Issues associated with the conveyors / boot end:
 Utilising 1050 belt on boot end and structure designed for
1400 belt.
 Belt speed for 1050 belt is 2 m/s vs 4 m/s for 1400 belt
requiring slow loading.
 Jiffy drives were too far apart causing belt slip and
tensioning issues.
 Combi drive had only a 7m loop take up requiring a belt
clipping station.
 Panel extensions taking 5 shifts on average.
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Crinum East - Improving the ABM System
 We have identified a number of problems that need to be
resolved if we are going to be successful with the ABM
mining system.
 We have commenced a Productivity Optimisation
Process with Mining Consultancy Services.
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Crinum East - Improving the ABM System
 Improving the ABM:
 Reduced to height of the ABM to allow us to flit under the
monorail and flexiduct in a 3.3m heading.
 Extended the tail to enable 2 cars per metre.
 Improved the panel standards (horizon control) to reduce the
amount of road works required prior to flitting.
 Modified the pick lacing so we cut a square profile.
 Made changes to the water circuit to reduce water usage.
 Made a lot of changes to the electrical system.
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Crinum East - Improving the ABM System
 Improving shuttle car efficiency:
 Improved horizon control to reduce tramming time.
 Currently evaluating the use of a Stamler feeder breaker to
allow unloading of the car on fast tram.
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Crinum East - Improving the ABM System
 Improving the monorail and flexiduct system:
 Trial of a monorail mule to assist packing up of monorail.
 Reducing the height of the trolly brackets to allow a 3.3m
heading height.
 Tighten flexiduct rings to prevent twisting.
 Adding additional trolleys and rings near vent fan.
 Purpose built T pieces for the flexiduct.
 A new inline removable monorail section instead of the
points currently utilised.
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Crinum East - Improving the ABM System
 Improving the conveyor system:
 Add additional jiffy drives to improve belt reliability and
resolve belt slip issues.
 Looking at improving the belt clipping station.
 Reducing panel extension times.
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Crinum East - Improving the ABM System
 MCS POP project:
 Mining Consultancy Services have a large amount of
experience and expertise in business analysis, mine design,
mining operations and people, productivity optimisation and
equipment design and selection.
 Currently responsible for the performance and monitoring of
60 continuous miner units world wide.
 Currently 2 months into the 9 month POP project.
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Crinum East - Improving the ABM System
 The 9 month process can be broken up into 2 phases
and 4 modules:
 Phase 1: Evaluate to current system and mining process to
establish production objectives and functional KPI’s (9
weeks).
 Phase 2: Implementation of the POP process, implementation
of initiatives and coaching and mentoring role (25 weeks).
 Crucial to the success of the project is onboard monitoring
on the miner to allow monitoring and evaluation of initiatives.
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Crinum East - Improving the ABM System
 The POP process.
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COM016
0%
COM017
COM018
Cutter
Roof Bolter
Power Distribution
Delay Type
Electrical Control
Wait on Tradesman
No Labour
Hydraulics/Pneumatics
COM019
Ventilation
Conveying
Flitting
Break Offs/Turns
Belts - Panel
Section Prep
Service Extn / Retn
Crib
Travel
Safety/Training
Meeting
Delay %
Crinum East - Improving the ABM System
 Analysis of downtime for each miner.
Comparison Of Continuous Miners
30%
25%
20%
15%
10%
5%
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Crinum East - Improving the ABM System
 After 2 months of the POP project, a number of areas of
opportunity have been identified:
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Reducing process delays.
Optimising cycle times.
Changing mining dimensions.
Modify 6/2 bolting pattern to a 4/4 bolting pattern.
Evaluate use of Stamler feeder breaker on front of boot end.
Reducing panel extension times.
Planning process.
Panel standards.
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Crinum East - Improving the ABM System
 Presentations have been made to every crew detailing
the development data over the last year.
 A workshop involving the development workforce has
been held to provide involvement and ownership of the
process.
 Currently designing Crinum specific reports that will be
automatically generated from the onboard monitoring.
This will use traffic light colour system and benchmark
their performance against specific targets.
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Crinum East - Targets for the next Year
 We have completed MG17 and due to commence MG19.
 Our Goals over the following year are:
 Develop MG19 with high panel standards.
 Achieve a minimum of 10% production improvement through
the POP project with MCS.
 Consistently achieve 4.0m per op hour.
 Achieve a minimum of 46 op hours per week and work
towards achieving 67 op hours per week.
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