gregory crinum acarp roadway development - operators workshop march 2008 roadway development at...

Gregory Crinum

ACARP Roadway Development - ACARP Roadway Development - Operators Workshop March 2008Operators Workshop March 2008

Roadway Development at Crinum MineRoadway Development at Crinum Mine

01.01.01

2Gregory Crinum

IntroductionIntroduction

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.

01.01.01

3Gregory Crinum

Crinum Mine - Technical DataCrinum Mine - Technical Data

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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4Gregory Crinum

Crinum Mine - EquipmentCrinum Mine - Equipment

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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5Gregory Crinum

Crinum Mine - Development RatesCrinum Mine - Development Rates

Averaged 140m per week in MG15

MG15 Weekly Development Metres

118

164

120

159

100

206

115

136

92

143

107

185

109

145 142

184

147

181

80

186177

205 201

125

213

166

128136

221

103

212

107

136

65

159

105 106

70

40

156

74

0

50

100

150

200

250

01 J

an

15 J

an

29 J

an

12 F

eb

26 F

eb

12 M

ar

26 M

ar

09 A

pr

23 A

pr

07 M

ay

21 M

ay

04 J

un

18 J

un

02 J

ul

16 J

ul

30 J

ul

13 A

ug

27 A

ug

10 S

ep

24 S

ep

08 O

ct

Week Ending (Date)

Me

tre

s

01.01.01

6Gregory Crinum

Crinum Mine - Development RatesCrinum Mine - Development Rates

Averaged 3.0m per op hr for 46.6 op hrs per week in MG15

MG15 Weekly Metres per Hour

3.69

3.092.843.00

3.233.49

2.882.96

2.19

3.33

2.68

3.43

2.40

3.223.09

3.91

2.67

3.69

3.203.44

2.953.01

3.47

2.66

3.38

2.86

3.82

2.963.032.862.902.973.24

1.91

2.842.762.36

1.79

2.502.84

2.31

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

01 J

an

15 J

an

29 J

an

12 F

eb

26 F

eb

12 M

ar

26 M

ar

09 A

pr

23 A

pr

07 M

ay

21 M

ay

04 J

un

18 J

un

02 J

ul

16 J

ul

30 J

ul

13 A

ug

27 A

ug

10 S

ep

24 S

ep

08 O

ct

Week Ending (Date)

Mat

res

per

Ho

ur

01.01.01

7Gregory Crinum

Decision Behind Crinum EastDecision 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.

01.01.01

8Gregory Crinum

Decision Behind Crinum EastDecision 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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9Gregory Crinum

Crinum East Mine PlanCrinum East Mine Plan

01.01.01

10Gregory Crinum

Crinum East TrenchCrinum East Trench

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11Gregory Crinum

Crinum East - Changes to DevelopmentCrinum 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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12Gregory Crinum

Crinum East - Production with Joy CMCrinum 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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13Gregory Crinum


Averaged 135m per week in MG17 with Joy miner.

MG17 Weekly Development Metres - Joy Continuous Miner

157134 131

169

244

40

188

114

167

91119

141

62

119

191

104

171

52

186

52

111

179

31

200

158

202

119

0

50

100

150

200

250

300

29 O

ct

05 N

ov

12 N

ov

19 N

ov

26 N

ov

03 D

ec

10 D

ec

17 D

ec

24 D

ec

31 D

ec

07 J

an

14 J

an

21 J

an

28 J

an

04 F

eb

11 F

eb

18 F

eb

25 F

eb

04 M

ar

11 M

ar

18 M

ar

25 M

ar

01 A

pr

08 A

pr

15 A

pr

22 A

pr

29 A

pr

Week Ending (Date)

Metr

es

01.01.01

14Gregory Crinum


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

3.743.44

3.85

2.96

3.70

2.67

3.24

2.592.612.842.77

3.13

2.38

3.403.03

3.353.113.25

3.723.25

3.003.44

2.38

3.13 3.293.113.50

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

29 O

ct

05 N

ov

12 N

ov

19 N

ov

26 N

ov

03 D

ec

10 D

ec

17 D

ec

24 D

ec

31 D

ec

07 J

an

14 J

an

21 J

an

28 J

an

04 F

eb

11 F

eb

18 F

eb

25 F

eb

04 M

ar

11 M

ar

18 M

ar

25 M

ar

01 A

pr

08 A

pr

15 A

pr

22 A

pr

29 A

pr

Week Ending (Date)

Metr

es p

er

Ho

ur

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15Gregory Crinum

Introduction of the ABMIntroduction 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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16Gregory Crinum


Monorail and flexiduct ventilation system to improve cutting rate and reduce manual handling of ventilation tubes.

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17Gregory Crinum


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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18Gregory Crinum

Crinum East - Production with ABM CMCrinum 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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19Gregory Crinum


Averaged 84m per week in MG17 with ABM miner.

MG17 Weekly Development Metres - ABM Continuous Miner

87

6654 52

95

119

96

50

93

148

38

60 5747

109

38

110

54

107

81

171

89

70

121

91

156

100

4462 64

85

0

20

40

60

80

100

120

140

160

180

06-M

ay

20-M

ay

03-J

un

17-J

un

01-J

ul

15-J

ul

29-J

ul

12-A

ug

26-A

ug

09-S

ep

23-S

ep

07-O

ct

21-O

ct

04-N

ov

18-N

ov

02-D

ec

Week Ending (Date)

Metr

es

01.01.01

20Gregory Crinum


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

2.562.642.702.36

1.09

3.13

3.56

3.13

2.582.85

2.532.22

1.46

2.61

2.192.00

2.202.25

2.82

2.25

2.71

2.17

2.692.812.682.742.38

3.38

2.72.56

3.27

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

06-M

ay

20-M

ay

03-J

un

17-J

un

01-J

ul

15-J

ul

29-J

ul

12-A

ug

26-A

ug

09-S

ep

23-S

ep

07-O

ct

21-O

ct

04-N

ov

18-N

ov

02-D

ec

Week Ending (Date)

Metr

es

01.01.01

21Gregory Crinum

Crinum East - Issues with the ABM SystemCrinum East - Issues with the ABM System

There were a number of issues associated with the ABM and the system supporting it:

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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22Gregory Crinum


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.

01.01.01

23Gregory Crinum


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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24Gregory Crinum


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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25Gregory Crinum


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.

01.01.01

26Gregory Crinum

Crinum East - Improving the ABM SystemCrinum 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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27Gregory Crinum


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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28Gregory Crinum


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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29Gregory Crinum


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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30Gregory Crinum


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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31Gregory Crinum


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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32Gregory Crinum


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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33Gregory Crinum


The POP process.

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34Gregory Crinum


Analysis of downtime for each miner.

Comparison Of Continuous Miners

0%

5%

10%

15%

20%

25%

30%

Safe

ty/T

rain

ing

Meeti

ng

Tra

vel

Cri

b

Serv

ice E

xtn

/ R

etn

Secti

on

Pre

p

Belt

s -

Pan

el

Bre

ak O

ffs/T

urn

s

Fli

ttin

g

Co

nveyin

g

Ven

tila

tio

n

Ro

of

Bo

lter

Cu

tter

Po

wer

Dis

trib

uti

on

Hyd

rau

lics/P

neu

mati

cs

No

Lab

ou

r

Wait

on

Tra

desm

an

Ele

ctr

ical

Co

ntr

ol

Delay Type

Dela

y %

COM016 COM017 COM018 COM019

01.01.01

35Gregory Crinum


After 2 months of the POP project, a number of areas of opportunity have been identified:

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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36Gregory Crinum


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.

01.01.01

37Gregory Crinum

Crinum East - Targets for the next YearCrinum 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.

gregory crinum acarp roadway development - operators workshop march 2008 roadway development at...

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