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

28

30

29

32

31

33

34

35

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

THANK YOU