Semimechanization sdls&lh ds

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Semimechanization sdls&lh ds

  1. 1. SEMI-MECHANISATION BY SDLs & LHDs I. Satyanarayana, M.Tech,MBA,MCA Dy. Manager, Project Planning, SCCL, isnindian@gmail.com, visit at www.slideshare.net/isnindian ISN
  2. 2. PRESENTATION ONSEMI-MECHANISATION BY SDLs & LHDs I. Satyanarayana, M.Tech,MBA,MCA Dy. Manager Project Planning ISN
  3. 3. CHRONOLOGY OF INTRODUCTION OF UG MECHANISATION IN SCCL1956 – Coal Cutting and Coal ploughing1962 – Gathering arm loaders and Shuttle Cars1976 – SDLs (GDK No. 9 Incline)1979 – Roadheaders1980 – LHDs (GDK No. 9 Incline)1983 – Longwall Technology1989 – Blasting Gallery Technology ISN
  4. 4. INTRODUCTION• In order to keep away with the arduous labor of loading coal manually, to avoid exposure of persons at face and improve productivity efforts are made to introduction of intermediate technology and continuous mining systems.• as a result, in India SDLs & LHDs have taken foot forward in intermediate technology. contd… ISN
  5. 5. INTRODUCTION• The Board and pillar method has been predominantly adopted in SCCL and in India for the extraction of coal seams due to shallow depth and good roof conditions.• Although every effort is made to introduce LW method of mining, it is not likely to replace the entire board and pillar method contd… ISN
  6. 6. STATUS OF SDLs AS ON 24.01.2011 ISN
  7. 7. STATUS OF LHDs AS ON 24.01.2011 ISN
  8. 8. Cycle of Operations•Drilling•Blasting•Supporting•Coal loading (SDLs & LHDs) ISN
  9. 9. OPERATION OF LHDs and SDLs Method of working The method of development and depillaring with LHDs/SDLs was similar to Conventional development of forming rectangular OR square pillars as per Regulation 99 of Coal Mines Regulations, 1957 and subsequent extraction of pillars by splitting and judiciously reducing it. Coal Preparation Coal preparation for LHD/SDL was done by conventional drilling and blasting.TransportationThe coal carried by LHD/SDL from the face was discharged on to thepony belt conveyor, which was maintained as near to the face aspossible, even though LHD/SDLISN cope with about 100m lead. can
  10. 10. LOAD HAUL DUMPERS (LHDs) ISN
  11. 11. Details of LHD• an electro-hydraulic powered underground mining equipment• used to collect the coal, haul upto the discharge point ofhopper/chain conveyor/belt conveyor located within 100 m fromthe coal face and to dump on it.• 50 HP (811 Model) Motor and 100 HP (912E Mode) Motor•Three forward and three reverse speeds.• The working pressure of hydraulic system is 2200 PSI anddischarge 16 GPM.• The hydraulic tank capacity is 210 ltrs.• Oil is cooled by a radiator and fan run by hydraulic motor.• The power to the machine is fed by a trailing cable 16 m2handled by a cable reeler, which can accommodate 100 m length. ISN
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  13. 13. LHD mechanization – where the gradient is 1 in 6 & flatter ISN
  14. 14. Load Haul Dumpers ISN
  15. 15. LHD ISN
  16. 16. LOAD HAUL DUMPER IN BLASTING GALLERY METHOD ISN
  17. 17. Capacity and Speed 6.15m3 ISN
  18. 18. Advantages of LHDs(a) Indigenous and : To save foreign exchange and to availability of spares reduce breakdown hours.(b) Robustness : To withstand difficult conditions.(c ) Compactness : To work in restricted underground space.(d) Reliability and : To enable to resist difficult conditions. susceptibility(e) Adaptability : For easy maintenance.(f) Portability : Easy to move from place to place.(g) Safety : Proper guides and covers. Elect. Protective devices. ISN
  19. 19. SAFETY FEATURES of LHDs1. HEAD LIGHTS2. OPERATOR’S CANOPY3. DUMP VALVE4. PARKING BRAKES & SERVICE BRAKES5. GONG BELL6. AUDIO VISUAL ALARM7. EMERGENCY STOP BUTTON8. DEAD MAN SWITCH9. FLOAT (OIL LEVEL) SWITCH10. TEMPERATURE SWITCH11. CABLE OVERRIDING SWITCH12. PILOT CORE PROTECTION13. PUSH BUTTON STATION14. BRAKE ACCUMULATORS ISN15. FIRE EXTINGUISHERS
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  21. 21. Details of LHD ..Contd•The temperature of hydraulic oil is kept well below 65o C.Cycle Time for LHD 811 Model1. Available time per shift - 390 minutes2. Time for trip - 5.7 minutes3. Number of trips per shift for LHD - 654. Output per shift for LHD - 72 tonnes5. OMS - 3.375 tonnes6. Output per drill - 60 tonnes ISN
  22. 22. BEST PRACTICES ..Contd Keeping LHD path clean, dry and flatSmooth and uniform discharge by LHD on the belt conveyorCategorisation of Spares & ensuring availability of fastmoving parts in underground stores.Providing appropriate tools for techniciansAvoiding acute anglesPreshift extention/retreating and maintenance of conveyor beltsPreshift maintenance of LHDsEasily shiftable tail end assemblyReplacing/overhauling Transmission and axles of LHDs (biannualProviding drill machine in each face and spare Gate EndPanels for LHDs Cable VulcanisingTyre and tube repairing and inflation ISN
  23. 23. METHOD OF DEPILLARING GOAF ISN
  24. 24. Manpower requirement for Depillaring district with 5 LHDs Sl. SHIFT Designation Gen. Shift Total No I II III 1. Under Managers 1 1 1 1 4 2. Asst. Engineers 1 NIL NIL NIL 1 3. Overman 1 1 1 1 4 4. Mining Sardars 1 1 1 1 4 5. Electrical Supervisors 1 Nil NIL NIL 1 6. Shotfirers NIL 6 6 6 18 7. Coal cutters NIL 24 24 24 72 8. Support Mazdoors 15 15 15 15 60 9. LHD Operators NIL 5 5 5 15 10. Conveyor Operators NIL 7 7 7 21 11. Fitters + Helpers 6 4 4 4 18 12. Electricians + Helpers 2 2 2 2 8 13. Conveyor shifting gang 6 NIL NIL NIL 6 14. Water Spraying 3 NIL NIL NIL 3 15. Ventilation (Mazdoors) 4 NIL NIL NIL 4 16. Tyndals 9 NIL NIL NIL 9 17. Gen. Mazdoors 25 15 15 15 60 18. Cable Vulcanizer 2 NIL NIL NIL 2 total 77 ISN 81 81 81 320
  25. 25. SIDE DISCHARGE LOADERS (SDLs) ISN
  26. 26. SDL mechanization – where the gradient is 1 in 4 & flatter ISN
  27. 27. Side Discharge Loaders ISN
  28. 28. SIDE DISCHARGE LOADER IN SEMI MECHANISATION ISN
  29. 29. SIDE DISCHARGE LOADER IN SEMI MECHANISATION ISN
  30. 30. COMPARISON BETWEEN SEMI-MECH & HANDSECTION 3 SDLs HS (2 Drills)Output (LTPA) 1.62 0.9Men on Roll(Nos) 181 281OMS (at dist. Level) (T) 2 1.2Cost of Production (Rs./T) 1859 4032Profit over HS (Rs./T) 2227 --Initial investment onP&M (Rs.Lakhs) 180 57 *Output from SDL depends on its availability & utilisation ISN
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  33. 33. SAFETY FEATURES of SDLs ISN
  34. 34. UNIVERSAL DRILL MACHINE ISN
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  38. 38. CODE OF PRACTICE FOR SDL OPERATOR ISN
  39. 39. CODE OF PRACTICE FOR SDL OPERATOR ISN
  40. 40. CODE OF PRACTICE FOR SDL OPERATOR ISN
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  45. 45. Code of Practice for Overman: He should inspect the route of LHD/SDL marching priorto marching and take the following precautions: Ensure no obstruction in the way of marching. Check thepresence of W-straps, bolts, chock timber, old pipes andother material that damage to the LHD/SDL and result toother breakdowns. Take necessary precautions to prevent dislodgment ofvertical supports, if any, due to moving trailing cable. Ensure that the persons engaged have taken all necessaryprecautions. Take necessary precautions while crossing track line, pipeline etc. And also avoid rubbing of trailing cable againsthard surfaces and to pillar corners. ISN
  46. 46. OPERATING PROBLEMS• Non-availability of machine• Poor utilization of machine• Lack of Coal preparation• Delay in supporting• Delay in machine tramming• Delay in tub supply or backup transport services (crusher, belts, bunkers etc.,)• Idle time due to shift change hours• Lack of spares availability ISN Contd…….
  47. 47. OPERATING PROBLEMS• Lack of on-hand trained crew• Lack of midlife overhaul of machinery• Lack of maintenance of machinery• Poor working environment• Timely not positioning of supervisors• Poor placement of orders• Unsatisfactory incentive schemes• Untrained mechanized district crew right from supervisor to workmen. ISN
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  50. 50. RECOMMENDATIONS ISN
  51. 51. PERFORMANCE SUMMARY ISN
  52. 52. Approved norms of SCCL for monitoring UGMM equipment performance Bucket Standard Standard ProductionEquipment capacity availability utilization (TPA/TPD) in Cu m SDL 1.1 91% 58% 54000/180LHD 811 1.5 91% 57% 60000/200LHD 912 2.7 91% 57% 100000/333BG LHD 2.7 91% 57% 100000/333 ISN
  53. 53. INPUTS FOR IMPROVING PRODUCTION ISN
  54. 54. 1. Improvement of availability and utilization of machinery – Idle time due to shift change hours can be reduced by implementing overlapping 4 shifts. – Proper maintenance of machinery i.e., strict scheduled maintenance should be followed. – By making availability of coal at max. no of working faces. – Reducing flitting distance of machine. – Timely availability of spares by follow up with firms and placement of RC & departmental contracts. – By introducing sufficient number of mechanized roof bolting machines with rated power pack/ air compressors. – Deployment of trained efficient supporting crew, technicians and operating personnel. ISN
  55. 55. 2. Working of full shifts.– Implementation of staggered shifts– Positioning of supervisors in time.– By improving good environmental conditions such are ventilation, supporting, drainage and house keeping.– Keep availability of material for supporting , ducting and spares.– Efficient back up services like pumping, work-shops, coal evacuation system, bunkers etc.,– Proper incentive schemes. ISN– Treating people with due regard.
  56. 56. 3. Other recommendations– Introduction of high capacity and cable less LHD’s– Good communication system at all levels.– Intensive monitoring at all levels.– Increasing length of cable by reducing diameter of cable or increasing drum diameter.– Mechanization of face drilling.– Introduction of multi job concept like ‘operator cum mechanic’, ‘coal cutter cum support men’ ISN Contd……
  57. 57. 3. Other recommendations– Introduction of equipment maintenance by OEM.– Design of suitable training module.– Out sourcing of non-core activities– Adjusting general shift man power in production and retaining only in statutory requirement.– Explore the workings at suitable gradient.– Avoiding water and slurry condition by proper maintenance of drainage system– Selection of educated and young persons as operation ISN crew.
  58. 58. CONCLUSIONAvailability of coal faces & more yield per blastMaintain less lead (30m)Continuous LoadingExtensions/Retreats & Pre-shift maintenance etcIncrease machine utilizationBetter working conditionsGood discipline, higher morale and well planned actionsTraining ISN
  59. 59. ISN

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