MINING SAFETY. Longwall Technology for Safe underground mining Adriayla Longwall a torch bearer. B. Bhaskara Rao GM ( I &PM ), SCCL

Transcription

1 Confederation of Indian Industry MINING SAFETY Longwall Technology for Safe underground mining Adriayla Longwall a torch bearer B. Bhaskara Rao GM ( I &PM ), SCCL Date: The Singareni Collieries Company Limited (A Government Company)

2 Introduction Structure Coal mining an overview Safety trends in mining Brief on SCCL Adriyala Longwall Project Significance and experiences.

3 Mining Any thing we use If it is not grown ( agriculture ) it is Mined Pre historic Industry stone age/metal age A natures gift Geo specific Major Economic activity globally : Direct or Indirect- Fuels economic growth of the nation. Impact Socio & Political International relations Yet it is Dirty,Hazardous Corporate Planning & not & Projects eco friendly 3

4 Mining Metal Mining Non Metal Coal Non Coal Coal mining became synonymous for mining -for its predominant proportion -risks and safety requirements -global share in energy.... Corporate Planning & Projects 4

5 Global Energy Consumption Coalcontinuestobe Key source of global energy Increasefrom26%to30% In Source: Corporate Planning & Projects 5

6 World Coal Scenario World Coal Production: 7,823 MT Major Producers of Coal as on : India : 3 rd place 8.5 % Share PR China MT USA 904 MT India 612 MT Indonesia 489 MT Australia 459 MT Russia 347 MT South Africa 256 MT Germany 191 MT Poland 143 MT Kazakhstan 120 MT SOUTH AFRICA 3% AUSTRALIA 6% INDONESIA 5.5% GERMANY 2% RUSSIA 4% POLAND 2% KAZAKHSTAN 2% Others 740 MT (Source IEA INDIA 8.5% Corporate Planning & Projects USA 12% 2014) RR CHINA 46% 6

7 In India

8 In India

9 Disasters in earlier years : Inundations Explosions Fires Major Causes of accident: 27 December 1975: Chasnala Mining disaster due to inundation, Dhanbad in Jharkand, India, 372 miners died. In recent past Roof and Side fall Haulage From the stage of major disasters, accident trend decreases by various measures. Corporate Planning & Projects 9

10 Major Statutes that Govern Mines Safety The Mines Act 1952 The Mines Rules 1955 The Coal Mines Regulations 1957 Mines Vocational Training Rules 1966 Indian Explosives Rules Indian Explosives Act Mines Rescue Rules Central Electricity Regulations 2010 Corporate Planning & Projects 10

11 Corporate Planning & Projects 11

12 SAFETY POLICY OF THE COMPANY 1. To continuously review all existing Safety practices and to improve and update them as and when the changed circumstances demand. 2. To ensure that every one in the Organization is aware of the safe working Methods and follow them in day-today work. 3. To develop the skills of employees as a skilled worker can only be a safe worker 4. To reduce the accident rates to the barest minimum and to achieve zero accident potential being the ultimate aim. Corporate Planning & Projects 12

13 - Risk Assessment - Risk Management Plan Current Trends - Safe Operating Procedures. - Duty Care System. - Self Regulation. - Inclusive Systems even family and colleagues involvement - Welfare and Social well being. - Training and Skill Development. Corporate Planning & Projects 13

14 Drivers of Change - End of Colonialism - Nationalization of Coal Industry. - Amalgamation of Smaller mines - Thrust on Opencast mining. - Militant Trade unionism. But what is the real game changer? Corporate Planning & Projects 14

15 TREND OF FATAL ACCIDENTS (Number of persons killed) In SCCL Fatalities

16 60 Fatalities in SCCL people died in Roof fall &17 in Inundation in Manpower (Number of Work Persons in Ten Thousonds) Production (In MT) Fatalities (Number of Persons)

17 Cause-wise Fatalities In SCCL Roof fall Side fall Rope Haulage Roof fall Side fall Rope Haulage

18 - Major accidents at GDK 7 LEP and GDK 8 A in 2003 But the company responded by positive aggressive changes on the core.. - Two Key Changes - Face Machnisation Minimise Exposure to the face - Men Transport Systems. - - Mechanization increases production and Productivity. - ReducenumberofmenexposedtoRISK. - There by reduce number of accidents/ fatalities. FromHereWhereWegoforSafeHighProductiveMinnigofCoal AdriyalaLongwallaTorchBearer.. Corporate Planning & Projects 18

19 COAL SCENARIO INDIA Reserves: Estimated Indian coal reserves 297 billion tons % India Total Reserves: Bt SCCL sharing 7% with billion 34% Depth wise Coal reserves as on (Bt) 59% Total INDIA % SCCL Total Reserves: Bt % SCCL % (Courtesy: infomine.com/index/pr/pb pdf)

20 UG mining technologies presently in vogue in India are : Manual Bord& Pillar system Semi-mechanized Bord& Pillar System With SDLs/ LHDs Blasting Gallary Method Continuous Miners : B&P liquidation & Development High Wall Mining Mechanized Longwall (PSLW) Mining System Short wall Mining Technology 20

21 Adriyala a Torch bearer 21

22 LOCATION Godavari valley coal fields Telangana Mines are located across 4 districts of Telangana i.e. Adilabad, Karimnagar, Warangal and Khammam Corporate Planning & Projects 22 22

23 SCCL at a glance HUMAN ASSETS 58,495 as on GROSS TURNOVER Rs. 14,078 Crs. ( ) Prov MT Coal produced ( ) Started in MT Target ( ) Regions - 3 Areas - 11 OC Mines 16 UG Mines - 31 Corporate Planning & Projects 23

24 SCCL Mile stones to improve safety 1948: Machine mining ( Joy loader & shuttle cars) 1951: Electric coal drills 1953: Electric cap lamps 1954: Flameproof electric equipment 1975: Opencast mining 1979: Side Discharge Loaders 1981: Load Haul Dumpers and Road Headers 1983: Longwall mining 1986: Walking Dragline 1989: Blasting Gallery method 1994: In-pit crushing and conveying 2002: Surface Miner 24 24

25 SCCL Mile stones to improve in safety 2004: Phasing out manual Coal filling launched. 2006: Continuous Miner. 2007: 3D Laser Scanner (for mine survey) 2008: ERP(SAP) (first Govt. Coal producing Company) 2008: Diesel operated UG machinery 2009: LED Cap Lamps 2010: High Wall Mining 2012: Air Conditioning in Underground 2014: High Capacity Longwall : Adriyala 25

26 In the eve of Reduction in Accidents and Improve in Safety SCCL introduces High Level Mining method. State of Art Technology In Underground Mechanization A Case Study of Adriyala Longwall Project FBL-55

27 Reasons for decline of U/g mining Availability of shallow reserves for immediate requirement. Need of immediate bulk production. Requirement of huge capital and long gestation limiting entrepreneurs High risk investments. Increases in manpower costs and low OMS in U/g method. High risks of strata control, fires, subsidence, gas problems etc. Non availability of indegenous equipments & limited markets 27

28 Challenges in U/G mining -ALP Ventilation Strata control Men transport Material transport Coal transport system Pumping and water management Automation systems

29 Future of Underground mining Longwall Technology

30 HISTORY OF LONGWALL IN INDIA First Longwall face in India: August 1978 at Moonidih, CIL First Longwall face in SCCL: GDK 7 Incline in September 1983 in SCCL Production from LW in India & SCCL: CIL achieved highest production In the year where as SCCL achieved highest production In the year PRODUCTION (LT) LONGWALL PRODUCTION (LT) CIL SCCL The experience from the first generation Longwall faces was not encouraging. Poor Utilisation of Man and Machine Problems with caveability of the roof Strata control problems Downtime of equipments by improper matching of the sub systems.

31 GLOBAL LONGWALL SCENARIO The world s most productive longwalls are located in the USA, Australia and the Shenhua coalfield of China. Experience of LW world wide USA 49 operating Longwalls producing over 175 million tonnes per year best achieving over 7 million tonnes per year. average production is over 3.8 million tonnes per longwall face per year Australia 9 operating Longwalls Producing over 47.5 million tonnes per year Best achieving over 7 million tonnes per year China Shenhua operating 07 major Longwalls producing over 200 million tonnes per year Producing between 5 and 10 million tonnes per longwall face per year.

32 LONGWALL MINING IN AUSTRALIA 28 faces produced 100Mt (only LW 92MT, Excluding Development) Average for all LW face > 3MT 10 faces produced over 4MT (Most of the new faces) High production mines 5 to 7MT from one face Beltana, Ulan, Newlands, Kestrel, Oaky, Creek..etc. Ulan Produced 6.3MT Trend is towards wider and longer faces (most of the new LW faces towards 300m. Ex: Ulan mine- 400m face length). One LW face per mine (moved away from 2 faces per mine) Description Capacities Low Medium High Production 2 2.5MT 3-5MT 7-10MT Face width m 250m m Support capacities in T >1700 Support type, Width 4leg, 1.5m 2leg, 1.75m 2leg, 2.0m Shearer Kw Up to 3000 AFC TPH Up to 3000 Up to 5000 State of the art in yrs. Early / mid 1990 s Early / mid 2000 s Current 32

33 Geo-Mining conditions Improper selection Faulty planning Analysis of the problem Management of Face Longwall support selection deficiencies Large expansion in opencast mining Research needs Standardization of equipment Planning Spare parts management Present actions and future needs Monitoring of performance (Source: Workshops and overhauling facilities Man power deployment Indigenization

34 ALP MINE PLAN

35 FR approved on: Production capacity: Capital outlay: MTPA. Rs Crores. STUDIES AND CONSULTANCIES Required studies was carried out by various scientific institutes like CIMFR, NIT(Warangal), BHU, ISM(Dhanbad). Other Consultancy services: Andy Rutherford Pty. Ltd, Australia. M/s Mine Advice Pty. Ltd, Australia Awarded value: Rs 5,87,84, List of Scientific studies awarded As per the guidelines of CSIRO, the FR proposals have been modified. Entriesto the property were made through Punch Entries on OC-II side for Adriyala property.

36 Activities in Construction Development Strata control ( cable bolts pictures can be in this head ) Equipment procurement. Ventilation ( Pictures of shaft fans etc. can be here ) Men transport Material transport system Floor concreting. Conveying system Dewatering Inbye water supply system.. Face installation : ( transport of equipment ) ( Like this list activities in proper order susbsequentslides be in that order highlight key point in the activity with photographs where ever available )

37 Development Four DOSCO s with twin bolters arrangement. One WIRTH Road header with twin bolters arrangement. TWO Refurbished AM 50. Overall length 11.18m Height (canopy) 2.25m Width 3.56m Machine weight 63T maximum working gradient 18 Total power 362 kw Overall length 10.29m Height 2.57m Width 3.6m Machine weight 65T maximum working gradient 18 Total power 360 kw

38 Strata control Gate roadways development Problem with working section 2 major falls in TG1 gate roadway etc. Guttering along the galleries ( Horizontal stress) Roof deformation Water seepage Change of working section o Roof section was lowered by leaving 0.3m coal against 0.75m shale+0.25mclay+0.1m shale. o Sand stone floor was exposed by cutting the stone floor for FSVs movement. o But roof Guttering problem found to be continuing. o Hence, a decision was taken lower the roof section further to reduce the effect of roof guttering.

39 Major recommendations by Russel Firth: Change in the cut troughs direction in view of the Major Horizontal Stress. Rigid Wire mesh Rigid wire mesh Single bolts in mesh overlap area Stable roof conditions Roadway with rigid wire mesh and single bolts without w strap Stable roof conditions

40 Pre Tensioning Cable bolts introduction for eliminating the vertical supports (OC Props). Face dip Supporting / preparation of the installation roadway with 8m width.

41 Equipment procured Major equipment (LW face equipment, Gate belt, 11 KV electricals, Wirth Road header) : Germany 11 KV electricals, Cables for 11 KV system, DOSCO Road header : UK Crane : US Ventilation Fans : Spain Over land and Trunk conveyors : China Free steered Vehicles, Spares for Free steered vehicles, Cable bolts and its accessories Total value: crores Details of equipment procured : Australia

42 Construction of Return Air shaft: Ventilation Return air shaft of finished diameter of 7.50m. & approximate depth of 468 m sunk at Adriyala for the purpose of ventilation. Type of Lining: Reinforced Cement Concreting of 300mm thick Grade M-20, Containing coarse aggregate of 20mm down gauge.

43 Ventilation arrangements Main Mechanical Ventilators : 400KW, Zitron make MMV m3 / min 43

44 Air Conditioning in UG mine Average surface temperatures in Coal fields of SCCL vary from 12 deg (Winter) to >50 deg (Summer). To create comfortable working conditions in the mines, high capacity fans are being installed in the mines. Air-conditioning system installed at VK-7 incline mine of KGM area and envisaged to install Air conditioning/spot coolers in its future deep mines. 44

45 Men and Material Transport system Man riding chair car system was provided in PE5. Floor concreting for movement of Diesel equipment Total length -1.8 km Width - 5.2m Grade -M 40

46 System of Men Transportation By Mine Cruisers

47 Coal conveyance System Total number of Gear heads 11 nos Capacities varying from - 1 X315KW to 4 X 500KW Speed - 4 m / sec Type of Drive - VFD Belt capacity TPH Belt Type - Steel cord (ST 800 to ST2500) Total Length 9km Total power KW

48 Conveyor installation Civil works: Construction of Foundation beds:

49 Templates fixing:

50 Overland belt conveyors A1 Conveyor A2 Discharge A3 Conveyor

51 Overland belt conveyors A1 Conveyor Stock pile arrangement

52 Overland belt conveyors A4 Conveyor

53 Overland belt conveyors B3 Conveyor Discharge

54 Overland belt conveyors B1 Conveyor Discharge B0 Conveyor B0 Conveyor Discharge

55 Overland belt conveyors Walk way

56 11 kv transmission to UG First time in India. Electrical System Existing installed power of the mine 6MVA Proposal for longwall Longwall Kw (including GB) Trunk belts Kw ( UG-6300Kw + SF 6465 Kw) Ventilation - 2 X 400Kw + 75Kw Pumps - 5 X 350HP and 4 X 190HP MRS / haulers Kw Air cooling plant - appox 300Kw Air compressor plant - 3 X 250 KW

57 SUPPORTS LOADING AT GERMANY

58 PRS & MATERIAL UNLOADING AT GDK10A Totaltonnage: 7354 T Local transport surface: Total equipment transportation from GDK 10A longwall shed to Punch Entry surface was done by 60 T trailer, 10 T Lorries and loading with 120 T groove, 10 T escort cranes.

59 Material Handling Different type of tools used: For Roof Supports: 25T D Links front side 2nos 10T D Links rear side 2nos GLVD Sling 6x37 32mm, 40T, 10.0 mtrlength 2nos GLVD Sling 6x37 24mm, 10T, 4.0mtr length-4nos Changed the above set of D Links and slings for every 30 Supports. For other material: 5T D Links 8 nos 10T D Links 6 nos GLVD Sling 6x19 24mm, 10T, 6.0 mtrlength -6 nos GLVD Sling 6x19 12mm, 5T, 5.0 mtrlength -8 nos GLVD Sling 6x37 32mm, 30T, 6.0 mtrlength -4 nos POLYSTER Round sling 5T, 12mtr length 8 nos POLYSTER Round sling 10T, 6mtr length 8 nos Changed the above set of D Links and slings for every 10 days. Types of methods adopted: Cranes: 120T Grove Crane 1no Escorts Crane 1no

60 Longwall Installation: Underground transport and installation: Total equipment transportation and installation was done by FBL diesel equipments from surface to Longwall face which was imported from Caterpillar - Australia. Approx T of equipment was transported by these vehicles. Machines used are: FBL-55 FBL-10 FBL-15 CHT-50-2No.s -2No.s -2No.s -4No.s Tools used: Chain binders: D links: 10 T, 05 T

61 Supports Transportation

62 Supports Transportation

63 Supports Transportation

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65 Shearer Loading & transportation

66 Shearer Loading & transportation

67 Shearer Loading & transportation

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71 Field trial permissions: DGMS permissions Total 16 no of equipment approvals obtained. Permissions obtained: Total 23 permissions have been obtained from inspectorate. Specific New Permissions: 8 m roadway without vertical supports. Extraction of 250m length Longwall face. Long development drivages and Gate road dimensions.

72 Over View of Adriyala Longwall Project Punch Entries Stock pile arrangement contingency 9km Trunk belts from Face to SILO Mine Control Center

73 AdriyalaLongwallProject Face operation * Standard Operating Procedures for every operation have been laid down and are strictly implemented.

74 Challenges for Growth High Cost : UG mining to be subsidized / cross subsidy High cost Imported equipment : Tax reliefs on capital equipment for infrastructure. DGMS approvals : Liberal frame work to use globally proved equipment Need of more players for shaft sinking, development etc. Business partnerships Risk gain share / MDOs

75 Thank You for your Attention