ACARP

1
ACARP
Australian Coal Association Research Program

• Australian Roadway Development
• Improvement Project
• OPERATORS WORKSHOPS
• September 2006

2
OBJECTIVE AND FORMAT

• Provide a forum for roadway development operators
  to
• Learn of emerging best practice and roadway
  development initiatives
• Learn of developments in equipment and technology
• Network with peers, and share their experience
  and learnings (and not just their successes)
• Identify areas for targeted research

3
FORMAT

• Four workshop subjects presented by best practice
  operators
• Each workshop comprises a 20-25 presentation and
  a 20-25 minute open forum for discussion and
  sharing of experiences and learnings
• Poster board presentations by OEMs and
  researchers
• Plenary session to
• Capture key findings
• Identify opportunities to improve the workshop
  process
• Identify other issues for future workshops
• Identify areas for targeted research
• Workshop report with copies of presentations to
  be provided to all participants

4
INTRODUCTION

• Prerequisites for attendance
• A passion for roadway development, and
• A willingness to participate in discussions and
  share experiences

5
ACARP
Australian Coal Association Research Program

• ROADWAY DEVELOPMENT
• TASK GROUP
• Guy Mitchell, BMA
• Glen Lewis, Xstrata Coal
• Bob Miller, Centennial Coal

6
2005 DEVELOPMENT CHALLENGE Why?

• Marked increase in demand for export coal.
• Significant increase in capital and production
  costs.
• Substantial improvements in longwall production
  and productivity are continuing to be achieved.
• Improvements in roadway development are generally
  failing to keep abreast of longwall improvements.
• Higher capacity, new generation mines are being
  planned.
• Older mines are still struggling to survive as it
  becomes more difficult to find solutions and
  successfully apply them.
• Unlikely that both will be realised if current
  roadway development activities and trends are
  remain unchanged.

7
2005 DEVELOPMENT CHALLENGE

• RDTG formed design a roadmap or strategy for
  targeted RD to improve roadway development.
• Previous attempts as one off Company
  initiatives have failed
• Poor problem scope, planning organisation
• Lack of Mine involvement and commitment
• Poor execution and patience
• Absence of information sharing (competitive
  edge)
• Industry wide problem where common sense suggest
  joint problem solving approach where we share
  successes and failures!
• Initial members were Anglo, BHPB, BMA,
  Centennial, Rio Tinto, Thiess, and Xstrata.
• References to July 2005 ACARP report identifying
  what incremental and step changes can and must be
  made in roadway technology and systems
• Development of new generation longwall mines
• Older mines to remain competitive

8
2005 DEVELOPMENT CHALLENGE

• Report Recommendations
• What operators/mine managers should do
• What mine owners should do to address key
  constraints
• What incremental/step change initiatives should
  be pursued by ACARP
• Focus on Key Elements
• Coal cutting and loading
• Roadway support
• Coal clearance
• Logistics (services supplies)
• Operators Workshop
• Industry practitioners with broad range of
  conditions
• Detailing sub elements of the development process
• Providing insight into where their gains have
  been made
• Process control/continuous improvement
• Roof/rib support practices and equipment
• Best practice maintenance
• Panel advances
• Opportunity for questions and discussions

9
ACARP
Australian Coal Association Research Program

• REVIEW OF AUSTRALIAN ROADWAY DEVELOPMENT
  CURRENT STATUS
• Gary Gibson, ACARP

10
2005 REVIEW

• Identify where past wins have been achieved and
  the lessons learnt.
• Identify incremental and step changes in roadway
  development technology and systems necessary to
• Enable new generation, high capacity longwall
  mines to be developed
• Provide productivity gains to enable existing
  mines to compete with the new generation mines.
• Identify specific RD opportunities for new
  technologies, equipment and associated systems.
• Build support and commitment for a targeted 7
  year RD program.

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INDUSTRY REVIEW PROCESS

• Reviews conducted with representatives from
• All longwall mines
• Bolting hardware suppliers Hilti, Jenmar, and
  One Steel
• Corporate offices - Anglo, BHP Billiton, BMA,
  Centennial, and Xstrata
• Geotechnical consultants - SCT, Seedsman, and
  Strata Engineering
• Mining contractors - HWE, Roche, Thiess, UGM, and
  Walters
• Mining equipment OEMs - DBT, Joy, and Sandvik
• Other OEMs Alminco, Continental, Hydramatic,
  and PJ Berriman
• RD organisations CET, Eikon CoalStream, GSS,
  and QCAT
• Regulators and service providers DNRM, DPINR,
  and Coal Services
• TBM OEM/developers IHI and Pacific Tunnelling
• In all, some 160 persons participated.
• Structured review process at mine sites, 1 on 1
  interviews elsewhere.

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BEST PRACTICE MINES

• A wide range of performance levels were reported
  across a wide variety of mining conditions and
  equipment.
• Factors other than mining conditions, and
  equipment must be at play significant
  differences with similar equipment and similar
  mining conditions!

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BEST PRACTICE MINES

• Key factors differentiating best practice mines
  and others
• Driven culture, desire to succeed, focus on
  getting things right, accountability.
• Understanding of roadway development as a
  process, and the application of short interval
  process control.
• Degree of involvement of employees.
• Focus on utilisation of personnel through
  provision of adequate fit for purpose
  equipment.
• High levels of reliability and availability
  engineered into equipment, with focus on
  maintaining equipment fit for purpose.
• Awareness of and aggressive application of new
  technology, equipment and systems to improve
  safety, productivity and costs .

14
HIGH PERFORMANCE MINES

• High performers in poor conditions were typically
  achieving similar or better development rates
  than poor performers in good conditions.
• Factors typically evident at high performing
  mines
• Major focus on and prioritisation of roadway
  development.
• Incentive schemes strongly linked to development
  performance.
• Likely utilisation of 12CM/12/30/32 continuous
  miners in a balanced, sequential cutting and
  bolting process.
• Ability to complete panel advances in 12 15
  hours.
• Effective mine planning.

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MAIN FINDINGS

• Later generation mines with good conditions are
  likely to establish 15Mtpa mines without major
  developments in mining equipment and systems.

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MAIN FINDINGS

• Infrastructure limitations likely to constrain
  older mines from making major improvements in
  mine capacity.
• Adverse conditions associated with depth (eg
  stress and gas) will pose additional productivity
  challenges to older mines, and to later
  generation mines as they mature.

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MAIN FINDINGS

• Technology developments are currently underway
  which will address some key process constraints
  in the short to medium term, providing potential
  to improve system capability across all mines.

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CURRENT DEVELOPMENTS IN TECHNOLOGY

• Five self drilling bolting (SDB) systems are
  currently in various stages of development, with
  a variety of civil sector SDB also available (but
  expensive).
• Sandvik releasing an upgraded ABM25(S) designed
  for difficult mining conditions and 4.8m wide
  roadways. Likely to incorporate Aro
  semi-automated bolting system.
• Joy mooted to be developing a new generation
  continuous miner for global roadway development
  market.
• DBT established a global roadway development
  group.
• Both IHI and Pacific Tunnelling have developed
  concepts and detailed engineering designs for
  TBMs, and project that they could be on site in
  18 24 months.

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CURRENT DEVELOPMENTS IN TECHNOLOGY

• Joy had 2 floor mounted 4FCT systems in operation
  in US mines, with 2 other systems then under
  manufacture for US mines.
• Sandvik were due to shortly release a roof
  mounted continuous haulage system.
• Continental anticipated releasing a roof mounted
  monorail based extensible and retractable
  development/longwall conveyor.
• Cutting Edge Technologies had reportedly
  completed designs for an extensible conveyor
  system.
• Eikon had completed design for a 250m3/hour coal
  slurry transportation system.
• Finalisation of the ACBM was reportedly stalled
  by a failure to complete contracted development
  of an automated bolting system.

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ROADWAY DEVELOPMENT CONSTRAINTS

• Roof and rib bolting, and installation of roof
  and rib mesh
• Cyclic nature of coal haulers, particularly
  beyond 70m from boot end
• Advancement of conveyor and panel services,
  particularly with dual CM units
• Routine installation of ventilation ducting
• The logistics of supply, transport, distribution
  and handling - particularly at older mines.
• Installation of long tendons as primary support
  becoming more widespread - installation equipment
  still fairly rudimentary
• The physical demands of the work environment, the
  extent of manual handling, an ageing workforce
• Coal cutting was not seen as a constraint at any
  mine, however the ability of machines to cut
  breakaways for cut throughs was considered to be
  a major failure of all machine configurations.

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NEW MINING SYSTEM

• The key attributes of a new roadway development
  mining system were identified as
• Integrated, continuous cutting, bolting and coal
  clearance system continuous mining.
• Automated bolting, with self drilling bolts.
• Integrated materials supply and logistics with
  components stored in magazines or cassettes
  allowing minimal manual intervention.
• Extensible (monorail mounted) face services (eg
  ventilation, power, water, compressed air, pump
  out).
• Extensible, self advancing panel conveyor.
• High capacity, automated installation of long
  tendon secondary supports.

22
INDUSTRY CONSTRAINTS

• Real or perceived constraints to successful RDD
  of new technology and mining systems
• Industrys ability and willingness to fund and
  sustain the RDD of new mining systems,
  particularly through tight economic conditions.
• Few mines have sufficient development float to
  allow critical resources and mine real estate to
  be deployed to developing new technology.
• Scarcity of managers, engineers, supervisors,
  operators and trades.
• Limited size of Australian market, and OEMs
  propensity to develop new technology as global
  products, and for development to be done
  in-house.
• Lead time from concept to successful
  demonstration is too long
• loss of project champions (eg promotion or
  turnover) and
• diminution of corporate energy and critical mass.
• Overly restrictive legislation limiting the
  development and application of new technologies
  and the use of light weight materials.
• Over zealous pursuit of absolute safety first by
  Inspectorate, with prosecutions in the event of
  less than absolute safety.

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RECOMMENDATIONS

• What mine operators and mine managers should do
  to improve development performance.
• What mine owners should do to address key
  constraints.
• What incremental change initiatives should be
  pursued by ACARP.
• What step change initiatives should be pursued by
  ACARP.

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MINE OPERATORS AND MINE MANGERS

• Pursue industry best practice roadway
  development.
• Fully embrace concepts of process control,
  continuous improvement, and involvement of all
  personnel in those pursuits.
• Commit to conduct of a routine roadway
  development benchmarking process across the
  industry.
• Commit and contribute to a regular best
  practice roadway development forum and enable
  development practitioners to share successes and
  failures, and learn of new practices,
  developments in RD, and emerging issues.
• Through publication of Proceedings from the
  forums, support the development of a body of
  knowledge of best practice roadway development.
• Give due recognition to development in the mines
  operation
• Adequately resource development to enable it to
  be properly accountable for its performance.

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MINE OWNERS

• Develop and commit to a long term investment
  strategy to support and sustain the research,
  development and demonstration of new mining
  systems and technology.
• Develop and commit to a long term strategy to
  develop the industrys skills base and overcome
  the scarcity of experienced mining professionals,
  engineers, supervisors, operators and trades
  personnel.
• Challenge the restrictive legislative framework
  being imposed on the industry, and the regulators
  resort to prosecution in the event of less than
  absolute safety.
• Fund, support and sustain
• routine roadway development benchmarking studies
• conduct of regular best practice roadway
  development forums, and
• development of a best practice body of
  knowledge.
• Challenge mine operators and mine managers if
  they fail to pursue industry best practice
  roadway development practices.

26
ACARP
Australian Coal Association Research Program

• ROADWAY DEVELOPMENT
• IMPROVEMENT STRATEGIES
• Guy Mitchell, BMA
• Glen Lewis, Xstrata Coal
• Bob Miller, Centennial Coal

27
BRAINSTORM TIME

• A quick exercise
• Your thoughts ideas
• Your opinions
• Whats good?
• Whats bad?

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WORKSHOP RESPONSES - MACKAY

• GOOD
• Clean separation of development from longwall
  equal focus individual business units
• Involvement of operators and others in all facets
  of the development process and activities
• Companies using data to identify opportunities
• Ownership of process and involvement is high at
  high-performing mines
• Focus on workforce and community
• Parallel-pathing of activities

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WORKSHOP RESPONSES - MACKAY

• BAD
• Lack of commitment by all stakeholders
• Right people lack control
• Industry becoming closed to new inexperienced
  people
• Operators dont have enough input into
  standardising processes
• Non-standardisation of processes
• Coal haulage continued use of shuttle cars
• Old technology used too long
• Failure of develop continuous haulage systems
• Unrealistic budgets
• Lack of investment in process
• People not able to be accountable
• People lack of work ethic
• Unrealistic expectations of machinery and
  peoples performance
• Fear of failure development behind budgets -
  reluctance to try new things
• Fear of prosecution
• Rosters affect effective communication
• Lack of knowledge and management focus
• Shift duration - operators become unproductive
  later in shift

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WORKSHOP RESPONSES - POKOLBIN

• SUCCESSES OF LAST 5 YEARS
• Hydraulic bolters in lieu of hand held bolters
• Focus on process, and integration of systems
• Set standards, with all shifts doing the same
  thing
• Achievements in primary and secondary support
  systems and products (installation systems
  require further RD)
• Machine monitoring improvements, almost to
  longwall standards
• Use of fit for purpose materials and equipment
  handling attachments - spent on ancillary
  equipment to improve materials handling and
  logistics systems
• Attitude of personnel harnessing power of
  people pride in their job maintenance of
  standards
• Senior management credibility doing what they
  said they would do
• Involvement of people in process
• Change in leadership model and supervisors role
  leader rather than lamp holder
• Age of workforce focus on ergonomics
• Increased focus on safety and development of
  safety systems approach
• Services handling systems monorails
• Increased KW installed in development equipment
• Radio control of machines success?
  reliability? exposure of people to pinch points?

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WORKSHOP RESPONSES - PENRITH

• RD SUCCESSES OF LAST 5 YEARS
• Geological and geotechnical developments for roof
  support determination
• Application of monorail systems
• Development of roof and rib support hardware by
  OEMs and suppliers
• Technology developments from ACBM project
• How do we wrap emerging technologies together as
  an integrated, cost effective system?
• RD ISSUES FROM THE PAST 5 YEARS
• RD on the run (roof and rib support) lack of
  industry support
• Reactive application of geotechnical design to
  support systems
• Failure to adopt other industry supply systems
• Lack of predictability of geotechnical conditions
• Pioneering development of equipment
• Further improvements in monorail systems required
• ACBM getting OEMs and operators to take it
  forward

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ACARP - INCREMENTAL CHANGE

• Demonstrate a high capacity, integrated mining
  system that incorporates then available, best
  practice technology.
• Pursue and expedite commercialisation of
  alternative self drilling bolt technologies and
  automated bolting systems, including potential
  retrofitting of automated bolting systems to
  existing CMs.
• Facilitate and expedite completion of the ACBM
  and associated technologies.
• Develop alternate skin reinforcement and
  confinement measures to eliminate use and
  handling of steel mesh.
• Facilitate development of an extensible, self
  advancing panel conveyor.
• Develop a high capacity, automated long tendon
  installation system for both primary and
  secondary support applications.

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ACARP - INCREMENTAL CHANGE

• Develop a mine economics modelling system that
  enables mines to properly evaluate the full cost
  of alternate development systems.
• Pursue other complementary technology
  developments including
• automation and robotics
• machine guidance systems
• light weight materials
• face pumping systems
• roadway construction and consolidation
• gas drainage
• Improve level of awareness and understanding of
  technologies being applied in other industry
  sectors
• Metalliferous and tunnelling
• Coal industry assessment by a technologist

34
ACARP - INCREMENTAL CHANGE

• Improve level of awareness and understanding of
  roadway development technologies and systems
  being utilised in mines overseas.
• Desk top review
• Technology mission if warranted.
• Develop software that will facilitate and enhance
  the adoption of the systems approach/ process
  control.

35
ACARP - STEP CHANGE

• (We recognise the problem but cant conceptualise
  the solution)
• Develop a vision to demonstrate a high capacity,
  integrated mining system by end 2008.
• Specification capable of sustained, continuous
  production at a level of 10MPOH, gt20 hours day
  (10/20).
• Develop a strategy for development and
  demonstration of the high capacity, integrated
  mining system.
• Develop a specification for the high capacity,
  integrated mining system
• Commission the design of a number of alternative
  systems
• TBM concept could provide an integrated,
  continuous cutting, bolting and coal clearance
  system at a number of mines.
• TBM provide good immediate ground support in
  difficult ground conditions.
• Construction industry approach simultaneous and
  parallel pathing of work activities

36
ACARP - STEP CHANGE

• Evaluate and select a design that best meets the
  industry specification and requirements, and
• Commission an OEM (or OEMs) to develop the
  technology and manufacture the integrated system.
• Establish a collaborative agreement to conduct
  demonstrations at appropriate mine site (eg
  highwall), either
• by a project team internally funded by the mine
  owner, or
• by an externally funded mining contractor
  (ACARP).
• Project manage the technology and equipment
  development process through to the conclusion of
  the field trials and demonstrations through to
  end 2008.

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WHAT HAS BEEN DONE TO DATE

• Report accepted by ACARP and key recommendations
  supported including
• Benchmarking studies on 6 monthly basis
• Regional Operators Workshops on 6 monthly basis,
  culminating in Operators Conference early 2008
• Review of civil and tunnelling sectors
• Alternate skin reinforcement and web-based
  operators network/MIS invited to make second
  round submissions
• Support for field trials of SDB project
• High capacity mining systems workshop scheduled
  November 2006 (coupled with L15 project?)
• Commitment to pursue opportunities identified in
  workshop processes

38
ACARP
Australian Coal Association Research Program

• KEY FINDINGS JULY 2006 BENCHMARKING STUDY
• Gary Gibson, ACARP

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JULY 2006 BENCHMAKING STUDY

• Contributions received from
• Mandalong
• Metropolitan
• Broadmeadow (BMA)
• Tahmoor
• Angus Place
• Beltana
• Austar
• North Goonyella
• Broadmeadow (HWE)
• Springvale
• Appin
• Glennies Creek and Kestrel reportedly well
  advanced
• Findings now to be separately reported to
  respondents and workshop participants, with
  close-off of responses 8 September 2006.

40
ACARP
Australian Coal Association Research Program

• PROCESS CONTROL AND CONTINUOUS IMPROVEMENT
• David Gibson and Matt Bonnard, Beltana

41
PROCESS CONTROL WORKSHOP - MACKAY

• How do you involve people in the selection the
  equipment?
• Form task groups to involve people from
  conception to completion. Benchmark other sites
  and consider all OEMs. Beltana to supply
  guidelines for equipment performance and
  expectations. People that will be using the
  equipment pick the best of what is available and
  engineer in changes to suit our requirements
• How much time per week you as Development
  Coordinator spending doing work for your process
  and not the rest of the mine?
• Approx 70 attributable to the process
• How do you get people to own the process?
• Firstly, development operates as a business unit,
  and recruits its own personnel, with personnel be
  selected for what they are good at (majority of
  personnel were recruited from South Bulga and
  were each well known for their various strengths
  and capabilities)
• We feed them with information and shift briefings
  are attended daily by each crew at the start of
  shift
• We listen to suggestions and act where
  appropriate, and involve them in the selection of
  their equipment
• We adopt sustainable manning levels
• Can you outline the incentive scheme?
• Two major components, 50 each for development
  metres and longwall tonnes
• We conduct fortnightly audits of panel standards
  including roadway alignment and horizon control,
  safety equipment, etc
• Safety performance is also factored into
  incentive scheme
• What are the top 5 delays, and do you have any
  magic wands?
• No magic wands top 5 delays section advance,
  travelling to section, flitting, stone dusting,
  supplying the miner

42
PROCESS CONTROL WORKSHOP - MACKAY

• What material handling issues have been
  identified with the new CM?
• Bolts handled by QDS pod system. Biggest issues
  are handling 1.7m mesh module and vent tubes.
  Mesh is stowed in the rib behind the miner and
  fetched as required, vent tubes are brought in
  when bolting and handled/installed from the miner
  platforms.
• Are you going to transfer the learnings to the
  new Blakefield mine?
• Yes, the process will be picked up and taken to
  Blakefield South although there will be a need
  for a much larger work force
• Face cycle?
• Approx 3.2 3.5 days including 8 hour
  maintenance shift and 18-20 hours for section
  advance
• Impact of say 30 increase in support density?
• Reduce development rate by 0.5MPOH (from 5MPOH)
• Shift roster?
• Seven day, four panel roster, 8 week rotation
• Rotate shifts each 2 weeks, that is, 2 weeks on
  night shift, 2 weeks on afternoon shift, 2 weeks
  on dayshift, two weekends, 1 week off
• Undermanagers work same roster but the
  development process management team works normal
  5 days
• Do you intend to utilise dual CM unit at
  Blakefield?
• Yes. The model has us running two twin miner
  panels at Blakefield
• Back bye maintenance?
• We are responsible for everything inbye of our
  portal. Done when we are cutting at the start of
  our cut sequence when there are no parallel tasks
  to do and also during our weekend maintenance
  windows.

43
PROCESS CONTROL WORKSHOP - POKOLBIN

• You mentioned panel auditing, what auditing do
  you do?
• Fortnightly audits of panel standards are
  conducted as part of the mines incentive scheme
• Typically audit alignment and width of roadways
  and compliance with other panel standards
• Have you sought or do you have an exemption for
  stonedusting?
• Yes, application currently being evaluated by
  Department
• What have you found to be the optimum break away
  angle?
• Have found 70 degrees to be optimum as it doesnt
  add too much additional development over life of
  panel
• Used to drive belt road and cut out a wedge for
  break away, now cut a 5.5m cut out in the cut
  through as the belt road is advanced. That
  enables CM to get a full head of coal when it
  commences cut through
• Who starts the panel advance?
• Whoever holes the cut through, no other fast
  rules, rotating shifts are employed
• Now considering cutting B heading again while
  belt road is being cleaned up
• What is the budget this year and how are you
  going against it?
• Budget 17.446km roadway development for single
  unit
• 11.18km completed YTD, and we are 186m ahead of
  budget YTD
• What are the major impediments to further
  improvement?
• Continued use of shuttle cars, need to utilise
  continuous haulage systems (going overseas next
  week to benchmark their performance)
• Panel advances are biggest delay, typically 20
  hours to complete and over life of panel that is
  significant given that we are currently
  completing two panel advances per week
• Face services an issue, but not convinced
  regarding monorail systems at this stage
• What fundamental changes do you expect as you go
  into deeper areas of mine?

44
PROCESS CONTROL WORKSHOP - PENRITH

• To get good scores you need equipment
  reliability. How do you achieve it?
• Firstly, you need good equipment supported by a
  good maintenance program, with 100 compliance
  with that program
• We use a 4-5 day window between panel change outs
  to give equipment a major work over
• Utilise two maintenance windows, 2 x 12 hour
  shifts of a weekend and one 8 hour dayshift mid
  week. Major maintenance jobs done on weekends
• How do you develop crew ownership of the
  development process?
• Firstly, development operates as a business unit,
  and recruits its own personnel, with personnel be
  selected for what they are good at (majority of
  personnel were recruited from South Bulga and
  were each well known for their various strengths
  and capabilities)
• We feed them with information and shift briefings
  are attended daily by all crews at start of their
  shift
• We listen to suggestions and act where
  appropriate, and involve them in the selection of
  their equipment
• We adopt sustainable manning levels
• Who tracks the development cycle process time?
• Crew supervisors report on a prepared shift
  report and are required to log performance in 15
  minute rests
• Development Maintenance Coordinator uses the
  mines PULSE system to record data
• Performance is tracked on a daily basis on a
  whiteboard in the crew muster area, weekly
  performance is tracked, reported and trended by
  the planner. Graphs displayed in muster area
  updated weekly.
• Are crew supervisors deputies, and how do you
  achieve sustainability if in fact they are
  deputies?
• Yes, crew supervisors are deputies and we
  typically have at least two deputies in a crew,
  sometimes 3. They step-up from operator to Crew
  Supervisor as required
• The step-up deputies/crew supervisors are paid at
  a rate higher than operators but slightly less
  than the nominated Crew Supervisor
• You noted that at 170m depth rib support density
  increases. Do you experience a change in
  development rates with increased rib bolting?
• Yes, we see a de-rating of development rates of
  some 15 with the increase in rib support and
  seam water make
• The 170m depth of cover is nominal and the change
  in rib support is driven by conditions. We
  commenced increased rib support at 130m depth of
  cover in the current gateroad

45
PROCESS CONTROL WORKSHOP - PENRITH

• What do the 12 man development crews comprise?
• Each crew comprises a crew supervisor plus an 11
  man crew, with the crew comprising a maintenance
  supervisor, 2 fitters, 2 electricians and 6
  operators one of which is a step up crew
  supervisor (deputy)
• You noted that development crews comprised 12
  personnel including the crew maintenance
  supervisor, how many people are used when cutting
  and loading?
• We typically cut out for 10-12m at a time and
  then bolt the 10-12m increments in one campaign
• We require that 5 people be on the CM when
  bolting up, and this will include whoever is
  available including SC drivers and trades
  personnel
• What does the weekend maintenance crew consist
  of?
• 1 crew supervisor, 1 operator, 2 fitters and 1
  electrician, plus supplementary contractor if
  required
• What sort of incentive scheme do you have?
• Two major components, 50 each for development
  metres and longwall tonnes
• We conduct fortnightly audits of panel standards
  including roadway alignment and horizon control,
  safety equipment, etc
• Safety performance is also factored into
  incentive scheme
• Do you have a system for controlling the
  development process?
• Dont do it down to the minute, but crew
  supervisors report in 15 minute increments on
  report forms which are customised for each shift
  in accordance with work scheduled for shift
• Debrief crew supervisors and crews at end of each
  shift
• Do you maintain during belt moves?
• No, not with the single CM unit. Maintenance is
  completed during the three scheduled maintenance
  windows
• What rosters do you work?
• Seven day, four panel roster, 8 week rotation
• Rotate shifts each 2 weeks, that is, 2 weeks on
  night shift, 2 weeks on afternoon shift, 2 weeks
  on dayshift, two weekends, 1 week off

46
ACARP
Australian Coal Association Research Program

• ROOF AND RIB SUPPORT PRACTICES AND EQUIPMENT
• John Vincze, Springvale

47
ROOF RIB SUPPORT WORKSHOP - MACKAY

• With self drilling bolts is it important to
  pre-tension the bolt?
• Yes, we believe it is important to tension the
  bolts as we go. At this stage we havent trialled
  any SDB but we will as soon as they are ready.
• How does galvanising the long tendons
  (spin-bolts) affect the metallurgy of the
  tendon/bolt?
• Dont know, thats a question for a metallurgist.
  Again we havent used them yet however we are
  considering them for use in the Mains where we
  have a high water content from adjacent old
  workings.
• What benefit do you get out of the galvanised
  mesh as compared to the standard mesh?
• Marked difference, they last a fair bit longer.
  It is more expensive and we only use it for
  reconstruction work in a light duty rib support
  role, and it is very easy to handle. Must note
  that we put a fair bit of support into it, with
  bolt spacing at 1 metre in accordance with the
  mines standard support rules. Also the large
  pizza plates give it a fair bit of support and
  provide good coverage over the mesh.
• With all the primary and secondary roof support
  materials, belt structure and other materials
  being used has there been any increase in manual
  handling injuries?
• Yes, but we try to minimise it. The PET delivers
  the pods to the panel and they are put onto the
  miner with a pod handler, and the operator only
  has to touch the 7 bolts when he goes to install
  them, and he drags the 8m bolts off the monorail.
• Trusses installed by contractors and they are
  delivered underground and unrolled on the job.
• Main injuries at the mine are strains, to the
  back, shoulder and arms, and we do notice that as
  the workforce ages they are more susceptible to
  these injuries.
• I noticed on one of the photographs that the
  miner appeared to have a slide arrangement to put
  the mesh onto the CM. Can you give us some more
  details of that?
• Yes, we have a slide arrangement for when we put
  the mesh onto the CM, it minimises the incidence
  of the mesh catching on the CM.

48
ROOF RIB SUPPORT WORKSHOP - MACKAY

• You mentioned light weight tensioners, can you
  give us more detail?
• They are lighter than previous ones used, but I
  am not certain how heavy they actually are. It
  certainly is an issue working at 3m height when
  lifting the tensioner overhead. We do get
  injuries, and we dont have a solution yet. We
  would certainly like to hear of one if there are
  any solutions.
• Do you post grout the 8m spin bolts?
• Yes, they are post-grouted with a thixotropic
  mixture which is the consistency of toothpaste.
  Also post grout the tendons and trusses but we
  use a strata binder grout for that, with the
  strata binder penetrating the strata as well.
• What else is suspended off the monorail system?
• 8m bolts, plastic (grout) tubing, maximum fifteen
  20 litre drums of oil, maximum 20 bags of
  stonedust (20kg each), fitters and electricians
  tool boxes, first aid equipment
• What is the make up of the production crews and
  what are they responsible for?
• Similar to what was at Beltana with dual
  continuous miners in gateroads and 6 miners on
  each CM, with 1 fitter, 1 electrician and 1
  deputy in the panel.
• Deputy manages the crews annual leave roster,
  with one tradesmen and 3 miners allowed off at
  any one time. Sick leave does impact upon numbers
  although we have good support from outbye crew.
• The three production crews cut coal, do belt
  extension and pipe extensions, with the dayshift
  outbye crew doing roadworks right up to the crib
  room, and doing the transformer moves, and
  transporting belt structure and supplies.
• 110m belt move is budgeted for 3 shifts,
  averages 17 hours with a best result of 11 hours.
  The belt move includes the belt and 6 air and
  water pipes, with a 4 fire main between the
  travel road and belt road every second pillar

49
ROOF RIB SUPPORT WORKSHOP - POKOLBIN

• What is the standard panel manning and what are
  the crews responsible for?
• A deputy, 12 operators, 1 fitter and 1
  electrician
• Dual CM unit in gateroads
• Headings at 48m centres, cut throughs at 140m
  centres
• Crew responsible for supplying panel, roadworks,
  pipework, belt structure
• Best panel advance 11 hours, budget 3 shifts but
  typically achieve 18 hours
• 1200mm longwall conveyor installed in development
• Transformer move every fourth pillar
• You mentioned you hade problems with Megabolts
  and they were no longer used, can you expand upon
  that?
• Had problems tensioning Megabolts off the CM,
  very heavy tensioning equipment
• We found that Megabolts were not flexible enough
  in our operating environment
• Also found them to be difficult to install and
  post-grout

50
ROOF RIB SUPPORT WORKSHOP - PENRITH

• Water was reported to be a major issue at
  Springvale, can you outline what you use to
  manage the mines water make?
• Have a number of Air 2000 pumps, 3.7KW and 37KW
  mono pumps
• Typically have fish tanks every 3-4 pillars along
  the longwall gateroads
• Water is pumped out to surface via a series of
  boreholes and in some instances we utilise a FBT
  (frigging big tanks) to transport water from the
  mine
• We have also drilled a 1.2km long borehole in
  advance of the longwall bleeder roadways to
  pre-drain the installation face area of future
  longwalls
• It was noted that you are awaiting the
  development of SDB. Hilti now have a self
  drilling bolt available now, why not utilise it ?
• The Hilti SDB system does allow the bolt to be
  pre-tensioned
• While Hilti have a SDB roof bolt, we have a
  greater need for a SDB rib bolt
• What type of rib mesh do you use along the
  longwall block side of gateroads?
• Steel rib mesh is now used although we were
  previously using Tensar mesh

51
ACARP
Australian Coal Association Research Program

• DEVELOPMENT AND OPTIMISATION OF CONTINUOUS MINERS
  
• (Best Practice Maintenance and Engineering)
• Alan Bruce, Crinum

52
CONTINUOUS MINER WORKSHOP - MACKAY

• How much roof and rib support is installed at
  Crinum?
• In good roof conditions there are 6 x 2100mm roof
  bolts installed per metre, with 2 x 1200mm steel
  rib bolts on the chain pillar side and 3 x
  cutables on the block side. When roof conditions
  deteriorate there are 8 x 2100mm bolts installed
  per metre.
• Platforms on the ABM25(S), why do they raise and
  lower?
• Our ergonomist recommended that operators only
  move their head through a 15 degree arc in order
  to minimise pinching of discs in the neck, and
  also required operators to be at a suitable
  height relative to the drills rigs
• The preferred operating height was above the
  preferred maintenance height, and to lift the
  machine components up 200mm to be above the work
  platform would have increased the overall machine
  height
• Then decided to install a moveable platform which
  was raised for operation and lowered for
  maintenance, thereby putting the operators at the
  correct height and avoiding increasing the
  machine height
• Where are the control for raising and lowering
  the platforms?
• There is another valve bank situated beside the
  rib bolter controls to operate the platforms and
  the mesh handler.
• How far back from the face are the roof bolts
  installed?
• The roof bolts will be installed at 2.6m from the
  face.
• The Joy Sumps Shearer addressed many of the
  ergonomic issues raised in your presentation, is
  there any benefit in revisiting that machine as a
  work platform?
• The Sumps Shearer is no longer being considered
  for development by Joy, but I definitely believe
  it had potential.
• What sort of improvement do you expect from the
  new ABM25(S)?
• The ABM25(S) is expected to give a 12 increase
  in development productivity
• What other improvement initiatives are being
  considered with introduction of the ABM25(S)?
• There are three different projects currently
  being undertaken. One is the ventilation-monorail
  system and its interface with the miner, the
  second is the supply cassette system, and the
  handling, carting and loading of supplies onto
  the miner, the third is the electrical
  requirements to run the machine, ie cable sizing
  and handling.

53
CONTINUOUS MINER WORKSHOP - POKOLBIN

• You stated that the work platform raised and
  lowered some 200mm for maintenance, can you
  explain that some more?
• Our ergonomist recommended that operators only
  move their head through a 15 degree arc in order
  to minimise pinching of discs in the neck, and
  also required operators to be at a suitable
  height relative to the drills rigs
• The preferred operating height was above the
  preferred maintenance height, and to lift the
  machine components up 200mm to be above the work
  platform would have increased the overall machine
  height
• Then decided to install a moveable platform which
  was raised for operation and lowered for
  maintenance, thereby putting the operators at the
  correct height and avoiding increasing the
  machine height
• What level of productivity improvement is
  expected with the ABM25(s) at Crinum?
• The ABM25(S) is expected to give a 12 increase
  in development productivity
• What was the increase in cost for the ABM25(S)
  relative to a new CM?
• I understand that VA spent some 6-7M to complete
  the development
• It cost BMA 0.5M more than an off the shelf
  machine
• Did it surprise you that you had to be so
  proactive with OEMs?
• I know what OEMs are like, they dont like making
  changes
• You have highlighted a number of changes to the
  on-board ventilation system. Do you consider that
  the on-board systems are worthwhile as compared
  to a conventional ducting system?
• Dont know, we have always had the on-board
  system
• Are any other changes to the roadway development
  system at Crinum being considered?
• Yes, always working to improve the system
• Looking at how to make the supply system work
  better, including QDS attachments, etc
• A participant noted that Crinum had developed and
  fitted a simple device to the MBE that allowed
  belt structure stands to be inserted with minimal
  manual effort

54
CONTINUOUS MINER WORKSHOP - PENRITH

• How well does the ABM25(S) break away and
  complete cut throughs?
• Same as the 12CM32, hasnt been identified as an
  issue at this stage
• With the electronic roof bolting controls is
  there any ability to monitor bolt torque and
  tension?
• Yes, there is an ability to monitor all CM
  functions and to record data on the surface
• In regard to the specific drilling energy
  function we monitor and record data for the two
  outside roof bolts
• Why have you fitted hydraulic traction drives on
  the CM?
• To create room on the machine, that is two motors
  that are not required
• Development and fitment of self drilling bolting
  systems are likely to require on board chemical
  injection storage and pumps and the space created
  by fitting the hydraulic traction units will
  allow retrofitting of SDB systems
• What factors were identified by OEMs when they
  did not submit tenders for development of the new
  Crinum CM?
• No analysis of why OEMs didnt submit tenders was
  completed
• Is Crinum a wet or dry pit?
• Dry now, although it was very wet initially
• Have you done any comparison of the availability
  of the electronically controlled roof bolting
  rigs?
• Still working on the comparison although it
  should be noted that we didnt have to send a
  fitter into the panel for the first 6 weeks that
  the bolters were being used (Note Crinum
  standard panel manning does not include trades
  personnel)
• You seem to have had a fair budget available to
  undertake all the necessary modifications?
• Small changes were taken at a time, with
  continual improvements being made over time

55
CONTINUOUS MINER WORKSHOP - PENRITH

• You reported that you have just had your best
  year of development at Crinum, what performance
  rates were achieved, MPOH and metres overall?
• Typically achieving 3.5 3.75MPOH
• Dont have an exact overall figure but it was the
  most metres achieved in any one year and we only
  operated the 3 CMs on a part time basis, rather
  than on a full time basis as in previous years
• Now that you have both upgraded 12CM32s and an
  ABM25(s) available, do you have any preference on
  how they will be deployed to mains and gateroad
  drivage?
• No preference however should note that we are
  moving to a highwall operation at Crinum East and
  there will be no mains development
• You noted that you changed from gear pumps to
  Rexroth pumps, were there any other changes
  necessary to accommodate that change?
• No, nothing different
• What did it cost for development of the ABM25(S)?
• BMA committed 300,000 up front to commence the
  development process and I understand that VA
  spent some 6-7M to complete the development
• The machine as delivered will cost 4.8M
• What level of productivity improvement is
  expected with the ABM25(s) and what other
  improvements are contemplated in roadway
  development at Crinum?
• The ABM25(S) is expected to give a 12 increase
  in development productivity
• Other improvements include introduction of
  monorail mounted ventilation systems and
  improvements to handling and installation of roof
  mesh and support materials

56
ACARP
Australian Coal Association Research Program

• PANEL ADVANCES
• Jim Richardson, United

57
PANEL ADVANCES WORKSHOP - MACKAY

• What improvements to the development services
  time?
• Panel advance could be sped up by utilisation of
  Development monorail system.
• Potential to get time down to 4.5 hours.
• Is there a specific development maintenance
  window, and does maintenance get done during
  development time?
• Maintenance for the belt road equipment is linked
  to a full shift (usually Thursday ) each week
  when Stop Belt maintenance is carried out.
• The travel road equipment is carried out when
  services are being advanced after the travel road
  miner has mined to 130m chainage.
• Why does the mine work a five day roster, why not
  seven day roster?
• 5 days are enough to maintain longwall
  continuity.
• Rosters are simple.
• Management are not burnt out.
• We are not paying penalty rates.
• Do you utilise detailed procedures to ensure that
  the belt extension process is consistently
  repeated?
• We have procedures detailed within the panel
  folder however we tend to achieve repeatability
  by utilising the same people to do the same job
  each time, so there is not a need to constantly
  refer to these procedures.
• With the introduction of the contractor based
  weekend production crews we have progressively
  involved them in the process to the point that
  this weekend they will complete their first solo
  panel advance.

58
PANEL ADVANCES WORKSHOP - POKOLBIN

• Can you go through the road clean up and cut
  through holing process?
• The travel road CM is advanced to 132m to
  complete overdrive before being pulled back to
  clean up travel road from outbye cut through to
  face
• Following clean up of travel road vent ducting is
  recovered and the extension of services is
  commenced
• Belt road CM completes 20m overdrive in belt road
  before commencing cut through
• When belt road CM holes it takes about 2 hours to
  complete bolt up, during which time a loader is
  used to doze up belt road into overdrive
• Belt road CM then trammed into belt road and an
  LHD cleans up the cut through into belt road
  overdrive, before CM trammed to face and loads
  out stowage at face into shuttle car
• Does the conduct of the panel advance on day
  shift and out of cycle require specialisation
  of day shift crew?
• Yes, that is one of the keys to our success, with
  the day shift crew developing their
  specialisation and repeating it each 4 days, with
  the same people doing the same thing each time
• What type of LTU drives are installed?
• Eddy current winches which tension the belt to
  7KN
• What is the name of the day shift supervisor?

59
PANEL ADVANCES WORKSHOP - PENRITH

• When do surveyors install the grade line and do
  the belt bolt mark-up?
• On the stop belt shift (typically Thursdays)
  although may have to do it during the panel
  advance if there is no belt stop shift between
  panel advances
• When are belt hanging bolts installed?
• On the stop belt shift (typically Thursdays)
  although may have to do it during the panel
  advance if there is no belt stop shift between
  panel advances
• Why not pre-hang the belt hanging chains rather
  than hang them at the start of the belt move?
• One fell down hit operator, and there have also
  been reports of then falling down and catching
  equipment
• Doesnt add too much time
• We use fully encapsulated 2100mm belt hanging
  bolts which are part of our roadway support
  system
• Participant reported that they pre-hung the
  chains and marked the grade line on the chains to
  expedite levelling of the conveyor structure
• How long are the longwall blocks, and do you have
  any problems pulling the belt out of the LTU over
  that distance?
• 3.2km long
• Problems are experienced at times due to soft
  floor conditions in inbye section of panel,
  however the utilise a second LHD to assist
• Do you have any issues involving contractors in
  panel advances given the strong union culture at
  the mine?
• Union role at mine not an issue, they have a
  position of Board and employees are kept fully
  informed on costs and profitability
• Employees recognise that contractors are there to
  assist them and to make the mine viable
• Contractors used on panel advances are drawn from
  other contract works being undertaken at the mine
  at the time (eg secondary support, ventilation)
  and are not specifically employed for panel
  advances

60
PANEL ADVANCES WORKSHOP - PENRITH

• When do you put the belt into the LTU?
• On the stop belt shift, approximately 2 hours
  to install
• How do you doze up the belt road?
• Use an LHD bucket to push up the floor material
  rather than use it as a conventional loader
  bucket. Then load it out with CM and shuttle cars
• How do you install the belt structure when
  pulling the boot end back with the LHD?
• We crowd the boot end back into the bucket and
  that separates the top and bottom belt and allows
  the idlers to be inserted between the belt
• Do you use the weekends when there is no
  production scheduled to complete preparation
  works for panel advance?
• Previously we used weekends to catch up on the
  belt hanging bolts, stone dusting and major
  component changes on the equipment, and
  maintenance of the travel road unit
• Now are working a 7 day week with mine employees
  on a 4X9.5 hour roster 4 days per week, with
  Walters working other 3 days to catch up on a
  development shortfall created by extended
  equipment overhauls, geology and EA negotiations
• Contractors trained to do belt advances and they
  are completed as they fall
• being utilised on 3X12
• What is the pillar cycle time?
• Typically 4 days in middle 20 pillars of gateroad
  development, extending out to 5 days at start and
  finish of panel due to mining conditions
• Do you use a second DCB?
• Yes, use a second DCB to leapfrog belt road DCB
  each pillar, with travel road CM powered directly
  off transformer which is moved every 2 pillars as
  part of panel advance

61
PANEL ADVANCES WORKSHOP - PENRITH

• Do you have any views regarding roof and floor
  mounted structure?
• 1200mm belt operates at 5.2m/s and needs to be
  high standard, and we utilise roof mounted
  structure to provide a high standard longwall
  ready conveyor
• Minimal works are undertaken on completion of
  gateroad development to get conveyor longwall
  ready
• What improvements could be made to panel advances
  at United?
• Considering use of monorail services management
  system in both headings to take the extension and
  relocation of panel services off the critical
  path
• Expect panel advances could then be completed in
  4.5 hours
• Do you use a breaker feeder?
• No, we load directly onto a grizzly style boot
  end
• The overall system is currently in balance and do
  not require a breaker feeder for surge capacity
• Do you mine any rock at all?
• Yes, seam thins at inbye end of longwall blocks
  and we take up to 400mm of roof stone
• Not a problem for conveyor system
• Which miner completes the cut through?
• Belt road CM completes the cut through
• The travel road CM pulls up at 132m after
  completing overdrive and is then pulled back to
  clean up travel road from outbye cut through to
  face (while belt road CM completes hole through),
  before recovering vent ducting and commencing
  extension of services