NewScene, UK CoalÂ’s official newsletter, reported that machine time on the 277 metre long face has been approaching a world class 80% of availability as a result of a Project 105 initiative. P105 is aimed at reducing mining costs to a target of 105 pence per gigajoule.
“When the Joy 4LS first started shearing the 1.73m of coal last February, face potential typically averaged 50%, peaking in the 60s for odd weeks until June. Since then, it has risen consistently and has peaked at an unprecedented 80%,” the newsletter reported.
The mine has approached the issue by concentrating on the detail and involving the workers in the actual unit.
“Involving the mean has had a double benefit,” said undermanager Andy Palmer. “For the first time, they fully understand the thought and detail that goes into planning our operations; in return, we learn from their experience and identify the delays which are costing us coal cutting time.”
The five major causes of operational delay – shearer operation, AFC power, support, conveyor systems, and men and transport delays – are reviewed systematically every week. This information is fed into a delay analysis action plan which is reviewed every week. Solutions are incorporated into the new daily and weekly plans.
Some examples include saving 12 minutes by a new way of dealing with pipe retractions. This operation no longer interferes with cutting time, which means a 10 minute save per shift.
Ensuring most face team members are competent to operate the mine watch system has also saved time.
“Every one minute delay typically costs us between £300 and £400 in lost production – so a 10 minute saving each shift on our top 10 faces amounts to around £500,000 a week,” said P105 director, Kevin Irving.
NewScene, also reported that a new Joy 7LS shearer capable of cutting up to 14m a minute, was to be installed at the mine. The powerful shearer will operate at 3,300 volts, while each cutting drum is powered by a 375kw motor housed within the ranging arm.
The mineÂ’s present 4LS shearers can cut up to 9m a minute but the mine is looking for a guaranteed average cutting speed of 11m a minute, regardless of the conditions.
The shearer has a thinner mainframe, larger ranging arm cylinders and a haulage pull of 63.5 tonnes – 10 times greater than the 4LS. It incorporates the Joy Network Architecture (JNA) control system.
