CHAPTER 1

INTRODUCTION
1.1 General
Roadheaders are the most widely used underground partial-face excavation machines for low
to medium strength rocks. They are used for both development and production in soft rock
mining industry (i.e. main haulage drifts, roadways, cross-cuts, etc.) particularly in coal,
sedimentary rocks, industrial minerals and evaporitic rocks. In civil construction, they find
extensive use for excavation of tunnels (railway, roadway, sewer, diversion tunnels, etc.) in
soft ground conditions, as well as for enlargement and rehabilitation of various underground
structures. Their ability to excavate almost also makes them very attractive to those mining
and civil construction projects where various opening sizes and profiles need to be
constructed.

In addition to their high mobility and versatility, roadheaders are generally low capital cost
systems compared to the most other mechanical excavators. Because of higher cutting power
density due to a small cutting drum, they offer the capability to excavate rocks harder and
more abrasive than their counterparts, such as the continuous miners and borers.

Roadheaders were first developed for mechanical excavation of coal in the early 50s. Today,
their application areas have expanded beyond the coal mining as a result of continual
performance increases brought about by new technological developments and design
improvements. The major improvements achieved in the last 50 years consist of steadily
increased machine weight, size and cutter head power, improved design of boom, muck pick
up and loading system, more efficient cutter head design, metallurgical developments in
cutting bits, advances in hydraulic and electrical systems and more widespread use of
automation and remote control features. All these have led to drastic enhancements in
machine cutting capabilities, system availability and the service life.

Machine weights have reached from 17 tons up to 120 tons providing more stable and stiffer
(less vibration, less maintenance) platforms from which higher thrust forces can be generated
for attacking harder rock formations. The cutter head power has increased significantly from
37 kW approaching to 500 kW to allow for higher torque capacities. Modern machines have
the ability to cut cross-sections over 100m2 from a stationary point.

1.2 Objective of the Thesis

An essential prerequisite of any mechanical excavation program is the need to know the
mechanical cutting or excavation characteristics of the coal or rocks to be cut. Failure to
determine these characteristics may result in failure to reach production objectives and in
breakdown of machines which will require expensive replacements. Therefore, before
installing costly coal mining or roadway driving machines, it is essential to determine the
machinability characteristics of rock materials and to estimate cutting performance of the
roadheaders Dosco Mk-2A roadheaders with a weight of 23-26 t were considered as medium-
weight machines at the time of the research (McFeat-Smith and Fowell, 1977), they were
found to be insufficient to provide high performance especially at medium strength rocks and
have been gradually replaced by heavier machines. Similarly, Dosco Mk-2A machines are
rarely in use nowadays and replaced to a larger extent by Mk-2B types with a weight of 37-44
tons. Therefore, Mk-2A can no longer be considered as a medium weight but should be
classified as a light-weight machine (Tucker, a., 1985).

The main objective of this thesis is to investigate the performance analysis of roadheader in
showing the efficiency of roadheader.

The rest of the thesis is organized as follows;

In Chapter 2, literature on roadheaders is reviewed.

In Chapter 3, literature review

In Chapter 4, cutting picks

In Chapter 5, mechanical aspects of heading machine

Conclusions and recommendations for future studies are presented in Chapter 6

 CHAPTER 2
BOOM TYPE ROADHEADER
2.1. Introduction

Boom-type roadheader generally is a partial face machine for excavating a roadway in such a
way that the material to be removed is disintegrated by the continuous rotation of cutting tools
and thrust against the surface of the material at the working face. Roadheader machines have
importance in roadheading not simply as a compromise between drill and blast techniques and
full-face machines, but as an economic and versatile form of mechanized roadheading where
the method of excavation is easily integrated with tunnelling operations.

2.2. Application and Advantages of the Partial-face Roadheaders

As in civil construction, the mining applications of the roadheaders have included long drives
such as tunnelling for long ore-body development drifts, long haulage tunnels, longwall
access drifts, and long crosscut developments.

In comparison to drill and blast methods, the main advantages of roadheaders are:

- One machine is capable of cutting, loading and assisting in the erection of supports.

- Compared with conventional driving, a greater advance per manshift is obtained.

- Roof control is improved since the roof and sides of the roadway are not shattered by
shotfiring.

- The machine is very stable, easily controlled and capable of cutting a large variety of
roadway sections and sizes.

- It is safer since the men are near to the unsupported strata only during the erection of
supports.

2.3. Classification of Boom-type Roadheaders

The roadheaders can be classified according to their times of introduction, their rock-cutting
abilities and their weights.
2.3.1 Classification According to Times of Introduction

2.3.1.1 First Generation

First generation machines were introduced in Western Europe in the 1960's. The lighter
models of these early boom miners weighed about 9 tons and could cut soft rocks having
compressive strength up to about 40 MPa.

2.3.1.2 Second Generation

Second generation machines were developed around 1970. These machines generally weigh
between 22-37 tons. Some of these machines can cut competent rock with compressive
strength as high as 85 MPa if the silica content of the rock is low.

2.3.1.3 Third Generation

The third generation, heavy-weight machines became available in 1976. These machines
weigh between 45-70 tons and can cut competent rock with compressive strength of 100 MPa.

2.3.1.4 Fourth Generation

Machine weights have reached up to 120 tons around 2000 which can be considered as fourth
generation machines. Such machines can cut economically most rock formations up to 100
MPa uniaxial compressive strength (UCS) and rocks up to 160 MPa UCS.

2.3.2 Classification According to Weight

Tucker (1985) classified roadheaders according to weight as:

- Light Duty; weight up to 30 t, cutting capabilities up to 70 MPa

- Medium Duty; weight between 34-45 t, cutting capabilities up to 100 MPa

- Heavy Duty; weight over 45 t, cutting capabilities up to 120 MPa

Atlas Copco – Eickhoff established the following classification according to weight

Class Weight
I <20T
II 20-30T
III 30-50T
IV 50-75T
V >75T
Table.1.classification according to weight

Neil et. al (1994) refer roadheaders as small size up to 30 t, midsize between 30-70 t and large
size between 70-120 t.

Table 2.1 shows the main types of roadheaders and Table 2.1 shows Mk-2A, Mk-2B and Mk-
3 machines which are the typical light, medium and heavy weight machines, respectively.
Table 2 Properties of typical roadheaders
Fig:1 Dosco Mk-2A

Fig: 2 Dosco Mk-2B

Fig:3 DOSCO Mk-3
2.4. Basic Components of Boom Type Roadheaders

2.4.1 Boom, Cutting Head and Picks

2.4.1.1 Boom

Roadheaders can have fixed or telescopic booms. Fixed boom requires the forward
movement of the machine body during sumping operations. Telescopic boom is advantageous
in that sumping can be carried out by the telescopic action of the boom without the movement
of the body.

2.4.1.2 Cutting Head

Boom type roadheaders can be divided into two groups according to the cutting action of the
head. (Gehring, 1989; Hekimoğlu, 1984; Alvarez et. al, 2003)

2.4.1.2.1 Milling Type Cutting Heads

For milling type, cutting head rotates in line with the axis of the boom perpendicular to the
roadway face; the primary cutting force is exerted sideways. The milling action rips the rock
from the face and throws the rock across the floor parallel to the front of the loader head (in
comparison, a ripping action throws the rock onto loader head). However, due to the
relatively simple in-line gearing between the milling cutting head and the drive motor,
milling heads can have smaller diameters than comparable ripper-head machines. Thus,
milling booms are better suited for selective mining of ore lenses or bands and for rather soft
to medium strength rocks.

2.4.1.2.2 Ripping type Cutting Heads

For ripping-type cutting, the cutting head rotates around an axis parallel to the roadway face.
The principle cutting force is provided by the rotary motion of the cutting head, and
downward thrust is provided by the boom. Such machines are more suitable for medium to
hard rocks.
 Fig: 4 Ripping type cutting head

Fig:5 Milling type cutting head

Comparison of ripper and milling type roadheader

Ripping (transverse) cutter heads cut in the irrection of face, and therefore they are more
suitable than milling heads of same weight and power. They are less affected by changing
rock conditions including hard rocks, if encountered. This feature enbales them to be used for
wider range of applications. These setting heads always cause certain over-break regardless of
the machine position.

Milling type head has lower cutting speed, which results into lower pick consumption. Pick
array on these heads is easier because both cutting and slewing motion go in same direction.

Borer type roadheader

These type of roadheaders have been designed to cut coal from the face by boring large
diameter holes. A large amount of coal is obtained without being actually cut therefore
proportion of large size coal is high. Numbers of design of this type of headers are available.
coal from face drops to the bottom and is pushed on a scrapper chain conveyor by rotating
arms. Scraper chain conveyor runs centrally through the machine and carries coal to the rear
end. The rear end can be swung either side up to 40 degree or luffed hydraulically. The entire
unit is supported on hydraulic cylindres which can tilt the cutting unit by 4 degree in
horizontal or vertical plane this allows borer to negotiate the irregularity of the seam. This
machine can drive the gallery of 1.8-2.3m high and 3.2-3.8m wide while advancing at a rate
of 0.3-0.75m/min.
 CHAPTER-3
LITERATURE REVIEW

To control dust in the underground, various technologies have been developed and applied all
over the world (Wang et al.,2013). They have played an important role in reducing dust
concentration for instance,water spraying has low dust suppression efficiency, especially for
dust particle with dia less than 2µm[1].Machine utilization time which is a very important
parameter in determining daily advance rate is much effected by the tunnel inclination,
decreasing from 38% to 8%(N. Bilgin et al). In Hereke Tunnel, in the inclined zone tunnel
excavation and ring montage were executed separately due to safety reason which reduce the
machine utilization time.[2].Geological problem occurring during roadheader excavation and
bit wear type and has been studied Experimental investigation and field application of
different cutting used for K.Thuro & R.J Plinnger et al[3].The selection and application of
roadheader for rock tunnelling (McFeat-Smith,& Fowell,et al).in different mining condition
were studied in canadian mines[4]. Criterian for selection of boom type roadheader and
geological limits was studied and analysed by (Tokairin,Y et al)[5]. Experimental
investigation and field application of different cutting picks used for different geo-mining
condition for cutting hard rock in underground tunnelling were studied by Chaobing Zhu et
al[6].Roadway drivage and shaft sinking was studied by (Barnes et al) to smoothen the mining
work in Brisbane colliery[7].Mining and tunnelling machinery was observed in various
mining condition for coal as well as metal mines and a handbook was prepared for selection
of various machine by stack & Barbara[8].Geology of project site was studied by M.Erdogan
et al[9] and several result were found by him for application of different mining machineries.
He studied different mines around the globe and gave some useful results. Roadheader
applications for driving sloping tunnels in western Kentucky pyro coal mine company was
studied by whitsell, S.R.,et al [10]
 CHAPTER 4
CUTTING PICKS

4.1. Cutting picks

Mainly there are three types of cutting picks.

(a) Radial pick

(b) Forward attack pick
(c) Point attack picks

4.2. Radial picks

These tools are designed such that axis of pick sank is normally parallel to the radial line of
cutting drum/head. They are generally suitable for cutting soft and medium hard rocks. Radial
picks generate lower forces than those of point attack tools. The Normal force is low
magnitude compared t cutting force; however as the pick become blunt, the ratio of normal
force to cutting force(fn/fc) increase several times. These picks are manufactured in various
size to suit a particular cutting condition.

Fig.6 radial cutting pick

The distance measured between tool tip and top of the pick shank is known as tool reach or
pick gauge and it is very important in cutting head design. Radial picks short gauge are
usually employed on roadheader cutting head while those of having long reach are frequently
found on shearer drums.

Fig:7 forward attack cutting tool

4.3.Point attack picks

Point attack tool are classified among the tangential picks and generally have the shape of
pencil and hence are known as “pencil pont cutting tool”. They consists of conical tip. Point
attack tool have previously found considerably use in coal cutting, however today they are not
favoured in this field. They have been increasingly employed in medium and hard rock
cutting and have become inventible tool on medium and heavy duty roadheaders.

4.4.Principle rock cutting variables

A number of pick cutting theory have been presented to describe mechanism in simplified
terms. Various aspect of cutting of rock have been reported from researchers. Some of them
are as follows:

(a) Both cutting force and normal force increase with depth of cut for all picks. In most
circumstances the increase is more or less linear.
(b) Cutting and normal force decrease non-linearly with increase in rake angle. The
optimum rake angle is 20 degree.
(c) For a chisel shaped pick, cutting and normal force increase with pick width.
(d) Cutting speed have no direct effect on pick cutting force or specific energy when tool
is not worn out.
(e) Cutting with an array pick involves each pick passing though rock in sequence. each
pick thereby have the opportunity to exploit the relief provided by an adjancent groove
produced by a preceding pick in the sequence.
(f) The value of optimum ratio for spacing groove and depth of cut for pointed picks has
been found to vary from 1.5-3.0 according to rock type.

4.5.Factors affecting tool life

Tungsten carbide is most widely used material for rock cutting tools because of its relatively
high hardness and high toughness property. The total usable life of a cutting pick for any
excavation machine is dependent upon its wear and fractures upon its resistance which in turn
will depend on parameter such as

(1) Pick geometry

(2) Operational factors
(3) The properties of pick material and
(4) Properties of rock being cut.

Currently understanding of these parameters is not well correlated and prediction of bit life is
still a trial and error process.
4.6.Pick geometry and operational factors on wear

Mainly two types of picks are in use radial and conical. Both of these vary in their angle of
attack, geometrical shapes, way of attachment to the machine and rotational movement during
cutting operation.

The study conducted on geometrical configuration of tool and operational factors affecting
tool wear are as under:

1. Tools with negative rake angle and rounded cutting edges.

2. The ideal cutting tool should be chisel shaped with large rake angle and back
clearance angle between 5-10 degree.
3. Bits should be selected for their wear and fracture resistance and the tool tip shape is
not likely to be a significant factor when measured over the whole tool life.
4. Radial tips are more quickly affected by wear than conical tools
5. Conical tools are more susceptible to friction sparking.
6. Tool force increase continuously with depth and spacing.
7. Increase of speed causes increased wear of the tool.

Process Problems

Poor cutting performance

Cutting High bit consumption, high tool wear

No cutter head penetration, smudging of cutter head

Soft soil behaviour and water (water-saturated mud)

Mucking Excavated blocks too big for haulage

Table 2: Main problems in roadheader excavation

4.7.Tool materials

The principal tool tip material used in the mining and civil engineering industries is cemented
carbide which is based upon the binary composition of tungsten carbide and cobalt. This
composite material, in which fine particles of very hard tungsten carbide(WC) are cemented
together with a tough cobalt (Co) binder, is used exclusively for roadheader and coal sheaere
drag tools. The WC-Co grades are known for their high hardness, high compressive strengths,
and modulus of elasticity. Since the use of WC-Co, considerable effort has been put into
developing analogous materials. Although materials substantially harder than tungsten carbide
are available, none have proved successful for rock cutting due to their low impact resistance.

4.8.Production of tungsten carbide pick tips

The stage followed during production are generally common for most tungsten carbide, and
the raw material and manufacturing techniques are significant factors influencing the ultimate
performance of carbides. The manufacturing stages basically comprise the production of
tungsten carbide powders and sintering. In order to produce tungsten metal, the tungsten ore
concentrate, being generally scheelite is processed to ammonium para-tungstate, tungstic
oxide or tungstic acid. The pure chemical is mixed with a pure carbon powder and heated in
non oxidising conditions with the objective of obtaining tungsten carbide. The next stage
involves the milling of tungsten carbide and cobalt particle together, so that the carbide grains
are coated with a layer of cobalt. This mixed powder should be free from impurities of the
correct size. The of the WC depend upon the type of produce required, whereas Co particle
size is usually finer than 1.5µm,since coarse grains cause the cobalt form platelets rather than
smearing over the WC grains, resulting in a loss of strength . After quality control checks, the
milled powder is pressed to produce the correct tip shape. The pressed compact is designed to
account for a 20% reduction in linear dimension during sintering. Sintering is the last stage in
the production of tungsten carbide material in which the WC-Co composite gains its final up
to 800℃ for about five hours.
 Fig :8 pick forces on a simple chisel pick

A simple chisel pick with the forces acting on it is illustrated in above Figure . The resultant
force Pa may be resolved into three mutually perpendicular components: cutting force Fe),
acting in the direction of cutting; normal force (Fn) perpendicular to the direction of Fc; and
sideways force (Fs) normal to the plane on which Fc and Fn lie. In rock cutting, the tool forces
continuously fluctuate due to the nature of the rock breakage which does not take a form. of
continuous chip as in metal cutting. The absolute magnitude of the pick forces shows a
decrease as the positive rake angle increases.

4.9.Tungsten carbide as a cutting tool material

Tungsten carbide is the most common cutting tool material used in rock cutting. The factors
that influence the performance and life of tungsten carbide are strongly dependent on the raw
materials and the manufacturing techniques Fowell and Altinoluk cover these aspects in their
works. The composition and micro structure of the constituents of tungsten carbide ultimately
determine itsphysical and mechanical properties. Cobalt and carbon are the most important
compositional . variables in producing tungsten carbide with a suitable blend of hardness,
compressive strength and transverse whereas theoretical content rupture strength Cobalt
carbon within 6.0 ranges from 6 to 15 % by weight of pure tungsten ± 0.11 limits has
significant. It is 6.12%. Any excess or deficiency of alloying impurities like iron chromite
sodium effect on hardness and strength In general, any of hardness and strength. Small
additions of titanium , nickel um or .sulphur can result in poor combination prevent
grain coarsening and increase hardness without affecting the transverse rupture strength.
titanium carbide (3- 5% by weight), however, could Equally important is the grain size
control; hardness and compressive strength increasing with decreasing grain size, whereas
the desirable grain size for best rupture strength is from 1µm to 3 µm. Porosity in the alloys'
structure is an unwanted parameter. High porosity give rise to poor transverse transverse
rupture strength but in hard metals, high densities up to 99.5% are achieved and uniformly
distributed porosity is usually present, which is not so harmful.

4.10.Gross failure of tungsten carbide tools

Tungsten carbide is a brittle material and is stronger when loaded in compression than in
tension. Further, its strength is enhanced in tri axial loading. Consequently bit designers aim
to ensure that the bit geometry and the mode of loading will not cause tensile stresses to be
applied to the bit during cutting. Also, where possible, they would mount cemented tungsten
carbide inserts in a tool body in a manner such that tri axial compressive stresses are applied
to the inserts. Despite these precautions, the bit inserts fail in a brittle manner, particularly in
hard rocks. One of the main factors responsible for this type of failure is the impact loading of
the bits; impact blow induces compressive stress waves in the bit insert, which are partially
reflected back from the available free surfaces as tensile stress waves, thus causing failure. In
other cases, fatigue can cause an incrementally extended crack with each loading cycle until it
fails. To prevent or minimize this type of cyclic failure it is important to minimize vibration
and a stiff drive to the cutting head is required. The failure may occur due to poor carbide
with low toughness and tensile strength, pores in the carbide or a thick braze. A thin braze
allows the waves to be transmitted to the insert carrier where it will be attenuated without
damage. Higher cobalt content also prevents impact failure but due to lower hardness it will
suffer more damage because of abrasive wear.

4.11.Temperatures during cutting operations and tungsten carbide tools.

The mechanical, chemical and metallurgical properties of tool materials are often temperature
dependent and any abnormal rise in temperature during cutting operations directly affects tool
properties like hardness and strength. Tool speeds underground are generally in excess of
1m/sec and in continuous operation, tool tips would reach very high temperature ranging from
600℃ to 900℃. Tungsten carbide tools at such high temperature begin to soften, thus causing
unwanted wear and early failure of bits.

4.12.Polycrystalline diamond compact (PDC) cutting tools

Hard rock cutting technology has been searching for synthetic cutting tool material that can
withstand the rigorous operating conditions and still can cut faster and longer. This kind of
durability from tools sets increasing demands for higher abrasive wear resistance and
toughness. As far as abrasive wear is concerned polycrystalline diamond compact (PDC) tools
are now available with 5-6 times higher hardness than tungsten carbide. However, PDC is
more susceptible to brittle failure than cemented tungsten carbide, because its fracture
toughness is 6.3 ksi as compared to 10.8 ksi of tungsten carbide with 6% cobalt. Traditional
abrasive wear is possible for synthetic diamonds when employed in coring bits. However,
these diamonds are prone to severe thermal degradation at temperatures above 750°C.
Synthetic diamond tipped drag tools hold a lot of promise as the next generation of hard rock
cutting tools. Further research needs to be done to provide answers to all the problems of
extreme rock cutting conditions.

4.13.Effect of cutting speed

Various types of cutting tools with varying composition and makes were tested, with and
without water jet assistance, at different cutting speeds. While details of the tests conducted
and the ensuing discussions are given elsewhere it was interesting to note that the wear flat on
the tool and rate of increase in cutting force component showed dramatic increases from
0.3m/s to 1 m/s cutting speed. The difference between 0.6 m/s to 1 m/s was negligible after 3
meters of cutting in terms of the tool and rate of normal force increase but at 0.3 m/s much
lower wear and lower forces were observed. Water jet assistance is essential to reduce the
wear rate at low cutting speeds but for higher speeds the benefit was lost for the conditions
employed during these investigation. There is benefit in cutting speed reduction in
prolonging tool life but the production rate may not be acceptable. Such a situation may be
justified in terms of tool costs when excavating isolated pockets of hard rock.
 Bit wear characteristic: eight types can be distinguished as below.

Bit wear type Bit wear type

1.New Bit: Perfect hard metal tip (insert of 5. Tip damage: Brittle fracture of the hard
tungsten carbide with a cobalt binder) in a metal insert because of high shear stress.
steel body.

2. Tip wear: Symmetrical wear of the hard 6.Total tip removal: The whole hard metal
metal (tungsten carbide) insert. insert has been pulled out of its steel
body

3. Asymmetrical wear: bits which are wom 7. Total wear out: the bit has been worn down
down on one single side. to a certain level, where no parts of the hard
metal insert are left.

4. steel wear: wear of the steel calibre in 8. Steel shank damage: the bit was broken
diameter as a result of chip grinding. below the steel body in the tool shank and
above the tool pockets.

Table 3: problem occurring during excavation: performance & tool wear

4.14.1 Occurring problem: Mucking

one lot the performance of the roadheader proved to be far behind from what had been
expected. Field studies soon discovered that this was not affected by poor cutting
performance, I was indeed a problem of the roadheader's mucking system. Due to the soft soil
behaviour the ick haulage could not transport as much material as excavated by the cutter
head. From time to time cutting process had to be interrupted, so that the workers had time to
shovel the forming mud in to the haulage device.

4.14.2 Causes

The geological situation was consequently mapped throughout the excavation works. The
geotechnical investigation program on both excavated material and undisturbed sample from
the tunnel face included-among others- grain size analysis, water permeability tests, thin
section analysis and powder swelling test. It was revealed that the mucking problem was
clearly related to the amount of clay and silt in the excavated series. The roadheader
performance generally decreases with an increasing, percentage of clay and silt. During the
excavation process the clay- and siltstone-layers were cut to small debris by the roadheader.
They were mixed together with sand from the sandstone-layers, that-unfortunately - are highly
water permeable. In combination with the encountered water inflow of 2 -5 l/sec this seemed
to be the right mixture to form a water-saturated mud. This material could no longer be
mucked by the road header's muck haulage.

4.15.1 Occurring problem: Bit consumption

During the excavation work of another lot, the roadheader suffered from an immense bit

consumption per day.

4.15.2 Causes

In most cases the hard metal bit was broken or even broken out of the bits steel body (wear
type 4 and 5). This pointed at highly abrasive rock with a high compressive strength, Indeed
there was a clear connection between enormous bit consumption and appearance of thicker

calcrete layers.
4.16 Effect of rock property on wear

Sedimentary rocks have almost exclusively been the main rock type where drag tools have
shown fare degree of success. The important property of sedimentary rocks that influence tool
are identified with hard mineral content,(commonly quartz but not always so) grain size and
angularity and sedimenting minerals limited use of drag tools has been reported in igneous
and metamorphic rocks due to their inherent strength and tool degradation properties. The
most commonly measured property that influences tool wear is the abrasively. In hard rock
frontal wear causes chipping of the carbide. Large wear spots were marked when drilling in
granite. While drilling sandstone and granite abrasive wear is more. Cutting tool material and
their properties have a direct effect on tool wear and its useful life. Selection of suitable tool
for the given operating conditions needs due consideration.

Fig 9 : Effect of rock properties on tool wear

4.17.Water jet assisted rock cutting

The use of water jet assistance with drag picks represents a technology which can overcorr
some of the limits of conventional rock cutting. Many of the potential advantages includ
reduction of cutting forces, reduction in tool wear, temperature control during cutting
eliminating sparks, reduced dust hazard and overall improved cutting process. Mechanical
assisted water Jet cutting has successfully been employed in coal strata and other similar
formations, but use of this mode of cutting in hard rock is minimal. It is the application of
water jet assisted cutting which holds promising prospects for increasing the overall
efficiencyCutting operations,including life of the cutting tools.

Fig 10: water jet assisted pick

4.18.Parameters of selection of road heading machines for driving of tunnel and

roadways in coal / rock

Selection of roadheading machine involve a lot of geotechnical factors which may be broadly
classified as under

(1) Geo- mining conditions.

(2) Availability of additional facilities.

(3) Economic aspects of the heading machine

Geo-mining condition take into account the geological feature of the rock, rock-mechanical
and mining characteristics of the site of excavation.

Economic aspect include the high capital requirement and its availability, machine utilization
and ultimate return with respect to machine performance. A mechanized heading requires
extensive back-up of sub system.

4.19.Geo-Mining Condition

Under this heading following feature should be considered:

4.19.1 Excavability of strata

It may be defined as the degree of ease with which a rock can be broken by mechanical
picks.in fact any method of measurement of excavability any strata has not been universally
defined. It depend mainly on following parameters:

(a) Compressive strength of rocks.

(b) Tensile strength of the rock.

(c) Toughness derived from the relation between compressive strength and tensile
strength of the rock.

(d) Plasticity of the rock.

(e) Discontinuities and other natural weakness of rock.

Compressive strength particularly, uniaxial variety is often taken as the index of excavability
of the rock. It is the most important criterion for obvious reasons. The harder the rock the
more difficult is to drive a roadway or tunnel through it by mechanical means. The tensile
strength and toughness are important as they affect the brittleness of the rock and thus
response to the shearing action of the cutting picks. Rock with higher brittleness (i.e with
lower toughness) will be easier to break.

Higher plasticity increases energy consumption necessary for cutting the rock as bonding
between grains are usually stronger in this condition. Moreover the deformation permitted

or tolerated by the rock of higher plasticity is higher. This causes greater loss of energy to
overcome this deformation before the rock really fails by the impact of cutting tool. Presence
of thin bands in rock even with much higher compressive strength than the host rock, may not
pose major problem but a thick band is always desired. Other than the problem of cutting
band, the danger of methane explosion in a gassy mine is often increased as sparks, may be
generated from the interaction of cutting tool and the hard strata.

An estimate of percentage of and grain size of quality and other abrasive materials helps the
judgement of wearing of pick and other machine parts and other machine parts hence
affecting their selection. Discontinuities and other weakness planes play typical roles on the
machine performance depending upon the orientation with respect to the line of attack with
picks on the rock face. Some weak plane in different orientation may help the performance of
the roadheader machine while these planes coincides or remain close to the breakage planes
developed by the shear produced during cutting, mechanical excavation becomes quite easier
but excessive fracture may create problem for the cutting drum to move freely.

4.19.2 Stability of roof

Stability of roof after rock excavation affect the selection of road header as it indicate time up
to which it can be kept unsupported. Fast heading with weak roof is not possible. Where roof
is competent but side walls are weak the situation becomes more complicated. Side falls can
be prevented by roof in bolting. Standability of roof in an excavation depends on the
following :

1 Competency of roof, floor and side wall rock.

2 Presence of water.
3 Creep criterion of roof and sidewall.

4.20.1 Type of rock

The floor the drivage of tunnel in rock should be strong enough to withstand the weight as
well as the reaction exerted by the operating roadheader machine. In soft floor these heavy
machines often face problem in movement.
4.21.Gradient of drivage

Roadheaders can negotiate an upward gradient of up to 10° effectively and in downward

gradient of about 12-15° while in operation. Thus gradient limits the selection of road heading
system. A steeper gradient causes loss of mechanical balance.

4.22. Presence of fault in rock

A number of discontinuity or faults are encountered during drivage ranging from few cm to
m. Roadheader can cut through softer rocks but if the compressive strength is high enough the
roadheaders cannot cut through them. On the other hand pick consumption also increase.

4.23. Presence of fold in rock

Minor folds do not cause sharp and abrupt variation in the dip of the seam and they don't
effect the roadheader performance much more. But major fold especially of undulating nature
cause sudden change in dip which may be too difficult for road heading machine to negotiate.

4.24. Availability of other facilities

4.24.1.Transportation of other excavated material

This is often biggest delay to high speed drivage the system should be capable enough
handling the peak load and more importantly must be capable of rapid extraction. Belt
conveyors are generally used in conjunction to the machine. The loop take-up system of the
conveyor should be capable of storing up to atleast 100m of belt.

4.24.2.Ventilation in underground excavation

All cutting machines there make dust there selection of machine should be such that it minin
dust production but cannot be eliminated. Dust production causes respiration problem to
workers. Ventilation system is required due to following reasons:

(a) To avoid build-up of gases.

(b) To dilute or remove gas

(c) To be able to keep up with machine adjustments.

4.24.3 Noise emission

Excessive noise level during drivage causes discomfort to the operators which may lead to
loss of efficiency of machine.

4.24.4. Economic Aspects Of Heading Machine

It depends upon following factors

4.24.5. Machine utilization and availability of time

Roadheader are continuous machines and have to be backed up by continuous material

handling system. Any failure in machine or in these additional system will certainly cause
loss in machine available time and machine utilization time.

4.24.6. Pay-back period and capital recovery

Pay-back period of the machine is the projected time over which it returns whole capital along
with depreciation and the interest in the form of output. This is inturn depends on rate of
interest and expected life of the machine. For a short pay-back period capital recovery rate for
this machine will be high and will demand very efficient utilization of machine to attain high
production and faster rate of advancement during tunnel construction.
 CHAPTER 5
MECHANICAL ASPECTS OF HEADING MACHINE

5.1. Types of existing roadheader in India

Presently three models of roadheader are used in Indian coal mines. They are

(1) Alpine Miners-50

(2) Dosco NBC Dintheader
(3) Dosco Roadheader MK-IIA & LH-100

The above mentioned roadheader machine expect LH-100 are being used in “Moonidih
colliery” there are some distinct difference between roadheading machines which are given
below.

In Dosco roadheader machine the transmission of power from electric motor is through
hydraulic system while in AM-50 it is mechanical. The control system in DOSCO is hydraulic
while in other it is electro mechanical. Dosco miner (LH-100 &MK-II) uses milling type
method and cutting force is exerted mainly sideways. When cutting harder rocks the machine
is braced against side wall with hydraulic jacks. This milling type cutter head are better suited
for selective mining. The ripper type cutting which are employed by AM-50 uses full weight
as counter reaction to the cutter head and balanced by the weight of the machine. Thus in this
type of cutting machine no setting jacks are required and machine appear to be stable. For
equivalent cutting capacity ripper type machine are lighter than milling type. It is claimed by
manufactures that the milling type cutting heads need less power transmission is direct and in
later case it is at right angle to the axis of cutter boom.

The method of debris collection in MK-IIA and LH-100 is by single chain scrapper which
encircle the heading machine. This system in general has problems in handling blocky rocks
and mucking on steep down slope. But as we observe under indian conditions the cutting head
does not produces blocky rock and these machine are not meant to operate in steep conditions.
AM-50 employ gathering drum loading system which is efficient and adopted in design of
modern boom machines. The material in case of dint-header is conveyed by chain mat of the
machine itself to the bridge belt conveyor. This system has been proved effective in all the
cases but highly fissured zones.

As far as the dust production is concerned the milling type machine have been proved to
produce lesser amount of dust than ripping type. One important aspect which comes into play
while considering the performance of roadheader is pick consumption which has been dealt in
a separate chapter.

5.2. Description of Roadheader used in Moonidih project

5.2.1.Alpine Miner AM-50

The Alpine Miner AM-50 is boom type roadheader designed to cut medium hard rock with an
unconfined compressive strength upto 1000 kg/cm2 (ie100MPa) the machine can however also
take thin seam of harder materials in its stride. This means AM-50 can cut most of the rock with
economic efficiency thus AM-50 has wide range of application, roadheading in the mining
and mineral industry, tunnel driving in civil/engineering work and face work in mines.

The AM-50 cutter heads were fixed in transverse direction to its drive motors. It has
electromechanical drive motor. The crawler moves on individually driven electric motors. In
total this machine has got 6 motors, except the cutter motor which is water cooled the
remaining all are air cooled motors. It is designed to negotiate gradient upto l in 4 and also
found in the field that the Dosco roadheader machine. Structural advantages such as easy
dismantling, low height, low weight make it suitable for use in all mining conditions except
the very thin seams and water mines, where humidity is more and tunnel constructions. This
machine is designed for maximum cutting range of 4.0 meters vertically and 4.8 meters across.
The selective cutting principle with which the cutting boom can be swung in all directions make
possible to cut any profile of tunnel and mining with in indicated range, without moving the machine.

The material is gathered by gathering arms on to the chain conveyor which is kept at the centre Part
of the machine. A single scrapper chain conveyor will be driven by an electric motor in turn take the
material from the front portion of the machine to the rear side bridge conveyor. By virtue of its
design it has got good stability while cutting as compared to Dosco and vibration due to the cutting is
nominal. Attachments are also available to give machine a greater upward reach. Because of machine’s
easy mobility the cross-cut range doesn’t have to be extended.
The Alpine miner AM-50 is composed of following assembly groups.
(1) Boom and cutter head
(2) Turrent
(3) Loading assembly
(4) Chain conveyor
(5) Crawler track assembly
(6) Frame
(7) Electrical system
(8) Hydraulic system
(1) Boom and cutter head

The cutter boom consists of cutter motor which directly drives the 3 stage spur gear system
and twin cutter heads. The water cooled cutter motor of special design is rated at 120 kw
and 800 rpm. It is available with closed circuit cooling or with a non- circulating system the
latter using cooling water for spray suppression of dust. Interchangeable gear wheels are used
to regulate the maximum output speed range. Several types of cutter heads are available and
the variety of picks differing in type, shape and finish. The picks are carbide tipped.
Boom and cutter head fitted with conical picks.

Fig: Boom and cutter head

(2)Turret
The turret provides vertical and horizontal position of cutter boom. In addition it forms the
link between divided frame. The turret consists of following main components, the bridge
girder with flange, disc based cutter boom and appliance for vertical swing. The boom is
slewed horizontally and hydraulic jack driving a spur rack and gear rim. The vertical
swing is affected by two hydraulic jacks moving on the base of the cutter boom.

(3)Loading assembly

The loading assembly consists of the apron, which can be raised or lowered hydraulically, the
two loader transmissions and two loading and gathering arms. The robust cast steel apron
(sometimes referred as gathering head) catches the cut debris, which are then gathered onto a
chain conveyor by loading arms. When lowered all the way to the floor, the apron also acts as
a front support to give the machine greater stability. The minimum width of the apron is 2.0
m additional attachments are available, however by means of which the width can be
increased to 2.5m to 3.0m the loading arms are driven by two single reduction bevel gear
loader transmission which are connected via dog coupling to the return shaft of the chain
conveyor. Bevel gear reduction ratio is 1:3.21 and bevel gear set is spiral toothed. There will
be right and left hand assembly for the two gathering arms.

(4) Chain conveyor

The cut debris picked up by loading arms are transported to the rear of the machine via single
chain conveyor through the center of the machine. In standard design the conveyor speed is
0.9m/s with a maximum capacity approximately 100 m3/hr. the throat opening beneath the
turret is large enough (400mm x 370mm) to allow the passage of relatively large lumps of
material. The dual reduction bevel/spur wheel transmission (1:13.23) located at the discharge
end of the chain conveyor are powered by electric motors (11 kw or 12kw each). Slipping
clutches are 11 employed between motor and transmission as a protection against
overloading, particularly in the event of blockage.

(5) Crawler track assembly

It is located to the either side of the machine-frame. The tracks are individually driven by 1l
kw or 12 kw motors via two self-locking worm type planetary with reduction ratio 1:257.4.
Individual track drive permits good maneuverability of the machine. The travelling speed is
m/min at 60 cycles. The self-locking action of the track gear assembly when the motors are
stopped helps the machine to negotiate gradient by acting as automatic brake. The connection
to the drive socket can be easily uncoupled so that the machine can be towed. To keep the
dimensions possible despite this large reduction ratio, the track transmission has been
designed as a combined worm gear and planetary gear mechanism. The worm gear drive
represent the input step of the reduction, a single threaded worm mates a 30 tooth worm gear.
The worm itself is high alloy case hardened steel with ground and polished tooth flanks. The
worm gear is of centrifugal cast phosphorous bronze. The planetary gear is the output step.
The sprocket driving the track chain is fastened to the planetary gear carrier which serves at
the same time as the drive shaft.

(6)Frame

The rugged two part frame carries the turret, the loading assembly, the hydraulic and
electrical system and the. operator's stand. At the rear of the frame a hydraulic stabilizer is
mounted at the Centre of the machine. When lowered this device gives additional stability
during the cutting operation, especially on uneven floors. Moreover the hydraulic stabilizer is
capable of lifting the rear of the machine clear off the ground. This is a considerable
advantage on uneven floors.

(7)Electrical Systems

The AM-50 miner electrical equipment comprising all motors, switch gear control, head-light
and cables is available in an explosion proof (permissible) or non-explosion proof (standard)
version protection of electrical equipment can be provided either by protective circuit or
supervision of the trailed power supply cable by an N-relay. The cutter motor is water-cooled
motor of special design with a capacity of 120 kw and 1800 rpm the motors rated at 13.24 kw
and 1800 rpm are also non-ventilated motors at rugged construction. All driving motors are
protected by overload relays as well as by thermal relays.

(8)Hydraulic Systems

Essentially the hydraulic system include the oil tank with built in axial piston pump, the
controls, the valves, as well as the back flow filter, the hoses and tube. The system uses a
pressure of 200 bar and can be operated with mineral oil or flame resistant hydraulic fluids
of HSc group (water glycol base). A pressure gauge and a thermometer on the control panel
show the operating pressure and temperature of the hydraulic fluid the axial piston pump is
driven by a 11 kw or 12kw motor. Its pumping capacity is co-ordinated with the output
speed of the cutter transmission to result in horizontal turret swing time of 11-13 sec. the
hydraulic fluid is cooled by water for the spraying device as the water passes through a
cooling built into the hydraulic tank.

5.3.Technical specification Of The AM-50 Road Header machine

Overall height 1645 mm

Overall length 7500 mm

Overall length (with through off chute for belt suspension) 8150 mm

Overall width ( without loader head i.e apron) 1910 mm

Overall weight 2400 metric tones (26.5 tons)

Width of crawler chassis 1850 mm

Width of crawler tracks 370 mm

Ground pressure under crawler track 1.4 kg/𝑐𝑚2

Width of apron 2, 2.5 and 3m

Maximum apron position above the bottom edge of the track 78 mm

Maximum cutting height above floor level (without cutter boom extension) 3758 mm

Maximum cutting depth below floor level 100 mm

( without cutter boom extension)

Maximum width of excavated section 4800 mm

( without cutter boom extension)

Length of cutter boom (without optional extension) 3200 mm

Maximum possible gradient ±16°

Travelling speed

(a) At 50 c/s motors(or cycle) 5m/min

(b) At 60 c/s motors 6m/ min

Chain speed of conveyor ( at 50 c/s motors) 0.9 m/s

At 60 c/s motors 1.1 m/s

Cutter boom assembly at 50 cycles (380-1000 v)

Rated power 100 kw

Rated speed 1470 rpm

Rated torque 650 N-m

Breakdown torque 1625 N-m

Cutter transmission 50 cycles

Output torque 10764Nm -12987 Nm

Output speed 88.7 rpm

Installed motor capacity at 50 cycles

Cutter motor 100 kw

Driving motor for hydraulic pump 11 kw

Driving motor for chain conveyor (2×11 kw) 22 kw

Motors for crawler tracks (2× 11 𝑘𝑤) 22 kw

---------------------------------------

total = 155 kw
 CHAPTER 6
PERFORMANCE STUDY OF ROADHEADER MACHINE

6.1.Retrospective view of roadheading machine used in india

Full statistical and system details of performance of roadheading machine at various coal
companies are not readily available. It therefore becomes rather difficult to judge performance
of machines in isolation from a system where complete backup support is restricted and
nominal production facilities such as uninterrupted power supply, water supply, workshop
facility etc are frequently absent. That the following have been achieved should be consider
encouraging.

6.2.Moonidih colliery

In a systematic programme to mechanize coal mining and development drivage at the mine,
two roadheading and two dint-header machines had been employed since 1978 and 1980
respectively. In order to generate the desired production capacity at the mine to fulfill the
present requirement of coal for various demands, like power production, steel production,
cooking pupose etc. No of longwall faces and roadheader were introduced. At present 2
roadheader are working in this project. The project is fully mechanized. We have two types of
drivage at the Moonidih.

(a) Rectangular gate roads (4.8𝑚 × 2.4𝑚)

(b) Arched main transport roads or lateral (4.8 𝑚 × 3.0 𝑚)

The coal of this mine is not very strong and compressive strength varies from 300-350
kg/𝑐𝑚2 .immediate roof is sandstone and shale whereas floor is shaly sandstone. Mine is
Degree-III gassy ( i.e rate of emission is more than 10m3 /tonne of coal production. Water and
gas problems are not much but except through the faults which are common in area,
displacement varying less than a meter to several meters.

Cycle time for an advance of 2m at roadheader face with girder and props support at the top
seam was observed as follows:

(1) Cutting time (1m) = 60 min (i)

 (2) Supporting time (per set)= 40 min (ii)
(3) Ventilation duct (extension)= 30 min (iii)
(4) Belt conveyor extension = 60 min (iv)

Total cycle time= (i)+(ii)+(iii)+(iv)

= 60 min+ 40 min+30 min+ 60 min

= 190 min

6.3.Evaluation of performance of roadheader machine at Moonidih colliery

The collected data at moonidih project for each working roadheader is given appendix. The
analysis of data for evaluation of performance of roadheader can be done by the following
indexes.

A) Weekly drivage per roadheader in meter

B) Percentage utilization of machine available time
C) Percentage loss due to breakdown
D) Environmental indexes
E) Geotechnical parameter
F) Socio-technical parameter

6.4. weekly drivage per roadheader in meter

Average progress of drivage for each roadheader can be calculated from the data given in the
appendix which is follows.

particular RH
Average progress/week (in meter) 18.5
Table- 5

The size of rectangular drivage at Moonidih mines is 4.8×2.4m2 . Roadheader machine cut
coal (320kg/cm2) 2 m in one cycle. In one cycle roadheader machines takes 190 min that
means roadheader will complete 2 cycle in one shift (480 min).
Therefore total drivage per week (6 days) of a roadheader for an ideal case should be

= 2 × 2 × 3× 6 meters= 72 meters

Therefore percentage of utilization of roadheader machine.

= (18.5)× (1/72) ×100

= 25.69%

Therefore it is found that percentage of utilization of roadheader machine is “very poor”.

6.5.Percentage utilization of machine available time

Percentage utilization of machine available time can be found by term reliability index which
is defined as the machine cutting hours to machine available hours. The reliability index
greater than or equal to 0.7 is said to be the machine performance is better but less than 0.7 is
said to be poor performance.

The result shows that only few hours are being used for the machine cutting against the
machine available time. Due to this reason the performance of roadheader is restricted. The
following are the factor on which machine utilization time depends.

Sr.no Main factor Variable

1. Down time Planned maintenance
spare availability

Un planned staff availability

Spare availability
Condition in tunnel

2. Support Types and amount

Required erection
System degree of
Mechanization
Ancillary Operations Grouting
 Lagging Boards

3. Debris disposal At the face cleaning gap

General mucking
Secondary breakage

Behind the face Conveyor

Mine cars
Water presence

4. Auxiliaries Ventilation
Dust extraction Water/ pumping equipment
Air ducts for extraction
Extension Truck
Power cable
Telephone
conveyor

5. Labour Availability
Experience /skill
Distance/ time method
Transport at face

6. Organization Management Bonus schemes

Communication

Shift time Total payable time

Production time

7. Final use Engineering tolerance Grade

Alignment

8. Water A problem of water of disposal and drainge

Table 6.Factors influencing machine performance
6.6 percentage loss due to break-down

Average percentage loss due to machine break down as well as other infrastructural support
system can also be calculated from the given data in appendix for roadheader which is shown
in the table-6.6.1

Particulars RH
Average weekly break down(%) 15.67%
Table 7.

It is found that average weekly percentage loss varies from up to 34%. This loss can’t be
removed completely but can be reduced to some extent if the factor associated with this is
taken in to consideration.

Major causes of time loss

Major factors causing time loss and thus reducing application of the machine are enlisted
below;

1) Machine breakdown
2) Power shut-down
3) Belt extension
4) Supporting of bad roof area
5) Pan extension

Pan extension may involve one shift whereas belt extension involves 6-9 shifts. progress of
machine some time hampered in case the area require intensive supporting system due to any
geological disturbance present.

The specific breakdown of machine involves.

1) Hydraulic pipe of any hydraulic system bursts

2) Plough plate bending
3) Hopper derailment
4) Nipple crack
5) Scrapper chain derailment
6) Problem in gate end box
 7) Belt snatching
8) Tightening of belt also involve some idle time with machine

6.6 Environmental Indexes

Under this following parameters are considered.

Geotechnical parameter

Sociotechnical parameter

6.6.1.Geotechnical parameter

The nature of geological setting of drivage site has a major effect on the performance of
roadheader machine and many aspect relating to safety, support design. Though geological
investigation is conducted before commencement of project in coal industry. But as the
project progresses the geological feature at the site do not meet with previous investigation.
At moonidih project it is found that the rock above and below coal seam is mostly sandstone
and shale. Wherever the roof is sandstone they have provided only roof bolting but when it is
shale having weak strata, they have provided better support (like steel post and steel beam)
for safety. When support is provided the machine has to be stopped which later affect the
drivage. Sometimes at the drivage face big boulders of the stone is found which also affect the
drivage. Boulders has to be removed by drilling and blasting method for further drivage.

6.6.2. Socio-technical parameter

The performance of roadheader in underground mine depends on the following socio-

technical parameters.

Ventilation

Dust problem

Temperature and humidity

Ventilation

When during entry the working face has to be supplied with fresh air by means of some
special ventilation devices. The supply of fresh air is mostly carried out by forced vibration by
fans and air ducts. The corresponding valid regulations concerning the quantity of fresh air to
be supplied have to be taken into consideration and depend on the following.

(a) Cross sectional area of drivage

(b) Horse power of diesel engine in operation, if any
(c) Dust concentration

Suction system

When applying this method the accumulated dust is removed from the face by means of air
duct. If the suction capacity is sufficient, the dust at the face is collected to a satisfactory
degree. Yet the problem in connection with the system is, that the sucked off dust is not
suppressed but is blown out again at the other place where it might have negative effect again.

There is no doubt that most efficient dust control at present consists of suction system
combined with subsequent suppression in the dust collector whereby the suction fans from an
integrated part of the dust suppression device.

Dust suppression system is not being used at moonidih project. Due to which dust production
during cutting coal causes much problem to workers. Sometimes it is found that dust
production causes visibility problem at the cutting face resulting in stopping the machine.
Hence machine performance reduce.

Temperature and Humidity

Acceptable thermal environment must be met, if safe productive and healthy working
conditions are to be achieved. Hot working conditions are being experienced in some of the
mechanized mines in development of heading machine as well as longwall faces, because of
high air temperature, high humidity and low air velocities. High temperature and humidity
limit the working hours and therefore productivity of men and roadheader machine.

In india the wet bulb temperature at any working place is not exceed 35.5℃. when wet bulb
temperature exceed 30.5℃ arrangement are to be made to ventilate the same with a current of
air moving with a speed not less than 1m/sec. at present the underground temperature of
moonidih colliery has been maintained to about 34-35℃. Hence the temperature and humidity
doesn’t causes much problem to the workers.
 CHAPTER-7
CONCLUSION

It appears that future prospects of replacement of conventional drivage method to a greater

scale by modern heading machines are bright in Indian coal industry. Roadheaders should
become more popular if effective machine productive hours and machine availability time are
improved. It was observed in previous chapter that the performance of roadheader was only
18.69% . It was concluded that performance of roadheading machines were poor.

7.1.Factors influencing performance of roadheading machines

Machine utilization for cutting coal was only a few hours of machine available time. Most of
the time is used for infrastructural support system due to which machines remain in idle
condition. Although uninterrupted operation of heading machines even in the most advance
countries of the world is yet to be achieved. However method study, data recorded over 1100
drivage shift in U.K mines in the recent past years revealed that the machine utilization for
productive operation was only 24% of the total shift time. The balance was consumed for
setting up time for supports etc (46%) and lost time (30%). Lost time are those which could
have been avoided. Roughly the breakdown of time holds good for machine operation in other
countries.

The rated capacity utilization factor for heading machines in drivage varied from 15-35% in
Russia. This value points to an exclusively important part of work associated with the
operation f machine eg: timbering, transportation, ventilation in particular and miscellaneous
jobs and days. A good number of design of drivage canopy support arrangement are
established to crease the productivity of heading machine by mechanizing the unproductive
delay in support erection.

7.2. Hardness of the material to be cut

The type of heading machine used at moonidih project are medium weight roadheader AM-
50. The strata where these machine are economically and effectively employed are often a
matter of contention. Sometimes this results from information obtained from various
available/published sales literature which are generally accompanied by a simple inverse
curve showing the fall of production from a machine with the increase of rock compressive
strength.

The following additional constraints were identified at moonidih project. As the major cause
of poor rate of advance of development drivage:

a) Single long heading of up to 1000 meter length was very difficult to ventilate and
maintain.

b) Although the machines were rated for ± 14° gradient, it became difficult to operate the
machine at a gradient more than ± 10° as the machine tended to creep away from the face
during cutting which led to reduce cutting pressure. In deep faces water accumulation
coupled with slouch due to crushed coal causes major problem.

c) Road drivage faces were characterized with high airborne dust concentration specially
when cutting in soft stones (such as shale) by roadheaders. Dust depression measures in
general were not to the extent desired.

d) For negotiation of bends /turning the machine involve dismantling and re-erection of
bridge belt conveyor, leading to loss of productive time.

e) Frequent faults and discontinuities caused problem in drivage as per design

specifications dintheaders are not compatible to mine stones whereas roadheaders are
compatible for stones of low compressive strength like shale etc. thus drilling and blasting
had to be negotiated for stones.

f) Success of any mechanized system mainly depends upon the availability of adequate
spare parts, and sales service by manufacturers, service engineers. Import of spares
normally take 12 months therefore actions were taken to manufacture some of the spare
parts indigenously.
 7.3.Design of sub-systems for better performance of roadheader

At moonidih mines total system design appears to be one of the major constraints in
achieving higher performance. While considering the deployment of drivage machine,
following, sub-system need to be designed adequately.

a) Ventilation sub-system

Drivage of long heading for single entry roadheader panel development need to be provided
with proper ventilation system to dilute the inflammable gases below the danger limit, keep
the temperature of gallery and working face comfortable and to keep the air born dust
concentration within permissible limit.besides these the system must be easy to be installed
and matched with fast speed of machine.

Overlap auxiliary ventilation of long headings is considered to be the most suitable with high
capacity fans, dust filtration unit and flexible to provide the above desired condition at the
face.

(c) Transport sub-system

While designing a belt conveyor behind the development machine, capacity is not a greater
problem compared with the speed of operation like extension and sorting of conveyor. this
could be achieved by 260 tph capacity belt conveyor with automatic motorized loop take up
system. The loop take up should be capable of sorting upto 100m of belt and , maintaining
constant tension in the belt by automatic laying off or taking up the belt. The immediate
structure of conveyor should be tabular, with pin type joints and push on idler bracket for
quicker extension of belt conveyor. The tail end unit of conveyor should be kid mounted and
capable of taking the bridge conveyor trolley either on itself or form a monorail suspension.
This will provide the overlap between bridge belt conveyor and outby conveyor the end unit
should be capable of being towed by the drivage machine with suitable connection.

The present system at moonidih doesn’t include this type of arrangement and has a small
chain conveyor between the bridge belt and outby fixed type of belt conveyor to provide the
overlap. This causes delays during extension of chain and belt conveyors resulting in frequent
stoppages of the machine.
 b) Environmental sub-system

It includes mainly air-born dusts, noise ,visibility and vibration control measure to be taken
from the designing stage . their periodic checking and remedial action for control within
permissible limits are the necessary pre-requisite for smooth operation of mechanized
drivage.

Suitable type of dust filters wet or dry type should be incorporated in the ventilation system.
One of the integral dust filter designed by MRDE is very compact which is used in Moonidih
mines. Noise level control can be achieved by suitable type of silencers provided with
auxiliary fans etc. personal ear-muffs are also useful. Visibility conditions at the face can also
be improved by dust control measures ie proper water spraying arrangement, complete and
sharp picks, periodic cleaning of water spraying nozzles integral provisions of front and back
lights

c) Support sub system

Quick and fast erection of support in mechanized drivage,if not provided may prove to be a
major hindrance in progress of machines. Machine is to wait till the lag in support is made-
up. One of the method is to provide, wherever suitable, mechanized roof bolting either
powered from the machine itself or independently powered. Numerous designs of
electrohydraulic drills are available from various manufacturers ranging from manually
operated to automatic drilling and installations of roof bolts. Ordinary grouted type bolts to
resin bolts and split set bolts are widely used. Simple goal-post supports of girders on wooden
props or steel supports are also common in drivage of short duration, whereas permanent or
semi-permanent drivages are to be supported by rigid or yielding type arches with suitable
lagging.

d) Directional control

Laser type light emitting direction control devices are very useful for long drivage. These
give a constant mark on the face to be sheen by the operator of the machine for directional
control.

7.4. Graphical comparison of running time, maintenance time v/s total

time, available time.
Total running time (from data) = 252 hrs

Total maintenance time(from data) =146.75 hrs

Total available time= 2142 hrs

Total time = 3864 hrs

7.5. Showing percentage of down time in total available time

Fig. Pie chart representing the downtime period

Code Parameters Code Parameters

1 Machine running time 6 Power Failure

2 Maintenance 7 Conveyor breakdown

3 Breakdown 8 Other problems
4 Face Preparation 9 Belt Extension
5 Bunker fall 10 Water Drainage
Conclusion and recommendations

Collating experiences of mechanized roadways drivage at moonidih, the following

generalized conclusion emerge:

 Total system design need to be considered right from the planning stage and ordering
of the equipment.
 Selection of right type of drivage machine prevailing geo-mining conditions is of
paramount importance.
 For achieving better performance quick setting supports or mechanized roof bolting
devices need to be used.
 For better transport sub system need to modify in belt conveyor arrangement, and
develop a take up loop system.
 Development of indigenous machine and spare parts need to be given due importance.
 Safety device and provisions stipulated by DGMS should be planned from initial
stage.
 Effective material supply arrangements should be planned and executed for each
drivage.
Bibiliography

1.Experimental investigation and field application of foam used for suppressing roadheader
cutting hard rock in underground tunneling xinxiao Lu , Deming Wang, School of Safety
Engineering, China University of Mining and Technology, Xuzhou 221116, China

2. Bilgin, N., Seyrek, T., Shahriar, K., 1988. Roadheader performance in Istanbul, Golden
Horn clean-up contributes valuable data. Tunnels and Tunnelling (June), 41-44.

3. Some geological and geotechnical factors affecting the performance of a roadheader in an

inclined tunnelN. Bilgin a,*, T. Dincer b, H. Copur c, M. Erdogan , Mining Engineering
Department, Faculty of Mines, Istanbul Technical University, Maslak, Istanbul 34469,
Turkey Problems occurring during.

4. McFeat-Smith, I., Fowell, R.J., 1979. The selection and application of roadheaders for rock
tunnelling. In: Proceedings of the Rapid Excavation and Tunnelling Conference, Atlanta, vol.
1, pp. 261-279.

5. Possibility of rock excavation by boom-type tunnelling machines. Australian Tunnelling

Conference, Melbourn, pp.253-259

6. Experimental investigation and field application of different cutting picks for cutting hard
rock. Thaobing Zhu a, Wei Shen ,State Key Laboratory of Coal Resources and Safe Mining,
China University of Mining and Technology, Xuzhou 221116, China

7. Barnes . J.W- roadway drivage & shaft sinking colliery guardian August-1981

8. Handbook of mining and tunneling machineries — Stack & Barbara

9. M. Erdogan, H. Copur Engineering Geology Division, Geology Engineering Department,

acuity of Mines, Istanbul Technical University, Maslak, Istanbul 80626, Turkey

10. Some of the contents were taken from the book " chakraborti P.K roadheading

11. Roadheader applications for driving sloping tunnels. Unrug, K.F., Whitsell, S.R.,
1984.1SRM Conference on Design and Performance of Underground Excavations,
Cambridge, pp. 313-319.
Downtime analysis of roadheader machine

Total avlb
DATE hrs hrs 1 2 3 4 5 6 7 8 9 10 11
06-10-
2017 144 108 9 3 3 33 36 24
13-10-
2017 144 0 0 0
20-10-
2017 144 0 0 0
27-10-
2017 120 0 0 0
03-11-
2017 144 0 0 0
10-11-
2017 144 0 0 0
17-11-
2017 144 0 0 0
24-11-
2017 144 108 28 10 18 7 20 25
01-12-
2017 144 108 20 3 7
08-12-
2017 144 108 11 5 16 16 15 18 42
15-12-
2017 144 108 22.5 8 15 28.5 34
22-12-
2017 144 108 29 14 3 16 15 16 29
29-12-
2017 144 108 34 17.25 33 2.75 2
05-01-
2018 144 108 23 11 14 28 32
12-01-
2018 144 108 21 4 24 18 2 39
19-01-
2018 144 108 21.5 4.5 51 17 6 8
26-01-
2018 144 108 14 10 34.5 13.5 36
02-02-
2018 144 108 15 15 9 43 26
02-09-
2018 144 108 9 12 46.5 26.5 14
16-02-
2018 144 108 21 6 24 26 31
23-02-
2018 144 0 0 0 0 0 0
TOTAL 3000 1512 278 122.75 237 293.5 48 2.75 32 235 110 25 24
ABREVIATION FOR TABLE
Code Parameters
1 Machine running time
2 Maintenance
3 Breakdown
4 Face preparation
5 Bunker fall
6 Power failure
7 Conveyor break down
8 Other problem
9 Belt extension
10 Water drainge
11 Manual cleaning