Self Drilling Rock Bolt Technology for the Coal Industry Advanced Solutions Ground Support Services...
-
Upload
margarita-rutledge -
Category
Documents
-
view
220 -
download
1
Transcript of Self Drilling Rock Bolt Technology for the Coal Industry Advanced Solutions Ground Support Services...
Self Drilling Rock BoltSelf Drilling Rock Bolt TechnologyTechnology
for the Coal Industryfor the Coal Industry
Advanced SolutionsAdvanced Solutions
Self Drilling Rock BoltSelf Drilling Rock Bolt TechnologyTechnology
for the Coal Industryfor the Coal Industry
Advanced SolutionsAdvanced Solutions
Ground Support Services Pty Ltd September 2007Ground Support Services Pty Ltd September 2007Ground Support Services Pty Ltd September 2007Ground Support Services Pty Ltd September 2007
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 22
SDRB Advanced Solutions SDRB Advanced Solutions SDRB Advanced Solutions SDRB Advanced Solutions
…it is all about productivity …it is all about productivity
A pick & shovel is cheaper than a Longwall…..but it is not as productive
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 33
SDRB Advanced SolutionsSDRB Advanced SolutionsSDRB Advanced SolutionsSDRB Advanced Solutions
In the future, ……we need to provide a leap forwardIn the future, ……we need to provide a leap forward in roadway productivity in roadway productivity In the future, ……we need to provide a leap forwardIn the future, ……we need to provide a leap forward in roadway productivity in roadway productivity
Similarly, we don’t use pit props any more……….Similarly, we don’t use pit props any more……….
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 44
Operating Costs * Operating Costs * Operating Costs * Operating Costs *
Total Cost of Operating a Continuous Miner Unit per year*Total Cost of Operating a Continuous Miner Unit per year* $6,640,000$6,640,000
Average number of metres driven per DayAverage number of metres driven per Day 100100
Number of Shifts per DayNumber of Shifts per Day 33
Average number of metres driven per shift Average number of metres driven per shift 3333
Total Actual Operating Hours per yearTotal Actual Operating Hours per year 3,0723,072
Operating Cost per Continuous Miner Unit Operating Cost per Continuous Miner Unit per hourper hour $2,161$2,161
Operating Cost per Continuous Miner Unit Operating Cost per Continuous Miner Unit per minuteper minute $36.02$36.02
* A continuous miner unit includes all equipment to drive a roadway based on ACARP Report on Roadway Development, by Gary Gibson, 2006
Costs of Operating a Miner & Installing Bolts:Costs of Operating a Miner & Installing Bolts:
Average Time to Install a standard rock bolt Average Time to Install a standard rock bolt 150 secs150 secs
Average Cost of Installing a standard rock bolt based on TIME Average Cost of Installing a standard rock bolt based on TIME ONLYONLY
$90.06$90.06
Average number of standard rock bolts installed per Continuous Average number of standard rock bolts installed per Continuous Miner Unit per year Miner Unit per year
51,20051,200
Average Average Cost of TIMECost of TIME to install standard rock bolts per to install standard rock bolts per Continuous Miner Unit per yearContinuous Miner Unit per year
$4,611,072$4,611,072
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 55
Advanced SDRB SolutionsAdvanced SDRB Solutions Advanced SDRB SolutionsAdvanced SDRB Solutions
Not just about supporting the roof
Mines need the Solutions to drive Roadways faster
Need to consider the whole Roadway
SDRBs available for many years in Europe (18 SDRBs)
Pumpable Resin SDRB
Advanced Self Drilling Bolt Technology
Conclusions
Not just about supporting the roof
Mines need the Solutions to drive Roadways faster
Need to consider the whole Roadway
SDRBs available for many years in Europe (18 SDRBs)
Pumpable Resin SDRB
Advanced Self Drilling Bolt Technology
Conclusions
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 66
Existing SDRBsExisting SDRBsExisting SDRBsExisting SDRBs
Wiborex
Romtech
DSI
MAI
Furen
Alwag Alwag
Stainless
CarboTech
Williams Hilti
Atlas Copco
Ischebeck
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 77
Pumpable Resin SDRB Pumpable Resin SDRB Pumpable Resin SDRB Pumpable Resin SDRB
resin fills bearing plate & also locks mesh in place resin fills bearing plate & also locks mesh in place
full encapsulation both inside and outside boltfull encapsulation both inside and outside bolt
Full bolt encapsulation maximises roof support Full bolt encapsulation maximises roof support
No gloving, no plastic film, no under-mixing or No gloving, no plastic film, no under-mixing or over-mixing over-mixing
Perfect resin mixing every timePerfect resin mixing every time
Resin fills bearing plate & locks mesh in placeResin fills bearing plate & locks mesh in place
Minimises water inflow from bolt holes Minimises water inflow from bolt holes
Minimises bolt corrosionMinimises bolt corrosion
Full bolt encapsulation maximises roof support Full bolt encapsulation maximises roof support
No gloving, no plastic film, no under-mixing or No gloving, no plastic film, no under-mixing or over-mixing over-mixing
Perfect resin mixing every timePerfect resin mixing every time
Resin fills bearing plate & locks mesh in placeResin fills bearing plate & locks mesh in place
Minimises water inflow from bolt holes Minimises water inflow from bolt holes
Minimises bolt corrosionMinimises bolt corrosion
visible resin at collar proves full encapsulationvisible resin at collar proves full encapsulation visible resin at collar proves full encapsulationvisible resin at collar proves full encapsulation
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 88
SDRB load transfer capacitySDRB load transfer capacitySDRB load transfer capacitySDRB load transfer capacityLoad Transfer Capacity about 2 x solid boltsLoad Transfer Capacity about 2 x solid bolts Load Transfer Capacity about 2 x solid boltsLoad Transfer Capacity about 2 x solid bolts
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 99
SDRB Underground TrialsSDRB Underground TrialsSDRB Underground TrialsSDRB Underground Trials
Once SDRB is placed in chuck, no manual handling
SDRB remains completely straight throughout drilling cycle
2m hole drilled in 24 secs (83mm/sec)
The water column inside the SDRB gets displaced by the resin
Plate gets pushed firmly up against mesh at about 400 Nm
End of bolt is completely clean
Points to Note:Points to Note:
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1010
SDRB SDRB SDRB SDRB
Refined the bolt designRefined the bolt design
Improved the equipment Improved the equipment
Improved resinImproved resin
Planning on undertaking a large scale installation Planning on undertaking a large scale installation
However – need to look at aHowever – need to look at a Total SolutionTotal Solution
Refined the bolt designRefined the bolt design
Improved the equipment Improved the equipment
Improved resinImproved resin
Planning on undertaking a large scale installation Planning on undertaking a large scale installation
However – need to look at aHowever – need to look at a Total SolutionTotal Solution
SDRB Progress:SDRB Progress:SDRB Progress:SDRB Progress:
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1111
Advanced SDRB SolutionsAdvanced SDRB Solutions Advanced SDRB SolutionsAdvanced SDRB Solutions
Not about products or systems - about Solutions
Need to consider the whole Roadway
How to support intersections? Long tendon support is often essential But installing long tendons from the miner is
slow Outbye cable bolting sometimes too late
How to support 3m+ ribs? Can only install 1.2m bolts from minerCan only install 1.2m bolts from miner
Not about products or systems - about Solutions
Need to consider the whole Roadway
How to support intersections? Long tendon support is often essential But installing long tendons from the miner is
slow Outbye cable bolting sometimes too late
How to support 3m+ ribs? Can only install 1.2m bolts from minerCan only install 1.2m bolts from miner
Bolt length is restricted by Roadway opening height
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1212
Advanced SDRB SolutionsAdvanced SDRB Solutions Advanced SDRB SolutionsAdvanced SDRB Solutions
Why can’t long tendons be installed quickly?
Long cable bolts are slow to install Drill string coupled & uncoupled Mostly manual handling
Why can’t long tendons be installed quickly?
Long cable bolts are slow to install Drill string coupled & uncoupled Mostly manual handling
Rock Bolt length restricted to roadway opening? Coupled bolts - slow Coupled self drilling bolts – still slow
Rock Bolt length restricted to roadway opening? Coupled bolts - slow Coupled self drilling bolts – still slow
Cable Bolt
Coupled Bolt
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1313
Advanced SDRB Solutions Advanced SDRB Solutions Advanced SDRB Solutions Advanced SDRB Solutions
Why can’t we have SDRBs that can be installed:
Quickly?
Automatically?
Be longer than the roadway opening?
Provide immediate support?
Provide high capacity roof support?
Why can’t we have SDRBs that can be installed:
Quickly?
Automatically?
Be longer than the roadway opening?
Provide immediate support?
Provide high capacity roof support?
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1414
Advanced SDRB SolutionsAdvanced SDRB Solutions Advanced SDRB SolutionsAdvanced SDRB Solutions
Outer Bar
Inner Bar
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1515
Advanced SDRB SolutionsAdvanced SDRB Solutions Advanced SDRB SolutionsAdvanced SDRB Solutions
Rock Face
Inner Bar Unscrews
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1616
Telescopic SDRB Telescopic SDRB Telescopic SDRB Telescopic SDRB
Drill Bit digs into Rock Face
Outer BarInner Bar
Inner Bar Unscrews
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1717
Telescopic SDRB Telescopic SDRB Telescopic SDRB Telescopic SDRB
Drill Chuck Position Fixed
Extension here
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1818
0
50
100
150
200
250
0 5 10 15 20 25
Telescopic SDRB: Telescopic SDRB: Drilling or ExtendingDrilling or Extending Telescopic SDRB: Telescopic SDRB: Drilling or ExtendingDrilling or Extending
Drilling: th
reads locked
Extending: threads unlocked
Axial Thrust (KN)
Res
isti
ve T
orq
ue
(Nm
)
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 1919
Telescopic SDRBTelescopic SDRBTelescopic SDRBTelescopic SDRB
Position Fixed
Distance to roof remains constant
1. Place Bolt in Chuck & fix in position. Begin to rotate – Axial force increases.
1
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2020
Telescopic SDRB Telescopic SDRB Telescopic SDRB Telescopic SDRB
2. Axial force increases - locking threads - enabling drilling
1 2
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2121
Telescopic SDRB Telescopic SDRB Telescopic SDRB Telescopic SDRB
3. Axial force decreases as hole drilled - unlocking threads – enabling extension
1 2 3
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2222
Telescopic SDRBTelescopic SDRBTelescopic SDRBTelescopic SDRB
1 2 3 4
4. Continued drilling & extension – operator can see full extension of Outer Bar
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2323
5
5. Chuck unlocked & travels to roof as drilling progresses
6 7
6. Drilling continued until hole fully drilled 7. Resin pumped
into Bolt for 30 secs
– Outer Bar fully encapsulated
- Nut then tensioned
- Total Cycle time ~2mins ~3.9m
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2424
Telescopic SDRBsTelescopic SDRBs Telescopic SDRBsTelescopic SDRBs Standard SDRBStandard SDRB Telescopic SDRBTelescopic SDRB
LengthLength 1.2 to 2.4m 1.2 to 2.4m 2.0 to 4.6m2.0 to 4.6m
Load transfer Load transfer capacitycapacity
1212 tonnes/100mm tonnes/100mm 2020 tonnes/100mm tonnes/100mm
Tensile Tensile Strength*Strength*
38 tonnes 38 tonnes 38 tonnes 38 tonnes
Drill TimeDrill Time approx approx 2525 secs secs approx approx 6060 secs secs
Resin Pump Resin Pump TimeTime
3030 secs secs 3030 secs secs
Total Total Installation Installation TimeTime
approx approx 6060 secs secs less than less than 120120 secs secs
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2525
60 x 2m long telescopic Rib SDRBs (blue)
215 x Standard SDRBs (yellow)
10 x 4m long telescopic Roof SDRBs (blue)
Telescopic SDRB TechnologyTelescopic SDRB TechnologyTelescopic SDRB TechnologyTelescopic SDRB Technology
55m of Roadway 55m of Roadway 55m of Roadway 55m of Roadway
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2626
Conclusions: Telescopic SDRB Conclusions: Telescopic SDRB Conclusions: Telescopic SDRB Conclusions: Telescopic SDRB
AutomaticallyAutomatically extendable extendable
Very fastVery fast bolt installation ~120 secs bolt installation ~120 secs
Very highVery high load transfer capacity above normal bolt horizon load transfer capacity above normal bolt horizon
Minimises Manual HandlingMinimises Manual Handling
Simplicity:Simplicity: No drill rods, No drive dollies, No changing drill bits, No resin cartridges No drill rods, No drive dollies, No changing drill bits, No resin cartridges
& No rotation to mix resin& No rotation to mix resin No Coupling No Coupling No Plastic RodsNo Plastic Rods No JacksNo Jacks No pushing rods or cables up holes No pushing rods or cables up holes
Improved ProductivityImproved Productivity
AutomaticallyAutomatically extendable extendable
Very fastVery fast bolt installation ~120 secs bolt installation ~120 secs
Very highVery high load transfer capacity above normal bolt horizon load transfer capacity above normal bolt horizon
Minimises Manual HandlingMinimises Manual Handling
Simplicity:Simplicity: No drill rods, No drive dollies, No changing drill bits, No resin cartridges No drill rods, No drive dollies, No changing drill bits, No resin cartridges
& No rotation to mix resin& No rotation to mix resin No Coupling No Coupling No Plastic RodsNo Plastic Rods No JacksNo Jacks No pushing rods or cables up holes No pushing rods or cables up holes
Improved ProductivityImproved Productivity
The world’s first automatically
extendable SDRB
The world’s first automatically
extendable SDRB
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2727
– – a revolution in ground supporta revolution in ground support– – a revolution in ground supporta revolution in ground support
Ground Support Services Pty Ltd September 2007
Telescopic SDRBTelescopic SDRBTelescopic SDRBTelescopic SDRB
© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 2828
EndEnd EndEnd