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Longwall Move (Setup) Spider No.1

Longwall Move (Setup) Spider No.1
Duty 1: Start-of-Shift Activities Duty 2: Enter Mine Duty 3: Section Setup  Duty 4: Face Preparation Duty 5:  Monorail Setup Duty 6:  Install Trolleys Duty 7:  Install Outby Equipment on Monorail
1. Duty 1: Start-of-Shift Activities
Change clothes
Get W-65 Priority 2
Conduct visual examination Priority 2
Seal and dents
Obtain PPE Priority 2
Safety glasses
Hearing protection
Steel toe shoes
Respirator
Hard hat
Cap lamp
Gloves
Obtain gas detector Priority 3
Check charge Priority 3
Conduct visual examination Priority 3
Check calibration Priority 3
Check in/Tag in
Put on safety glasses
Company policy
Conduct exam Priority 3
Enter the mine by elevator
Get on mantrip
Ensure mantrip has been pre-op'd (follow JSA)
Travel to main track
Check signal lights
Follow mine plan
2. Duty 2: Enter Mine
Conduct travelway examination - Self Preformed Safety Assessment Priority 3
Observe for mobile equipment
Maintain 300' clearance between trips
Check roof conditions Priority 2
Check for cracks, loose rock, taking on weight, water
Check for loose ribs Priority 2
Check for overhang
Check for ledges
Check for sloughing
Look for uneven bottom
Rough spots and bumps in the road
Soft spots/low spots
Look for track damage
Bent or broken rails
Switch damage
Loose fish plates
Observe the high voltage cable
Look for damage
Look for downed high voltage cable
Look for guarding and shielding
Look for clearance
Minimum of 12"
Look for roadway debris
Look for crib blocks, rock, banding material, cable, bolts and knocked out timbers
Check for damaged bolts
Correct and/or report any unsafe conditions Priority 2
Exit mantrip
Maintain a 3-point contact Priority 2
Observe walkway Priority 2
Look for slip hazards Priority 2
Look for trip hazards Priority 2
Look for fall hazards Priority 2
Meet with foreman Priority 3
Discuss longwall setup activities Priority 3
Supplies
Condition of longwall
Condition of scoops
Condition of mule
Maintenance needed on scoops and mule
Attend safety talk Priority 2
Required company policy
Discuss close calls Priority 2
Discuss information passed on from previous shift
Discuss any stop work authority Priority 2
Discuss roof control plan/condition Priority 3
Required company policy
Discuss longwall setup plan and activities for the day Priority 2
Multiple tasks may be conducted at the same time
Find out what your task assignment is
Find out what other tasks are being performed and their status
Obtain and examine tools Priority 2
Conduct Self Preformed Safety Assessment Priority 3
hammer
channel locks
lady slipper bar
solenoid wrench
flat tip screw driver
chisel
6 or 8 inch adjustable wrench
Other hand tools as needed
3. Duty 3: Section Setup
Conduct exam Priority 3
Establish dinner hole
Look for suitable place in the headgate area Priority 2
Normally #2 entry, crosscut 2 to 3
Area should be dry, good top, good ribs and rock dusted
Place emergency equipment in dinner hole
Refer to JSA for dinner hole setup
Establish material storage area map
Note on storage map locations of materials and equipment
Hoses
Monorail
Trolleys
Cables
Head drive
Pan line
Welder
Air compressor
Pump
Shearer
Chain boxes
Drive motors
8 bay
Tail drive
Minnie master
Stageloader
Tailpiece
Small parts and fittings
Pod duster
Make copies of map and distribute to workers
Motor crew
Foreman
Setup crew
Outby boss
Place a supply of maps with the emergency supplies
Post a copy of the storage area map in dinner hole
Note updates
Establish unloading points
Keep free from obstructions
Place signs "Unloading point only"
Slag track crossing as needed
Establish scoop haulway
Bring setup tool box into working area
Check to see if spads are installed to set head drive
Run mine compressed air to headgate area
At least 1" line
Remove all debris and materials Priority 3
4. Duty 4: Face Preparation
Pre-op scoop
Examine roof and rib for support according to roof control plan Priority 3
Check for cracks, loose rock, taking on weight, water
Check for overhang, check for ledges, check for sloughing
Remove trash or debris from face Priority 3
Scoop the face
Dispose scooped materials appropriately
Rock dust the face
Use bantam duster
Hook to PTO on scoop
Position scoop bucket toward tailgate
Dust should travel away from scoop
Park scoop and lower bucket to bottom
Fill scoop bucket with rock dust
Dust face
Number face brattice from the headgate to the tailgate
Pump water as needed
Establish communication Priority 3
Install temporary phone line
Install three phones
Headgate
Tailgate
Mid-face
5. Duty 5: Monorail Setup
Conduct exam Priority 3
Examine belt line travelway, roof, rib, and floor Priority 3
Check for cracks, loose rock, taking on weight, water
Check for overhang, check for ledges, check for sloughing
Move debris Priority 3
Pre-op lo-trac
See JSA
Check hangers
Take monorail carrier and place outby on belt line where monorail is to be hung
Place monorail winch on the belt line
Place high voltage distribution box on the belt line
Place water pressure board on the belt line
Load lo-trac trailer with monorail and chain
1 chain for each joint of monorail
20 to 25 joints of monorail
Begin installing monorail from mule train to face
Visually check the roof and rib prior to setting each monorail Priority 3
Check for cracks, loose rock, taking on weight, water
Check for overhang, check for ledges, check for sloughing
Install first section of monorail
Place chain in one side of hanger bracket
Lock chains into the slots of the outby and inby hanger brackets
Lift inby end of the monorail to the hanger Priority 2
CAUTION: THIS IS A MINIMUM OF A THREE PERSON JOB
Use good lifting techniques
Place chain thru the monorail clevis
Place loose end of chain into the chain hanger and lock in the slot
Lift outby end of monorail, wrap chain around monorail and lock into hanger bracket
Dead end
Install second monorail
Slide monorail from trailer
Lift the outby end to meet the previous installed rail
Place male end of monorail into the receiver
Lift the inby end and install pin on the outby end Priority 2
May be a drive pin or slide pin over top of male coupling
CAUTION: THIS IS A MINIMUM OF A THREE PERSON JOB
Use good lifting techniques
Place chain in one side of hanger bracket
Lock chains into the slots of the outby and inby hanger bracket
Place chain thru the monorail clevis
Place loose end of chain into the chain hanger and lock in the slot
Repeat for remaining monorails
At end of shift, hang reflective flag on the end of last monorail installed Priority 2
Remove all debris and materials Priority 3
6. Duty 6: Install Trolleys
Conduct exam Priority 3
Obtain and examine tools and materials Priority 2
1/2" ratchet
3/4" deep well socket
1/2" bolts
3/4" nuts
3/4" open or box wrench
Hammer
Begin at the headgate
Slide seven special trolleys into the monorail Priority 3
These trolleys are for hanging miscellaneous items like water board, distribution box, winch, etc.
CAUTION: These trolleys are very awkward to handle, there are numerous pinch points, and use good lifting techniques, minimum of two persons
See photo
Slide four regular trolleys onto the monorail
Bolt 5' chain from trolley to trolley
Slide a master trolley into the monorail
Master trolley has super stecko fitting welded to the trolley
Every 5th trolley is a master
Install 5' chain
Repeat this cycle until loading the trolleys become difficult to push
Pull connected trolleys outby using the lo-trac
Tie trolleys off at the outby end of the monorail
Stretch the trolley towards the headgate and immobilize at headgate
Utilize the lo-trac
At end of shift, hang reflective flag on the end of last monorail installed Priority 2
Remove all debris and materials Priority 3
7. Duty 7: Install Outby Equipment on Monorail
Conduct exam Priority 3
Obtain and examine tools and materials Priority 2
Chisel
Hammer
Anti-seize
Wire brush
Rags
Punch
Screw driver
Ensure there are two people to install outby equipment on monorail Priority 2
CAUTION: This requires clear communication between the lo-trac operator and spotter
Beware of pinch points and unexpected equipment movement
Brakes must be locked on the lo-trac before spotter secures chains
Install winch
Obtain lo-trac
Place winch on fork
Cable spool facing inby
Travel to the outby end of monorail
Drop outby end of monorail
Align winch with end of monorail
Tram lo-trac to align the winch up with monorail
Slide trolley on winch on monorail track
Tram about 5' onto the monorail
Lift winch and monorail back to roof with lo-trac
Reattach monorail to chain hanger
Secure winch by chaining off
Install AB distribution box
Pick box up with lo-trac with box access cover facing the belt Priority 2
Install on monorail by pinning the box to the two special trolleys
Install water board
Pick up with lo-trac
Hang to monorail by pinning the two special trolleys
Install two 5' spreader bars
One between distribution box and water board
One between water board and first trolley
Remove all debris and materials Priority 3