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Longwall Move (Tear Down) Spider No.2

Longwall Move (Tear Down) Spider No.2
8:  Roof Bolting with the Pan Line Bolter 9:  Remove Face Chain 10: Remove pan line in sets of two 11: Remove Headgate Drive 12:  Disassemble Shearer 13:  Removing Pan Line Pinner 14:  Hose and Cable Removal
1. 8: Roof Bolting with the Pan Line Bolter
Make Exam Priority 3
Follow Roof Control Plan
Make gas exam Priority 3
Gas test required every 20 minutes
Raise canopy Priority 2
Anyone assigned to run this bolter must be task trained
Lower stab jack
Check roof and rib Priority 2
Obtain starter steel with bit
1 1/2"
Place starter steel in chuck
Raise bit to roof
Slowly start steel rotation
Drill hole 2' deep
Lower steel
Stop rotation
Remove start steel
Replace with finishing steel
1 3/8' bit
Raise bit into hole
Start rotation
Finish drilling hole to 6'
Lower and stop rotation
Remove steel
Assemble pin, plate and T-board
Insert resin cartridge into the hole
Insert assembled pin into hole
Insert wrench into drill chuck
Raise to the top and rotate bolt
Check torque according to Roof Control Plan Priority 3
Lower the boom
Raise stab jack
Lower canopy
Swing boom and rotate to next face bolt
Repeat bolting sequence
Remove temporary jack
Move temporary jack forward 5' and reinstall Priority 3
Get in the seat of the bolter
Tram bolter up 5'
Dead man has to be activated for tramming bolter
Repeat bolting sequence
2. 9: Remove Face Chain
Conduct Exam Priority 3
Everyone on the longwall must be aware of chain removing activities. When pulling the top chain, you need positive communication with anyone working on the pan line
Follow cutting and welding plan
Chain must be cut at tail gate before you can pull
Cut face chain
Make continuous gas tests Priority 3
Wet area down Priority 2
Rock dust 10'in all directions Priority 2
Cut chain on connection link
Shut torches down Priority 2
Cut power cables at the junction box of the #1 and #2 motor
Hook mule to chain
Notify anyone working on the pan line that chain pulling is about to start Priority 3
Everyone on the longwall must be aware of chain removing activities. When pulling the top chain, you need positive communication with anyone working on the pan line
Obtain and examine necessary tools Priority 3
Torches
Gas detectors
Rock dust
Burning goggles
Welding gloves
Striker
Water hose
Allen wrench
Socket set
Hammer
Assorted wrenches
Chain boxes
Mule
Scoop
Pull chain 250' to connector
May take several pulls
Remove #1 and #2 motor cables from the 8-bay box, lock and tag Priority 3
Follow lock-out/tag out procedures
Remove 6 Allen head bolts and remove access door
Hook door to mule or scoop with #8 chain Priority 3
Only Grade 8 chain 3/8"or better should be used
Pull door out of work area
Caution: Keep people clear while pulling with chain
Repeat process until all chain is removed
3. 10: Remove pan line in sets of two
Conduct Exam Priority 3
Obtain and examine the following tools Priority 3
Use lady slipper bar
Hammer
3/8" punch
Chisel
Shovel
Gloves
Safety glasses
Channel locks
Screw driver
Prepare pan line for removal
Clean dog bone socket
Take out keepers
Remove dog bone on both sides
Place dog bone in pan line
Pull accu-trac pin on headgate side where pan is being separated
Pull keeper pin
Push accu-trac pin out toward shield
Lift accu-trac, replace pin and keeper
Remove horizontal pin for the pan clevis
Remove keeper
Slide pin out
Pull relay bar back
Reinstall pin and keeper in clevis
Open two cable tray doors
Drop cable to the bottom
Move pinner cable to toe of shield
Pan line removal
Notify scoop operator that first set of pans are ready
Communicate with scoop operator and other employees in area Priority 3
Caution: Notify all personnel in the area of the danger of pan line removal. Use start up signals before starting scoop and moving
Scoop will take two pans each time
Repeat process every two pans until all pans are removed
4. 11: Remove Headgate Drive
Conduct Exam Priority 3
Obtain and examine the following tools Priority 3
Use lady slipper bar
Hammer
3/8" punch
Chisel
Shovel
Torches
Striker
Water hose
Fire Extinguisher
Rock dust
Methane detector
Goggles
Welding gloves
3/4" socket set
2 rock bars
5/8" Grade 8 chain
Drawing of headgate drive, highlighting parts to be removed
Lock out/Tag out #1 and #2 drives Priority 3
Follow lock out/tag out procedures
Unplug at 8 bay box
Cut cable at junction box
Use bow saw/hack saw
Remove dog bone face side
Remove #2 headgate motor and gear case as a units
Remove all top covers
Load on pallets and send out
Remove the 6 bolts on gear box mounting
Take 5/8" Grade 8 chain and chain gear box to canopy to support while being removed Priority 3
Take coupling cover off and remove the spline keeper
Slide the gear coupling apart
Utilize shield to free the gear case
Bring the mule in and load the #2 motor and gear case
Unload gear box
Repeat for removing #1 motor and gear case except for removing top covers and utilizing shields
Remove dog bones
Clean dog bone socket
Take out keepers
Remove 6 dog bones
As per drawings
This is to separate the drive from stage loader, pan line and face conveyor
Shields can be used to maneuver head drive for bone removal
Place dog bones in pan line
Pull the head gate drive back utilizing the shields
Cut stage loader chain, top and bottom
Make continuous gas test Priority 3
Be sure to make gas test in the tunnel
Wet area down Priority 2
Rock dust 10' in all directions Priority 2
10 pound fire extinguisher and/or 240 pounds of rock dust
Cut chain
Follow cutting and welding plan
Shut torches down Priority 3
Remove adapter plate
Remove 6 horizontal pins from head drive to the adapter plate
Remove the 3 dog bones in the adapter plate
As per drawing
Remove shield clevis horizontal pin
Remove the keeper
Slide the pin out
Pull the relay bar back
Reinstall pin and keeper
Bring the mule in and load the adapter plate
Lift all the cables and hoses from headgate drive and hang up to the roof
Use come-a-long
Remove head drive with duck bill scoop Priority 3
Caution: Notify all personnel in the area of the danger of the head drive. Use start up signals before starting scoop and moving
Bind with a winch cable
Tram scoop Priority 3
Store in designated area
5. 12: Disassemble Shearer
Conduct Exam Priority 3
Obtain and examine tools Priority 3
Torches
Hand wrenches
Metric
Standard
Methane detector
Striker
Goggles
Welding gloves
Water
Rock dust
Fire extinguisher
Allen wrenches
Metric
Standard
Hack saw
Socket sets 1/2" drive
Metric
Standard
Lady slipper bar
Rock bar
Channel locks
Chisel
Hammer
Sledge hammer
3 sets of 3 ton come-a-long
T-Boards
Cribs
Crib blocks
6 X 6 X 24"
Wedges
4' pin punch
Torque multiplier (18 to 1)
1" to 3/4" drive adapter
Socket sets 3/4" drive
3/4" drive impact wrench
Three 12" puller bolts
Use lock out/tag out procedures as required Priority 3
Follow lock out/tag out procedures
Remove shearer drums
Remove water spider
Remove 12 mounting bolts and see drawing
Insert three 12" puller bolts into puller holes
Thread puller bolts into the spider equally Priority 2
Attach come-a-long to one of the puller bolts to stabilize the spider Priority 3
Caution: The spider is very heavy and must be supported from unexpected motion
Tighten the puller bolts equally in a clockwise motion until spider is free Priority 2
Lower the spider to the bottom utilizing the come-a-long
Remove cutter drum
Loosen bolts with torque multiplier
Look in the drum
Put torque multiplier on the bolt
Place the handle against the inside of the drum to lock the tool in place
Insert the male part of 1/2" ratchet in the female receptacles in the torque multiplier
Turn counterclockwise wise or left to loose bolts
Remove 18 bolts with impact wrench
Loosen drum
Utilize 4 of the mounting bolts as puller bolts
Thread puller bolts equally in clockwise motion until drum is free
Remove the puller bolts
The drum is self supporting on its mount
Remove the puller bolts
The drum is self supporting on it's mount
Reinstall the spider using the come-a-long Priority 2
Secure spider to drum with 4 bolts
Remove ranging arms
Block ranging arms securely using 6 X 6 crib blocks
One crib
Place crib under the cutting motor and arm
This allows the ranging arm to cantilever and takes the pressure off the ranging arm pins
Remove access covers to the ranging arm pins
Remove the ring fetter Priority 3
Per instructions and drawing
There are two pins and four ring fetters and repeat for each pin
Install 3 come-a-longs to support the ranging arm
2 come-a-longs at the motor
1 come-a-long on the ranging arm near the drum
Remove the two ranging arm pins
Remove water lines in the hinge area
Remove the cover from the ranging arm jack pin - 4 bolts
Leave jack attached to shearer
Remove ranging arm jack pin
Drive pin toward shields to remove
The shearer hydraulic system can be used to help free the pin
Repeat this cycle on the second shearer drum and ranging arm
Remove shearer plug
Lock out/tag out shearer on 8 bay box Priority 3
Follow lock out/tag out procedures
Cut the cable at the shearer stand-off
Cut the motor guts
Ensure water is cut off at headgate and tagged
Disconnect water at the shearer
Disconnect bretby chain from shearer
Notify the scoop operator that shearer is ready to be moved
Store shearer in designated area according to plan
6. 13: Removing Pan Line Pinner
Conduct exam Priority 3
Bolt the roof as per the longwall move plan up to the last pan Priority 3
This bolting is a continuation of bolting being done on face
Stop the bolter
Disconnect the pan that the bolter is sitting on
Connect winch cable from the scoop to the pan line that the bolter is sitting on staying under the shield
Instruct the scoop operator to advance the pan and the bolter as instructed by the bolter operator
Normally 5'
Install bolts according to Roof Control Plan Priority 3
Repeat this cycle until all roof is supported Priority 3
Remove bolter power at power center
Lock out/Tag out Priority 3
Follow lock out/tag out procedure
Cut bolter cable
Instruct scoop operator to scoop up pan line and bolter
Secure with winch cable Priority 3
Remove bolter from face area and put in designated location Priority 2
See Longwall Move Plan
7. 14: Hose and Cable Removal
Conduct SPSA Exam Priority 3
Obtain and examine tools Priority 3
Pull rope
Channel locks - 320 and 640
Hammer
Lady slipper bar
Chisel
Punch
Rock bar
Penetrating oil
Staple puller
Anti seize
15/16" socket ratchet-3/8" drive
Side cutters
Bypass the methane monitors
Double check all outgoing power from the 8 bay box is off and locked and tagged out Priority 3
Follow lock out/tag out procedures
Isolate the emulsion pressure lines at the head gate Priority 3
Turn off pressure valves located on the back flush filters at the stage loader
Open bypass valves on the back flush filters to bleed pressure
Tag out the valves that have been turned off and opened
Turn water off at head gate mini master
Call outby and have water turn off at the header
Bleed the water pressure at first shield
Lower cables and hoses previously hung at the head gate
Use come-a-long
Cut all cables at the corner
Disconnect all hoses at the coupler nearest the corner
Plug pressure and return emulsion lines
2" super staple and 2" regular staple
Tram mule to mid-face
Secure all cables and hoses to the mule with a pull strap
Notify everyone on face that the cables are going to be pulled Priority 3
Notify all personnel in the area of the danger of cable removal. Use start up signals before starting scoop and moving
Pull cables and hoses out the head gate to the designated area
See Longwall Move Plan