The comprehensive excavation process, which can realize the combined operation of all operations such as coal breaking, coal charging, coal transportation, support, spray dust removal, etc., has high mechanization degree, high construction speed, high efficiency, small damage to surrounding rock and work safety. Etc. Including coal roadway comprehensive mechanized tunneling technology (coal section > 4/5 roadway section), semi-coal rock roadway (1/5 lane section < coal section <4/5 lane section) comprehensive mechanized tunneling process and rock roadway (coal section <1 /5 lane section) Comprehensive mechanized tunneling process.
The process flow is:
Coal cutting → coal loading → coal transportation → temporary support → permanent support → extended belt conveyor
The key processes are the coal cutting process and the support process. The management of the comprehensive mining face is mainly the management of the roof and electromechanical equipment. Whether the top and bottom plates and the two gangs are straight depends directly on the coal cutting effect. The coal cutting process is the key to realize the “seven lines†of the driving face. The quality of the coal cutting process directly affects the engineering quality of other processes such as support and extension tape conveyor.
The specific procedures are as follows:
First, cutting coal
1. Key person: the driver of the roadheader.
basic requirements:
(1) The driver of the roadheader must pass the training test and obtain the certificate before being able to take the certificate.
(2) The driver of the roadheader must be familiar with the structure, performance, technical indicators and operating principle of the roadheader being operated, be able to operate the machine proficiently and accurately, be familiar with the operating procedures and operating procedures, and be able to judge and handle the generality correctly and quickly. malfunction.
(3) The roadheader is operated by the front and the second driver. The driver is responsible for cutting and is responsible for the driver's side lane specifications; the deputy driver is responsible for the roadway specifications on the other side to ensure that the roadway is shaped. While the crew is walking, the deputy driver is responsible for observing the crew's walking route and safety conditions, preventing the crew from colliding with the support, bumping the pipelines and equipment, and injuring personnel.
(4) The driver of the roadheader must have the ability to identify disasters such as roof, transportation, fire, water, gas, etc., and will deal with general disasters and properly avoid disasters.
(5) The roadheader has all kinds of protection, the action is sensitive and reliable, the operation handle is flexible and accurate, and it must meet the perfect requirements.
(6) The section specifications of the roadway to be dug are in accordance with the operating procedures and standardization requirements. When there is over-excavation or under-excavation and a step on the bottom plate, the driver of the crew is held accountable.
(7) The super-empty top operation shall not occur in the driving face. If there is an empty top operation in the handover class, the driver of the crew on duty should be investigated.
2. Key points: Ensure that the top and bottom plates are straight and straight, and the roadway is formed regularly.
3. The key link: the coal cutting process.
(1) The driver of the roadheader should pay attention to the conditions of the top floor, coal seam, coal quality change and scraper conveyor load. Adjust the traction speed and cutting height at any time to ensure that the top floor is leveled and the two sets are straight to meet the design requirements. Special circumstances and timely shutdown processing.
(2) The driver of the roadheader should work closely with the work surface supporter and the belt conveyor driver to start and stop in the prescribed order.
(3) When cutting a cycle and starting to support, the blade must be brought into contact with the bottom plate, the electrical control circuit is disconnected, the isolating switch on the roadheader is disconnected, and the power supply of the roadheader is cut off.
(4) When the class needs to be replaced or supplemented, the electric control circuit of the roadheader must be disconnected, the roadheader is disconnected, and the power supply of the roadheader is cut off.
(5) When there is water in the roadway, measures must be taken to protect the electric control box, wiring chamber, electrical control console, hydraulic oil tank, etc., to prevent water ingress and moisture.
(6) When the roadheader cuts hard rock, there should be protective measures to protect the roadheader from damage.
(7) In the event of personal safety, equipment safety and other emergencies, emergency stop means may be used to stop the machine.
(8) During the operation of the roadheader, the driver must always pay attention to the operation of the roadheader. When abnormal sounds or other abnormal conditions are found, the driver must be contacted in time to find out the cause and handle it before starting.
(9) Coal cutting generally adopts a coal cutting method in which the cutting head rotates counterclockwise. The cutting sequence is from bottom to top, firstly pulling the groove from the bottom of the roadway, and then cutting back to the top of the roadway. The top and bottom plates are required to be cut horizontally and the two sets are cut vertically.
(10) Special case cutting method
1 According to different properties of coal rock, determine the best cutting method. If the rock is fragile, it should be excavated at the top of the roadway section; the section is semi-coal rock, which should be started in the coal seam where the coal and rock joints are located or in the softer part. The driver should operate in the correct cutting cycle and pay attention to the following:
A. When excavating a semi-coal rock roadway, the coal should be cut first, and then the rock should be cut, that is, according to the procedure of soft first and then hard.
B. Cutting must consider the bedding of coal rock, the cutting head should move in the direction of the bedding, and should not cross the bedding.
C. Cutting the whole coal, you should first brush the four sides and then crush the middle part. D. For hard coal, take a top-down cutting sequence.
E. For the more broken roof, the method of leaving the top coal or cutting section should be adopted.
2 The coal mining is soft, the bedding is obvious, the joint development is good, and the roofing condition is better. The cutting face is first cut in the middle of the working face, and then the cutting arm is circulated clockwise to make the circumferential cutting. Finally, use the cutting head to help.
3 When the working surface width exceeds the positioning and cutting performance of the roadheader, the working surface can be cut twice, that is, the 2/3 section is cut along the left side of the working surface, then the roadheader is moved to the right side, and then the remaining 1/3 is cut. 3 sections.
(11) Using the cutting head to move the cutting up and down and left and right, the initial section shape can be cut. When the cutting section has a certain difference from the actual required section, the second trimming can be carried out, and finally the design section requirements are met.
(12) When there is a large area of ​​hard rock, the cost of comprehensive excavation and cutting increases, and the unit can not effectively carry out the cutting operation, the rock pre-split blasting into cracks should be carried out by means of the vibration gun, and then the cutting operation is carried out. Or exit the unit using the general excavation method;
4. Operation process:
Before the roadheader is started, the driver must patrol the roadheader to inform all personnel to evacuate to a safe place and confirm that there are no people or obstacles within the machine's rotation range before starting the roadheader in the following order. as follows:
Preparation, inspection and processing → notify the personnel to evacuate to a safe place → place each emergency stop button in the unlocked position → switch the electromagnetic switch box to the “connected†position → ring the alarm bell → start the oil pump motor → start the transfer conveyor → start scraping Plate conveyor → start loader → start spray pump → start cutting motor → start cutting coal
5. Coal cutting standard
(1) Cut the two gangs and the top floor of the straight roadway according to the design section, and reach the “two flats all the way†(the top plate is flat, the bottom plate is flat, the two sets are straight), and the shed legs and the shed beams, the front beams and the branches are not cut and supported. Anchor bolts and anchor cables are not allowed to forcibly cut hard rock.
(2) Before cutting coal, the center line must be taken first. The cutting head is cut in strict accordance with the cutting sequence diagram. The top and bottom plates are cut flat, and the two sets are cut straight, which meets the design requirements.
(3) In the process of coal cutting, strictly follow the prescribed top distance and achieve the maximum control top distance (cycle progress + one support spacing), and must immediately stop and power off after supporting work.
(4) The operation of coal cutting by the roadheader should be “two lowâ€, “four enough†and “one regular†and meet the standardization requirements.
"Two low": low cutting power and low consumption of picks.
“Four enoughâ€: According to the section size and specification quality required by the operation regulations, the cutting should be wide enough, high enough, deep enough, and far enough.
“One regulationâ€: the section of the cut roadway, the contour of the surrounding area is regular, not only meets the support requirements but also does not appear over-excavation and under-excavation, and there are no steps, knives and bottom corners.
(5) There should be no horse sheds and bottom sills and floor steps in the roadway. When the length of the horse shed and the bottom raft is lm, the maximum protruding part is ≤200 x 200mm; when the bottom step is lm, the largest protruding part is ≤200 x200mm.
(6) The bolt support roadway requires the lane width midline to any one of the error tolerance range -50 ~ 150mm, the lane height allowable error - 30 ~ 150mm, the frame support roadway width and height error allowable range - 30 ~ 50mm, slope Meet the requirements of the operating procedures and measures.
6. Notes
When one of the following conditions occurs, it should be stopped in time for processing.
(1) When the front and rear of the roadheader are not lit, it is strictly prohibited to turn on the machine;
(2) When the inside and outside of the roadheader and other dust-reducing devices cannot be used normally, it is strictly prohibited to start the machine;
(3) It is strictly forbidden to turn on the gas when the head gas exceeds the limit or the ventilation is poor;
(4) If there is abnormal situation such as gas emission, permeable indication, increased roof pressure, fault, ground pressure change, noise, odor, etc. during the cutting process, stop immediately;
(5) When a stall occurs during the coal cutting process;
(6) When abnormal vibration, sound and odor are found inside the roadheader, or parts are damaged;
(7) When large pieces of coal, sputum, sundries or support articles are found on the scraper conveyor above the boring machine;
(8) When the operating handle or the "stop" control button fails;
(9) When the bridge-type transfer machine is derailed or the streamer is stuck;
(10) When the scraper conveyor has broken chains, cracks, shrinkage, deformation, etc.
Second, the process of shipping coal
The coal transportation process is also an important process in the excavation process. Its normality directly affects the coal cutting efficiency of the roadheader, thus affecting the single-entry level and work efficiency.
1. Key person: belt conveyor driver
basic requirements:
(1) The driver of the belt conveyor must undergo professional technical training. After passing the examination, the driver can be certified and can operate independently.
(2) Familiar with the structure, performance, technical characteristics, working principle, signal system and various protection devices of the equipment, which can eliminate general faults and familiar with the transport system and related regulations of the belt conveyors involved.
(3) Master a certain basic knowledge of electromechanical and familiar with (the relevant provisions of the Coal Mine Safety Regulations).
(4) Master the knowledge of fire prevention and use common fire extinguishing equipment (dry powder fire extinguisher, foam fire extinguisher, etc.).
(5) Belt conveyors must be equipped with positive and negative drivers, and each class must be no less than 2 people.
(6) No one shall ride a belt conveyor, and may not use belt conveyors to transport equipment and bulky materials.
2. Key points: no coal piles should appear on the belt head to ensure normal operation of the equipment.
3, the key link: the belt extends in place, the upper and lower support rolls are complete and flexible, and the equipment is running normally.
4, the operation process
Start: Issue the driving signal → After receiving the driving return signal → Start the auxiliary equipment → Confirm the front belt conveyor opens and transport the line → Press the belt conveyor start button to start the belt conveyor
Stop: Confirm that the rear conveyor is out of service → After the coal is not on the tape → Press the stop button to stop the belt conveyor
5, operating standards
(1) Before starting the machine, first issue the power-on warning signal, all the personnel leave the rotating part, receive the power-on reply signal or the warning is over, press the power-on button, the non-soft start control belt should be jogged first, no abnormality can be officially started. .
(2) Pay attention to whether the belt is deflected during operation and whether the sound is normal. Pay attention to whether the tape joint is damaged or not.
(3) Pay attention to the tightness of the tape during transportation, keep the head steady, the position of the intermediate frame is correct, and the tailstock of the machine head is stable.
(4) Pay attention to check whether the motor temperature and bearing temperature (sliding bearing temperature is not more than 65 °C, rolling bearing temperature is not more than 75 °C) is normal and the foundation bolt is firm.
(5) Pay attention to observe whether the drums and drive wheels are working properly.
(6) The belt frame is firmly and reliably connected and stable; the roller is complete, the rotation is flexible, and the roller frame is firm.
(7) The tensioning device is reliable and elastic.
(8) The distance between the tape cleaner and the tape is not more than 2~3mm, and there is enough pressure, and the contact length should be greater than 85% of the bandwidth.
(9) All kinds of protection (slip, coal, deviation, temperature and smoke alarm device) and electrical lockout must be in good condition; the signal is clear and reliable.
(10) When a fault or abnormality is found during operation, it should be stopped and inspected in time. When checking and disposing, the power should be cut off and the switch should be closed.
6, matters needing attention
When one of the following phenomena occurs during the operation of the belt conveyor, it should be immediately shut down urgently and properly processed before continuing operation.
(1) The conveyor belt is deflected, torn, and the joint is broken at once;
(2) The conveyor belt is slippery or boring;
(3) The temperature of the electrical or mechanical components is out of limit or the operation sound is abnormal;
(4) The fusible plug of the fluid coupling is melted or the working medium in the coupling is ejected;
(5) There are large pieces of coal, long materials, etc. on the conveyor belt;
(6) When it is dangerous to personal safety;
(7) When the signal is unknown or the conveyor is down;
(8) Coal clogging occurs on the nose;
(9) The coal on the tape is serious;
(10) The lubrication point is overheated or smoke occurs;
(11) There are other abnormalities that must be stopped immediately.
Third, the support process
Temporary support and permanent support are included in the support process. The two complement each other and are indispensable.
1. Key person: support worker.
basic requirements:
(1) The support workers must undergo professional technical training, and they can be certified to work after passing the examination.
(2) The support workers must master the roadway section, support form and support technical parameters and quality standards as specified in the operating procedures.
(3) The driver of the shotcrete machine must master the structure and performance principle of the sprayer and the mixer. And know the general knowledge of fault handling and repair, maintenance, and master the spray technology.
(4) Anchor support workers should be familiar with the support principle of anchor bolts and anchor cables, bolt and anchor cable structure and main technical parameters; be familiar with the working environment, be able to use the supporting tools skillfully, and be familiar with the performance and structure of the bolt machine. And work principle, and can eliminate general faults, and check and maintain before and after use.
(5) Familiar with the operating procedures and master some basic knowledge of roof management.
(6) The support worker should work closely with the driver of the roadheader.
2. Key points: timely support and guarantee the quality of support, providing a safe working environment for the stope.
3. The key link: the support process. Timely support, to ensure that the support is in place, without leaving an empty roof, the top plate supports a straight line before and after the support, the plate and the top plate are in close contact, to achieve the pre-tightening force requirements.
4. Operation process:
Preparation, inspection and treatment → temporary support → standard eye positioning → drilling work → installation work
5, the standard requirements are specific:
(1) The driver of the roadheader is strictly excavated according to the prescribed air-top distance. When the maximum air-top distance is reached, the driver must immediately stop and power off. The support worker should move forward and probe in time. The front-exploration support must be completed according to the requirements. Support must be made of channel steel #10 and above, length not less than 4m, each row of anchors is arranged with a front probe beam), and semi-circular or sleepers are used.
The top plate is tightly fastened. All personnel must work under the conditions of support, and empty top work is strictly prohibited.
(2) Before the support, carefully carry out the “knocking and asking top†safety inspection. The inspection personnel should be no less than two people, one person observes and one person handles to prevent accidents. Processors must use long-handled tools to handle dangerous rock, pumice , and live rafts in a safe, secure location. Knocking on the top should start from a place with good support, first from the outside to the inside, first from the top to the back, and then from the inside out for a comprehensive and detailed safety inspection.
(3) The order of support must be carried out from the outside to the inside, and the anchors in the middle are supported first, and the sides are supported on the back. Long and short sets of brazing should be used when drilling a small section of a roadway.
(4) When using anchor support, the material, variety, specification, strength, structure and anchoring material, specifications, ratio and performance of anchor and anchor rod body and fittings must meet the design requirements. The installed tray is firm and basically close to the wall and is not loose.
(5) For every 300 bolts or l00m range, take no less than 3 samples for the pullout test, and the pullout force shall not be less than 90% of the design value. The spacing error between bolts is ±100mm, the hole depth error is 0~+50mm, the bolt direction and the contour of the roadway are ≤5o, and the exposed length of the bolt (no pallet) ≤50mm.
(6) The deviation angle between the anchoring axis of the anchor cable and the design axis should not exceed 30 degrees, the minimum value of the prestress after the anchor cable is locked is not less than 90% of the design, and the hole depth error range is 0～+200mm, the exposed length error The range is 350mm. The anchor cable is anchored at the end, the anchorage length is not less than 1.5m, and the thickness of the anchor cable into the stable rock formation is not less than 1.2m. In order to enhance the stirring effect, the pressure within the first ends of the two anchor cross section 200mm steel ring, respectively, in a 50mm and 200mm from the head of each press, and 500mm from the end of lead wire tie # 14, to enhance the agitation effect cable anchor . After the anchor hole is drilled, it is necessary to leave a water control time of 30 minutes before the anchor cable can be attached.
(7) For the horizontal roadway supported by the shed, the allowable deviation of the forward tilt and the backward tilt of the bracket is ±1 degree (the vertical line of lm is not more than 17mm), and the allowable deviation of the angle of the mountain of the inclined roadway bracket is +1 degree. The position and quantity of the (pull) rod and the backing plate meet the requirements; the bracket column is dug to the solid bottom, and the bottom beam is laid on the solid bottom, the depth of which is not less than the design 30mm; the tolerance of the bracket spacing is ±100mm, and the tolerance of the bracket beam is ≤ 100mm, bracket beam horizontality tolerance ≤ 50mm.
(8) Support should be timely and effective. The roof bolt support should be horizontally and vertically arranged in a row, and the front and rear lines are in a straight line.
(9) The roadway with a height of more than 2.8m must be protected by the support. The distance from the working face of the protective support should not exceed 5m.
6, matters needing attention
In case of any of the following conditions, you should stop the eye treatment immediately.
(1) The pressure on the top plate is large, and the temporary support is not kept up.
(2) When the electric drill leaks and the temperature rises above the specified level (60 degrees).
(3) There is gas in the inside, when there is abnormal sound, when the gas exceeds the limit.
(4) There are red, sweat, cold air, fog, water, water, roof pressure, floor bulging or cracking, water inrush, water color, smell and other signs of water permeability. Time.
(5) When the eye is not water.
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