MSHA - Interactive Training - JTA Spiders - Longwall Move (Tear Down) Spider No.2

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

Wet area down

Rock dust 10'in all directions

Cut chain on connection link

Shut torches down

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

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

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

Follow lock-out/tag out procedures

Remove 6 Allen head bolts and remove access door

Hook door to mule or scoop with #8 chain

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

Obtain and examine the following tools

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

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

Obtain and examine the following tools

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

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

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

Be sure to make gas test in the tunnel

Wet area down

Rock dust 10' in all directions

10 pound fire extinguisher and/or 240 pounds of rock dust

Cut chain

Follow cutting and welding plan

Shut torches down

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

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

Store in designated area

5. 12: Disassemble Shearer

Conduct Exam

Obtain and examine tools

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

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

Attach come-a-long to one of the puller bolts to stabilize the spider

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

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

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

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

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

Bolt the roof as per the longwall move plan up to the last pan

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

Repeat this cycle until all roof is supported

Remove bolter power at power center

Lock out/Tag out

Follow lock out/tag out procedure

Cut bolter cable

Instruct scoop operator to scoop up pan line and bolter

Secure with winch cable

Remove bolter from face area and put in designated location

See Longwall Move Plan

7. 14: Hose and Cable Removal

Conduct SPSA Exam

Obtain and examine tools

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

Follow lock out/tag out procedures

Isolate the emulsion pressure lines at the head gate

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

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


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