BEHAVIOR OF SHIELD SUPPORT IN

LONGWALL MINING
A THESIS SUBMITTED IN PARTIAL FULFILLMENT
OF THE REQUIREMENTS FOR THE DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MINING ENGINEERING
BY

CHANDAN KUMAR
110MN0392

Department of Mining Engineering

National Institute of Technology
Rourkela
2014

BEHAVIOR OF SHIELD SUPPORT IN

LONGWALL MINING
A THESIS SUBMITTED IN PARTIAL FULFILLMENT
OF THE REQUIREMENTS FOR THE DEGREE OF
BACHELOR OF TECHNOLOGY
IN

MINING ENGINEERING
BY

CHANDAN KUMAR
110MN0392
Under the Guidance of

Prof. S. Jayanthu

Department of Mining Engineering

National Institute of Technology
Rourkela
2014

National Institute of Technology

Rourkela

CERTIFICATE
This is to certify that the thesis entitled, - BEHAVIOR OF SHIELD SUPPORT IN LONGWALL
MINING submitted by Mr. Chandan Kumar, 109MN0392, in partial fulfillment of the
requirement for the award of Bachelor of Technology Degree in Mining Engineering at the
National Institute of Technology, Rourkela (Deemed University) is a record of original research
work carried out under my supervision.
To the best of my knowledge, the matter embodied in the thesis has not been submitted to any
University/Institute for the award of any Degree or Diploma.

Prof. S. Jayanthu
Department Of Mining Engineering
National Institute of Technology
Rourkela 769008
Date:

ACKNOWLEDGEMENT
First and foremost, I express my sincere appreciation and gratitude to Prof. S. Jayanthu for
allowing me to carry on the present topic Behavior of Shield Support in Longwall Mining and
later on for their inspiring guidance, constructive criticism and valuable suggestions throughout
this project work. I am very much thankful to them for their able guidance and pain taking effort
in improving my understanding of this project.
I would also like to extend our sincere thanks to the Mr. D.Lalit Kumar, Mines Manager of GDK
10 Inc, SCCL and other officials, who helped me during my sample and data collection in their
respective regions.
Last but not the least; I would like to thank all my friends who have patiently extended all sorts of
helps for accomplishing this project.

Chandan Kumar
Department of Mining Engineering
National Institute of Technology, Rourkela
Date:

CONTENTS
ITEMS

TOPIC

PAGE NO.

ABSTRACT

LIST OF TABLES

ii

LIST OF FIGURES

iii

INTRODUCTION

1.1

Objective of the Project

2.2

Methodology

LITERATURE REVIEW

2.1

Longwall Mining Method

2.2

Behavior of Shield Support

2.2.1

Mechanics of roof behavior and shield loading

2.2.2

Effects of Load Distributions in Front and Rear Legs

2.2.3

Working under Weak Roofs

2.2.4

Roof sag over Shield Support

Numerical Modelling

12

FLAC

13

GEOMINING CONDITION

19

3.1

Geological and Mining Conditions

20

3.2

Mining Method

22

Investigation of chock shield Performance

24

FIELD OBSERVATION

25

Chock Behavior

31

CHAPTER - 1

CHAPTER - 2

2.3
2.3.1
CHAPTER 3

3.2.1
CHAPTER - 4
4.1

4.1.1

Leg Pressure

31

4.1.2

Leg Closure

31

NUMERICAL MODELLING

32

Sequence of Modeling

33

ANALYSIS

51

6.1

Behavior of Shield

52

6.2

Numerical Model

52

CHAPTER 7

CONCLUSIONS

54

REFERENCES

55

CHAPTER 5
5.1
CHAPTER 6

ABSTRACT
Field observation were conducted on behaviour of chock shield support of capacity 800T during
extraction of longwall panel no. 3D2 at 250 m depth and 150 m face length of GDK 10A Incline,
Singareni Collieries Company Limited. Chock leg pressures and leg closures were regularly
monitored at different stages of extraction of longwall panel.
During extraction of the panel, maximum leg closure and pressure on the chock shield were 600
mm and 490 bar, respectively (not on all chocks). Setting and yielding pressures were 300 bar and
400 bar corresponding to setting load and yielding load 600 T and 800 T, respectively. During
major fall condition, 27% of chock shields were loaded upto 800T. During normal periods,
maximum load was about 640T.
Parametric studies for depth covers of 150 m to 1200 m for the face advance of 6 m to 150 m was
simulated in 2D numerical model. At each depth, a fall in vertical stress was found between 80 m
to 100 m face advance indicating major roof fall and for 250 m depth cover, it was varying from
6 MPa to 4.5 MPa. Vertical stress and roof sag above the support was increasing as the depth was
varying from 150 m to 1200 m and maximum found was 50 MPa and 1500 mm respectively at
1200 m depth and 150m face advance.

LIST OF TABLES
Table No.

Table

Page No.

2.1

Behavior of Shield Support Analysis by other Investigators

16

3.1

Details about the panel 3D2

21

3.2

Specification of Shield Support

22

4.1

Condition of Chock Shield as the Face Advances

30

5.1

Property of Coal and Sandstone

34

6.1

Vertical stress over supports as different face advance and depth as

48

per numerical model

6.2

Roof sag of roof over supports as different face advance and depth

49

as per numerical model

6.3

FLAC Results vs. Field Investigation Data

ii

50

LIST OF FIGURES
Figure No.

Figures

Page No.

2.1

Longwall mining method

2.2

Horizontal and vertical force produced from strata dynamics

2.3

Roof behavior and shield loading

2.4

Working under weak roof

2.5

Main roof sag

10

2.6

Periodic weighting

11

2.7

Detached immediate roof

11

2.8

Deflection of immediate roof

12

2.9

General solution procedure in FLAC

15

3.1

Borehole data of the GDK 10 A Incline Mine

20

3.2

Fault crossing between 3D1 and 3D2 panel

21

3.3

Shield Support used in 3D2 panel

23

3.4

Goaf fall behind the shield

23

3.5

Channel for the purpose of shifting the shield

24

4.1

Average leg pressure of chock no. 41-70

26

4.2

Average leg exposure of chock no. 41-70

26

4.3

Average leg pressure of chock no. 71-101 and chock no. 41-70

27

4.4

Average leg pressure of chock no. 41-70 and chock no. 1-40

27

4.5

Leg Pressure at the time of Local Fall at a Distance of 15 m

28

4.6

Leg Pressure at the time of Main Fall at a Distance of 61 m

28

4.7

Leg Exposure at the time of Local Fall at a Distance of 15 m

29

4.8

Leg Exposure at the time of Main Fall at a Distance of 61 m

29

5.1

Grid generated to simulate 6 m of extraction

35

5.2

Grid generated to simulate 20 m of extraction

35

5.3

Grid generated to simulate 40 m of extraction

36

5.4

Grid generated to simulate 60 m of extraction

36

5.5

Vertical Stress over the shield supports after 6 m face advance

37

at a depth of 250 m
iii

5.6

Vertical Stress over the shield supports after 20 m face advance

37

at a depth of 250 m
5.7

Vertical Stress over the shield supports after 40 m face advance

38

at a depth of 250 m
5.8

Vertical Stress over the shield supports after 60 m face advance

38

at a depth of 250 m
5.9

Vertical Stress over the shield supports after 80 m face advance

39

at a depth of 250 m
5.10

Vertical Stress over the shield supports after 100 m face

39

advance at a depth of 250 m

5.11

Vertical Stress over the shield supports after 150 m face

40

advance at a depth of 250 m

5.12

Roof sag over the shield supports after 6 m face advance at a

40

depth of 250 m
5.13

Roof sag over the shield supports after 20 m face advance at a

41

depth of 250 m
5.14

Roof sag over the shield supports after 40 m face advance at a

41

depth of 250 m
5.15

Roof sag over the shield supports after 60 m face advance at a

42

depth of 250 m
5.16

Roof sag over the shield supports after 80 m face advance at a

42

depth of 250 m
5.17

Roof sag over the shield supports after 100 m face advance at

43

a depth of 250 m
5.18

Roof sag over the shield supports after 150 m face advance at

43

a depth of 250 m
5.19

Vertical Stress over the shield supports after 6 m face advance

44

at a depth of 250 m in case of clay bed included

5.20

Vertical Stress over the shield supports after 20 m face advance

at a depth of 250 m in case of clay bed included

iv

44

5.21

Vertical Stress over the shield supports after 40 m face advance

45

at a depth of 250 m in case of clay bed included

5.22

Vertical Stress over the shield supports after 60 m face advance

45

at a depth of 250 m in case of clay bed included

5.23

Roof sag over the shield supports after 6 m face advance

46

5.24

Roof sag over the shield supports after 6 m face advance

46

5.25

Roof sag over the shield supports after 6 m face advance

47

5.26

Roof sag over the shield supports after 6 m face advance

47

CHAPTER 1
INTRODUCTION

1. INTRODUCTION
The success of longwall mining depends to a large extent on the capacity and design of shield
support. Throughout the history of longwall mining, shield support design has been a critical issue
to the success of mining operation. To make mining operations safe and sound the study of
behavior of shield support and its design is very essential for complete success of the mine. Support
design and prediction of its behavior are very essential in determining the type of mechanism to
be practiced for better production and benefit. A lot of studies and researches has been carried out
in the field of behavior of shield support.
India stands in third position among largest coal producers in the world having a reserves of around
240 billion tones. The shallow coal seams which are extracted through opencast mines, are
gradually being exhausted. So, taking this consideration, researchers are focusing to develop a
highly productive underground methods that can be used to extract coal at a faster rate and can
fulfill all the demand of power. So bulk production and safer modes of extraction has become
important for future needs. The most proven and efficient method till now is longwall technology
which is highly productive as well as safer.
The first mechanized longwall mining in India was practiced in Moonidih colliery in August 1978.
After that popularity of longwall began to increase due to its high production rate. SCCL has been
a pioneer in the field of longwall technology. Even SCCL was not the first company to implement
the longwall technology in India but its high success rate in longwall technology has set a milestone
for other mining companies. Its production is 3000-4000t/day they which can be compared to
opencast mining methods.
Longwall technology was first implemented in SCCL in 1983 in GDK7/ VK7 mines where two
faces was successfully extracted. After that equipments were shifted to GDK 11 A, where it was
2

proved unsuccessful because of the poor strata and underrating of supports. After that improved
power supports were brought and implemented in GDK 10A Incline which was proved very
successful and production rate was increased and a yearly production of about 3.5MT.
1.1 Objectives of the Project
This study is focused on behavior of shield support in longwall mining and shall concentrate to
evaluate on the following areas:
To study the shield behavior in a underground longwall coal mine
Simulation of the field conditions in FLAC 5.0 software.
Interpretation of the results generated from simulating the models in FLAC 5.0 to
determine the shield behavior.
To validate the results generated against the data collected from the mine.
1.2 Methodology
Following steps were taken to fulfill the study:
Longwall panel 3D2 of GDK 10A Incline was chosen for detailed study of project.
Data related to chock shields was collected for database analysis.
The Geotechnical conditions of a panel of that mine were simulated in models.
Analysis of results
Conclusion

CHAPTER 2
LITERATURE REVIEW

2. LITERATURE REVIEW
Longwall technology in mining is a relatively very new and successful methods compared to other
methods and now it is getting more popularity due to its high production rates and safety
parameters.

It is evolving with new techniques, technology, equipment, face management

practices and systems appearing as a direct means to continually improve all aspects of operational
and financial performance.
Longwall mining is very successfully practiced in USA, Australia and also in China which are the
major coal producers in the world. Developed countries mainly use this technology for the coal
production and it can be said that major development in this technology has been done by these
nations. Though this technology is not very successful in India due to varied reasons, but SCCL
has brought a revolution in the Indian scenario by successfully using longwall mining at a large
scale for extraction of coal.
2.1 Longwall Mining Method
A longwall panel is about 1000 to 2000 meters long with a typical width of around 150-200 meters
and for a seam of thickness near about 3-4 meters. This can be assumed as a very long and wide
pillar with modes of access on either sides. These mode of access are termed as gate roads and
tail roads. For extracting the coal from the panel, double drum shearer is used and the roof at the
face is supported by shield supports. The coal is extracted by the repeated back and forth movement
of the shearer along the coal face. The cutted coal is transported to a conveyor chain called
armoured conveyor chain to the bridge stage loader where they are crushed to smaller pieces and
from there it is transported to the surface with the help of conveyor belts.
The Longwall mining has numerous advantages over the conventional mining methods which
include:
5

 high Recovery of coal

lower Operating Costs
Easier to Supervise.
Easier to train Miners.
Works under weak roof.

Fig. 2.1: Longwall mining method

2.2 Behavior of Shield Support

Success of longwall almost depends upon performance of shield supports. So it becomes necessary
to have information about shield behavior in different geological condition. The factors influencing
the load coming on supports are setting load density, height of caving block, yield characteristic
of supports and fractured zone near the face.
Roof support selection should take into consideration (Source: G W Mitchell):
1. Support resistance
2. Roof and floor pressure distribution
6

3. Cutting height range

4. Collapsed and transport height
5. Travelling access through the support
6. The setting and yield pressure
7. Hydraulic circuit
8. Support control system and,
9. Speed of operation
Support load and resistance:
The relationship between the load generated by a shield and the stiffness of support in terms of
roof sag is critical in controlling the roof above the longwall. The capability of the shield to control
roof above it can be expressed in terms of ground reaction curve.
2.2.1 Mechanics of roof behavior and shield loading (Source: M. Barczak)
Most of the roof structure is capable of transferring its weight on solid coal in front of face and on
goaf material as the face advances. Immediate roof are less stable and immediately separate from
the roof as the face advances. So, shield support should be capable of holding this vertical load
and horizontal load coming due to strata dynamics.

Fig.2.2: Horizontal and vertical force produced from strata dynamics (Source: M. Barczak)
Loading distribution among the supporting elements must follow the conservation of energy law,
i.e. total work done by coal, shield supports and goaf material must be equal to the roof loading.
The required support capacity is determined by estimating the height of caving zone.

Fig.2.3: Roof behavior and shield loading (Source: M. Barczak)

8

2.2.2 Effects of Load Distributions in Front and Rear Legs (Source: M. Barczak)
When the load in front leg is higher, horizontal force acts towards the face and as a result, no
tensile stress in immediate roof exposed between canopy tip and dace line. It implies a stable roof
condition. Conversely, when the load in front leg is smaller, horizontal force acts towards the goaf
resulting in an unstable roof condition.
2.2.3 Working under Weak Roofs (Source: M. Barczak)
Problem encountered working under weak roofs are generally breaking of roof over rear half of
canopy. If the caving line moves forward of line of resultant thrust, then back leg will try to push
upward into broken roofs. This will cause lowering of front portion resulting in essentially
unsupported roofs over AFC and this may also cause the damage of shield supports.

Fig.2.4: Working under weak roof (Source: M. Barczak)

2.2.4 Roof sag over Shield Support (Source: M. Barczak)
Strata behavior from the perspective of support loading can be categorized into four categories:
a. Main roof sag
b. Periodic weighting
c. Free block formation in the immediate roof, and
d. Deflection of immediate roof beam

Main Roof sag

Shield has no influence on main roof sag, so in case of main roof sag setting pressure should be
reduced to provide necessary accommodation of main roof.

Fig.2.5: Main roof sag (Source: M. Barczak)

Periodic Weighting
Periodic weighting is generally develop in main roof or partial caving zone. Like to main roof
sag, support has no influence on periodic weighting. So, for controlling the periodic weighting,
setting pressure is reduced.

10

Fig.2.6: Periodic weighting (Source: M. Barczak)

Formation of a Free Block
The front abutment pressure has potential to create free block formation as the coal is removed.
Shield can equilibrate this strata but has no control on its formation. For equilibrate this block, a
support capacity equal to that block is required. So, to avoiding wasting available capacity, only
nominal setting capacity is required.

Fig.2.7: Detached immediate roof (Source: M. Barczak)

11

Deflection of Immediate Roof Beam

Shield resistance can more influence the deflection of immediate roof. Deflection of immediate
roof decreases with increase in shield stiffness. Deflection of immediate roof also depends upon
shield resistance if it is capable of preventing the bed separation or providing the sufficient
friction resistance to prevent the slippage of layers from each other.

Fig.2.8: Deflection of immediate roof (Source: M. Barczak)

2.3 Numerical Modelling

Numerical modelling is a powerful tool to solve the problem related to rock mechanics in various
area like civil and mining engineering. Understanding of caving behavior of rock is the primary
need to control the strata and estimating the capacity of shield support in longwall. Various norms
and method has been developed to predict the behavior of strata but they have very limited
application due to based on some empirical equations and two dimensional beam theories. It is

12

very difficult to predict the behavior of each section of roof with these equations. So, there is a
need of something which can predict the behavior of each section of roof carefully. In these
consideration, numerical modelling has a wide application. Development in area of numerical
modelling, it become easy to predict the geological behavior. Now, we can simulate the field
conditions in these numerical modelling softwares and can analyse it in very easy way and success
fully.
2.3.1 FLAC
FLAC is an explicit two dimensional finite difference program, which can simulate the geological
conditions related to civil and mining field. It provides the facility of simulating the underground
extraction with support like roof bolting, hydraulic props, cable bolting, simple props, beams etc.
It creates grids with different zones and divide the problem into small parts. It analyze each small
zones separately. Many parameters like vertical and horizontal stress, vertical and horizontal
displacement, vectors of these parameters can be plot. It is also capable to calculate factor of safety.
Problem Solving With FLAC (Source: Itasca, 2005)
The problem is solved by using FLAC in the following sequence of steps:
Grid generation
Boundary and initial conditions
Loading and sequential modeling
Choice of constitutive model and material properties
Ways to improve modeling efficiency
Interpretation of results

13

Steps for Numerical Analysis In Geo-mechanics

Step 1: Define the Objectives for the Model Analysis
Step 2: Create a Conceptual Picture of the Physical System
Step 3: Construct and Run Simple Idealized Models
Step 4: Assemble Problem-Specific Data
Step 5: Prepare a Series of Detailed Model Runs
Step 6: Perform the Model Calculations
Step 7: Present Results for Interpretation

14

Fig.2.9: General solution procedure in FLAC (Itasca, 2005)

15

Table 2.1: Behavior of Shield Support Analysis by other Investigators

Year

Author

Title

1987

S.S. Peng

Support capacity and He

roof

Description

behavior

examined

at behavior of roof, floor

longwall faces with and

shield supports

the

support

on

longwall

faces

equipped

with

hydraulic

powered

supports. He found
that

the

most

important factor in
determining

face

stability was periodic

weighting.

He

designed an empirical
equation for support
capacity.
1992

Thomas M. Barczak

Examination

of He

described

the

design and operation details

of

design

practices for longwall criteria

of

shield

shields

supports.

He

also

observed

that

load

distribution
the

among

supporting

elements must follow

the

law

of

conservation

of

energy in such a way

that combined work
of
16

coal,

powered

supports

and

goaf

must be equal to the

load

imposed

by

strata.
2002

Ramaiah and Lolla

Selection of Powered

They suggested that

Roof Supports for

width and length of

Weak Coal Roof

longwall

pillars

influence
significantly the stress
abutments,

goaf

formation,

support

requirements,

and

other factors. The face

length

should

sufficient
allow

be

wide

full

to

caving,

bulking

and

reconsolidation of the
overburden

strata.

The goaf must be able

to support the load
coming on it.
2011

B Ramesh Kumar and Selection of powered They observed that in

others

roof supports- 2-leg case

of

shields vs 4-leg chock immediate

shields

week
roof

condition, at the time

of main and periodic
weightings, the front
legs were more loaded
than rear legs because
of

17

crumbled

and

premature

caving

nature of immediate
roof.
2013

G. Benerjee

Application
numerical

of He

presented

the

modeling overview of division

for strata control in of caving strata in

longwall mining

cola

measure

formation and details

of observation of load
on support at the face,
movement

of

the

strata overlying the

coal seam in a typical
underground
coalmine along with
application of three
dimensional
numerical model.
2013

M.S.V Ramayya and Design of longwall They predicted the

others

panel- A case study distance

for

no.2

seam

Ramagundam
SCCL

local,

of periodic and main fall

area, and

capacity

of

supports at the time of

these falls.

18

of

CHAPTER 3
GEOMINING CONDITION

19

3.1 Geological and Mining Conditions

GDK.10A Incline is situated at Ramagundam Area III of SCCL in Karimnagar District of Andhra
Pradesh in the Godavari valley coal field. GDK 10A Mine covers an area of 855.7 Ha at present
i.e. between Longitude 790 33 45 to 790 35 and North latitude of 180 38 15 to 180 41 45.
The longwall panel 3D2 is situated in front the fault crossing at 206 m of 3D1 panel (already
extracted). The present panel is in the north side. Workings were carrying out in the 6 m thick no.
1 seam. The seam is dipping at about 1 in 6; the depth of the workings is 187 m minimum and 260
m maximum. The borehole section is shown in Figure 2. The longwall face was extracted along
the dip-rise and was retreated in strike direction.
The 6 m thick seam was being worked in the middle section to a height of about 3 m, leaving 2 m
thick coal in the immediate roof. It was overlain by a 0.8 m thick clay band, and the thicker and
stronger members of medium grained white sandstone forms the main roof.

Fig.3.1: Borehole data of the GDK 10 A Incline

20

Fig.3.2: Fault crossing between 3D1 and 3D2 panel

Table 3.1: Details about the panel 3D2

Name of the seam

No.1seam

Depth

Max - 310 M, Min -175 M

North side workings

LW Panel 3E (Virgin)

Length of the panel

432.5 M

Face length

150 M

Total thickness of the seam

6.20 Mts.

Average seam gradient

1in 6.0

21

Working section

3.3 M along the floor

Nature of roof

Coal with a clay band (0.30 m)

Nature of floor

Grey sand stone

Supports in the face

4x800T Chock shields (IFS)

No. of supports at the face

101

3.2 Mining Method

In GDK 10A incline, retreating longwall method is being followed as mentioned above. In 3D2
panel, face length was 150 m and panel length was 432 m. Extraction was going on in lower section
of coal bed for a height of 3 m. 101 IFS type of four leg shield capacity of 800T were being used
for supporting the roof. Specification of shield support is as below:
Table 3.2: Specification of Shield Support
Support Capacity And Type

4*800T, IFS Chock Shield

Make

MECO International

Yield Pressure

43.4MPa (6400 psi)

Canopy Length

4.5 m

Open Height

33.6 m

Closed Height

1.65 m

Web Depth

0.6 m

Range

2.2-3.3 m

Canopy

4.5x1.5 m

Support density at 850 mm

After cut 94.16T/m2

Before cut 110T/m2

web & 3 m height

22

Fig.3.3: Shield Support

Setting and yield pressure of shields were 300bar and 400bar respectively. For cutting the coal, a
shearer of capacity of 800TPH with drum dia. 1.83m and web width 0.85 was being used. For
conveying the coal from the face an AFC having capacity 1200TPH were used. Production of the
panel was 1085T per day. Local fall and main fall were observed after a retreat of 41m and 72m
respectively. Maximum subsidence observed was 1.1m.

Goaf fall

Fig.3.4: Goaf fall behind the shield

23

For shifting the shield, a wire with one long portion tightly inserted in ground was used. Bottom
channel of shield as shown in figure below was tied with one end of a chain and other end of the
chain was connected with free portion of wire rope ant hydraulic pressure was applied resulting
in inward motion of channel producing forward motion in shield.

Fig.3.5: Channel for the purpose of shifting the shield

3.3 Investigation of chock shield Performance:
The performance of chock shield was investigated by separately measuring the closure of
legs and the pressure changes in each individual leg of the chock shield supports. The leg closure of
the chock shield was measured by measuring the leg exposure by using tape in every shift and being
noted for further records. The leg pressure of the powered support was measured using the pressure
indicators provided on the powered support. The pressure of both the rear legs was measured by only
one indicator.

24

CHAPTER 4
FIELD OBSERVATION

25

Leg Pressure and Leg Closure

chock no. 40-70

400

PRESSURE(IN BAR)

350
300
250
200
150
100
50
0
0

50

100

150

200

250

NO. OF DAY

Fig.4.1: Plot of average leg pressure of chock no. 40-70

chock no. 40-70

100

LEG EXPOSURE(IN CM)

90
80
70
60
50
40
30
20
10
0
0

50

100

150

200

NO. OF DAYS

Fig.4.2: Plot of average leg exposure of chock no. 40-70

26

250

chock no. 71-101(series 1) and chock no. 41 -70(series 2)

400

PRESSURE(IN BAR)

350
300
250
200
150
100
50

1
8
15
22
29
36
43
50
57
64
71
78
85
92
99
106
113
120
127
134
141
148
155
162
169
176
183
190
197
204
211
218
225

0
NO. OF DAY
Series1

Series2

Fig.4.3: Plot of average leg pressure of chock no. 71-101 and chock no. 41-70

chock no. 41-70(series 1) and chock no. 1 -40(series 2)

400
350
300
250
200
150
100
50

1
7
13
19
25
31
37
43
49
55
61
67
73
79
85
91
97
103
109
115
121
127
133
139
145
151
157
163
169
175
181
187
193
199
205
211
217
223
229

Series1

Series2

Fig.4.4: Plot of average leg pressure of chock no. 41-70 and chock no. 1-40

27

450
400
350
300
250
200
150
100
50
0

LEG PRESSURE REAR

LEG PRESSURE FRONT

1
5
9
13
17
21
25
29
33
37
41
45
49
53
57
61
65
69
73
77
81
85
89
93
97
101

Pressure(in bar)

Leg Pressure and Leg Exposure at the time of Local Fall and Main Fall

Chock no.

450
400
350
300

Pressure(in bar)

Fig.4.5: Leg Pressure at the time of Local Fall at a Distance of 15m

LEG PRESSURE REAR

LEG PRESSURE FRONT

250
200
150
100
50

1
5
9
13
17
21
25
29
33
37
41
45
49
53
57
61
65
69
73
77
81
85
89
93
97
101

0
Chock no.

Fig.4.6: Leg Pressure at the time of Main Fall at a Distance of 61m

28

LEG EXPOSURE FRONT NORTH (CM)

140
120
100
80
60
40
20

1
4
7
10
13
16
19
22
25
28
31
34
37
40
43
46
49
52
55
58
61
64
67
70
73
76
79
82
85
88
91
94
97
100

0
Chock number

Fig.4.7: Leg Exposure at the time of Local Fall at a Distance of 15m

120

LEG EXPOSURE FRONT NORTH (CM)

100

80

60

40

20

1
4
7
10
13
16
19
22
25
28
31
34
37
40
43
46
49
52
55
58
61
64
67
70
73
76
79
82
85
88
91
94
97
100

0
CHOck NUMBER

Fig.4.8: Leg Exposure at the time of Local Fall at a Distance of 61m

29

Table 4.1: Condition of Chock Shield as the Face Advances

S.No Weighting

Date
/Shift

Local

7-912 /

Avg.
retreat

Area of expo.

15.4 m

1652.75 m2

Local

24-912 /

36.6 m

2621.40 m2

Local

28-912 /

52.5 m

4001.49 m2

Local

0610-12
/

58 m

(25.95x154.20)

10006 m2

III
4

(17.00x154.20)

PRE
3

(10.75x154.20)

PRE
2

Observations

(39.40x154.20)

C70 to T.G entire stone roof fallen

in the goaf (up to 1 m thick of
stone).
No bleeding
C45 to C98 Coal roof behind the
chock shield fallen in the goaf (up
to 1m thick of stone).
No bleeding
Stone of 5-6 m fallen in goaf.
C02 to C22 stone roof fallen in the
goaf (up to 1 m thick stone).
No bleeding
C50 to C80 stone roof fallen in the
goaf (up to 1 m thick).

III
5

Goaf

0910-12
/ III

61.85
m

10633 m2
(68.95x154.20)

Load observed in chocks C45C80.Pressure(350.38)

MAIN
weighting

78.1 m
1910-12
/ P, I,
II, III

Weighting observed from C55 to

C73
Bleeding of supports C58 to C83

Periodic
weighting

95.2 m
27112012
/ P, I,
II, III

Bleeding of supports from C55-71

30

4.1 Chock Behavior

4.1.1 Leg Pressure
a. From Fig.4.7 and Fig.4.8, it was observed that leg pressure in chock no. 41-70 were more
than other sections i.e. shields in middle sections were more loaded than sides.
b. From Fig.4.1, Fig.4.2 and Fig.4.3, it was observed that after a regular interval, there was a
fall in leg pressure.
c. Maximum rear leg pressure and front leg pressure at the time of local fall at a distance of
15 m was 400 bar and 340 bar respectively.
d. During major fall condition 27% of chock shield were loaded upto 800T. During normal
periods, maximum pressure was about 340 bar.
e. Maximum rear leg pressure and front leg pressure at the time of main fall at a distance of
61 m was 400 bar in both leg.
f. During extraction of the panel, maximum pressure on the chock shield was 490 bar
respectively.
4.1.2 Leg Closure
a. Leg exposure was increasing and decreasing after a regular interval.
b. During extraction of the panel, maximum leg closure was 600 mm.
c. During local fall at a distance 15 m, maximum leg closure was 500 mm.
d. During main fall at a distance 61 m, maximum leg closure was 600 mm.

31

CHAPTER 5
NUMERICAL MODELLING

32

5. NUMERICAL MODELLING
The longwall panel was modeled using FLAC5.0 with face length of 150 m and panel length of
400 m at 150 m, 250 m, 350 m, 600 m, 900 m and 1200 m depth at a face advance of 6 m, 20 m,
40 m, 60 m, 80 m, 100 m and 150 m with an initial opening of 6 m. At face chock shield support
was simulated with load of 749 tons. The longwall panel was simulated to plot their vertical
displacement and vertical stress contours over support. Two type of simulation were done; first
was taking on coal of thickness 6.5 m only and the second was with clay band in the
immediate roof. With clay band was the original field condition and this was simulated for a
depth of 250 m with face advance of 6 m, 20 m, 40 m and 60 m and the results coming were
compared to field data.
5.1 Sequence of Modeling
1. Development of the total seam layout at different depths above mentioned with the coal layer
6.5 m high and an extraction height of 3 m.
3. Development of longwall face at different positions mentioned above.
4. Installation of chock shield supports with parameters as:
Compressive yield = 7350000N
Stiffness = 0.5 mm per ton
Along the two edges a typical roller type boundary condition was given as parameter and bottom
was fixed along both X and Y direction... To estimate the in situ stress the following formula was
adopted and the horizontal and vertical stress were simulated.
Vertical stress = x H . (i)
33

Horizontal stress = 3.75 + 0.015 H . (ii)

Where, = specific weight of the overlying rock mass and
H = depth cover
Gravitational loading was simulated by the model itself. To generate pre-mining conditions, the
models were run for an initial analysis to generate the in situ stresses. Then longwall openings
were added to the model and the simulation were executed to obtain equilibrium conditions. The
models were executed to the following coal and sandstone parameters. It was assumed that roof
convergence was equal to total leg closure.
Table 5.1: Property of Coal and Sandstone
Property

Coal

Sandstone

Bulk Modulus

3.67 GPa

6.67 GPa

Shear Modulus

2.2 GPa

4.0 GPa

Density

1430 kg/m3 2100 kg/m3

Tensile Strength

1.86 MPa

9.0 MPa

Cohesion

1.85 MPa

6.75 MPa

Friction Angle

300

450

34

Grid Generated to Simulate the Model for Different Stages of Extraction at a Depth 250 m

Fig.5.1: Grid generated to simulate 6 m of extraction

35

Fig.5.2: Grid generated to simulate 20 m of extraction

Fig.5.3: Grid generated to simulate 40 m of extraction

36

Fig.5.4: Grid generated to simulate 60 m of extraction

Modelling Plots for Roof sag and Vertical Stress over the Supports for 250 m Depth

Fig.5.5: Vertical Stress over the shield supports after 6 m face advance

37

Fig.5.6: Vertical Stress over the shield supports after 20 m face advance

Fig.5.7: Vertical Stress over the shield supports after 40 m face advance

Fig.5.8: Vertical Stress over the shield supports after 60 m face advance

38

Fig.5.9: Vertical Stress over the shield supports after 80 m face advance

Fig.5.10: Vertical Stress over the shield supports after 100 m face advance

39

Fig.5.11: Vertical Stress over the shield supports after 150 m face advance

Fig.5.12: Roof sag over the shield supports after 6 m face advance

40

Fig.5.13: Roof sag over the shield supports after 20 m face advance

Fig.5.14: Roof sag over the shield supports after 40 m face advance

41

Fig.5.15: Roof sag over the shield supports after 60 m face advance

Fig.5.16: Roof sag over the shield supports after 80 m face advance

42

Fig.5.17: Roof sag over the shield supports after 100 m face advance

Fig.5.18: Roof sag over the shield supports after 150 m face advance

43

Modelling Plots for Roof sag and Vertical Stress over the Supports for 250 m Depth in case
of Clay Band Included i.e. in actual field condition

Fig.5.19: Vertical Stress over the shield supports after 6 m face advance

Fig.5.20: Vertical Stress over the shield supports after 20 m face advance

44

Fig.5.21: Vertical Stress over the shield supports after 40 m face advance

Fig.5.22: Vertical Stress over the shield supports after 60 m face advance

45

Fig.5.23: Roof sag over the shield supports after 6 m face advance

Fig.5.24: Roof sag over the shield supports after 20 m face advance

46

Fig.5.25: Roof sag over the shield supports after 40 m face advance

Fig.5.26: Roof sag over the shield supports after 60 m face advance
47

Table 5.1: Vertical stress over supports at different face advance and depth as per
numerical model
Face advance

Vertical Stress
( in MPa)

Depth
6m

20 m

40 m

60 m

80 m

100 m

150 m

150 m

2.6

3.6

3.6

4.5

250 m

2.4

3.2

5.5

4.5

11.5

350 m

2.8

17

600 m

5.5

10

28

900 m

12

14

16

10

14

1200 m

16

18

18

14

50

Note: For 250m depth, modelling was also done for face advance of 125m and 174m and the
vertical stress was found to be 7.5MPa and 4MPa respectively.

48

Table 5.2: Roof sag over supports at different face advance and depth as per numerical
model
Face advance
Roof sag
Depth

(in mm)

6m

20 m

40 m

60 m

80 m

100 m

150 m

150 m

20

23

26

32

38

40

60

250 m

30

34

37

48

54

56

100

350 m

50

50

70

100

100

500

610

600 m

100

100

110

200

240

600

800

900 m

160

200

200

250

250

700

1000

1200 m

250

250

300

500

700

1000

1500

Note: For 250 m depth, modelling was also done for face advance of 125 m and 174 m and the
Roof sag was found to be 56 mm and 160 mm respectively.

49

Observation
a. Vertical stress was increasing with face advance but for interval 80 m to 100 m, a fall in
vertical stress was observed. For 250 m depth, stress in this interval was varying from
6MPa to 4.5MPa.
b. Vertical stress and roof sag above the support was increasing as the depth was varying from
150 m to 1200 m and maximum found was 50 MPa and 1500 mm respectively at 1200 m
depth and 150m face advance indicating a pressure beyond the yielding pressure of choosen
support resulting in failure of the choosen support at 1200 m depth.

Comparison of Modeling Results with Field Data at a depth of 250 m in case of clay bed

Table 5.3: FLAC Results vs. Field Investigation Data

Field
result(maximum
roof sag over
support in mm)
55

Maximum vertical
stress over support
(in MPa)

6m

FLAC
result(maximum
roof sag over
support in mm)
45

20 m

300

310

40 m

250

230

60 m

250

320

7.5

Face advance

50

CHAPTER 6
ANALYSIS

51

6. ANALYSIS
6.1 Behavior of Shield
Chock Shields in middle section were more loaded than sides because roof are supported by coal,
goal material, shields and also by rocks in sides; so as we move further from middle section,
contribution of rock in supporting the roof will increase.
Leg closure and leg pressure were decreasing in some intervals because decrease in load coming
on shield due to roof fall.
6.2 Numerical Model
From Table 5.3, it can be seen that actual field values were greater than the FLAC generated values
due to:
a. Failure to simulate all the geological features present in the seam.
b. The deformation caused due to the vibrations generated from the shearer.
c. The pressure caused due to presence of water table or aquatic sources.
The results of roof sag collected from FLAC modelling shows a regular increase while field data
shows increment and decrement both after some regular intervals. The reason may be that FLAC
produces a continuum modelling in which immediate and main roofs never break (it only sag)
resulting in gradual increase in roof sag.
The results of vertical stress over the support collected from modelling shows a decrease in stress
in between 80 m-100 m face advance due to occurring of roof fall. From modelling data of 250 m
depth, it can be seen that there is a decrease in vertical stress in between 80 m-100 m and 150 m174 m face advance.

52

CHAPTER 7
CONCLUSION

53

7. CONCLUSIONS
Based on the observation of the field data and output obtained from FLAC, the following
conclusions are drawn:
a. An increasing rate of roof sag was observed from the results of the simulated models as the
seam is extracted due to generation of continuum model resulting in lack of breaking of
roof.
b. Vertical stress was increasing with face advance but for interval 80 m to 100 m, a fall in
vertical stress was observed. For 250 m depth, stress in this interval was varying from
6MPa to 4.5MPa.
c. Vertical stress and roof sag above the support was increasing as the depth was varying from
150 m to 1200 m and maximum found was 50 MPa and 1500 mm respectively at 1200 m
depth and 150m face advance indicating a pressure beyond the yielding pressure of choosen
support resulting in failure of the choosen support at 1200 m depth.
d. Maximum rear leg pressure and front leg pressure at the time of local fall at a distance of
15m was 400 bar and 340 bar respectively.
e. Maximum rear leg pressure and front leg pressure at the time of main fall at a distance of
61 m was 400 bar for both leg.
f. During major fall condition 27% of chock shields were loaded upto 800T. During normal
periods, maximum load was about 680T.
g. During extraction of the panel, maximum leg closure and leg pressure were 600 mm and
490 bar respectively.

54

REFERENCES
1. Thomas M. Barczak, Examination of Design and Operation Practices for Longwall Shields,
Bureau of Mines Information Circular, USA.IC.9320 (United State Department of the
Interior), 1992.
2. Wilson, A.H. 1975. Support load requirements on longwall faces, Min. Engr., No.173,
3, June, Pp 479-491.
3. Park D, W., Peng S.S., Carr F., Hendon G.W., 1992. Analysis of longwall Shields and their
interaction with Surrounding Strata in a Deep Coal Mine, The Mining Engineer, October,
pp -161-167.
4. G W Mitchell, Longwall mining (monograph-26, Australian Coal Mine Practices), pp
341-345.
5. Ward, M.B. and Pala, J. 2006: response of powered supports and pillars to initial longwall
in under a strong main roof, 19th Conference on Ground Control in Mining, Morgantown,
West Virginia, 2006.pp 23-26
6. Venkat Ramaiah, M.S and Sudhakar Lolla (2002) Selection of Powered Roof Supports
for Weak Coal Roof, Journal of Mines, Metals & Fuels, April, 2002.V 128 Pp 62-64
7.

Issac, A.K. and Smith, P.E., 2008: support of longwall workings in thick seam
extraction, American Mining Congress Minexpo International 2008, April 2428, 2008,
Chicago, Illinois. Pp 132 - 139

8. Ward, M.B. and Pala, J. 2006: response of powered supports and pillars to initial
longwall in under a strong main roof, 19th Conference on Ground Control in Mining,
Morgantown, West Virginia, 2006.pp 23-26

55

9. Singh, G S P, Singh U K, 2009. A numerical modelling approach for assessment of

progressive caving of strata and performance of hydraulic powered support in longwall
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Edition (FLAC Version 5.0) April 2005
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lake Macquire, Vol-VI, Pp 23-26.
13. Hosseini Naved, Orace Kazeon, Shahriar Kauresh, Kamran Gostashi,2001: Studying the
stress redistribution around the longwall mining panel using passive seismic velocity
tomography and guaranteed estimation, The Mining Engineer , V 467 Pp 34-38.
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Rourkela, 2013

56

57