HYDRAULIC PROP

Basically consists two oil filled cylinders, inner cylinder and outer
cylinder. The piston head is fitted to the lower cylinder, this does not
slide down until it reaches yielding load the lower components are
mostly made of double walls. The outer walls protect prop against dirt,
dust and action of water. The inner tube serves as a cylinder for the
ram to move. When the pump is operated by a detachable handle, the
oil is pumped to this cylinder through non return valve. The ‘ram’ is
pushed up under the hydraulic pressure thus developed. The pump is
operated till the prop is set on its predetermined load, ranging from 7
to 10 tonnes. The spring loaded relief valve in the upper region of
upper component is operated by a lin k attached on the outer side
For withdrawal a cable is attached to the link, and on its being
tensioned a part of the link releases the valve. As the oil returns to
reservoir through the return valve, the ram moves downwards and the
prop is released.

There are two ways of building pressure:

a) Closed circuit system: A built in pump is provided in the prop

itself and forms an integral part of it. Pump is operated by handle.

b) Open circuit system: An external pump serving for number of

props, from one central site is connected through hosepipes

The load bearing capacity of Hydraulic Props is 40tonnes when the

load exceeds 40tonnes a relief value operates. The relief valve is a
capsule permitting adjustment and tested prior to insertion in the prop
and is set to correct yielding pressure, which is around 200 to 500
Kg/cm2

Hydraulic props must be handled carefully. They shall not be left lying
on the floor and prop must be withdrawn before full closure before it
becomes ‘solid’. In the long wall faces, due to developing of scratches,
the inner cylinder looses oil-sealing capacity, which renders the prop
ineffective.
Hydraulic props were further improved by making the hydraulic prop,
cap and the chain conveyor movement in a single unit called “walking
support” or “powered chocks”. Modern longwall mining employs self-
advancing hydraulic powered supports at the face area. The support
not only holds up the roof, pushes the face chain conveyor and
advances itself but also provides a safe environment for all associated
mining activities

Parts Of Powered Supports According to Cemal and Ergin

(1983),
all powered supports, regardless of type, consist of a canopy, a base,
hydraulic legs and control system.

1) CANOPIES: The canopy size ranges from 1.61 to 9.4 m2 with

maximum roof pressure at yield about 4.2-33.2 kg/cm2. Solid roof
canopies have been found to maintain an average of 41% contact area
with the roof; contact area increases to an average of 68% when an
articulated canopy is used.

2) BASES: Bases are available in any size. Generally, bases for frame
supports are split into two halves, whereas solid bases are used for
chock and shield supports. A solid base provides better stability. Each
base is provided with skids; the most popular design is a combination of
a rear skid and a single split forward skid. Guide bars are used to
transfer the ram jack force to guide the support units during advance
without undue side loads. The optimum size of the base for a specific
seam floor is such that its unit loading pressure at yield is less than the
bearing capacity of the floor rocks
. 3) LEGS (JACKS): The bore diameter of the hydraulic legs of powered
supports ranges from 10 to 30 cm with operating pressures of the
hydraulic pump. When the legs are raised against the roof, the total
load exerted on the roof is

P = Pi x A x n (1) Where; P = total setting load, in kilograms Pi =

operating hydraulic pressure, in kilograms per square centimetre A =
cross-sectional area, in square centimetres n = number of legs

Thereafter, when the roof starts to cave, the hydraulic legs are forced
to retreat and hydraulic pressure in the legs increases. The pressure at
which the yield valve will open is called the yield pressure; the
corresponding load applied on the roof is called the yield load. Most
support capacities are designed to incorporate the yield loads.

4) HYDRAULIC POWER SUPPLIES: There are four types of hydraulic

fluids for powered supports: 1) 5% soluble oil-in-water emulsion; 2)
40% water-in-oil emulsion; 3) 50% glycolin-water solution; 4) refined
petroleum based oil. The basic requirements for powered support
hydraulic fluids are low cost, low viscosity, non-flammability, and high
resistance to chemical change upon contact with air. Also, the fluid
should be highly resistant to foaming. Lubricity and corrosion
protection is also important to protect moving parts

5) CONTROL SYSTEMS: Supports can be controlled in various ways:

1) individual support manually; 2) individual support manually from the
neighbouring unit; 3) manually from selected points at the face; 4)
automatic control from the gateway.

Types of Powered Supports According to Cemal and Ergin

(1983),
 there are four major types of powered supports which are designed for
various conditions. These are Chock: Frame, Shield and Chock-shield
types of supports.

1. Chock Powered Supports The chock type of powered support is

the earliest used. It is hydraulic in nature. The old type of chock
powered support is composed of a block (chock) of one horizontal and
four vertical pistons. The vertical pistons support the roof and the
horizontal piston pushes the conveyor. Currently, there are chock
powered supports having six legs (Fig. 2.3). The back of the chock is
protected from caving blocks and the rigid canopy has elongations to
cover the roof after the cutting machine has passed.
2. Frame Powered Supports The frame type is composed of two
different supports of two- and three- leg units. The two- leg unit is
connected to the conveyor and advances with the cutting machines to
cover the freshly opened area of the roof. The three- leg pieces are
used to support the back of the face; after the cutting machine has
passed, they advance and align again with the two- leg units. Modern
frame powered support now has canopy which is articulate and has
prolongations to cover the face area right after the cut (Fig. 2.4).

1, hinge; 2, hydraulic control assembly; 3, leafspring thrusters; 4, centre

base; 5, footplates with centering base; 6, shifting cylinder; 7, leg; 8;
articulated canopy
3. Shield Powered Supports Shield supports were developed in
order to keep up with easily caving faces. The shield supports consist of
an inclined plate whose lower end is hinged to a horizontal base plate
that sits on the floor, while the upper end is hinged to a horizontal roof
canopy in contact with the roof (Fig. 2.5). Due to various developments
made on shield supports, we have three types of shield supports: (i)The
“Calliper” shield, (ii) The “Lemniscate” Shield and (iii)The Four- leg
Support Shield.
Important Dimensions Related to Supporting
Yielding Pressure: This is given by the formulae:
Py = 1.25 Pi
Where, Py = yielding pressure, in kg/cm2

Pi = operating or setting pressures, in kg/cm2

Distance between supports:

this depends on the roof and floor conditions, bearing capacity of the
support, gob conditions (caving), and rate of advance. It is usually
taken as 1.2 m from centre to centre. It is shown as ‘c’ in Fig. 2.2.

Unsupported face distance:

This is the small distance between the coal at the face and the end of
the canopy. This distance increases as the winning machine cuts. It is
shown as lo in Fig. 2.2.

Load Density:
Load density is given by the formulae

n = F / (ls + lo) c
where, n = load density, in tonnes per square metre

F = carrying capacity, in tonnes

ls = length of canopy, in metres

lo = length of unsupported face, in metres

c = distance between supports, in metres

Hydraulic powered roof supports are self advancing structures
which are interconnected along the length of the longwall face.
Each unit along the line is also connected to each pan of the
AFC.
The function of the powered supports are to:
 To control strata deformation, fracture and movement
around the coal face,
 To maintain a safe and coal producing working
environment,
 To limit the amount of roof to floor convergence,
 To prevent broken rock from entering the work area, and
 To secure and advance all plant on the coal face including
the roof supports.
Each support structure consist of a roof canopy connected to a
base via a shield and leminscate linkages. Side shields mounted
to the canopy prevents excessive debris falling into the work
space during support advancement. The hydraulic legs of a each
type of support are inclined or splayed at an angle. This is to
prevent the legs from buckling under the immense loads that
they support. In Australia, the most comon types of supports
used are :
 Chock shield supports
 Shield Supports
 HYDRAULIC LEGS
 The forces required at the support line to control strata
deformation are supplied by a set of hydraulic legs acting
between the base and roof canopy. The hydraulic pressure
to the legs are supplied from a power pack system which
could be located remote from the longwall face or mounted
 on a Pantechnicon at the main gate end of the longwall
face.

 SETTING PRESSURES
 The initial force applied to the strata is known as “setting
pressure”. Once this pressure level is achieved the
hydraulic supply is removed but the pressure is retained in
the support legs by means of a non return valve. A
guaranteed setting pressure, also known as Positive Setting
Pressure, insures the preset full pump pressure is being
maintained on each support unit along the face. This is
achieved by the incorporation of Positive Set Circuit in the
hydraulic circuit of the support system.

 YIELD LOADS
 The term “yield load” refers to the maximum resisting
force of the support and is determined by a preset yield
valve in the leg of the powered support. The yield valve
generally releases the fluid from the support leg circuit at a
constant pressure and in such a manner to insure that, even
during yield, the fine control of convergence is still
achieved. In Australia the setting load of the supports is
80% of the yield load.
 Support capacities in Australia vary and are dependent
upon geological and geoenvironmental factors. In general
the support capacities can be between 650 tonnes to over
1100 tonnes. For example, Baal Bone mine, located near
Lithgow NSW, uses a 630 tonne yield load 4 leg chock
shiled support for a depth of cover up to 240 metres.
Another example is Crinium mine, located near Lilyvale
QLD, uses a 950 tonne yield 2 leg support for a depth of
cover of 130 metres.

 SUPPORT ADVANCEMENT
 As the shearer traverses along the coal face the supports are
advanced to enable the shearer to cut a fresh web of coal
when it returns. There are two methods of advancing
powered supports, these are:

 Conventional Method of Advancement

 In the conventional method the supports are stood up to the
conveyor before the shearer cuts a web of coal. After the
shearer passes the support an extension bar from within the
canopy of the support is extended. This gives support to the
newly exposed roof until the conveyor and the support are
advanced to their new position
.
 Immediate Forward Support (IFS) Method of
Advancement
 In the IFS method the supports are stood back from the
conveyor before the shearer passes. This is to allow the
support to be advanced once the shearer has passed it to
offer immediate forward support. The conveyor is then
advanced afterwards.

 SUPPORT CONTROL SYSTEM

 The various functions of the powered supports are
controlled by an electro-hydraulic control system. The
simplest method utilises a control valve mounted on each
support which is used to operate the functions of that
support (lowering and raising legs, support advancement
and conveyor push). This method is termed “unit control”
and has a major disadvantage in that the operator is located
in the powered support whilst it is moving. For this reason
this method has been superseeded by more sophisticated
systems.
 The “adjacent control” method, as the name suggests,
allows the operator to control the powered supports from
the adjacent unit by using a similar type of control valve.
This allows the operator to remain within a support which
is set to the roof. This system can be extended so that not
only does the adjacent support lower, advance and set to
the roof, but once this is completed a signal is transmitted
to the next support so that it too can be operated with the
operator at the one location. This can be continued for any
number of supports but is restricted to a comfortable seeing
distance of around 8 to 10 supports. On completion of the
advance cycle of this group of supports the operator will
walk through to the start of the next group and continue
advancement. The type of system is termed “batch
control” or “bank control”.
 It is also possible to remove the operator from the face
completely and allow them to control the supports from a
console at the face end. However, in most cases the
operation is still carried out on the face because of mining
considerations and the requirement to operate supports in
conjunction with other face equipment.
This type of shield has two sets of legs inclined forward into the
canopy and the other two inclined backwards and connected to
the goaf shield.
The main features of the 4 leg shield are:
 The front legs connect the base and the canopy and the rear
legs connect the base and the top shield member
 The top canopy is hinged to the main rear canopy to
allow the canopy to articulate along the line of the face
 The base is connected to the rear shield with a lemniscate
linkage
The two legs of the support are connected into the canopy at an
inclined angle and the supports are usually operated in
Immediate Forward Support (IFS) mode.
The main features of the 2 leg shield are:
 The support density is not uniform throughout the working
range
 The lemniscate linkage ensures that the front of the top
canopy maintains a constant distance from the coal,
between the fully closed state and fully open position
 Full use of the reverse mounted ram
 Side ram shields ensures good flushing protection
EQUIPMENT
Chocks (also known as "Powered Supports", "Supports" or
"Shields")

Roof support in early longwalls (in the days of hand mining) was
by timber props and bars, withdrawn from the goaf side as the
faces advanced and re-used if still intact. Eventually these were
replaced by steel bars supported by yielding props (eg friction
props where resistance to yield was provided by a wedge system
or hydraulic props which were individual props filled with fluid
which could be pumped with an internal hand pump and released
using a valve).

In time the hydraulic props (now referred to as legs) were

combined in pairs, mounted on a base and joined with a roof
canopy, with adjacent pairs being connected by a frame
containing a horizontal hydraulic cylinder. This enabled
each "chock", as the 4 leg sets were called, to advance itself
with one pair of legs, released from the roof, pushing against the
2nd pair which remained set. Such chocks were set along the
length of the face forming a continuous line of "self-advancing
supports", sometimes also referred to as "goal post supports
or chocks".

Further development saw the legs being mounted closer together

on a single solid base with a solid, cantilevered roof canopy
allowing the front line of legs to be a little further from the face
while still providing adequate support close to the freshly exposed
roof. The horizontal cylinder in these chocks attached the chock
base to the face coal haulage system (an AFC – see later notes).
The cylinders were used to push the AFC forward and then drag
the chocks forward one at a time as the face advanced. The
chocks were interconnected with hydraulic hoses and connected
back to a pumping arrangement in the gate road by a hydraulic
fluid reticulation system. The hydraulic fluid used was (and still
is) mostly water with a low concentration of soluble oil, partly to
assist in lubrication but mostly to inhibit corrosion. At times 6 leg
chocks were used with 4 close together at the rear and 2 close to
the AFC, leaving a travelling way between them.

Over time the rear of the chocks was partially closed-in with
flexible arrangements of steel plates, chains and timber to try and
prevent broken material from flushing through from the goaf into
the face area.

Similar support systems were developed where the 4 vertical legs

were replaced by 2 larger legs set at the rear of the base and
angled towards the face. These had a somewhat larger canopy
with a rear section connected to the base with a "lemniscate"
linkage which enabled the base and canopy connection to be fully
covered, while the main canopy remained essentially parallel to
the base at whatever set height was used. These supports were
called "shields" instead of chocks.
Again, over a period, further developments combined the best
aspects of chocks and shields into what were referred to
as "chock-shields" but are now often referred to using either
term by itself, but the terms "supports" is probably the most
common term now used (and the term used in this document).

Most modern supports are two leg types, though four leg shields
and chock-shields are also in use, all four legs mounted towards
the rear of the base with the front pair angled towards the face
and the rear pair towards the goaf.

The rear section of the chocks which contains most of the

operating valve systems and the legs, is partially covered by side
plates as well as being enclosed from above and behind. These
side plates have a top cover and can slide sideways, pushed by
small hydraulic cylinders, so that the chocks can stand skin-to-
skin and provide continuous cover over the full length of face.

In a further development the front tip of the roof canopy is

articulated and connected to another small cylinder allowing a
greater load to be applied to the roof at this point to improve roof
control.

For thick seams, where coal falling from the face can be a hazard
supports can be fitted with an articulated plate attached to the
support tip which can swing down and provide a horizontal
support to the exposed face. Once again this is controlled
hydraulically and obviously has to be lifted clear again before the
next web of coal is cut.

Most modern supports are fitted with "base lifters" another

hydraulic arrangement which allows the base to be lifted up, a
very useful function in soft floor conditions where support bases
may sink into the floor and limit the ready advance of the face.

Modern supports are very complex pieces of equipment, made

even more complex by the primary method of operation being via
remote control or automated, requiring electronic control and
monitoring, with manual control also being fitted. Longwall faces
are also now extensively illuminated and these functions require
hydraulic and electrical connections from support to support and
back to the maingate area, a typical face carrying many hoses
and cables. The hoses and cables between supports need to be
flexible and have sufficient length to allow for the distance any
support will be advanced ahead of adjacent supports.

Because of the high setting pressures of modern supports a two

stage setting system may be used, an initial "low pressure" set
(of the order of 320 bar) being boosted to the final set by a high
pressure supply (of the order of 420 bar) - yet another set of
hoses to be included.

Supports are designed to operate through a range of heights to

accommodate variations in working heights and possibly some
degree of unplanned loss of roof or floor. It is also necessary that
they can be closed down low enough to allow transport around
the mine in whatever height is available. Support legs are often
multi-stage legs to allow additional travel.

Support widths vary, mostly between 1.5 and 2m. Note that as a
chock is made wider the load/metre run along the face which can
be applied to the roof reduces for a given leg capacity. Also the
wider a support, the heavier it becomes and more difficult to
handle. As a support is made narrower it becomes less stable if
subjected to uneven ground. Also the narrower a support, the
more supports are required for a given face length and with each
support requiring a set of control valves and interchock hoses, so
the greater the cost. The ideal support width will be the best
compromise between the conflicting aims.

An aspect of support design beginning to receive more attention

is ergonomics. When a face is "closed-up", especially in lower
height seams, travelling along the face can be very arduous. To
increase the width of walkways involves extending the length of
the supports which has ramifications on roof loading and strata
control (as well as costs), so some degree of compromise is
required.

There is a tendency to design for "average" size personnel which,

by definition, means that half the workforce are likely to
experience some difficulty or discomfort. It may be better, within
reason, to design for the tallest and widest person likely to travel
the face. Allowance has to be made for equipment being carried
on a regular basis (cap lamps, self rescuers, etc).

The purpose of the roof supports on a longwall face is not to

prevent roof movement but to control it so that the immediate
roof remains essentially intact where the coal is cut and within
the area of the face where personnel have to work. Once the
work area has moved forward it is acceptable, indeed desirable,
that the roof collapses or "caves" (a term frequently used). The
ideal situation is that the roof caves immediately behind the
supports as they are moved forward; if the collapse is delayed
the roof strata will hang out into the goaf in a cantilever putting
extra load on the supports.

This cantilever effect was largely responsible for early failures of

longwall mining in Australia, circa 1970. Supports at that time
had been developed in Europe where roof strata was generally
weaker and laminated and caved readily. Support loading
capacities of 100 tonnes or less were adequate to control the
roof. In Australia more massive strata is common which breaks
and falls less readily and the cantilever effect leads to very high
chock capacities being required, sometimes over 1000 tonnes.

In order to prevent damage to the hydraulic legs, chocks are

designed to yield (ie release the hydraulic pressure) at a set
value, so the roof is allowed to lower in a controlled fashion.
For best roof control a high chock set pressure is required, as
close as possible to the yield pressure – it is not practical to set at
the yield pressure.

As the roof lowers, the strata above will begin to bend and then
beds will fracture under tension from the higher levels extending
down towards the immediate roof (these fractures being known
as "goaf breaks"). Ideally these fractures should reach the roof
as the rear of the supports passes that point, allowing immediate
caving.