Equipment Configuration of Opencast Mining and HEMM ManagementA.HafeezB.Sc. (Engg); MBA

HEMM Management

Catering for the machinery needs of an industrial enterprise, exercising efficient and effective control over their operating and supporting resources to ensure production is maintained at requisite level with minimum overall costs

Equipment management ensures that the right equipment is: in the right place at the right time in the right condition in the right quantity at the right cost

The efficient and effective control of equipment, of its operating and support resources ensuring users valid requirements at economic costs at all times

Various activities within the purview of Equipment ManagementFormulation of requirementProcurementTrialsLogistic support planningEngineering support planningMaterial support planningOperating aspects and policies

(cotinued)

Equipment Management activities (continued)Standardisation and rationalisationUse of computers in equipment managementIn service equipment managementDiscard and withdrawal Defects and modificationsTechnology updateDisposalConcept of quality in equipment managementTraining operators, technicians, support personnel

Production of CoalSelect technologySelect plant/eqptAcquire plant/eqptInstall/com-missionUseful lifeReplaceDiscardModify/upgradeMarket Plant/ machyManufacture m/c & plantR&D new tech- nologyAdaptabletechnology Life Cycle Approach-Coal Industry

4 M's of ManagementManMachineMaterialMoneyThe 5 th one beingthMaintenance

MaintenanceConcept, Practices and Role

DefinitionTerm describes the overall activities of a repair and maintenance organisation

Often refers to servicing of equipment to ensure continued operation at a desired levels. Includes lubrication, cleaning, adjustments, replacements

Definition (continued)

In generalised sense covers all actions to return equipment to functional state at required performance levels when it fails to do so

Definition (continued)All actions which have an objective to retain an item in, or restore it to, a stage in which it can perform the required functions. The action include the combination of all technical and corresponding administrative, managerial, and supervision actions.

Bushing Seizure / Rotation / WearCase Scoring / Scuffing / CrackSeal Leakage / Shaft Scoring / Shaft BreakageJammed / Scoring on spool / HousingSet Pressure disturbed / Orifice BlockageScoring on Piston / BarrelChoked FilterSqueezed FilterPunctured FilterExternal LeakageDamaged / Choked BreatherWear & TearWorn Out / Seized disc / platesNormal Failures those are usually reportedRequirement of Maintenance

Abrasive WearParticles between adjacent moving surfacesErosive WearParticles and high fluid velocityAdhesive WearMetal to metal contact (loss of fluid)Fatigue WearParticle damaged surfaces subjected to repeated stressCorrosive WearWater or chemicalFive Mechanisms of WearRequirement of Maintenance

Hydraulic Cylinder WearPiston Seals& BearingsConsequences of Cylinder Wear

Rod seal wear:External oil leakageBronze bushing wear:Loss of rod alignmentPiston seal wear:Loss of cylinder speedLoss of holding abilityPiston bearing wear:Loss of alignmentBronze BushingRod WiperRod SealRequirement of Maintenance

WEARSimply speaking it is :LOSS OF MATERIAL FROM THE INTERFERENCE OF TWO BODIES WHEN SUBJECTED TO RELATIVE MOTION UNDER LOAD

ABNORMAL WEAR IN INDUSTRIESABRASIVE WEAR50 %ADHESIVE WEAR15 %EROSIVE WEAR8 %FRETTING WEAR8 %CHEMICAL WEAR5 %

Cyclicality ofWear processIt is required to avoidRequirement of Maintenance

Maintenance RequiredDue toBad Haul RoadsTo Prevent Break Downs

BAD Parking PracticeBAD LoadingMaintenance RequiredTo Prevent Break DownsDue to Unmatched Eqpt & Wrong Parking

MaintenanceWhen to do it ?How to do it ?Where to do it ?Why to do it ?

Only in the Safe Environment of Workshop ?NOMaintenance -Where to do it ?

Maintenance can be classified as under

PREVENTIVE MTS. CAN BE FURTHER CLASSIFIED AS UNDER

PREVENTIVE MAINTENANCE It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing Preventive Mts.

PERIODIC MAINTENANCE (TIME BASED MTS. TBM) Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

PREDICTIVE MAINTENANCE This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to Periodic Mts. Predictive Mts. Is condition based mts. It manages trend values, by measuring and analyzing data about deterioration employs a surveillance system, designed to monitor conditions through an on-line system.

CORRECTIVE MAINTENANCE It improves equipment and its components so that Preventive Maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability.

PREVENTIVE MAINTENANCEPERIODICAL MAINTENANCEDAILY MAINTENANCEBREAK DOWN MAITENANCE

DAILY MAINTENANCEENGINE Check For Engine Oil LevelWater Level In Radiator Draining Of Water From Water Separator Of Fuel Filter HousingV BeltsEngine Oil Leakages

DAILY MAINTENANCETRANSMISSIONCheck ForOil Level In TransmissionOil Leakages Hose Assays.

DAILY MAINTENANCEHYDRAULIC SYSTEMCheck ForOil Level In Hydraulic Oil TankOil Leakages From Hoses Of Hyd. SystemAny Leakages From Hyd. Pump, Steering Gearbox, Steering Cylinder, Hoist Cylinder and Control Valve

DAILY MAINTENANCEGeneralCheck ForAuto Electrical SystemAir Cleaner ElementAir Inflation Of TiresGreasing SystemAir System and Draining Of Water From Air-tankLooseness Of Nuts and Bolts

PERIODICAL MAINTENANCE250/300 HrsENGINEChange of Engine Lubricating OilChange of Engine Lubricating Oil Filter Element ( full flow)Change of Engine By-Pass Oil Filter ElementChange of Diesel Oil ( fuel ) Filter ElementChange of Corrosion Resistance ElementCleaning of Breather Element of Engine

PERIODICAL MAINTENANCETRANSMISSIONCleaning of Breather Element of TransmissionDIFFERENTIALCleaning of Breather Element of DifferentialCheck the Lubricating Oil Level

PERIODICAL MAINTENANCEFINALDRIVECleaning of Breather Element of Final DriveCheck the Lubricating Oil LevelGENERALa) Greasing of all greasing point

PERIODICAL MAINTENANCE500/600 Hrs MtsENGINERepeat of 250/300 Hrs MtsTRANSMISSIONCleaning of Breather Element of TransmissionChange of Transmission Oil Filter Element

PERIODICAL MAINTENANCEDIFFERENTIALCleaning of Breather Element of DifferentialCheck the Lubricating Oil LevelFINALDRIVEa) Cleaning of Breather Element of Final driveb) Check the Lubricating Oil Level

PERIODICAL MAINTENANCE

GENERALa) Greasing of all greasing point

PERIODICAL MAINTENANCE 750/900 Hrs. Mts. Repetation of 250/300 Hrs Mts.

PERIODICAL MAINTENANCE1000/1200 Hrs. Mts.ENGINEChange of Engine Lubricating OilChange of Engine Lubricating Oil Filter Element ( full flow)Change of Engine By-Pass Oil Filter ElementChange of Diesel Oil ( fuel ) Filter ElementChange of Corrosion Resistance ElementCleaning of Breather Element of Engine

PERIODICAL MAINTENANCETRANSMISSIONChange of Transmission OilChange of Transmission Oil Filter ElementCleaning of Breather Element of TransmissionDIFFERENTIALChange of Lubricating OilCleaning of Breather Element of Differential

PERIODICAL MAINTENANCEFINAL DRIVEChange of Lubricating OilCleaning of Breather Element of Final driveCheck for proper Torque of Final drive AxleHydraulic SystemChange of Lubricating OilCleaning of Breather Element of Hydraulic TankCleaning of Suction-screen ElementChange of Return line Filter Element

WHAT DO WE MAINTAIN

HEMM

Heavy Earthmoving Machinery

Technology options in coal mining

The most economical method of coal extraction from coal seams depends on the depth and quality of the seams, and also the geology and environmental factors of the area being mined. Coal mining processes are generally differentiated by whether they operate on the surface or underground. Two types of mining operation for coal production :Opencast MiningUnderground Mining

Opencast MiningOpencast mining , also known as Open pit mining and Open cut mining and Strip mining, refers to a method of extracting rock or minerals from the earth by their removal from an open pit or borrow.The term is used to differentiate this form of mining from extractive methods that require tunneling into the earth.

MININGOPENCAST

A typical cross sectional view of Jayant opencast Mine in Northen Coalfields limited60 M50 -55 MTURRA SEAM : 20 MP.B. SEAM : 10-12 M

A view of Nigahi Mines, NCL

A 24/96 Dragline in operation

Opencast MiningOpen cast coal mining recovers a greater proportion of the coal deposit than underground methods, as more of the coal seams in the strata may be exploited.In the United States, UK, and South Africa, a coal mine and its accompanying structures are collectively known as a COLLIERY.In Australia colliery usually only refers to an underground coal mine.

Opencast MiningIn India usually underground mines are referred to as a COLLIERY and open cast mines are normally known as a mine.Globally, about 40% of coal production involves surface mining.

Shovel and dumper systemThis system was introduced by erstwhile NCDC in their mines for mechanized coal production using up to 4.6 Cu.m shovel with 25/35 tonner dumpers. Electric rope shovels of the size of 10 Cu.m and above have been introduced in the opencast mines of CIL around 1985.Introduction of shovels of the size of 20 Cu.m and above are from 1988.

Shovel and dumper systemHydraulic shovels were introduced in the mines of CIL during 1980s, majority of them are in the size range of 2.7 4.2 Cu.m. Some higher size hydraulic shovels upto 11.8 Cu.m bucket capacity are also working presently. Hydraulic shovels of 16 Cu.m are being considered for induction. In future still higher size of hydraulic shovels up to 25 Cu.m bucket capacity are likely to be inducted.

Shovel and dumper systemRear dumpers of 85 tonne capacity were introduced around 1981. 120T and 170T rear dumpers have been introduced mostly in 1990s. Rear dumpers of 240 T capacity are already proposed to be introduced in some of the opencast mining projects of CIL.

Dragline for OB removalDragline application in opencast mining is in vogue from the pre nationalization period (before 72-73). OC mines have been planned with draglines wherever found applicable during the post nationalization era (after 72-73), as well.Dragline application eliminates the need for transport equipment and thus, reduces the cost of OB removal requirement compared to shovel dumper system of mining.

Surface MinersSurface Miner has found application in mining industry for rock cuttings having low compressive strength of around 50 Mpa. In this equipment, drilling & blasting operation is not required for extraction. It also cuts the rock to a size under 200mm, thereby eliminating the requirement of primary crushing.

Surface MinersSurface Miner generally cuts the strata layer by layer and depth of the cut varies from 0.20 m to around 0.60 m. This special feature of the machine makes it useful even for mining of thin coal seams having thin bands, in appropriate mining conditions conducive to the deployment of surface miners. Presently it is being used in many mines of SECL,MCL and CCL.

Use of HEMM O/C mines of CILCoal Production :Coal India Limited achieved a production level of 403.73 million tonnes in 2008-09 which is higher by 24.29 mllion tonnes (growth of 6.4%) over the previous year. Increase in production is through Open cast mining and 359.77 MT were produced by open cast mining during the year.

Use of HEMM O/C mines of CILOB Removal :In open cast mining OB removal is an important performance criterion as through this activity coal is exposed. Growth in OB removal is necessary to ensure growth in coal production in the subsequent period. During the 10th plan i.e. 2002-03 to 2006-07, the growth in OB removal has been from 501.17 Mcum (2002-03) to 537.65 Mcum (2006-07) i.e. 1.4% per annum.

Use of HEMM O/C mines of CILCompared to this the OB removal achieved in 2008-09 is 646.30 Mcum i.e. a growth of 108.65 Mcum (20.20%).

Number of open cast mines as on 01.04.2009

Large open cast mines of CIL

Population of HEMM (01.09.09)

DraglinesDraglinesShovelsShovelsDumpersDumpersDozersDrillsDrillsEquipment and Technology

BEML BH 85-1 Rear Dumper

Rear Dumper BEML BH100

LIEBHERR Rear Dump Truck T-282B (cap 444T Electr Drive)

TEREX/ UNIT RIG Rear Dump Truck (AC Drive)

CATERPILLAR Rear Dump Truck 793D (cap 240T Mech Drive)

Bulldozer BEML BD 355

Front End Payloader BEML 656

Motor Grader BEML BG605A

LeTourneau L-950 Pay Loader (bucket cap 13.8 cuM)

Blast Hole Drill: DMH/DML SP 250 mm

Rotary Blast Hole DrillsSee Video

SUPERIOR Highwall Miner in operation

A dragline in operation at Nigahi Project, NCL

Inpit-Crusher

Surface Miner - MCL

Most common size equipment (01.09.09)EquipmentModelApp. Price (in Cr)

Dragline24 Cum (17)20315-20 Cum (9)17010 Cum (11)1564-6 Cum100

Most common size equipment (01.09.09)EquipmentModelApp. Price (in Cr)

R/Shovel42 Cum (3*)8620 Cum (9)6512.5 Cum (9)2810 Cum (113)17-258 Cum (2)175 Cum (197)7.5

Most common size equipment (01.09.09)

EquipmentModelApp. Price (in Cr)

Dumper85/100 T (660)2.63 to 350 T (675)0.85190 T (17)12240 T (24)12

Most common size equipment (01.09.09)

EquipmentModelApp. Price (in Cr)

Dozer400-410 HP (379)2.5300-320 HP (534)1.6

Most common size equipment (01.09.09)

EquipmentModelApp. Price (in Cr)

Drill311 mm (16)12250 mm (247)2.25160 mm (370)0.85 to 0.90

Largest size equipment proposed to be inducted

ER Shovel-42 CumDumper-240 TDozer-850 hpDrill-381 mmWater sprinkler-70 kl

Largest size equipment proposed to be inducted

In future, ER shovels of 55-60 Cum bucket capacity along with 400 T Rear Dumpers and Hydraulic Excavators up to 34 Cum with 320 T Rear Dumpers may also be considered if geo mining and economics of the project permit.

Dragline Mines in CIL (2006-07)

Dragline Mines in CIL (2006-07)

OC mines of CIL having higher capacity Rear Dumper & ER Shovel (06-07)

OC mines of CIL having higher capacity Rear Dumper & ER Shovel (06-07)

Performance of HEMMPerformance of HEMM is measured in terms of % Availability & % Utilization during the year

Worked Hours + Idle Hours % Availability = ------------------------------ X 100 Total Shift Hours

Performance of HEMM

Worked Hours% Utilization= --------------------------- X 100Total Shift Hours

Norms for Availability & Utilization of HEMM

Availability & Utilization of HEMM of OC mines of CIL during 2002-03 to 2007-08

Availability & Utilization achieved during 2002-03 to 2006-07

Draglines :% Availability-91% to 93% of Norms% Utilization-93% to 96% of norms

ER Shovels :% Availability-83% to 86% of Norms% Utilization-64% to 67% of norms

Availability & utilization achieved during 2002-03 to 2006-07

Hydraulic Excavators :% Availability-80% to 84% of Norms% Utilization-52% to 61% of norms

Rear Dumpers:% Availability-83% to 91% of Norms% Utilization-56% to 58% of norms

Availability & utilization achieved during 2002-03 to 2006-07Dozer:% Availability-77% to 84% of Norms% Utilization-47% to 49% of norms

Drill:% Availability-85% to 91% of Norms% Utilization-48% to 50% of norms

HEMM used in open cast mines are highly capital intensive. This necessitates maximizing the machine Availability and Utilization by minimizing the down time and idle time.

Norms of Life Expectancy of HEMM for Survey - Off

Norms of Life Expectancy of HEMM for Survey - Off

Norms of Life Expectancy of HEMM for Survey - Off

Mine Capacity & Capacity UtilizationMine Capacity :The capacity of an open cast mine is the summation of material handling (coal & OB) capacities, expressed in million cubic meter, of each existing mining system (viz. D/L, shovel dumper system) in the mine, based on sanctioned Project Report(s).

For shovel dumper system, both excavation and transportation capacities are calculated and the critical of these two is considered for capacity.

Mine Capacity & Capacity UtilizationActual Excavation :Coal production in MT / Sp. Gr. + OB removal in Mcum + OB rehandling (loose) in Mcum / 1.3

Note :Production from departmental excavation system is only considered.OB Rehandling done is added to the actual excavation, only when it is so provided in the project reports workload.

Capacity Utilization :

Actual excavation during the year (Mcum)= ------------------------------------------------------- x 100Mine capacity during the year (Mcum)

Mine capacity, Actual Excavation & Capacity Utilization of OC mines of CIL during 2002-03 to 2006-07

There is no addition of new mines or capacity enhancement of existing mines with departmental equipment in recent years. In fact open cast mines has reduced from 163 during 2002-03 to 157 during 2006-07. Departmental mine capacity has hovered around 627 Mcum during 2002-03 to 643 Mcum during 2006-07.

Thank YouMaintenance is a scienceWhen Practiced, it's an Art

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