230463911-Equipment-Configuration-of-Opencast-Mining-and-HEMM-Management.ppt
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230463911-Equipment-Configuration-of-Opencast-Mining-and-HEMM-Management.ppt
230463911-Equipment-Configuration-of-Opencast-Mining-and-HEMM-Management.ppt
- 1. Equipment Configuration of Opencast Mining and HEMM Management A.Hafeez B.Sc. (Engg); MBA
- 3. 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
- 4. 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
- 5. The efficient and effective control of equipment, of its operating and support resources ensuring users valid requirements at economic costs at all times
- 6. Various activities within the purview of Equipment Management Formulation of requirement Procurement Trials Logistic support planning Engineering support planning Material support planning Operating aspects and policies (cotinued)
- 7. Equipment Management activities (continued) Standardisation and rationalisation Use of computers in equipment management In service equipment management Discard and withdrawal Defects and modifications Technology update Disposal Concept of quality in equipment management Training – operators, technicians, support personnel
- 8. Production of Coal Select technology Select plant/eqpt Acquire plant/eqpt Install/com- mission Useful life Replace Discard Modify/ upgrade Market Plant/ machy Manufact ure m/c & plant R&D new tech- nology Adaptable technology Life Cycle Approach-Coal Industry
- 9. 4 M's of Management Man Machine Material Money The 5 th one being th Maintenance
- 10. Maintenance Concept, Practices and Role
- 11. Definition Term 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
- 12. Definition (continued) In generalised sense covers all actions to return equipment to functional state at required performance levels when it fails to do so
- 13. 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.
- 14. Bushing Seizure / Rotation / Wear Case Scoring / Scuffing / Crack Seal Leakage / Shaft Scoring / Shaft Breakage Jammed / Scoring on spool / Housing Set Pressure disturbed / Orifice Blockage Scoring on Piston / Barrel Choked Filter Squeezed Filter Punctured Filter External Leakage Damaged / Choked Breather Wear & Tear Worn Out / Seized disc / plates Normal Failures those are usually reported
- 15. 1.Abrasive Wear Particles between adjacent moving surfaces 1.Erosive Wear Particles and high fluid velocity 1.Adhesive Wear Metal to metal contact (loss of fluid) 1.Fatigue Wear Particle damaged surfaces subjected to repeated stress 1.Corrosive Wear Water or chemical Five Mechanisms of Wear
- 23. Hydraulic Cylinder Wear Piston Seals & Bearings Consequences of Cylinder Wear Rod seal wear: External oil leakage Bronze bushing wear: Loss of rod alignment Piston seal wear: Loss of cylinder speed Bronze Bushing Rod Wiper Rod Seal
- 24. WEAR Simply speaking it is : “LOSS OF MATERIAL FROM THE INTERFERENCE OF TWO BODIES WHEN SUBJECTED TO RELATIVE MOTION UNDER LOAD”
- 25. ABNORMAL WEAR IN INDUSTRIES l ABRASIVE WEAR 50 % l ADHESIVE WEAR 15 % l EROSIVE WEAR 8 % l FRETTING WEAR 8 % l CHEMICAL WEAR 5 %
- 28. Cyclicality of Wear process It is required to avoid Requirement of Maintenance
- 29. Maintenance Required Due to Bad Haul Roa To Prevent Break Downs
- 30. BAD Parking Practice BAD Loading Maintenance Required To Prevent Break Downs Due to
- 31. Maintenance When to do it ? How to do it ? Where to do it ? Why to do it ?
- 32. Only in the Safe Environmen t of Workshop ? NO Maintenance -Where to do it ?
- 35. Maintenance can be classified as under
- 36. PREVENTIVE MTS. CAN BE FURTHER CLASSIFIED AS UNDER
- 37. 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.
- 38. 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.
- 39. 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.
- 40. 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.
- 41. PREVENTIVE MAINTENANCE PERIODICAL MAINTENANCE DAILY MAINTENANCE BREAK DOWN MAITENANCE
- 42. DAILY MAINTENANCE ENGINE Check For Engine Oil Level Water Level In Radiator Draining Of Water From Water Separator Of Fuel Filter Housing V – Belts Engine Oil Leakages
- 43. DAILY MAINTENANCE TRANSMISSION Check For Oil Level In Transmission Oil Leakages Hose Assays.
- 44. DAILY MAINTENANCE HYDRAULIC SYSTEM Check For Oil Level In Hydraulic Oil Tank Oil Leakages From Hoses Of Hyd. System Any Leakages From Hyd. Pump, Steering Gearbox, Steering Cylinder, Hoist Cylinder and Control Valve
- 45. DAILY MAINTENANCE General Check For Auto Electrical System Air Cleaner Element Air Inflation Of Tires Greasing System Air System and Draining Of Water From Air-tank Looseness Of Nuts and Bolts
- 46. PERIODICAL MAINTENANCE 250/300 Hrs ENGINE a)Change of Engine Lubricating Oil b)Change of Engine Lubricating Oil Filter Element ( full flow) c)Change of Engine By-Pass Oil Filter Element d)Change of Diesel Oil ( fuel ) Filter Element e)Change of Corrosion Resistance Element f)Cleaning of Breather Element of Engine
- 47. PERIODICAL MAINTENANCE TRANSMISSION a)Cleaning of Breather Element of Transmission DIFFERENTIAL a)Cleaning of Breather Element of Differential b)Check the Lubricating Oil Level
- 48. PERIODICAL MAINTENANCE FINALDRIVE a)Cleaning of Breather Element of Final Drive b)Check the Lubricating Oil Level GENERAL a) Greasing of all greasing point
- 49. PERIODICAL MAINTENANCE 1.500/600 Hrs Mts ENGINE Repeat of 250/300 Hrs Mts TRANSMISSION a)Cleaning of Breather Element of Transmission b)Change of Transmission Oil Filter Element
- 50. PERIODICAL MAINTENANCE DIFFERENTIAL a)Cleaning of Breather Element of Differential b)Check the Lubricating Oil Level FINALDRIVE a) Cleaning of Breather Element of Final drive b) Check the Lubricating Oil Level
- 51. PERIODICAL MAINTENANCE GENERAL a) Greasing of all greasing point
- 52. PERIODICAL MAINTENANCE 750/900 Hrs. Mts. Repetation of 250/300 Hrs Mts.
- 53. PERIODICAL MAINTENANCE 1000/1200 Hrs. Mts. ENGINE a)Change of Engine Lubricating Oil b)Change of Engine Lubricating Oil Filter Element ( full flow) c)Change of Engine By-Pass Oil Filter Element d)Change of Diesel Oil ( fuel ) Filter Element e)Change of Corrosion Resistance Element f)Cleaning of Breather Element of Engine
- 54. PERIODICAL MAINTENANCE TRANSMISSION a)Change of Transmission Oil b)Change of Transmission Oil Filter Element c)Cleaning of Breather Element of Transmission DIFFERENTIAL a)Change of Lubricating Oil b)Cleaning of Breather Element of Differential
- 55. PERIODICAL MAINTENANCE FINAL DRIVE a)Change of Lubricating Oil b)Cleaning of Breather Element of Final drive c)Check for proper Torque of Final drive Axle Hydraulic System a)Change of Lubricating Oil b)Cleaning of Breather Element of Hydraulic Tank c)Cleaning of Suction-screen Element d)Change of Return line Filter Element
- 56. WHAT DO WE MAINTAIN
- 58. 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 Mining – Underground Mining
- 59. Opencast Mining Opencast 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.
- 60. MINING OPENCAST
- 61. A typical cross sectional view of Jayant opencast Mine in Northen Coalfields limited 60 M 50 -55 M TURRA SEAM : 20 M P.B. SEAM : 10-12 M
- 62. A view of Nigahi Mines, NCL
- 63. A 10 Cum shovel loading Coal in 85 T dumper 2000 T OF COAL LOADED IN 45 MIN (Approx.) IN MOTION RAPID LOADING SYSTEM (SILO) A 10 Cum shovel loading Overburden in 120 T dumper A 24/96 Dragline in operation
- 64. Opencast Mining • Open 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.
- 65. Opencast Mining In 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.
- 67. Shovel and dumper system • This 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.
- 68. Shovel and dumper system Hydraulic 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.
- 69. Shovel and dumper system Rear 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.
- 70. Dragline for OB removal • Dragline 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.
- 71. Surface Miners Surface 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.
- 72. Surface Miners Surface 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.
- 73. Use of HEMM O/C mines of CIL Coal 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.
- 74. Use of HEMM O/C mines of CIL • OB 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.
- 75. Use of HEMM O/C mines of CIL Compared to this the OB removal achieved in 2008-09 is 646.30 Mcum i.e. a growth of 108.65 Mcum (20.20%).
- 76. Number of open cast mines as on 01.04.2009
- 77. Large open cast mines of CIL
- 80. BEML BH 85-1 Rear Dumper
- 81. Rear Dumper BEML BH100
- 82. LIEBHERR Rear Dump Truck T-282B (cap 444T Electr Drive)
- 83. TEREX/ UNIT RIG Rear Dump Truck (AC Drive)
- 84. CATERPILLAR Rear Dump Truck 793D (cap 240T Mech Drive)
- 85. Bulldozer BEML BD 355
- 86. Front End Payloader BEML 656
- 87. Motor Grader – BEML BG605A
- 88. LeTourneau L-950 Pay Loader (bucket cap 13.8 cuM)
- 89. Blast Hole Drill: DMH/DML SP 250 mm
- 90. Rotary Blast Hole Drills See Video
- 91. SUPERIOR Highwall Miner in operation
- 92. A dragline in operation at Nigahi Project, NCL
- 93. Inpit-Crusher
- 94. Surface Miner - MCL
- 95. Most common size equipment (01.09.09) Equipment Model App. Price (in Cr) Dragline 24 Cum (17) 203 15-20 Cum (9) 170 10 Cum (11) 156 4-6 Cum 100
- 96. Most common size equipment (01.09.09) Equipment Model App. Price (in Cr) R/Shovel 42 Cum (3*) 86 20 Cum (9) 65 12.5 Cum (9) 28 10 Cum (113) 17-25 8 Cum (2) 17 5 Cum (197) 7.5
- 97. Most common size equipment (01.09.09) Equipment Model App. Price (in Cr) Dumper 85/100 T (660) 2.63 to 3 50 T (675) 0.85 190 T (17) 12 240 T (24) 12
- 98. Most common size equipment (01.09.09) Equipment Model App. Price (in Cr) Dozer 400-410 HP (379)2.5 300-320 HP (534)1.6
- 99. Most common size equipment (01.09.09) Equipment Model App. Price (in Cr) Drill 311 mm (16) 12 250 mm (247) 2.25 160 mm (370) 0.85 to 0.90
- 100. Largest size equipment proposed to be inducted ER Shovel - 42 Cum Dumper - 240 T Dozer - 850 hp Drill - 381 mm Water sprinkler - 70 kl
- 101. 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.
- 102. Dragline Mines in CIL (2006- 07)
- 103. Dragline Mines in CIL (2006- 07)
- 104. OC mines of CIL having higher capacity Rear Dumper & ER Shovel (06-07)
- 105. OC mines of CIL having higher capacity Rear Dumper & ER Shovel (06-07)
- 106. Performance of HEMM • Performance of HEMM is measured in terms of % Availability & % Utilization during the year Worked Hours + Idle Hours % Availability = ------------------------------ X 100 Total Shift Hours
- 107. Performance of HEMM Worked Hours % Utilization = --------------------------- X 100 Total Shift Hours
- 108. Norms for Availability & Utilization of HEMM
- 109. Availability & Utilization of HEMM of OC mines of CIL during 2002-03 to 2007-08
- 110. 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
- 111. 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
- 112. Availability & utilization achieved during 2002-03 to 2006-07 Dozer: % 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
- 113. 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.
- 114. Norms of Life Expectancy of HEMM for Survey - Off
- 115. Norms of Life Expectancy of HEMM for Survey - Off
- 116. Norms of Life Expectancy of HEMM for Survey - Off
- 117. Mine Capacity & Capacity Utilization • Mine 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.
- 118. Mine Capacity & Capacity Utilization • Actual Excavation : – Coal production in MT / Sp. Gr. + OB removal in Mcum + OB rehandling (loose) in Mcum / 1.3 Note : i)Production from departmental excavation system is only considered. ii)OB Rehandling done is added to the actual excavation, only when it is so provided in the project report’s workload.
- 119. Capacity Utilization : Actual excavation during the year (Mcum) = ------------------------------------------------------- x 100 Mine capacity during the year (Mcum)
- 120. Mine capacity, Actual Excavation & Capacity Utilization of OC mines of CIL during 2002-03 to 2006-07
- 121. 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.
- 122. Thank You Maintenance is a science When Practiced, it's an Art