PRESENTATION ON SUMMER TRANING(JUNE 1, 2013 TO JULY 15, 2013)

SOUTH EASTERN COAL FIELD LIMITEDGEVRA PROJECT, GEVRA

LOVELY PROFESSIONAL UNIVERSITYPHAGWARA, PUNJAB

AKHILESH KUMAR (11013343)DEPT. OF MECHANICAL ENGINEERING

ABOUT COAL INDIA LIMITED (CIL)

• ESTABLISHED IN NOVEMBER 1975, GOVERNMENT TAKING OVER PRIVATE COAL MINES.• MANAGES 200 ESTABLISHMENT LIKE WORKSHOPS AND HOSPITALS, 26 TECHNICAL & MANAGEMENT

TRANING INSTITUTE, 102 VOCATIONAL TRANING CENTERS.• PRODUCES 81.1% OF INDIA’S COAL PRODUCTION.• COMMANDS NEARLY 74% OF THE INDIAN COAL MARKET.• 76% OF TOTAL THERMAL POWER GENERATION CAPACITY.

MISSION OF COAL INDIA :- TO PRODUCE PLANNED QUALITY OF COAL EFFICIENTLY & ECONOMICALLY IN AN ECO-FRIENDLY MANNER WITH DUE REGARD TO SAFTEY, CONSERVATION & QUALITY.

SECL, GEVRA PROJECT• LARGEST OPEN CAST MINE IN INDIA & ASIA, AS WELL AS WORLD’S SECOND LARGEST.• WAS OPENED IN 1981• IN 2011 IT PRODUCED 35 MILLION TONNES OF COAL AND REMOVED 23264000 CU. M. OF OVERBURDEN.

PLAYS A KEY ROLE IN “INDIA’S GROWTH STORY”

PROJECT UNDERTAKEN:- BASIC STUDIES OF HEMM (HEAVY EARTH MOVING MACHINES) DEPLOYED IN A COAL MINES.

THERE WERE FOUR DEPARTMENT. NAMELY,

EXCAVATION WORKSHOP SHOVEL SECTION

DRILLING SECTION DOZER SECTION

EXCAVATION WORKSHOP

THIS WAS FURTHER SUB-DIVIDED INTO THREE SECTIONS

DUMPER SECTION TYRE SECTION

GRADER AND CRANE SECTION

DUMPER SETION

THERE WERE 5 TYPES OF DUMPER

MK30B- 120Te ELECTRICAL DUMPER (9 NOS.)BH100- 100Te DUMPER (24 NOS.)KOMATSU 785-7- 100Te DUMPER (19 NOS.)CAT 777D- 100Te DUMPER (9 NOS.)CAT-793D- 240Te DUMPER (16 NOS.)

MK30B- 120Te ELECTRICAL DUMPER

• THESE WERE OF TEREX COMPANY WITH DETROIT ENGINE PRODUCING 2500 hp POWER.

POWER FLOW DIGRAM

BH100- 100Te DUMPER• CAPACITY OF 100 TONNE WITH

CUMMINS ENGINE PRODUCING 733 hp.• IC DIESEL, 4 STROKE, TURBOCHARGED

COOLED, DIRECT INJECTION, WATER COOLED ENGINE.

• THEY ARE AIR START ENGINE & NEED 135 psi OF PRESSURE.

• THERE ARE AUTOMOTIC LUBRICATION SYSTEM.

• THREE TYPES OF BRAKE1. SERVICE BRAKE2. PARKING BRAKE3. RETARDER BRAKE

KOMATSU 785-7- 100Te DUMPER

CAT 777D- 100Te DUMPER

CAT-793D- 240Te DUMPER

• LOAD CARRYING CAPACITY OF ABOUT 240 Te. AND TOTAL LOAD OF 368 Te.

• HAS 16 CYLINDER CATERPILLAR ENGINE PRODUCING 2500 hp.

• TOTAL LOAD IS ABOUT 368 Te.• FUEL CONSUPTION ABOUT 80-90

liters/hr. WITH FUEL TANK CAPACITY OF 5000 liters.

• IT HAS ABOUT 40 SENSING POINTS AND CONTAINS 5 ECM’S AT ENGINE, BRAKE, HYDRAULIC SYSTEM, CHASIS AND TRANSMISSION.

• BRAKES ARE EITHER HYDRAULIC OR NUMETIC.

TYRE SECTION

• THESE BEARS ALL THE LOAD OF DUMPER.• 34% LOAD TO FRONT AND REST 66% TO

THE REAR TYRES.• THER ARE OF TWO TYPES 1. RADIAL TYRES 2. CROSS-PLY TYRES• AIR FILLED INSIDE SHOULD BE MOISTURE

FREE AND RIM SHOULD BE CLEAN AND PAINTED.

• NITROGEN IS FILLED INSIDE THE TYRE AS IT IS COOLING GAS AND INCREASES THE LIFE OF THE TYRE.

• TEMPERATURE INCREASES UPTO 60 °C IN WORKING CONDITION.

• LIFE OF TYRE IS CALCULATED IN TERMS OF TKPH.

CRANES AND GRADER SECTION

CRANES

• THEY ARE USED TO LIFT HEAVY PARTS OF THE OTHER HEMM, EVEN DUMPERS.

• THERE WERE 9 CRANES IN THE PROJECT WHICH HAD LOAD LIFITING CAPACITY OF 150, 70, 55, 40, 8 Te.

• THEY WERE OF BEML, MANITOWOC, HYDRA COMPANY.

• THESE WERE HYDRAULIC CRANE, TRUCK MOUNTED WITH CUMMINS ENGINE PRODUCING 232 hp @ 2500 RPM.

• IT IS 4 CYCLE, TURBOCHARGED & AFTERCOOLED.

• THEY HAD BOOM LENGTH OF ABOUT 34-38 ft.

GRADER

• COMMONLY REFFERED AS CONSTRUCTION MACHINE WITH LONG BLADE USED TO CREATE A FLAT SURFACE.

• THEY WERE OF CATERPILLAR, BEML AND KOMATSU COMPANY.

• MACHINE WAS TOTALLY HYDRAULIC WITH DIFFERENT CYLINDERS PERFORMING DIFFERENT FUNCTIONS.

• HAD KOMATSU, 6 CYLINDER ENGINE PRODUCING 280 hp.

SHOVEL SECTION

SHOVEL FUNCTIONS

GENERALLY THERE ARE 4 FUNCTION OF A SHOVEL MACHINE.THEY ARE• CROWD :- IT IS TO & FRO MOTION OF BUCKET.PERFORMED USING RACK & PINION

MECHANISMS.• HOIST :- IT IS UP & DOWN MOVEMENT OF BUCKET.IT IS PERFORMED USING

MAGNETORQUE ASSEMBLY.• PROPEL :- IT IS FORWARD & BACKWARD MOVEMENT OF WHOLE MACHINE.IT IS

PERFORMED USING PROPEL MOTOR.• SWING :- HERE THE MACHINE SWINGS 360° ON ITS AXIS.

POWER FLOW DIGRAM

DRILL SECTION

DRILLING MACHINE

• THESE ARE USED FOR DRILLING AND THEN BLASTING THE SURFACE.

• TOTAL THERE WERE 15 DRILING MACHINE OF PIT VIPER, IDM, RECP-750, ROTA COAL COMPANY.

• THESE ARE EITHER ELECTRONICALLY OPERATED OR ENGINE MOUNTED.

• ANGLE DRILLING CAN ALSO BE DONE.• THESE CAN DRILL UPTO 381 mm

DIAMETER AND 40 m DEPTH IN 11 min.• LARGE AIR COMPRESSURE ARE

INSTALLED TO GENERATE LARGE AIR PRESSURE TO DRILL THE SOIL BED.

POWER FLOW IN A DRILLING MACHINE

DOZER SECTION

BULL DOZER MACHINE

• THEY ARE HEMM & PLAYS A KEY ROLE IN COAL PRODUCTION IN A COAL MINE.

• IT IS A CRAWLER, EQUIPPED WITH A METAL PLATE USED TO PUSH LARGE QUANTITY OF SOIL, SAND AND OTHER MATERIAL.

• THERE WERE 13 DOZER MACHINE.• THEY MOUNTED WITH CUMMINS

ENGINE WHICH PRODUCES 860 hp OF POWER.

• THEY ARE USED TO MAKE ROADS IN A COAL MINES FOR TRANSPORTATION OF DUMPER, CRANES, DRILLING MACHINES AND OTHER VECHILES.

ANNUAL PRODUCTION OF SECL, GEVRAYEAR 2012-2013

FURTHER DEVELOPMENTS IN THE PROJECT

FOR THE YEAR 2013-2014 THE ANNUAL PRODUCTION OF COAL WAS TRAGETED TO BE 48 MILLION TONNES. SO FOR THE PRODUCTION OF SUCH HUGE AMOUNT, MACHINES OF LARGER CAPACITIES WERE ORDERED.SUCH AS

• 360 Te DUMPER• 150 Te CRANES• BUCYRUS 42 CU. M. SHOVEL EQUIPMENT• TRUCK MOUNTED PIT VIPER DRILLING MACHINE• 555 CAT DOZER MACHINE

THANKS!!!AKHILESH KUMAR

DEPT. OF MECHANICAL ENGINEERING