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MECHANISATION
OFUNDERGROUND COAL MINING
METHOD
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NCL CIL
EMS in Rs 1450.00 1400.00
OMS 12.53 4.15
Wage Cost in Rs/T 115.72 337.35
Cost of Production Rs/T 585.82 681.34
Sale Value. Rs/T 1020.25 923.21
Wage Cost / Cost of Production % 19.75 49.51
Wage Cost / Sale of Coal % 11.345 36.54
WAGE COMPONENT IN TOTAL COST
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WHY MECHANISATION NEEDED FORUNDERGROUND MINES
(i) WAGE COST PER TONNE OF COAL IS AS HIGHAS 50% APPROX. OF SALE VALUE OF COAL.
(ii) GLOBALISATION & LIBERALISATION OF
ECONOMY HAS RESULTED IN TO COMMERCIALCOMPETITION FROM IMPORTED COAL
(iii) IMPORTED COAL AT COASTAL AREA IS
CHEAPER THAN DOMESTIC POWER GRADE
COAL WHEN COMPARED TO PER MILLION
K.CAL. COAL.
(iv) LANDED COST WILL BE AFFECTED BADLY IN FUTURE
IF THE RAILWAY FREIGHT OR GOVT. LEVIES ARE
INCREASED.
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(v) MOST OF THE SUPERIOR GRADE OF COAL IS BLOCKED
AT GREATER DEPTH BEYOND THE ECONOMIC REACH OFOPENCAST MINE
(vi) OUT OF APPROX. 256 BILLION TONES OF COAL,
APPROX. 80 BILLION TONES IS AMENABLE FOR OPENCAST
MINE . BEFORE THE O/C RESERVES ARE EXHAUSTED ,
THERE IS IMMEDIATE NEED TO ESTABLISH APPROPRIATE
MASS PRODUCTION TECHNOOGY
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1974 - 751
1
98
MECHANISEDMINING
PICK MINING
MANUAL MINING
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2002 - 03
64
0
46 MECHANISED MINING
PICK MINING
MANUAL MINING
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2011 - 2012
99
0
1
MECHANISED MINING
PICK MINING
MANUAL MINING
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PRESENT TECHNOLOGYAVAILABLE
BORD & PILLAR METHOD WITH
MANUAL LOADING
BORD & PILLAR METHOD WITH SDL
LOADING
MASS PRODUCTION TECHNOLOGY
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 1 2 3 4
MINEOMS
LOADER OMS Vs MINEOMS
(LOADER : U/GMANPOWER) Vs MINEOMS
(SURFACE MAN : U/GMAN) Vs OMS
UNDERGROUND PRODUCTIVITY
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WHERE DO WE NEED TO MECHANISE
1. COAL WINNING OPERATION
i) GETTING OF COAL FROM FACE
ii) TRANSPORTATION OF COAL ALONG GATE
SYSTEM
iii)TRANSPORTATION OF COAL THROUGH
TRUNK SYSTEM
iv) HANDLING OF COAL AT SURFACE
2. COAL FACE MECHANISATION
i) GETTING OF COAL
ii) SUPPORT OF THE EXPOSED ROOF
iii) LOADING OF COAL
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iv) TRANSPORTATION OF COAL FROM FACE
TO GATE ROADS
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CONSTRAINTS OF BORD &
PILLAR METHOD 1. IT IS CYCLIC
2. LIMITATIONS OF COAL PREPARATION
3.LABOUR INTENSIVE
4.LOW PRODUCTION CAPACITY
5.LOW DISTRICT PRODUCTIVITY
6.VERY SENSITIVE WITH INCREASE OF WAGECOST
7.EXPOSURE OF MORE WORKMEN TO
HAZARDOUS AREA
8.INHERENT HIGH ACCIDENT POTENTIAL
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CRITERIA FOR MASS PRODUCTION
TECHNOLOGY FOR U/G
1.Continuous in operation.
2. High production capacity
3. Higher man productivity
4. Increased safety
5. Higher recovery of coal
6. Adoptability of technology
7. Return on investment
8. High reliability of production
9. Efficient starta control
10.Better protection to environment
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AVAILABLE MASS
PRODUCTION TECHNOLOGY
1. Continuous Miner
2. Highwall Mining
3. Powered Support Longwall system.
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STRENGTH OF CONTINUOUS MINER
TECHNOLOGY
BORD & PILLAR MINING CONTINUES TO BE THE
BACK STAY OF U/G MINING
OUR WORKMEN - SUPERVISORS ARE
CONVERSANT WITH BORD & PILLAR MINING
REQUIRES LESSER GEO-TECHNICALINVESTIGATION THAN PSLW
COST OF EQUIPMENT IS LESSER THAN PSLW
NOS.OF EQUIPMENT IS LESSER & EASY TO
MAINTAIN
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DOES NOT REQUIRE MUCH TIME FOR
INSTALLATION & FACE TRANSFER
FACE IS EQUALLY PRODUCTIVE LIKEPSLW
TECHNOLOGY IS FLEXIBLE
IT IS CONTINUOUS IN OPERATION
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CONFIGURATION OF EQUIPMENT
1. CONTINUOUS MINER
2. SHUTTLE CARS
3. MOBILE ROOF BOLTER
4. SCOOP/LHD
5. LUMP BREAKER
6. BELT CONVEYORS
7. ELECTRICALS
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Joy12CM15 Continuous Miner
2 x 170kW Cutter Power
530 kW Installed Power
1.8 to 4.6m Cutting Range
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Roadway Section
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Shuttle Car 10SC32B(13.7 Tonne Capacity)
4 Wheel Drive
4 Wheel Steering
Hydraulic Cable
Reel Take-up
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Model: BF-14B-3-7C
Throughput: 250-500 tph
Coal size in: 700x500x400mm
Coal size out: -200mm
Breaker motor: 112kW
Width: 1270mm
Stamler Feeder Breaker
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UK Coal Mine
Joy 12CM15
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Twin Entry Development Layout
30 m
30 - 70 m
Feeder-BreakerBelt Shuttle CarContinuous
Miner
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Twin Entry Longwall Layout
200m
2000m
30m
Typical Multi Pass Continuous Miner
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Typical Multi-Pass Continuous Miner
Operation
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Shuttle
Car
Routes
in
5
Entry
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Highwall Mining in India:
Challenging Opportunities!
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What is Highwall Mining?
Equipment
Mining Methods
How to Start in India?
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What is Highwall Mining?
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Highwall Mining: Mining a visible coal seam by making
rectangular, mainly parallel, unsupported drives,using an unmanned cutter head and coaltransport system, controlled from a mining unitpositioned outside the drive, in front of the seam
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Equipment
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Base Unit
Length base approx. 20.1 meters
Width base approx. 9.2 meters
Weight base approx. 160 tonnes
Length of pushbeams 6.27meters 6 tonnes each
50 pushbeams per miner
Max. force in: approx. 170 tonnes,
out: approx. 350 tonnes
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Tracks
Four hydraulically powered tracksarticulate over 90 degrees for
straight and cross travel
Circle mode for accurate heading
Each track 1 meter verticalmovement for adjusting seam dip
and floor contour
Turning of each track is achievedautomatically
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Reel and Chain
Power chain for
Electrical cables for cutter
Hydraulic lines
Closed circuit cooling water lines forcutter motors
Methane sensor cable
Control cableHoses protected by steel plates and links
Hose chain approximately 330 meters
Automatically unwinds/winds into/from
channel on pushbeam
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Pushbeams
Pushing Cutterhead straight in
Transporting coal
Pulling Cutterhead back
Enclosed
Stackable
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Pushbeams
Striker Plates
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Cutter Heads
Interchangeable, for
seams 0.8 to approx. 5meters
Width 2.9 to 3.5 metres
Automatically following
seam contour
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Anchoring
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Generator
Motor Generator Set
Capacity 1550KW & 2000 KW
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Controls
Touch screen technology
Automatic shearing, various options
Automatic sumping, various options
Straight holes due to rigid string inhorizontal direction
Follows layers due to flexibility in
vertical direction
Accurate heading is important toensure parallel cuts
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Mobility
Public road transport:Operational within three daysexcluding travelling time.
Optional:Machine movers for longer hauls,fully assembled
Example:
During 9 months SHM-20 was movedto 7 different mining pits - somemoves over 6 kilometers in distance
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Production
Penetration 300 meters
Dip of up to 12 degrees
Monthly production typicallyaround 100,000 tonnes
Operates with a 3 / 4 man crew
Up to 70% recovery, subject to
- Coal compressionresistance
- Overburden load
- Seam height / Pillar
stability
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Typical Highwall Mining
Entries
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Video
Strength of Technology
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Strength of Technology
1. Recovers coal otherwise lost
2. Safe: No man underground3. Economical: Cheaper than U/G mining4. Proven: 45 Machines working now5. Enclosed Pushbeams: No ash dilution
6. Screw Conveyors: Simple, can handle wetcoal7. Compact: Narrow bench or trench8. Tracks: Easy travelling and positioning9. Modular: Easy to relocate mine to mine
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Mining Methods
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Mining Methods
Contour Mining
Trench Mining
Bench mining
Highwall Mining
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Contour MiningOutcrop of Seams
Trench Mining
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Trench MiningFlat Seams
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Bench Mining Top Down
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Bench Mining
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Blast Bench
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Mine Floor Coal
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Highwall Mine Seam
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Highwall Mine Seam
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Blast 2nd Bench
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Blast 2nd Bench
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Mine Floor Coal Bench 2
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Highwall Mine Seam 2
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Highwall Mine Seam 2
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Strip Seam 3
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Strip Seam 3
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Strip Seam 3
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Highwall Mine Seam 3
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Highwall Mine Seam 3
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Ready!
Highwall Mining
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O/C Pit Limit
Wh b A li d
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Where to be Applied:
1.Thin Seams
2.Beyond Strip Limit
3.Coal Blocked in Boundaries
5.Spoils, Roads, Power Lines
6.Villages
B fit
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Benefits
Coal otherwise lost can be recovered
Low cost per ton compared to underground
Up to 100.000 ton per month per machine
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STENGTH OF MECHANISED LONGWALL
ALL OPERATIONS ARE MECHANISED
IT IS CONTINUOUS NOT CYCLIC
VERY HIGH PRODUCTIVE
VERY SAFE VERY HIGH PRODUCTIVITY
HIGH CONSERVATION OF COAL
EFFICIENT STRATA CONTROL
NO BLASTING - NO POLLUION OF ENVIRONMENT
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ARMOURED FLEXIBLE CONVEYORS
FUNCTION OF AFC
1/ To receive coal from shearer and carry it along the coal
face.
2/ To provide base for the Shearer and anchorage for
Shearer chain 3/ To provide anchorage to powered support or advance
4/ To enable a system of continuous mines because the
conveyor being flexible
MAIN COMPNENTS OF AFC
1/ Drive Unit
2/ Return Unit
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ANCIALLARY EQUIPMENT
SPILL PLATE
TO PREVENT SPILLAGE OF COAL
TO ANCHOR POWERED SUPPORT
TO GUIDE POWER LOADER
TO PROTECT CABLE & HSES
RAM PATE
TO SCRAP & LOAD FLOOR COAL
TO PROVIDE PATH FOR SHEARER
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Lesson learnt from past
Inadequate Geotechnical investigation & assessment.
Lack of matching infrastructure.
Delay in gate road drivages.
Non-availability of required spares. Non-existence of R&D study during operation.
Low Accident potential.
Higher recovery of coal.
Wide gap between max. production achieved & average
production.
Least Impact of wage cost due to rise in EMS.
Production to the tune of 1Million tonne per year is achievable.
Strength of Powered Support
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Strength of Powered Support
Longwall Technology
Higher Production.
Higher Productivity.
Most safe mining method.
Highest recovery.
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0
50
100
150
200
250
300
1990 1991 1992 1993 1994 1995 2004
Production year wise
Productioninmillionshorttonne
Continious Miner
LongwallConventional
Others
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0
20
40
60
80
100
120
1976 1983 1993 1996 2004
Years
%P
roductionbyLongwall/Underg
round,NumberofLongwall
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
AnnualProductionperLongwallinmilliontonne
Number of longwall%Longwall/Underground production
Annual Production in million tonne
Milestone of Longwall production 2003
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Milestone of Longwall production 2003-
2004
USA produces 189 MT from 46 longwall.
2 longwall produces >10 MT/year of cleaned coal .
8 longwall produces >8 MT/year of cleaned coal.
Australia produces 65 MT from 26 longwall.
Shanhua group produces 73.84 MT from 5 longwall mines.
Yujialing produced 11.64 MT.
Diliuta produced 10.94 MT.
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Productivity
USA -14 tonne per hour
-14800 tonne per man year
Criteria for Planning of Longwall
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Criteria for Planning of Longwall
Project
Geology.
Cavablity & support design.
Selection of equipment.
Coal clearance.
Spares management.
Gate road drivages.
Major parameters for evaluation
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Major parameters for evaluation
of Support
Support efficiency.
Roof to floor convergence.
Active horizontal force. Roof cavity.
Canopy contact condition.
Uniformity of Support load.
Leg resistance.
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Gate road drivages
Single entry.
Double entry.
Three entry. Four entry.
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Number of entries for longwall gate road drivages
0
10
20
30
40
50
60
70
80
1979 1985 1990 1995 1996 2004
Years
%d
rivage
system
2 entry
3 entry4 entry
others
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Higher up time
Higher capacity-Reliable equipment.
5000 7
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0
500
1000
1500
2000
2500
3000
3500
4000
4500
1980 1990 2000
TPH,LongwallProductivityIndex
0
1
2
3
4
5
6
Milliontonneperyear
TPH
Longwall Productivity Index
Million ton per year
How Delay Matters
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0
5
10
15
20
25
30
0 2 4 6 8 10 12
SHEARER SPEED IN M/MIN
NUMBEROFSHEARSPERDAY
D = 0
D = 30
D = 60
D = 120
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0
10
20
30
40
50
60
70
80
90
1979 1982 1985 1988 1990 1992 1994 1996
Years
%o
ftotalLongwallface
100-150
151-200
201-250
251-300
301-350
Panel Length
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0
10
20
30
40
50
60
70
80
1979 1985 1990 1995 1996
Years
Numberof
Panels
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Optimization of Shearer cutting
sequence
Uni-directional.
Bi-directional.
Half web. Partial opening.
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Comparison of the Production vs Seam height for different mining sequence
0
1000
2000
3000
4000
5000
6000
Seam Height Uni directional Bi directional Half Opening Half Web
Cutting sequence
ProductioninTPH
Series1
Series2
Series3
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ECONOMICS
Sl.No. Description Rajendra Colliery(Longwal started from Dec'981997-98 1998-99 Upto July'99 Upto July'98
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Rs./T % of total Rs./T % of total Rs./T % of total Rs./T % of total
cost cost cost cost
1 O.M.S 0.76 -- 1.92 -- 2.94 -- 0.71 --
2 E.M.S. 391.95 -- 448.31 -- 434.57 -- 366.05 --
3 Wage Cost 524.81 46.5 235.11 33.57 148.64 30.68 518.07 53.99
4 O/H Cost 45.91 4.07 43.88 6.27 40.9 8.44 39.23 4.095 Store Cost 158.18 14.02 43.55 6.22 34.66 7.15 80.3 8.37
6 Power Cost 168.68 14.95 77.84 11.11 69.57 14.36 188.19 19.61
7 Coal Tran.cost 30.81 2.73 33.79 4.82 41.8 8.62 31.24 3.26
8 Interest 113.99 10.1 206.65 29.5 50.47 10.42 26.1 2.72
9 Description 58.04 5.15 54.56 7.79 77.19 15.93 45.26 4.7210 Misc. cost 28.1 2.49 5.07 0.01 21.23 4.38 31.13 3.24
11 Prod. cost 1128.52 -- 700.45 -- 484.46 -- 959.52 --
12 Sale value 890.85 -- 930 -- 874.63 -- 977
13 Profit (-) 237.67 -- 229.55 -- 390.17 -- 17.28 --
Sl.No. Description Balrampur Colliery (Longwal started from May'98)1997-98 1998-99 Upto July 99 Upto July'98
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Rs./T % of total Rs./T % of total Rs,/T % of total Rs./T % of tota
cost cost cost cost
1 O.M.S. 1.04 -- 1.39 -- 3.86 -- 1.67 --2 E.M.S. 319.27 -- 361.34 -- 375.9 -- 321.85 --
3 Wage cost 310.62 37.32 362.55 31.69 97.84 22.47 193.82 34.54
4 O/H Cost 49.88 5.99 56.04 6.76 43.43 9.97 71.06 12.66
5 Store cost 129.97 15.62 117.73 14.21 72.91 16.74 109.31 19.48
6 Power cost 171.19 20.57 120.75 14.57 70.93 16.29 95.18 16.96
7 Coal Trans.cost 26.78 3.21 19.32 2.33 21.36 4.91 17.98 3.2
8 Interest 56.62 5.12 134.19 16.2 38.19 8.77 17.69 3.2
9 Depreciation 42.51 5.11 81.74 9.87 61.44 14.11 32.06 5.11
10 Misc. cost 44.72 5.37 36.24 4.37 29.36 6.74 23.99 4.2811 Prod. cost 832.29 -- 828.56 -- 435.46 -- 561.09 --
12 Sale value 852.02 -- 888.17 -- 837.37 -- 919.89 --
13 Profit 19.73 -- 59.61 -- 401.91 -- 358.8 --
TECHNOLOGYTECHNOLOGY WISE COST PERFORMANCEWISE COST PERFORMANCE
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250.55-199.60-58.64-576.44Profit/Loss (Rs / Te)13
818.95740.59861.28797.27Sale Price (Rs/Te)12
568.40940.19919.921373.71Total Cost (Rs/te)11
82.5497.8561.7949.71Depreciation
(Rs/Te)
10
59.1953.9842.9442.01Interest (Rs/Te)9
94.35108.10103.1499.12Store Cost (Rs/Te)8
86.47136.9683.18217.22Power Cost (Rs/Te)7
133.61433.83469.49871.02Wages Cost (Rs./Te)6
23.51%46.14%51.04%63.41%Wages cost as % of
Total
5
375.58386.76403.22428.19EMS (Rs.)4
2.820.900.880.51OMS (Te)3
CDCCGrade2
6.791.991.550.87Rev.Production (LT)1
BALRAMPUR
LONGWALL
BANGWAR
SDL
PIPARIA
MANUAL +
SDL
CHACHAI
UG
MANUAL
DESCRIPTIONSl.No
Australian longwall production for 2003-2004
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US Longwall production 2004
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TEN FACTS ABOUT LONGWALL
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TEN FACTS ABOUT LONGWALL
Geology is not the cause of roof fall
100% of roof falls are caused by people
95% of roof falls are avoidable Poor roof conditions are frequently caused
by faulty roof supports
Roof falls statistically occur after ashutdown
TEN FACTS ABOUT LONGWALL
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TEN FACTS ABOUT LONGWALL
A 950 TON ROOF SUPPORT WILL HOLD THE
WEIGHT OF TWO FULLY LOADED BOEING
747 WITH 400 PASSENGERS
SET LOAD IS MORE IMPORTANT THAN
YIELD LOAD
LONGWALL ROOF FALLS COST INDUSTRY
MILLONS OF DOLLAR EVERY YEAR
TEN FACTS ABOUT LONGWALL
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TEN FACTS ABOUT LONGWALL
The powered roof support system on a
modern longwall is the most physically
abused, grossly neglected and totallymisunderstood integration of leading edge
technology that exists today
YOU can make a defference.
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THANK YOU
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What is Support Capacity
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What is Rated Load Density or Load Density at yield
Capacity of Support
RLD =
Maximum Span X Spacing
Overall Rated Load density = X .RLD
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y
X Depends on
1) System Hydraulic Leakage
2) Deviation of span
3) Deviation of setting load & yield load
What is Load on the support
What is the caving height
Height of extraction
Caving height = H = ------------------------------
Bulk factor - 1
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EXPERIENCE AT JHANJRA
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EXPERIENCE AT JHANJRA
i) Support density of 55 T/Sq.m.(KM 130) was less.ii) Where H/t ratio more than 10 - no significant strata
problem.
iii) Panel experienced strata problem where H/t 8 or less.
iv) Support density of 88T/Sq.m. proved better for strata
control point of view.
v) MLD/RLD was 0.8 with 55 T/sq.m.
vi) MLD/RLD was 0.6 with 88 T/sq.m.
vii) Subsidence 57% to 58% of Height of Extraction
viii)Convergence 7%- 8% of Height of Extraction
Borehole details of Panel 1 of Rajendra U/G Mine
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Borehole Number Position of centre
from start of face
BH 1 30m
BH 2 150m
BH 5 300m
BH 6 600m
BH 7 1050m
PhysicoMechanical Properties of overlying Strata
SL. DETAILS B.H.NO B.H.NO B.H.NO B.H.NO B.H.NO
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NO 1 2 5 6 7
1. Position from startof panel
30m 150m 300m 600m 1050m
2. Depth of highest
R.Q.D. strata
24m 41m 39m 51m 36m
3. R.Q.D value 73% 84% 58% 57% 66%
4. Depth of CoalSeam
62.50m 63.0m 63.25m 57.00m 56.00m
5. Total Hard Cover 38.50m 39.00m 39.25m 42.00m 38.00m
6. Seam Thickness 2.75m 3.3m 2.75m 2.15m 2.10m
7. Average WorkingHeight
2.40m 2.73m 2.73m 2.7 m 2.7 m
R Q D of the beds Comp. Strength in MPa Tensile Strength in MPa
PHYSICO-MECHANICAL PROPERTIES OF STRATA INDIFDIFFFERENT PANELS AT BALRAMPUR MINE :
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Depth (m)P-1 P-2 Panel P-1 Panel P-2 Panel P-1 Panel P-2
00.00 - 12.00 00 00 00 00 00 00
12.00 - 14.00 42 19 00 2.18 00 0.20
14.00 - 17.00 92 25 8.04 2.18 0.83 0.20
17.00 - 20.00 76 18 12.75 9.38 1.00 1.18-2.65
20.00 - 23.00 82 50 9.35 16.8 1.19 1-1.16
23.00 - 26.00 56 50 8.90 16.59 1.02 -
26.00 - 29.00 16 50 8.90 13.1 1.02 1.58-2.91
29.00 - 32.00 21 27 13.32 16.24 1.57 1.34-3.54
32.00 - 35.00 30 57 9.27 12.22 0.59 0.98-2.11
35.00 - 38.00 65 24 10.22 - 0.65 0.57-1.79
38.00 - 41.00 96 64 9.69 43.66 0.66 1.03-1.81
41.00 - 44.00 96 71 6.82 22.27 0.92 0.44-2.89
44.00 - 48.00 34-60 71 13.96 - 2.14 1.34-1.59
48.00 - 51.00 Coal 40 18.72 14.93 5.11 0.90-1.43
51.00 - 54.00 51 12-85 18.96 - 1.94 0.74
54.00 - 57.00 87 Coal 5.5 40.36 - -
DEPTH
Borehole cross section of BH-2 & BH-6
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ROOF STRATA DETAILSBALRAMPUR INCLINES
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Panel P-1 Panel P-2
Soil/ weathered
sand stone in M
21.2 22.8 13.6 14.0
Depth of cover in
meter
47.5 49.3 53.6 54.0
Medium to coarse
gr. Sst (hard
cover) h
(in meter)
26.3 26.5 40.05 40.05
Seam thick in m
(extractedthickness in m(h))
2.4
(2..25)
2.4
(2.25)
2.25
(2.25)
2.25
(2.25)
h/t - Hard cover/
seam thickness
ratio
10.9 11.0 17.8 17.8
BALRAMPUR
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BALRAMPUR
i) Higher average RQD - 81-90
ii) Higher H/t. ratio 10.9 - 17.8
RAJENDRA
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RAJENDRA
i) RQD average 70. Lesser than Balrampur &
same in the range of Jhanjra. However, the high
RQD(84) was above the coal seam 3 - 5 mtrs.
ii) Moderately cavable (CI - 3513) against Jhanjra
(2426 - 3076 ).
iii) Higher H/t ratio 13.2 - 14.2
EXPERIENCE AT BALRAMPUR 1ST PANEL UPTO
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FACE ADVANCEMENT OF 160 MTRS.
i) Panel started 11.5.98
ii) Periodic fall varies 20 -25 mtrs. interval
iii) First main fall at 80 mtrs.- extracted area 12000 sq.m.
16 supports in the mid zone collared.
iv) 2nd main all at 160 mtrs. when exposed area 24000 sq.m.
-- Convergence max. 630 mm
-- Peak leg pressure - 400 kg./sq.cm.
-- 13 supports got collared.v) Face was re-started after taking the following actions:
-- To increase yield fro 35 MPa to 40 MPa
-- To provide max. hydraulic travel in leg
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- To install positive set valve
-- To induce caving by deep hole blasting from surface.
-- To restrict the overhang to max. 36 mtrs. & Blasting to
at an interval of 15 m from face.
vi) First blasting was done at 178 m from strart of face when
face was at 191 mtrs.
vii) During blasting PPV at 15 m face on surface -67 mm/sec.
PPV at centre of face at U/G -149 mm/sec.
PPV at main gate at U/G - 51 mm/sec. PPV at tail gate at U/G - 31 mm/sec.
viii) Radial distance from the edge of chock to blast hole - 22m
Sl. No. Description Specification
Details of the explosives charge column are given as under :
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1 Type of explosive Acquadyne
2 Cartridge dia 83 mm
3 Cartridge weight 2.78 Kg.
4 Blast hole diameter 100 mm
5 Loading density 9 Kg/m
6 Detonation velocity 3400 - 4300 m/sec
7 Density 1.12 to 1.2 mgs/cc
BOTTOM DECK
1 Length of the charge column 3 m
2 Nos. of cartridge 10
3 Total weight of explosives 27.8 Kg.
TOP DECK
1 Length of column 2.5 m
2 Nos. of cartridges 8
3 Total weight of explosives 22.2 Kg.
4 Total no. of hole per blasting 9 to 13 nos.
5 Total explosives charge per hole 50 Kg. (Approx.)
6 Length of span of blasting 60 to 70 m
SURFACE GROUND MOVEMENT STUDY
S b id G id
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Subsidence Grid
At start of panel at 6m interval along centre of panel from(-) 30m to 56m
From 56m onwards at 15m interval
Details of induced blasting
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The trend of loading on supports before blasting and after blasting.
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Load inT/m2
45-65 65-70 70-75 75- YL Total
Overall Frequency 98 13 8 5 124
Percentage 80 10 6 4 100
Before Frequency 29 2 - - 31
Blasting Percentage 94 6 - - 100
After Frequency 69 13 6 5 93
Blasting Percentage 74 14 7 5 100
INTERVAL BETWEEN THE PERIODIC WEIGHTINGS AT BALARAMPUR
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(5-10)m (10-20)m (20-30)m > 30 m Total
Before Frequenc
y
2 3 3 1 9
Blasting Percentag
e
23 33 33 11 100
After Frequenc
y
2 15 9 1 27
Blasting Percentag
e
7 56 33 4 100
Complet
e
Frequenc
y
4 18 12 2 36
Panel Percentag
e
11 50 33 6 100
Frequency of periodic weighting at Rajendra
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Range (5-10)m (10-20)m (20-30)m
Before blasting 5 % 67 % 28 %
After blasting 14 % 81 % 5 %
Complete panel 11 % 76 % 13 %
Subsidence Percentage before and after blasting
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Days from the
undisturbed day
3rd day 9th day 14th day
Before blasting 3.7 to 13.5 83 to 96 98 to 100
After blasting 50 to 70 84 to 99 95 to 100
Subsidence Profile before & after weighting on 10.02.2000
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MLD i 65 65 70 70 75 75 t YL T t l R k
Loading frequency and MLD during periodic weightings :
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MLD in
T/m2
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Cumulative Convergence experienced
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Cumulative Convergence experienced
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Cumulative Convergence in mm/hr
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Cumulative Convergence in mm/hr.
Convergence mm/hr < 40 40-60 60-80 > 80 Total
Before Frequency 1 1 1 2 5
Blasting Percentage 20 20 20 40 100
After Frequency 16 3 1 1 21
Blasting Percentage 76 14 5 5 100
Observation
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-- Magnitude of weighting on support reduce.-- Smoothening of subsidence profile.
-- Support performance improved
-- Maximum subsidence 118 cm i.e. 52.4% of seamextracted when face advanced 3.4 D and length of face
2.9 D
-- In low RQD regime, subsidence used to reach closer to
the Longwall face and crack on surface had appeared
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the Longwall face and crack on surface had appeared
within 4 mtrs. of face.-- Frequency of periodic weighting increased.
-- Pressure Profile of leg circuit did not change.
-- Convergence in leg redued.
-- % subsidence reduced from over 50% to 42.3% after
blasting due to increase of bulking factor.
-- At 15 mtrs. interval blasting
12% of max. on 3rd day ater blasting.
60% of max. on 7th day after blasting
- At 20 mtrs interal blasting:
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-- At 20 mtrs. interal blasting:
17% of max. on 3rd day63% of max. on 7th day
-- At 30 mtrs. interval
11% of max. on 3rd day
33% of max. on 7th day
-- At 60 mtrs. interval
3% of max. on 3rd day
7% of max. on 7th day
CONCLUSION
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-- p1 - initial support resistance after cut was 69 T/sq.m. &increased to 79 T/sq.m.-- p2- started with 79T/sq.m.
-- P16- started with 79 T/sq.m.
-- Before blasting, high convergence 126 mm/min. was
observed.
-- Due to presence of stony bed with 9/10 times the
thickness of extraction, the caving was incomplete.
-- H/t ratio was 11, 18 & 14 in different panels.
-- Induced caving by blasting, reduced the intensity of
convergence but loading on support was higher.
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-- Rate of face advance proved to have direct influence
on convergence i.e. higher rate over 9/10 m/day
contributed to roof control problem.
-- Average rate of advance of 6/7 mtrs./day had better
strata control.
-- Ratio of MLD/RLD was high in the mid zone ie.
35 to 80 nos. supports. It is almost equal during
major weighting.
-- Induced caving had
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Induced caving had
i) Increased loading on supportsii) Reduced convergence
iii) Increased periodicity of weighting between 10 - 20 m
iv) Reduced periodicity beyond 30 m.
v) Increased initial subsidencevi) Blasting increased better bulk factor
vii) Blasting interval 20 m is established to be optimum.
viii) Support resistance should be around 105-110T/sq.m.
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-- H/t ratio should be more than 15 if support resistance isless than 90 T/sq.m.
-- Higher support resistance may reduce the H/t ratio.
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HOW TO MAKE MECHANISATION A
SUCCESS
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EFFECT OF DELAYS IN LOGWALL
PERFORMANCE
FACTORS WHICH GUIDE PRODUCTION
DELAY ANALYSIS
COST OF LOST TIME
HOW DELAY MATTERS
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0
5
10
15
20
25
30
0 2 4 6 8 10 12
SHEARER SPEED IN M/Sec
NUMBER
OFS
HEARSPER
DA
Y
D = 0
D = 30
D = 60D = 120
Machine Time18 hours
Face Length150 meter
Cutting SequenceHalf
face
Fleeting Speed6 m / min
DOWNTIME ANALYSIS OF MECHANISED LONGWALL FACES
OPERATING WITHIN CIL - OTHER THN MOONIDIH
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Name of Mine Panel No. MRT in MAT lost de to breakdown in % age MAT lost due to d in%age
%ge of Shearer AFC/STL Gate P.pack/ Elect. Total in Shift Bad geo- Power Face pre- Out bye TotalMAT belt chock %age of change mining failure paration clear- in %ge
MAT time condit- and ance of MAT
ion others
DHEMO W-8 30.5 10.07 15.53 5.03 1.13 3.91 35.67 4.93 4.89 5.98 6.19 11.9 33.98
MAIN W-9 38.46 1.63 12.6 7.8 2.92 -- 24.95 -- -- 1.75 11.48 23.34 36.59
SETALPUR PH-2 37.81 6.44 10.95 6.16 5.84 4.25 33.64 10.98 -- 5.04 5.96 6.57 28.55
PH-3 20.26 6.86 11.22 10.4 24.9 4.89 58.27 3.86 -- 5.13 7.82 4.66 21.47
PATHA-
KHERA Panel 35 11.8 9.26 1.13 2.4 8.9 33.49 -- -- -- 29.56 1.95 31.51
Panel 30.13 17.22 7.15 0.86 7.33 7.47 40.03 -- -- 0.23 24.02 5.59 29.84
Panel B 46.21 12.9 12.95 1.25 1.82 15.31 44.29 -- -- -- 4.9 4.61 9.5Panel 4 42.65 13.5 7.19 0.7 3.6 7.5 32.49 -- 1.7 1.4 17.52 4.24 24.86
Panel-5 22.88 34 8.88 0.6 1.17 7.67 52.32 -- 0.33 0.3 16.3 1.87 24.8
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DOWN TIME ANALYSIS OF MECHNISED LONGWALL FACES
Panel No. MAT lost due to breakdown in percentage MAT l lost due to delay
MRT in % Shearer AFC/STL Gate/belt P.Pack/ Elect. Total in Shift Bade Geo- Out bye
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of MAT Chock % of MAT Change mining delay
condition includingPower failure
Balrampur 54.49 11.53 1.88 0.07 0 0.78 14.26 0 21.02 10.23
P-2
DOWN TIME ANALYSIS OF MECHNISED LONGWALL FACES
MAT lost due to breakdown in percentage MAT l lost due to delay
Panel No. MRT in % Shearer AFC/STL Gate/belt P.Pack/ Elect. Total in Shift Bade Geo-Out bye
of MAT Chock % of MAT Change mining delay
condition including
Power failure
RajendraP-16
panel 51.98 14.63 4.04 0.68 0.18 1.86 21.39 0 16.69 9.94
DELAY ANALYSIS
BALRAMPUR P-1 PANEL
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54%
18%
28%
MRT
B/DOWN
IDLE HRS
DOWNTIME ANALYSIS
BALRAMPUR P-2 PANEL
12%
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63%
19%
4%
2%
SHEARER
AFC/STL
GATE BELT
POWER PACK
ELECTRICAL
MONTHWISE PRODUCTION
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MONTHWISE PRODUCTION
RAJENDRA P-16 PANEL
0
20000
40000
60000
80000
100000
120000
140000
DEC'98 JAN'99 FEB'99 MARCH'99 APRIL'99 MAY'99 JUNE'99 JULY'99
MONTH
PRODN
IN
TE
MONTHWISE PRODUCTIVITY
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MONTHWISE PRODUCTIVITY
RAJENDRA P-16 PANEL
0
500
1000
1500
20002500
3000
3500
4000
4500
5000
DEC'98 JAN'99 FEB'99 MARCH'99 APRIL'99 MAY'99 JUNE'99 JULY'99MONTH
AV.PRODNP
ER
DAY
INT
MONTHWISE FACE OMS
RAJENDRA P-16 PANEL
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0
10
20
30
40
50
60
DEC'98
JAN'99
FEB'99
MARC
H'99
APRIL'9
9
MAY'99
JUNE'9
9
JULY'9
9
MONTH
FACE
OM
S
IN
TE.
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MONTHWISE PROFITRAJENDRA P-16 PANEL
0
100
200
300
400500
600
700
800
DEC'98 JAN'99 FEB'99 MARCH'99 APRIL'99 MAY'99 JUNE'99
MONTH
PROFIT/TE
INR
HOW TO REDUCE MACHINE DOWNTIME
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-- ANALYSIS OF BREAKDOWN
-- PREVENTION
-- APPRAISAL
-- FAILURE RECTIFICATION
/--------------------\
: Prevention : : 3% :
: -------------------:- /----------------------\
: Appraisal : : Prevention :
: 7-10% : : 6-8% :
: ------------------- : : ----------------------- :
: Failure : : Appraisal 1-2% :
: 15-22% : : Failure 2-5% :
: -- ----------------------------------------------------- :
MAINTENANCE PROCESS
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0
10
20
30
4050
60
70
80
90
100
Break Down Preventing Predictive
AVAILA
BILITY
Series1
OBJECTIVE OF MAINTENANCE ENGINEER
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1. IDENTIFICATION AND DETECTION OF TROUBLE AS
QUICKLY AS POSSIBLE.
2. GETTING THE EQUIPMENT RIGHT AT FIRST AND
WITH MINIMUM POSSIBLE TIME 3. PREVENTION AGAINST OCCURRENCE OF
EQUIPMENT FAILURE
4. CONTINUOUS IMPROVEMENT ON QUALITY
DEFICIENCY IN P.P.M.
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(i) It is basically time-based maintenance (ii) It is regardless of its operating condition and
based on past performance.
(iii)It relies on judgment and skill of the
maintenance crew (iv) It stands on the theory of probability and
definite prediction is not possible.
(v) Internal inspection is time consuming.
(vi) Over and under maintenance are quite common
(vii)Inspection is carried out when machine is idle
and not in running condition.
RELIABLITY
LONGWALL EQUIPMENT WORKS IN A CHAIN.
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Q
ROLL OF MANAGEMENT 1. PROPER INFRASTRUCTURAL FACILITY
2. TRAINED AND SKILLED WORK FORCE
3. PROPER LIAISON AND INTERACTION WITH
EQUIPMENT MANUFACTURERS
4. INTRODUCTIN OF MANAGEMENT INFORMATION
SYSTEM TO GENERATE AND MONITOR
OPERATION DATA
5. GENERATION OF AN EFFECTIVE MAINTENANCE
MANAGEMENT CULTURE
-- TOTAL QUALITY MANAGEMENT CONCEPT
CUSTOMER SATISFACTION
DATA GENERATIONS
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FREQUENCY OF INSPECTION
INSPECTION REPORTS
FAILURE REPORTS
SPARES CONSUMED
TIME TO RECTIFY EFFICIENT PROGRAMME FOR REFURBISHMENT
REDUCE TURN AROUND TIME.
JUST IN TIME CONCEPT OF SPARE
TESTING BY STIMULATION
INDIGENOUS DEVELOPMENT OF SPARES
REGULAR EVALUATION
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USE OF COMPUTER -- DELAY ANALYSIS (EASY)
-- OWNERSHIP COST. REPCOST.
-- PRODUCTION PERFORMANCE TREND
-- MACHINE PERFORMANCE -- RCM
-- SPARE MANAGEMENT.
TRAINING
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BASIC TRAINING SCHEME 1. CLASS ROOM THEORETICAL TRAINING
FOLLOWED BY
2. CLOSE SUPERVISION ON JOB TRAINING.
3. ADVANCED THEORETICAL CLASS ROOM
TRAINING
4. DEPLOYMENT ON ACTUAL JOB.
5. REFRESHERS TRAINING.
FURTHER TRAINING ON
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-- SELF MOTIVATION.
-- LEADERSHIP.
-- TEAM BUILDING -- PROBLEM ANALYSIS
-- COMMUNICATION SKILL
-- LISTENING SKILL
-- WORK STANDARD
-- SAFETY AWARENESS