Workshop on Technology Development for reaching

250 MT (19-20)

Mahanadi Coalfields LimitedMahanadi Coalfields Limited

Trend and Coal production projection

0.00

50.00

100.00

150.00

200.00

250.00

300.00

in M

T

in MT 110.44 127.00 150.00 167.00 187.00 222.00 250.00

13-14 14-15 15-16 16-17 17-18 18-19 19-20

Estimated demand & Gap

Demand of coal IN MT (at 100% satisfaction level) as per FSA/LOA

Year 15-16 16-17 17-18 18-19 19-20

Demand 199.00 242.00 242.00 242.00 242.00

Prod 150.00 167.00 187.00 222.00 250.00

Gap 49.00 75.00 55.00 20.00 -8.00

Projected Coal production upto 2019-20

0.00

100.00

200.00

300.00

in M

T

On-Going 79.95 101.45 115.75 132.25 160.75 172.00

Completed+ existing 47.05 48.55 51.25 54.75 57.25 41.00

Future 0.00 0.00 0.00 0.00 4.00 37.00

TOTAL 127.00 150.00 167.00 187.00 222.00 250.00

14-15 15-16 16-17 17-18 18-19 19-20

Year  14-15 15-16 16-17 17-18 18-19 19-20

UG 1.50 1.50 1.50 1.50 1.50 1.50

OC 125.50 148.50 165.50 185.50 220.50 248.50

TOTAL 127.00 150.00 167.00 187.00 222.00 250.00

Coal production projection Year wise upto 2019-20Coal production projection Year wise upto 2019-20

Coal & OB Projection

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

Co

al-M

T, O

B-M

Cu

M

Coal 127.00 150.00 167.00 187.00 222.00 250.00

OB 94.00 177.00 202.00 231.00 275.00 351.00

14-15 15-16 16-17 17-18 18-19 19-20

Additional Shovel required to achieve 250 Mty by 2019-20

 Capacity 15-16 16-17 17-18 18-19 19-20 Total

34 Cum 2 1 03

20-22 Cum 1 4 2 4 11

9-10 Cum 7 27 35 5 4 78

5-6.5 Cum 3 6 8 - - 17

2.5-4.3 Cum - 4 2 - - 6

Grand Total 115

  Replacement of Shovel

Existing

14-15

15-16

16-17

17-18 18-19

19-20

Total

 

10 Cum 12 -

4.5 -6.5 Cum 40 2 2 4

2.5 to 4.3 Cum 37 2 4 5 2 1 14

Capacity 15-16 16-17 17-18 18-19 19-20 Total

35 T 7 8 31 - - 46

50/60 T 48 108 139 - - 295

85-100 T 63 229 328 55 53 728

190 T - 6 36 20 52 114

240 T - 20 20 - - 40

Total 1223

Additional Dumper required to achieve 250 Mty by 2019-20

     

Replacement of Dumper

Existing

14-15

15-16 16-17

17-18

18-19 19-20

Total

50/60 T 284 34 31 66 17 10 - 158

Additional Dozer required to achieve 250 Mty by 19-20

 Capacity 15-16 16-17 17-18 18-19 19-20 Total

770-850 HP(with Ripper attachment) 4 17 9 5 3 38

410 HP 15 25 41 9 9 99

 Replacement of Dozer

 Existing 14-15 15-16 16-17 17-18 18-19 19-20

Total

410 HP 75 9 20 1 16 2 - 48

320 HP 31 - - 1 5 1 - 7

Additional Drill required to achieve 250 Mty by 2019-20

  15-16 16-17 17-18 18-19 19-20 Total

250 mm 8 31 46 9 8 102

150-160 mm 12 26 30 4 5 77

 Replacement of Drill

Existing

14-15 15-16 16-17 17-18 18-19 19-20 Total

  250 mm 34 1 4 1 6

160 mm 55 7 6 1 3 2 19

Additional Surface Miner required to achieve 250 Mty by 2019-20

15-16 16-17 17-18 18-19 19-20 Total

3000-3800mm

3 8 14 3 4 32

Additional Loading machine (Pay loader) required to achieve 250 Mty by 2019-20

15-16 16-17 17-18 18-19 19-20 Total

>5 cum 5 11 13 - - 29

>10 cum - 1 4 3 4 12

Replacement Loading M/C(Pay loader)

Existing

14-15 15-16 16-17 17-18 18-19 19-20 Total

>5cum 10 4 1 5

Additional equipment required for UG upto 2019-20

Capacity Nos Existing Replacement

Continuous Miner

1.4 to 4.6 M 2

SDL 1 cum 9 18 18

Low HeightSDL

0.8 cum 6

Low HeightSDL

1 cum3

LHD 1.2 cum 2 29 20

LHD 2.7 cum 4

Roof Bolter Quad bolter 2

Shuttle Car 15 Te 6

Conveyor Belt Conveyor 11800 m

Roof Bolter 15

Tube/pipe conveyorRequirement/

Capacity

Hingula 5 Km

Bhubaneswari 3.5 km

Other P&M ( other than HEMM) requirement to achieve 250 MTOther P&M ( other than HEMM) requirement to achieve 250 MT

Washery  

Jagannath washery 10 Mty

Hingula washery 10 Mty

Kulda washery 10 Mty

Basundhara washery 10 Mty

Siarmal washery 10 Mty X 4

Lakhanpur integrated 20 Mty & 10 Mty

Other P&M ( other than HEMM) requirement to achieve 250 MTOther P&M ( other than HEMM) requirement to achieve 250 MT

 

Kaniha/Gopalji SILO 30 Mty

Lingaraj SILO 16 Mty

Bhubaneswari SILO 20 Mty

Ananta SILO 15 Mty

Bharatpur SILO 15 Mty

Hingula SILO 15 Mty

Gopalprasad SILO 15 Mty

Talabira-II &III SILO 20 Mty

Lakhanpur SILO 30 Mty

Kulda SILO 10 Mty

Siarmal SILO 40Mty

Rapid Loading System including SILO requirement to achieve 250 MTRapid Loading System including SILO requirement to achieve 250 MT

Technological Development & Mechanization of Mines Proposed

Present technologyProduction level

in 19-20SDL/LHD with Bord & Pillar in UGMan-riding system in UG 1.5 MT

Dragline & Shovel-Dumper combination for OB removal , Loader-Tipper for coal production in OCSurface miner for blast free coal production in OC 248.5 MT OITDS, GPS for better monitoringFuture technologyContinuous miner in UGHigher capacity Shovels & DumpersPipe conveyor for coal transportationRipper dozer for blast free OB removal in OCRLS with SILO for faster loading of wagons

Award of Contracts

Sl Projects Key Contracts for EPC, OB removal, coal removal etc.

Timeline

1 Kaniha OCP Award of contract for MDO Sep-172 Siarmal OCP Award of contract for MDO Dec-16

Issues with BEML (A) Delay in supply of spare parts. Spare parts of a module is not

supplied in full rather it is supplied in piecemeal due to which repair of particular assembly and equipment is delayed.

(B) BE-1600 Hydraulic Excavator 9.5 cum. 06 nos. supplied to MCL

are going under frequent breakdown, due to Failure of engines, Hydraulic pumps & Hydraulic tubes, Cooling system and other components since its commissioning.

The performance of BEML :

Year 2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

% Availability

Model

Present

population

BE 1600 D 6 - 79 66 55 39 45 50

BE 1000 D 12 - 84 71 68 54 52 53

BE 1000 E 5 69 64 72 69 57 66 69

The performance of BEML :

Year 2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

% Breakdown

Model

Present

population

BE 1600 D 6 - 14 29 41 58 51 46

BE 1000 D 12 - 10 23 27 42 44 43

BE 1000 E 5 27 32 24 27 40 30 27

(C) The performance of BH-100 Ton Dumpers after warranty period is very poor due to failure of Engines, Transmission and other components. Performance is as below :

Year 2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

% Availability Present population 29 Model BH-100 (100T) - 63 76 61 55 34 38

(C) The performance of BH-100 Ton Dumpers after warranty period is very poor due to failure of Engines, Transmission and other components. Performance is as below :

Year 2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

% Breakdown Model Present

population

BH-100 (100T) 29 - 30 19 35 42 63 59

(D) Recently, supplied BH-60 Ton Dumpers are giving problems like Cabin Vibration, Regular failure of suspension, Air Conditioning compressor mounting bolt loosening problem, Sensors are not working, Camera monitoring foundation bracket failure & Transmission pump failure etc.

(E) Recently supplied BD-355 Dozers are also not performing to the mark and giving troubles like :

Automatic release of blades sometimes Misalignment of cabin Non functioning of Air Conditioner Fuel Injection Pumping problem Starting problem etc.

ISSUES WITH M/S.H.E.C., RANCHI

There is general delay in supply of equipment as well as spare parts.As HEC is facing financial constraints, they are demanding advance payment for supply of equipment for recently ordered 10 cum. Electric Rope Shovel

ISSUES WITH M/S. PROMTRACTOR (JSC), RUSSIAPerformance of 15 nos. 410 HP Dozers are very very poor due to abnormal failure of engine & transmission even in warranty period. The performance is as below :

M/s. Promtractor (JSC), Russia has no Indian service provider for supply of spare parts and maintenance and also not supporting well for supply of spare parts and services.

Year 2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

Company M/s. Promtractor (JSC), Russia

% Availability

Model Present Populat

ion

Promtractor T-25.01CB-1 15 - - 71 53 31 24 11

% Breakdown

Model

Promtractor T-25.01CB-1 - - 23 43 67 74 88

Thank you

All HEMM should be supplied with Guaranteed Spare Parts Supply (GPS) or Maintenance and Repair Contract (MARC) for life time.

SUGGESTIONS FOR SUPPLY AND MAINTENANCE OF EQUIPMENT

Guarantee for initial 2-3 years is meaningless as machine will perform initially better than when it gets older after 03 years. Hence, guarantee for later period is more important.

Cost of equipment quoted is very less but spare parts are very costly which ultimately result into higher cost of production. If life cycle cost is adopted this can be eliminated.

Buy back system is to be incorporated in case of spare parts which are not consumed during warranty period. Some manufacturers are reluctant for life time guarantee due to uncertainty in foreign currency fluctuation. This problem can be sorted out by incorporating currency escalation/de-escalation clause.

SUGGESTIONS FOR SUPPLY AND MAINTENANCE OF EQUIPMENT

4-5 years satisfactory performance may be introduced instead of one year as per existing standard NIT.

At least 30-40% of the tendered quantity may be considered for meeting the prove ness criteria instead of at least one number as per existing standard NIT.

Tender finalization should be 60/40 basis as per earlier system to have a check on L-1 bidder both in price as well as performance.

The equipment which are not having base in India should not be given chance for participation in open tender as there is also problem of spare and service support because of non availability of India Agent. There should be a provision of consignment store having major population nearer to the project.

Modification in Proveness criteria