Issues related to Technology & Spares Management
A Presentation by ECL
20th January, 2015
Production built-up Program of ECL
ECL’s share in 1 billion te coal by CIL in 2019-20 is 62 million te.
Year
Coal Prod
(MT)
Abs. Grwth.
(MT)
% Grwth
2013-14
36.05
2014-15 (Plan)
38.00
2015-16 (Proj)
42.03
4.03
10.60%
2016-17 (Proj)
46.94
4.91
11.68%
2017-18 (Proj)
51.68
4.74
10.10%
2018-19 (Proj)
56.56
4.88
9.44%
2019-20 (Proj)
62.00
5.44
9.62%
Technology Requirement for UG Production
Intermediate Technology
Existing 2015-16 2016-17 2017-18 2018-19 2019-20
SDL
Low Height
17
3
2
-
8
2
Standard Height
202
22
91
21
-
26
Standard Height (1.5 cum)
17
-
15
-
-
-
Standard Height (3.0 cum)
7
2
-
2
1
2
Low Height
1
-
-
-
-
-
LHD
Technology Requirement for UG Production
Mass Production Technology
Existing 2015-16 2016-17 2017-18 2018-19 2019-20
(a) Cotinuous Miner Package (1 CM + 2 Shuttle Car + 1 LHD + Roof Bolter etc)
Requirement of Std. Ht. CM
3
-
-
-
1
2
Requirement of Low Ht. CM
-
-
2
1
-
-
-
1
-
-
-
1
(b) Powered Support LW
Requirement of PSLW
Technological Issues for increasing UG Production
Sl.
No
Issues
Increasing working
height of CM
1
Description
At present, CM is permitted to extract
seams up to 4.5 Mts. It should be
increased to extract coal seams of more
than 4.5 Mts - preferably up to 6.0 Mts;
maximum upto 8m, in single lift
Single stage extraction
by CM (i.e., only
Practised in other countries like South
development by Room Africa & USA
& Pillar method)
Benefits
Increase in % extraction
of coal for higher
production &
productivity
Low gestation period,
Better % recovery
Restriction in use of Diesel operated
RAM -CAR/ SHUTTLE CAR in gassy mines Higher Productivity and
of Degree -II & Degree -III for
scale of Production
Use of diesel operated coal transport
2 machine in gassy mines
Restriction in use of Diesel Operated
Reduced travel time will
of higher degree
Multi purpose Free Steered vehicle for improve effective
man & material transport in gassy mines working hour and hence,
of Degree-II & Degree-III
productivity
Technological Issues for increasing UG Production
Sl.
No
Issues
Description
Benefits
3
Non availability of Top Coal
Thick seam mining by
Caving Equipment for thick
Longwall method
seam Long wall Mining
Increase in % extraction of
coal for very high scale of
production
4
Coal extraction rate in
High speed stowing/ depillaring panels is restricted
void filling technology due to unavailability of high
speed Stowing Technique
Extraction of seams below
water-logged and heavily
built-up areas at increased
rate
5
High speed drivage of
i.e., Speed > 80 m per month
incline
Gestation period will reduce;
early start of coal
production; continuous coal
evacuation through belt.
6
High speed Shaft
Sinking & Deepening
Fast access to deeper/ lower
virgin seams
High speed Shaft Sinking &
Deepening
Technology/HEMM requirement for OC Production
Sl.
No
I
1
2
3
II
1
2
3
4
III
1
2
3
4
IV
1
2
Equipment
Description
ER SHOVEL
20 m3
10 m3
4.6/5 m3
HYD SHOVEL
10 m3 & above
4.5-5.5 m3
2.7-4.2 m3
1-2 m3
DUMPERS
170T/190T
100T
50T/60T
35T/40T
CR DOZER
410HP
320HP
2015-16
(No)
2016-17
(No)
2017-18
(No)
2018-19
(No)
2019-20
(No)
1
1
4
-
2
1
-
3
0
-
1
4
4
3
2
1
3
-
2
3
-
2
-
4
7
14
18
3
13
8
4
21
3
5
3
5
37
4
4
0
0
4
8
1
5
6
3
Technology/HEMM requirement for OC Production
Sl.
No
V
Equipment
Description
2015-16
(No)
2016-17
(No)
2017-18
(No)
2018-19
(No)
2019-20
(No)
-
-
-
-
W DOZER
1
VI
410HP
1
RBH DRILL
1
250mm
1
-
0
-
2
2
160 mm
10
3
3
1
4
VII
GRADER
280 HP
1
-
2
2
2
-
-
-
3
-
-
-
2
-
1
VIII
1
IX
1
CRANES
More than 40T
WATER SPRINKLER
28Kl
2
Issues with Equipment manufacturing Cos.
BEML
Performance of dozers and 35T dumpers requires improvement
 Frequent problem being faced with newly supplied D155 &
D355 Dozers with Joy stick arrangement.
 Failure to supply spare parts within delivery time stipulated in
Depot Agreement.
Issue: To improve the quality of newly supplied equipment and ensure
supply of spare parts within delivery time.
L&T
Performance of recently supplied hydraulic shovel
 It has gone down because of failures of major assemblies like
cracking of boom, final drive failures, fast wearing of bucket
assy., hoses etc.
HEC
Performance of recently supplied 5 cum electric rope shovel, model
EKG 5A
 It is not upto the mark. There are number of failures of major
sub-assemblies.
 HEC is also not supplying spares against Guaranteed
Availability Contract in time.
Issues with Equipment manufacturing Cos.
Caterpillar Since it has taken over BE, they have to take care of supply of spare
parts of Dragline and Electric rope shovel of Marion and BE making
respectively.
Joy Global Presently the Company takes 6 months to 9 year to supply spare
parts after LC
 Long supply time : This hampers the availability of high capacity
equipment like 10 Cum & 20 Cum electric rope shovel. Should
make arrangement to supply spares within 3 to 4 months time.
 Not supplying PLC & SLC system components and spares for
20 cum rope shovel deployed in Rajmahal whereas they are
supposed to support ECL for supplying these spares for whole life
of the equipment. This is going to affect availability of 20 cum
shovel, the main digging equipment at Rajmahal OCP.
 To rationalize price of Spares: The Company increases the price
of spares at their will. This should be rationalized as per market
trends.
Issues of Technology upgradation
Technology upgradation: Present Status
(a) Higher capacity and technologically
advanced equipment: being procured.
(100 T dumpers have replaced 85T Dumpers &
190T dumpers have been proposed as replacement
of 170T Dumpers)
Issues to be addressed

Proximity
Warning
Device
in
dumpers
presently provides an
audio- visual warning to
the operator when it
detects objects in front or
rear of the dumper up to 8
meters from the sensor
mounting. This should be
enhanced to at least 25 to
30 meters.

Tail Gate Protection
system in dumpers is not
full proof. It has to be
redesigned by the OEMs
in
consultation
with
DGMS.
(b) Equipment with self-diagnostic tools: being
procured.
(e.g., Vehicle Health Monitoring System, Payload
Monitoring System, etc. which provide data to
analyze and improve mine efficiency, reduce
failure and improve maintenance practices.)
(c) HEMM with more safety and comfort
features: being procured.
(e.g., AC cabin, proximity warning device, rear
vision camera etc. for safety & productivity of the
operator and the equipment.)
Issues related to Maintenance & Spares Management
Maintenance and Spare Parts Management:
Present Status
Issue to be addressed
(a) Equipment Procurement in ECL is with one year
warranty followed by two years guaranteed
availability.

to ensure that the bidder (both global & domestic) has
sufficient service support & spares backup

to ensure high availability of newly procured
equipment

to ensure smooth availability of spares

to have sufficient time for finalizing spares
procurement process (RC or Depot Agreement ) in
case of new equipment model.
Consignment
Store
concept for prompt
supply of quality spares
with zero inventory (like
BEML consignment store
at Rajmahal Area) - May
be considered for other
High Producing Areas or
at some central location
for a group of smaller
Areas, by BEML and
other major suppliers.
(b) Depot Agreement: ECL is having depot agreement
with all major OEMs to ensure smooth supply of
spares.
Issues of Technology upgradation
1.
Extensive use of Surface Miner & Ripper especially near habitation &
near to sensitive structures.
2.
OB disposal through belt after sizing.
3.
Transport of coal through tube conveyors.
4.
Use of highwall technology wherever possible/feasible.
Thank You