Mahanadi Coalfields Limited Workshop on Technology Development for

Mahanadi Coalfields Limited Workshop on Technology Development for reaching 250 MT (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 Prod 150. 00 167. 00 187. 00 222. 00 250. 00 Gap 49. 00 75. 00 55. 00 20. 00 -8. 00

Coal production projection Year wise upto 2019 -20 Year 14 -15 15 -16 16 -17 17 -18 18 -19 19 -20 UG 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

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 20 -22 Cum 1 4 2 4 11 03 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 Total Existi ng 14 -15 1516 10 Cum 40 2 37 2 4 18 -19 2 2. 5 to 4. 3 Cum 1718 12 4. 5 -6. 5 Cum 1617 1920 4 5 2 1 14

Additional Dumper required to achieve 250 Mty by 2019 -20 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

Total Replacement of Dumper 50/60 T Existi 14 ng 15 284 34 1516 16 -17 31 66 17 -18 1819 19 -20 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 Total Existi ng 14 -15 15 -16 16 -17 17 -18 18 -19 19 -20 410 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 Existing 14 -15 15 -16 16 -17 17 -18 1 4 1 6 1 3 18 -19 19 -20 Total Drill 250 mm 34 160 mm 55 7 6 2 19

Additional Surface Miner required to achieve 250 Mty by 2019 -20 15 -16 30003800 mm 16 -17 17 -18 18 -19 19 -20 Total 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 Existi Loading M/C ng 14 -15 15 -16 16 -17 17 -18 4 1 18 -19 19 -20 Total (Pay loader) >5 cum 10 5

Additional equipment required for UG upto 2019 -20 Capacity Nos Continuous Miner 1. 4 to 4. 6 M 2 SDL 1 cum 9 Low Height SDL 0. 8 cum 6 Low Height SDL 1 cum LHD 1. 2 cum 2 LHD 2. 7 cum 4 Roof Bolter Quad bolter 2 Shuttle Car 15 Te 6 Conveyor Belt Conveyor 11800 m Roof Bolter Existing Replacement 18 18 29 20 3 15

Other P&M ( other than HEMM) requirement to achieve 250 MT Tube/pipe conveyor Requirement/Capacity Hingula 5 Km Bhubaneswari 3. 5 km

Other 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

Rapid Loading System including SILO 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 40 Mty

Technological Development & Mechanization of Mines Proposed Present technology SDL/LHD with Bord & Pillar in UG Man-riding system in UG Dragline & Shovel-Dumper combination for OB removal , Loader-Tipper for coal production in OC Surface miner for blast free coal production in OC OITDS, GPS for better monitoring Future technology Continuous miner in UG Higher capacity Shovels & Dumpers Pipe conveyor for coal transportation Ripper dozer for blast free OB removal in OC RLS with SILO for faster loading of wagons Production level in 19 -20 1. 5 MT 248. 5 MT

Award of Contracts Sl Projects 1 Kaniha OCP 2 Siarmal OCP Key Contracts for EPC, OB removal, Timeline coal removal etc. Award of contract for MDO Sep-17 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 populati on 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 populati on 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 Present population 29 Model BH-100 (100 T) 2008 - 2009 - 2010 - 2011 - 2012 - 2013 - 201409 10 11 12 13 14 15 % Availability - 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 : Model BH-100 (100 T) Year 2008 - 2009 - 2010 - 2011 - 2012 - 2013 - 201409 10 11 12 13 14 15 % Breakdown Present population 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 : Ø Ø Ø 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), RUSSIA Performance of 15 nos. 410 HP Dozers are very poor due to abnormal failure of engine & transmission even in warranty period. The performance is as below : Year 2008 -09 2009 -10 2010 -11 2011 -12 2012 -13 2013 -14 2014 -15 Company M/s. Promtractor (JSC), Russia % Availability Model Promtractor T 25. 01 CB-1 Present Populati on 15 - - 71 53 31 24 11 % Breakdown Model Promtractor T 25. 01 CB-1 - - 23 43 67 74 88 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.

Thank you

SUGGESTIONS FOR SUPPLY AND MAINTENANCE OF EQUIPMENT Ø 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 Ø 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. Ø 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. Ø 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/deescalation clause.

Modification in Proveness criteria Ø 4 -5 years satisfactory performance may be introduced instead of one year as per existing standard NIT. Ø 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. Ø 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. Ø 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.