59268158 Underground Mining

7/31/2019 59268158 Underground Mining

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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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Strip Seam 3


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Strip Seam 3


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Strip 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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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



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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



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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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151/191

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


158/191

Cumulative Convergence experienced


159/191

Cumulative Convergence experienced


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161/191

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


After Frequency 16 3 1 1 21


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


164/191

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.


167/191

-- 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


168/191

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.


169/191

-- 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.


170/191


171/191

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


175/191

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


176/191

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


179/191

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


180/191

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.


182/191

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


183/191

-- 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


185/191

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.


186/191

(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.


187/191

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


188/191

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


189/191

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

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