STEEL AUTHORITY OF INDIA LIMITED

1. INTRODUCTION

1.1 FORMATION:

The Committee of Public undertaking of the Fifth Lok Sabha was the first Parliamentary Committee to undertake a significant review of the formation of SAIL.

Objectives of the Department of Steel:

1. Rapid growth of the industrial sector, of the economy, of the state as a leading agent of the growth process; and

2. Ability of the Government to divert investment into areas which are strategic from the point of view of future development.

Based on the above consideration, the proposal to set up a holding company for Steel and associated input industries were approved by the Government in January, 1972. Accordingly, the formation of the Steel Authority of India Limited was approved by the Government in December, 1972. The company was incorporated on January 24, 1973 with an authorized capital of Rs. 2, 000 crores. In 1978 SAIL was restructured as an operating company managing the steel plants at Rourkela, Bhillai, Durgapur, Bokaro.

1.2 PRESENT STATUS:

Today, SAIL is one of the largest entity in the country, with assets more than Rs. 10, 000 crores. Its innate strength lies in its technologies and professionals and a trained manpower of 2,00,000 and a sales turnover of around Rs. 11,000 crores.

1.3 SAIL-FOR FUTURE MODERNISATIONS AND EXPANSIONS:

1. 100% production of steel through Basic Oxygen Furnace(BOF) route2. 100% processing of steel through continuous casting3. Value addition by reduction of semi finished steel4. Auxiliary fuel injection system in all the Blast furnace5. Energy saving schemes6. Adherence to environment norms.

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2. LAYOUT OF MEGHAHATUBURU IRON ORE MINES

The Meghahatuburu Iron Ore Mines(MIOM ) is one of the captive iron ore mines of Bokaro Steel Plant. MIOM is about 385 km away from BSL in south. This mine is connected by broad gauge railway line to the Steel Plant.

Meghahatuburu Iron Ore Mines has been designed for an output of 4.25 MT of washed lump and fines. In both the mines, mining is being done by Shovel-Dumper combination, with complete mining being done by Shovel-Dumper combination and ROM being washed in ore beneficiation plant.

Meghahatuburu mines, have a total capacity of 8.55 million tones of ore. The quality of iron ore at MIOM is good with Fe content being 63%. Composite material from MIOM is likely to give an aluminia-silica ratio of 1.5 and total gauge less than 5%.

2.1 LOCATION:

Longitude: 85° 16’ east

Latitude: 22° 04’ north

Altitude: 918 m above main sea level

2.2 TYPES OF ORES:

Hard massive/hard laminated(Fe:60-65%)

Self laminated(aluminous: 58-63%)

Self laminated (siliceous: 60-65%)

Blue Dust (>Fe:65%)

Laterite (Fe: 57-59%)

The wastes are laterite, shale, BHQ, and BHT and Phyllites.

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2.3 WATER SOURCES FOR MIOM:

Karo and Pardih Nala for drinking water

Ghagirathi and Kumdi Nala for industrial water

2.4 MIOM RATED CAPACITY:

ROM: 5.0 MT

Lump Ore + Fine Ore: 4.25 MT

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3. WORKING METHOD

Ore Processing:

In case of MIOM,, iron ore is being washed to reduce the gangue content(i.e. almunia and silica) thereby it increases the Fe content in the ore. Washing also improves the handling characteristics of the iron ore fines.

The washing process involves scrubbing, wet screening and classification. The material is scrubbed in the scrubber, then fed to vibrating screen (single or double deck) where water is sprayed for good washing and screening. In wet screening, lump is separated from the fines and is carried to the washed lump ore stock pile by conveyors. The undersize (-10 mm size fine ore mixed with water) is fed to the classifier.

Micro fine ore (-65 mesh) gets into classifier and the same is allowed to overflow having 18-20% of solid waste material. Rakes product (+65 mesh) with 14 to 17% moisture are fed to the dewaterises screen to reduce the moisture content by 4 to 5%. The washed fines with 10 to 11% moisture from the dewateriser are carried to the washed fines stockpile by conveyors. In the stockpile the water percolates to the bottom of the pile bringing down the moisture content to the around 6.9% in the washed fines. The collected moisture at the bottom is drained out from the stock.

MECHANICAL DEPARTMENT

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All SAIL plants have been provided with Central Engineering Shops to facilitate repair/reconditioning of component, sub assemblies and assemblies as well as a substantial part of their spare requirement.

There are mainly two sections:

1. MECHANICAL SEVICESTypes of HEMMS’s:

1. Dumpers:i. M/s BEML: 50T capacity

ii. M/s KOMATSU: 100T capacity2. Dozers(BEML)3. Front End Loader(KOMATSU)

Machine Shop: The shop usually consists of light and heavy Machining Section equipped with Lathes, Planners, Horizontal and Vertical Boring machines, Slotting machines, Grinders etc.

2. FIELD MACHINERY SECTIONTypes of HEMM’s:

a) Hydraulic Excavatori. BEML: BE-1000

ii. KOMATSU: PC 2000-8b) Drill

IDM-30

4. MECHANICAL SERVICES

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4.1 DUMPER SECTION

Types of Dumpers in MIOM:

1. Make: BEML(Bharat Earth Movers Limited)Model : BH50MEngine: Cummins KTTA-19CCapacity: 50T

2. Make: KUMATSUModel: HD785-7Engine: Komatsu SAA12V140E-3Capacity: 100T

USES

Dumpers are used for transportation of bulk materials (Iron Ore). These dumpers are loaded at shovel pit and unloaded at hopper or waste dump yard.

4.1.1 BH50M REAR DUMPER:

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4.1.1.1 COMPONENT DESCRIPTION

ENGINE

The 210M HAULPAK is powered by a Cummins KTTA-19C diesel engine. The truck is capable of speeds up to 35 MPH(55.67 km/h).

TRANSMISSION

The engine drives a remote-mounted Alisson CLT-6062 transmission incorporporating a TC683 torque converter. The transmission has six speeds “Forward” and one “Reverse” and uses Allison transmission Electronics Control(ATEC) for complete automatic shift sequencing.

DYNAMIC RETARDING

Dynamic retarding is actuated by depressing the operator’s retarder pedal which applies oil-cooled, rear mounted, wet disc brakes only; the front brakes are not applied.

SERVICE BRAKE SYSTEM

The service brakes are controlled by an all hydraulic actuation system. Depressing the service pedal actuates front dry disc brakes and rear wet disc brakes.

POWER STEERING

The HAULPAK Truck is equipped with an orbital power steering system mounted under the cab floor with noise and vibration isolators. Emergency power to safety steer the truck while stopping is provided by an accumulator.

FINAL DRIVE

Planetary Final Drive has full floating axle shafts and a plug-in differential carrier assembly.

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Fig. 1 BH50M Dumper

4.1.1.2 SPECIFICATIONS

ENGINE

Cummins…………………………………………… KTTA-19C

Number of cylinders…………………………………………...6

Operating cycle……………………………………… 4-Stroke

Rated Brake HP(SAE) 700 Hp(522 kW) @ 2100 RPM

Flywheel HP (SAE) 648 HP (483 kW) @ 2100 RPM

Maximum Torque

…... 267 kgm (2618 N.m) @ 1400 RPM

4.1.1.3 TRANSMISSION ALLISON/HM-PPD CLT-6063 w/ATEC

Torque Convertor……………………………………..TC683

6 Speeds Forward………………………………2 REVERSE

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4.1.1.4 FINAL DRIVE

Ratios:

Bevel Set (Differential)……………………….. 3.85:1

Planetary……………………………………… 5.70:1

Total Reduction……………………………………..… 21.93:1

Maximum Speed………………………… 35MPH(56.7km/h)

4.1.1.5 24VDC ELECTRICAL SYSTEM

Batteries……………………………….. Two 12 Volt Batteries in Series

Capacity……………………….………. 200 Ampere-Hour

Alternator ……..………………............ 24 Volt,75 Amperes output

Starter………..………………………… DELCO-REMY

Lighting……..………………………… 24 Volt-DC

4.1.1.6 CAPACITIES

SERVICES CAPACITIES U.S. Gallons Liters

Engine Lube Oil:

Cummines (Incl. Lube oil filters) 14.2 53.8

Cooling System 48 181.7

Fuel tank 203 770

Hydraulic System 48 545.0

Hydraulic Tank 95 359.6

Transmission 20 75.6

Final Drive 56 212.6

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4.1.1.7 HOIST SYSTEM

Tandem Pump Capacity:

Shaft End.....................................................................................94 gpm (355 l/min) @ 2100 RPM

Cover End………………………………………………………80 gpm (303 l/min) @ 2100 RPM

Relief Valve Pressure Setting 2750 psi (18.9Mpa)

Hoist Cylinders…………………………………………….…… 2- Stage Hydraulic Cylinders

Filtration………………………………………………………Full-Flow, remote-Mounted Filter

4.1.1.8 STEERING

Turning Circle…………………………………………………………… 69 ft.(21.0m)

Pump Capacity…………………………………………………………… 22.7 gpm(85.9lpm)

System pressure…………………………………………………………... 2750 psi(19.0 Mpa)

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4.1.2 KUMATSU HD785-7 DUMPER:

Fig. 2 Kumatsu HD 785-7 Dumper

4.1.2.1 SPECIFICATIONS

WEIGHT

Empty: 72,300 kg

Max. load: 91,000 kg

Gross: 163,300 kg

Weight Distribution:

Empty: (front) 33,980(47%) kg

(Rear) 38,320 (53%) kg

Gross: (front) 51,440(31.5%)kg

(Rear)111,860(68.5%) kg

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4.1.2.2 PERFORMANCE

Dump Body Capacity:

Struck: 40 m3 and Heaped(2:1): 60 m3

Max. travel speed: 65 km/h

Gradeability (sin ϴ): 35%

Min. turning radius: 10.1 m

Dumping angle: 48°

Adaptation to highland(high altitude): 2,350 m

4.1.2.3 ENGINE

Model: KOMATSU SAA12V14OE-3

Type: 4-cycle, water cooled, V type in-line 12 cylinder, direct injection, with turbocharger and after cooler

No. of cylinders- Bore x stroke: 12-140 16 mm⨯

Piston Displacement: 30.5{30,500} l{cc}

Rated output: 895/1,900{1,200/1,900} kW/rpm{HP/rpm}

Max. torque: 5.076/1,350{518/1,350} Nm/rpm{kgm/rpm}

Fuel Consumption: 206{154} g/kWh{g/HPh}

Stating Motor: 24V, 90A

Battery: 12V,200Ah 4 units⨯

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4.1.2.4 POWER TRAIN

Torque Converter:

Structure: 3-element, 1-stage, 2-phase

Lock-up clutch: Hydraulically actuated, wet-type, multiple-disc clutch

Transmission:

Type: TORQFLOW planetary gear[Fully automatic, electrically-hydraulically actuated, force-feed type pump]

Reduction gear:

Type: Spiral bevel gear, splash lubrication

Reduction ratio: 3.357

Differential type: Straight bevel gear, splash lubrication

Final Drive:

Type: Planetary gear, splash lubrication

Reduction ratio: 6.333

4.1.2.5 STEERING SYSTEM

Type: Fully Hydraulic steering system

4.1.2.6 BRAKE SYSTEM

Service Brake:

Front wheel: Oil cooled multiple disc brake, Hydraulically Controlled

Rear Wheel: Oil cooled multiple disc brake, Hydraulically Controlled

Parking Brake: Multiple disc wet type disc brake, Hydraulically released spring type

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4.2FRONT END LOADER

4.2.1 INTRODUCTION

This machine is intended mainly for the following operations.

1. Digging operations2. Levelling operations3. Pushing operations4. Loading operations

4.2.2 FEATURES1. Console and steering post with neat foot area and no protrusions, giving the same

comfortable feelings an automobile.2. Fully hydraulic sharp, effective brake control with no need to drain water or any need to

worry about freezing or rust.3. Maintenance-free, wet type disc parking brake(also acts as emergency brake)4. One-touch panel control and air conditioner with new refrigerant installed.

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HL 770-9A FRONT END LOADER

Fig. 3 HL 770-9 FRONT END LOADER

4.2.3 SPECIFICATIONS

4.2.3.1 PERFORMANCE

Bucket Capacity: 3.9 m3

Rated load: 7000 kg

Travel Speed:

Forward

1st: 7.0 km/h

2nd: 12.5 km/h

3rd: 22.2 km/h

4th: 35.3 km/h

Reverse

1st: 7.2 km/h

2nd: 13.2 km/h

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3rd: 23.1 km/h

4th: 36.6 km/h

Maximum rim pull: 19420 kg

Minimum turning radius:

Outside of bucket: 6960mm

Centre of outside tyre: 5820 mm

4.2.4 WEIGHT

Operating weight (including 1 operator: 80 kg(176 lb)): 21640 kg

4.2.5 ENGINE

Model: Komatsu SA6D125E-2 diesel engine

Flywheel horsepower: 194 kW (236 HP)/2250 rpm

Max. Torque: 1048.6 Nm (107 kgm)/1400 rpm

Starting motor: 24 V, 7.5 kW

Alternator: 24 V, 50 A

Battery: 12 V, 150 Ah × 2 pieces (145F51)

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4.2.6 ENGINE DEFECTS AND REMEDY Table-1

Problem Main causes RemedyEngine oil pressure caution pilot lamp lights up

1. Engine oil pan oil level is low(sucking in air)

2. Clogged oil filter catridge

3. Defective tightening of oil pipe joint oil leakagefrom damaged pan

4. Defective engine oil pressure sensor

1. Add oil to specified level, see CHECK BEFORE STARTING

2. Replace catridge3. (Check, repair)4. (Replace sensor)

Steam is admitted from top part of radiator (pressure valve)

1. Cooling water level low, water leakage

2. Loosen fan belt3. Dirt or rust

accumulated in cooling system

4. Clogged radiator fin or damaged fin

5. Defective thermostat6. Loose water tank cap

(high altitude operation)

7. Defective water level sensor

1. Add cooling water, repair

2. Check, replace fan belt tension

3. Change cooling water, clean inside of cooling system

4. Clean or repair5. (Replace thermostat)6. (Tighten cap or

replace packing)7. (Replace water level

sensor)

Water temperature gauge is in red rangeCooling temperature monitor lights up

Water temperature gauge is in white range

1. Defective thermostat2. Defective monitor

1. Replace thermostat2. Replace

Engine does not start when starting motor is turned

1. Lack of fuel2. Air in fuel system3. Defective fuel

injection pump or fuel4. Starting motor cranks

engine sluggishly

5. Preheating pilot lamp does not light up

6. Defective compression

1. Add fuel2. Replace place where

air is sucked in3. (Replace pump or

nozzle)

4. Adjust valve clearance

Exhaust gas is white or blue 1. Too much oil in oil pan

2. Improper fuel

1. Add oil to specified level

2. Change to specified fuel

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4.3 DOZERS

Make: BEML

Model: BD 355X

Engine Model: S6D170-1

Flywheel HP: 410

Numbers: 5

4.3.1 POWER TRAIN OF DOZERS

1. Engine2. Torque Convertor3. Universal Joint4. Torque flow Transmission5. Steering Brake6. Steering Clutch7. Sprocket8. Final Drive9. Track

4.3.2 USES

To create flat surface in zigzag plane which punches earth and rocks with a blade installed at machine front end.

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Fig.4 BEML 355X Dozer

4.3.3 SPECIFICATIONS

No. of cylinders- Bore X Stroke: 6-170 × 170 mm

Total Piston Displacement: 23150 cc

Firing Order: 1-5-3-6-2-4

4.3.4 DIMENSIONS

Overall length: 1873 mm

Overall width: 1265 mm

Overall height: 1922 mm

4.3.5 PERFORMANCE

Flywheel HP: 410/2000 HP/rpm

Maximum torque: 176/1400 kg/rpm

High idling: 2200 rpm

Low idling: 650 rpm

Maximum fuel consumption ratio: 164 g/HP

Dry weight: 2700 kg

Fuel pump: Bosch Pe-Pd type

Governor: Bosch RSUV centrifugal all speed type

Lubricating oil amount: 58(43)

Coolant Amount: 163

Alternator: 24V, 45 A

Starting Motor: 24V, 11kW × 1

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Battery: 12V, 200 Ah × 2

Turbo Charger: K K K/India

4.3.6 DEFECTS WITH THEIR REMARKS Table-2

Sl no. Inspection Fault finding tool Remarks1. Engine speed Multi-Tachometer Digital reading pressure sensing

type 60 to 200000 rpm 2. Pressure valve

performanceRadiator Cap Tester 0 to 2 kg/cm2

3. Leakage in cooling water system

Radiator Cap Tester 0 to 2 kg/cm2

4. Radiator blockage(wind speed)

Anemometer(Air speed gauge)

1 to 40 m/s

5. Compression pressure

Compression gauge kit 0 to 70 kg/cm2

6. Blow by pressure Blow by checker 0 to 50 mm H207. Valve clearance Feeler gauge 0.4, 1.00 mm8. Exhaust gas color Handy smoke checker Dirtiness 0 to 70 % with standard

color

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5. FIELD MACHINERY SECTION

5.1. HYDRAULIC EXCAVATORS (SHOVEL)

Make: BEMLModel: BE-1000Capacity: 5.4 cubic meterNumbers:03

5.1.1 POWER TRAIN

1. Swing motor(Front end)2. Centre swivel joint3. Swing motor(Rear end)4. Travel relief valve5. R.H 4-Spool control valve6. Final Drive7. R.H Travel motor8. Engine9. P.T.O

No.2 pumps10. Charging and P.T.O lubrication11. Swing pump

No. 1 pump12. L.H.S- Spool control valve13. Free swing connection valve14. Swing control valve15. Swing brake solenoid valve16. Travel speed selector solenoid valve17. Free swing solenoid valve18. Swing machinery19. Swing Circle

5.1.2 USES

These machines do the loading work. These ae designed for the purpose of digging, lifting and moving materials. Shovel buckets made of heavy steel usually seem folded at the back to home a socket for the machine.

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BEML BE-1000 EXCAVTOR:

Fig. 5 BEML BE-1000 Excavtor

5.1.3 SPECIFICATIONS Table-3

Reservoir Kind of Fluid Capacity/LTEngine oil panP.T.OSwing machinery Case(each)Final drive case(each)Hydraulic system

Engine oil

611513451200

Carrier roller(1 piece)Track roller(1 piece)Idler roller(1 piece)

Gear oil1.3-1.40.70-0.780.70-0.78

Fuel tank Diesel 1140Cooling system Water 160

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5.1.4 DEFECTS WITH THEIR REMEDIES Table-4

DEFECTS CAUSE REMEDY1. Machine deviates

excessivelyTVS Valve defective Replace

2. No change in output when made switch separated

Resistance defective Replace

3. Swing does not work Solenoid valve defective Replace4. Excessive hydraulic

driftDefective hydraulic switchDefective timerDefective solenoid valve

Replace

5. Travel speed does not switch

Defective solenoid valve Replace

6. Excessive deviation in travel during simultaneous operations

Defective shutter valve Change

7. Control levers are extremely heavy

PPC valve defective Replace

8. Engine stalls or engine speed drops during operation

Servo valve defective Replace

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5. 2 DRILL

Model: IDM-30

Make:ATLAS CAPCO

5.2.1 USES

Drills are commonly used in working of metal construction. The drill are fitted with a cutting too attachment to drill the earth.

Fig. 6 Atlas capco Drill IDM-30

5.2.2 SPECIFICATIONS

Model: IDM 30 Engine power pack, IDM 30-E electric motor driven power pack

Drill diameter: 152/165 mm dia hole

Operation wt.: 28500 kg

Pull down: High torque radial piston hydraulic motor feed through roller chain

Pull down: High torque radial piston hydraulic motor feed through roller chain

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Pull down capacity: 13600 kg

Feed speed (Max): 13 m per min

Relation Torque: 28407 in lb.(max)

Speed range: 0-100 rpm

Tower construction: Rugged one channel frame construction handle 25 feet rod tower raised on lowered by a hydraulic cylinder

Drill pipe change: An indexing type carousel houses three drill rods one hydraulic cylinder moves the carousel. Another cylinder is used to bring the drill pipe in loading position rotating on its own axis. Both the cylinder are controlled cabin.

Angle drilling: Optional

Range: 0-30° in steps of 5°

Leveling Jacks: Four can type leveling jacks with 40° stroke two numbers on drill end and two numbers on rear end.

Under carriage: Crawler type tracks equipped with replaceable triple grouser pads. Each track has 8 bottom rollers and 2 carrier rollers for standard machines. In case of long machines call tracks have 9 bottom rollers and 2 carrier rollers.

5.2.3 TYPES OF SYSTEM

1. Power Pack2. Hydraulic system3. Pneumatic system4. Propulsion5. Feed6. Rotary head system

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5.2.4 DEFECTS WITH THEIR REMEDIES Table-5

DEFECTS CAUSE REMEDY1. Air discharge

capacity too lowEngine speed too low

Check air cylinder, check engine filter

Blocked air cleaner

Check restriction filter

High pressure air is escaping

Check for leak

2. Excessive vibration

Engine speed too low

Check for leak

3. Oil seal leaks Improperly fitted seal

Check throttle operation

4. Oil flows back into air filter

Fault unloader valve

Check free operation of unloader valve

5. Compressor over heats

Low oil level

Top oil level

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6.CONCLUSION

Meghahatuburu Iron Ore Mines has been designed for an output of 6 MT of washed lump and

fines. Mining is being done by Shovel-Dumper combination, with complete mining being done

by Shovel-Dumper combination and ROM being washed in ore beneficiation plant.

Iron ore is being washed to reduce the gangue content(i.e. almunia and silica) thereby it

increases the Fe content in the ore. Washing also improves the handling characteristics of the

iron ore fines.

SAIL Mine of MIOM have been provided with Central Engineering Shops to facilitate

repair/reconditioning of component, sub assemblies and assemblies as well as a substantial part

of their spare requirement.

It also provide services to Heavy Earth Moving Machines which contain Dumper,

Dozer, Motor Grader, Front End Loader, Crane, Excavator and Drill Machines.

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7.REFERENCES

1. Introduction to physical metallurgy By Sideny H. Avner

2. Machine Tools By Dr. R. Kesavan

3. www.sail.co.in

4. http://en.wikipedia.org/wiki/

5. www.bemlindia.com

6. www.komatsu.com

7. india.cat.com

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