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7/28/2019 Sail Project on hemm

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BHAGWANT UNIVERSITY

A PROJECT REPORT ON**Study of Heavy Earth Moving Machines (HEMM)

In Meghahatuburu Iron Ore Mine (MIOM)**

Submitted By:

SARFARAZ ALAM

Branch: Mechanical Engineering


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FOREWORD

We feel immense pleasure to complete our Vocational Training here at

meghahtuburu Iron Ore Mines. We have learnt a lot during our training

period and this will cherish in our memories for long. In this regard we

have here prepared a project report on Study ofHEMMs(Heavy Earth

Moving Machines). We have emphasized on the well mannered

representation of facts in a simple way.

For this we would like to extend our greatest thanks to all those people

who have helped us in the completion of this project especially- Mr.

R.P.Selvam (AGM mechanical services) Sir under without whom we would

not have been able to present this project.

SPECIAL THANKS TO

Mr. P.KUMAR, Asst. Mgr.(Mech)

Mr. D. K. DE, DY. Mgr (Mech.)

Mr. S. MOHANTY, Asst. Mgr. (Mech.)

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STEEL AUTHORITY OF INDIA LIMITED

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 wasrestructured as an operating company managing the steel plants at

Rourkela, Bhillai, Durgapur, Bokaro.

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.

SAIL-FOR FUTURE MODERNISATIONS AND EXPANSIONS

1. 100% production of steel through Basic Oxygen Furnace(BOF) route


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2. 100% processing of steel through continuous casting

3. Value addition by reduction of semi finished steel

4. Auxiliary fuel injection system in all the Blast furnace

5. Energy saving schemes

6. Adherence to environment norms.

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%.

LOCATION

Longitude: 85 16 east

Latitude: 22 04 north

Altitude: 918 m above main sea level

TYPES OF ORES

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


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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.

WATER SOURCES FOR MIOM

Karo and Pardih Nala for drinking water

Ghagirathi and Kumdi Nala for industrial water

MIOM RATED CAPACITY

ROM: 5.0 MT

Lump Ore + Fine Ore: 4.25 MT

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.


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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 toreduce 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.

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MECHANICAL DEPARTMENT

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. DOZER SECTION

Types of HEMMSs:

a) Dumpers:

i. M/s BEML: 50T capacity

ii. M/s KOMATSU: 100T capacity

iii. M/s CATERPILLAR: 100T capacity

b) Dozers(BEML)

c) Front End Loader(KOMATSU)


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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 SECTION

Types of HEMMs:

a) Hydraulic Excavator

i. BEML: BE-1000

ii. KOMATSU: PC 2000-8

b) Drill

IDM-30

DOZER SECTION

Types of Dumpers in MIOM:

1. Make: BEML(Bharat Earth Movers Limited)

Model : BH50M

Engine: Cummins KTTA-19C

Capacity: 50T

2. Make: CATERPILLAR

Model: 777D

Engine Model: CAT-3508 EU1

Engine HP: 850

Capacity: 100T


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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.

BH50M REAR DUMPER

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 operators 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.


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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.

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

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

Torque Convertor..TC683

6 Speeds Forward2 REVERSE

FINAL DRIVE


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Ratios:

Bevel Set (Differential)..3.85:1

Planetary...5.70:1

Total Reduction..21.93:1

Maximum Speed 35MPH(56.7km/h)

24VDC ELECTRICAL SYSTEM

BatteriesTwo 12 Volt Batteries in Series

Capacity.200 Ampere-Hour

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

Starter...DELCO-REMY

Lighting..24 Volt-DC

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 Tank95

359.6


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Transmission20

75.6

Final Drive..56

212.6

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

ReturnFull Flow, 12 Micron- Absolute

STEERING

Turning Circle..69 ft.

(21.0m)

Pump Capacity22.7

gpm(85.9lpm)

System pressure.. .2750

psi(19.0 Mpa)


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DUMP TRUCK

(MACHINE MODEL HD785-7)

(SERIAL NO.7001 and Up)

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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PERFORMANCE

Dump Body Capacity:

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

Max. travel speed: 65 km/h

Gradeability (sin ): 35%

Min. turning radius: 10.1 m

Dumping angle: 48

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

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

POWER TRAIN


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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]

No. of speeds: F7, R2

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

STEERING SYSTEM

Type: Fully Hydraulic steering system

BRAKE SYSTEM

Service Brake:

Front wheel: Oil cooled multiple disc brake, Hydraulically

Controlled


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Rear Wheel: Oil cooled multiple disc brake, Hydraulically

Controlled

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

spring type

Retarder: Oil Cooled multiple disc brake, Hydraulically Controlled

FRONT END LOADER

INTRODUCTION

This machine is intended mainly for the following operations.

1. Digging operations

2. Levelling operations

3. Pushing operations

4. Loading operations

FEATURES

1. Console and steering post with neat foot area and no protrusions,

giving the same comfortable feelings an automobile.


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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.

SPECIFICATIONS

PERFORMANCEBucket 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

3rd: 23.1 km/h

4th: 36.6 km/h

Maximum rim pull: 19420 kg

Minimum turning radius:


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Outside of bucket: 6960mm

Centre of outside tyre: 5820 mm

WEIGHT

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

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)

ENGINE DEFECTS

Problem Main causes RemedyEngine oil pressurecaution pilot lamp lightsup

1. Engine oil pan oillevel islow(sucking in air)

2. Clogged oil filtercatridge

1. Add oil tospecified level,see CHECK BEFORE STARTING

2. Replace catridge


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3. Defectivetightening of oilpipe joint oilleakagefromdamaged pan

4. Defective engineoil pressuresensor

3. (Check, repair)4. (Replace sensor)

Steam is admitted fromtop part of radiator(pressure valve)

1. Cooling waterlevel low, waterleakage

2. Loosen fan belt3. Dirt or rust

accumulated incooling system4. Clogged radiator

fin or damaged fin5. Defective

thermostat6. Loose water tank

cap (high altitudeoperation)

7. Defective waterlevel sensor

1. Add cooling water,repair

2. Check, replace fanbelt tension

3. Change cooling

water, cleaninside of coolingsystem

4. Clean or repair5. (Replace

thermostat)6. (Tighten cap or

replace packing)7. (Replace water

level sensor)

Water temperaturegauge is in red rangeCooling temperaturemonitor lights up

Water temperaturegauge is in white range 1. Defectivethermostat2. Defective monitor

1. Replacethermostat2. Replace

Engine does not startwhen starting motor isturned

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

injection pump orfuel

4. Starting motorcranks enginesluggishly

5. Preheating pilotlamp does notlight up

6. Defectivecompression

1. Add fuel2. Replace place

where air issucked in

3. (Replace pump ornozzle)

4. Adjust valveclearance

Exhaust gas is white or 1. Too much oil in oil 1. Add oil to


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blue pan2. Improper fuel

specified level2. Change to

specified fuelExhaust gasoccasionally turns

1. Clogged aircleaner elementblack

2. Defective nozzle3. Defective

compression

1. Clean or replace2. Replace nozzle

DOZERSMake: BEML

Model: BD 355X

Engine Model: S6D170-1

Flywheel HP: 410

Numbers: 5

POWER TRAIN OF DOZERS

1. Engine

2. Torque Convertor

3. Universal Joint

4. Torque flow Transmission

5. Steering Brake

6. Steering Clutch

7. Sprocket

8. Final Drive


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9. Track

USES

To create flat surface in zigzag plane which punches earth and rocks with a

blade installed at machine front end.

SPECIFICATIONSNo. of cylinders- Bore X Stroke: 6-170 170 mm

Total Piston Displacement: 23150 cc

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

DIMENSIONS

Overall length: 1873 mm

Overall width: 1265 mm

Overall height: 1922 mm

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


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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

Battery: 12V, 200 Ah 2

Turbo Charger: K K K/India

DEFECTS WITH THEIR REMARKS

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

sensing type 60 to 200000rpm

2. Pressure valveperformance

Radiator CapTester

0 to 2 kg/cm2

3. Leakage incooling watersystem

Radiator CapTester

0 to 2 kg/cm2

4. Radiator

blockage(windspeed)

Anemometer(Air

speed gauge)

1 to 40 m/s

5. Compressionpressure

Compression gaugekit

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

colorHandy smokechecker

Dirtiness 0 to 70 % withstandard color


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FIELD MACHINERY SECTION

HYDRAULIC EXCAVATORS (SHOVEL)

TYPES

1. Make: BEML

Model: BE-1000

Capacity: 5.4 cubic meter

Numbers:03

2. Make: KOMATSU

Model: PC 2000-8

Capacity: 9.5 cubic meter

Numbers:02

POWER TRAIN

1. Swing motor(Front end)

2. Centre swivel joint


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3. Swing motor(Rear end)

4. Travel relief valve

5. R.H 4-Spool control valve

6. Final Drive

7. R.H Travel motor

8. Engine

9. P.T.O

No.2 pumps

10. Charging and P.T.O lubrication

11. Swing pump

No. 1 pump

12. L.H.S- Spool control valve

13. Free swing connection valve

14. Swing control valve

15. Swing brake solenoid valve

16. Travel speed selector solenoid valve

17. Free swing solenoid valve

18. Swing machinery

19. Swing Circle

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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SPECIFICATIONS

Reservoir Kind of Fluid Capacity/LTEngine oil panP.T.O

Swing machineryCase(each)Final drive case(each)Hydraulic system

Engine oil

6115

13451200

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

Gear oil

1.3-1.40.70-0.780.70-0.78

Fuel tank Diesel 1140Cooling system Water 160

DEFECTS WITH THEIR REMEDIES

DEFECTS CAUSE REMEDY1. Machine deviates

excessivelyTVS Valve defective Replace

2. No change inoutput whenmade switchseparated

Resistance defective Replace

3. Swing does notwork

Solenoid valve defective Replace

4. Excessive Defective hydraulic Replace


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hydraulic drift switchDefective timerDefective solenoid valve

5. Travel speed doesnot switch

Defective solenoid valve Replace

6. Excessivedeviation in travelduringsimultaneousoperations

Defective shutter valve Change

7. Control levers areextremely heavy

PPC valve defective Replace

8. Engine stalls or

engine speeddrops duringoperation

Servo valve defective Replace

DRILL

Model: IDM-30

USESDrills are commonly used in working of metal construction. The drill are

fitted with a cutting too attachment to drill the earth.

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.

TYPES OF SYSTEM

1. Power Pack

2. Hydraulic system

3. Pneumatic system

4. Propulsion

5. Feed

6. Rotary head system


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DEFECTS WITH THEIR REMEDIESDEFECTS CAUSE REMEDY

1. Air dischargecapacity toolow

Enginespeedtoo low

Check air cylinder, check engine filter

Blockedaircleaner

Check restriction filter

Highpressure

air isescaping

Check for leak

4. Excessivevibration

Enginespeedtoo low

Check for leak

5. Oil seal leaks Improperly fittedseal

Check throttle operation

6. Oil flowsback into airfilter

Faultunloadervalve

Check free operation of unloader valve

7. Compressorover heats

Low oillevel

Top oil level

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