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

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 of HEMMs(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.) *****************************************************

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 was restructured 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

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%)

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.

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
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. ii. iii. M/s BEML: 50T capacity M/s KOMATSU: 100T capacity M/s CATERPILLAR: 100T capacity

b) Dozers(BEML) c) 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 SECTION

Types of HEMMs: a) Hydraulic Excavator i. ii. BEML: BE-1000 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

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.

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) Maximum Torque ... 267 kgm (2618 N.m) @ 1400 RPM 648 HP (483 kW) @ 2100 RPM

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

Torque Convertor..TC683 6 Speeds Forward2 REVERSE

FINAL DRIVE

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
Engine Lube Oil:

U.S. Gallons

Liters

Cummines (Incl. Lube oil filters).14.2 Cooling 181.7 Fuel 770 Hydraulic 545.0 Hydraulic 359.6

53.8

System..48 tank...203 System..48 Tank95

Transmission20 75.6 Final 212.6 Drive..56

HOIST SYSTEM
Tandem Pump Capacity: Shaft End........................................................................................94 gpm (355 l/min) @ 2100 RPM Cover End.80 l/min) @ 2100 RPM Relief Valve Pressure Setting (18.9Mpa) Hoist Cylinders.2Hydraulic Cylinders Filtration.Full-Flow, Mounted Filter gpm (303

2750 psi Stage remote-

ReturnFull Flow, 12 Micron- Absolute

STEERING
Turning Circle..69 ft. (21.0m) Pump Capacity22.7 gpm(85.9lpm) System pressure.. psi(19.0 Mpa) .2750

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

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

Torque Converter: Structure: 3-element, 1-stage, 2-phase Lock-up 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 clutch: Hydraulically actuated, wet-type,

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

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.

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 emergency brake) type disc parking brake(also acts as

4. One-touch panel control and air conditioner with new refrigerant installed.

SPECIFICATIONS 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 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

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 Remedy Engine oil pressure 1. Engine oil pan oil 1. Add oil to caution pilot lamp lights level is specified level, up low(sucking in air) see CHECK 2. Clogged oil filter BEFORE STARTING catridge 2. Replace catridge

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

Water temperature gauge is in red range Cooling temperature monitor lights up

Water temperature gauge is in white range Engine does not start when starting motor is turned

3. Defective tightening of oil pipe joint oil leakagefrom damaged pan 4. Defective engine oil pressure sensor 1. Cooling water level low, water leakage 2. Loosen fan belt 3. Dirt or rust accumulated in cooling system 4. Clogged radiator fin or damaged fin 5. Defective thermostat 6. Loose water tank cap (high altitude operation) 7. Defective water level sensor 1. Defective thermostat 2. Defective monitor 1. Lack of fuel 2. Air in fuel system 3. Defective fuel injection pump or fuel 4. Starting motor cranks engine sluggishly 5. Preheating pilot lamp does not light up 6. Defective compression 1. Too much oil in oil

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

1. Add cooling water, repair 2. Check, replace fan belt tension 3. Change cooling water, clean inside of cooling system 4. Clean or repair 5. (Replace thermostat) 6. (Tighten cap or replace packing) 7. (Replace water level sensor) 1. Replace thermostat 2. Replace 1. Add fuel 2. Replace place where air is sucked in 3. (Replace pump or nozzle)

4. Adjust clearance 1. Add oil

valve

Exhaust gas is white or

to

blue Exhaust occasionally turns gas

pan 2. Improper fuel 1. Clogged air cleaner element black 2. Defective nozzle 3. Defective compression

specified level 2. Change to specified fuel 1. Clean or replace 2. Replace nozzle

DOZERS
Make: 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

9. Track

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

SPECIFICATIONS
No. 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

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. 1. 2. 3. 4. 5. 6. 7. 8. Inspection Engine speed Pressure valve performance Leakage in cooling water system Radiator blockage(wind speed) Compression pressure Blow by pressure Valve clearance Exhaust gas color Fault finding tool Multi-Tachometer Radiator Tester Radiator Tester Remarks Digital reading pressure sensing type 60 to 200000 rpm Cap 0 to 2 kg/cm2 Cap 0 to 2 kg/cm2 1 to 40 m/s 0 to 70 kg/cm2 0 to 50 mm H20 0.4, 1.00 mm Dirtiness 0 to 70 % with standard color

Anemometer(Air speed gauge) Compression gauge kit Blow by checker Feeler gauge Handy smoke checker

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

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. 11. Charging and P.T.O lubrication Swing pump

No. 1 pump 12. 13. 14. 15. 16. 17. 18. 19. L.H.S- Spool control valve Free swing connection valve Swing control valve Swing brake solenoid valve Travel speed selector solenoid valve Free swing solenoid valve Swing machinery 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.

SPECIFICATIONS
Reservoir Engine oil pan P.T.O Swing machinery Case(each) Final drive case(each) Hydraulic system Carrier roller(1 piece) Track roller(1 piece) Idler roller(1 piece) Fuel tank Cooling system Kind of Fluid Capacity/LT 61 15 13 45 1200 1.3-1.4 0.70-0.78 0.70-0.78 1140 160

Engine oil

Gear oil Diesel Water

DEFECTS WITH THEIR REMEDIES

DEFECTS 1. Machine deviates excessively 2. No change in output when made switch separated 3. Swing does not work 4. Excessive CAUSE TVS Valve defective Resistance defective REMEDY Replace Replace

Solenoid valve defective Defective

Replace

hydraulic Replace

hydraulic drift 5. 6.

7. 8.

switch Defective timer Defective solenoid valve Travel speed does Defective solenoid valve not switch Excessive Defective shutter valve deviation in travel during simultaneous operations Control levers are PPC valve defective extremely heavy Engine stalls or Servo valve defective engine speed drops during operation

Replace Change

Replace Replace

DRILL
Model: IDM-30

USES
Drills 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

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

DEFECTS WITH THEIR REMEDIES

DEFECTS 1. Air discharge capacity too low CAUSE Engine speed too low Blocked air cleaner High pressure air is escaping Excessive Engine vibration speed too low Oil seal leaks Improperl y fitted seal Oil flows Fault back into air unloader filter valve Compressor Low oil over heats level REMEDY Check air cylinder, check engine filter Check restriction filter Check for leak

4. 5. 6. 7.

Check for leak Check throttle operation Check free operation of unloader valve Top oil level

************************************************************