INDUSTRIAL

TRAINING
REPORT

SUBMITTED BY GUIDED BY SUBMITTED TO

ABHAY PACHAURI MR. SANJAY SINGH MR. SAROJPATI

SINGHA

B.Voc. (AUTO. ENGG.) MANAGER OF TRAINING

OFFICER

DAYALBAGH UNIVERSITY DUMPER MAINTAINANCE SASAN COAL

MINES

(R.NO.149001)
 ACKNOWLEDGEMENT

I would like to thank to all the SUPERVISORS and STAFF of

WORKSHOP SASAN POWER Ltd.. Who accorded me permission
to undergo practical training at WORKSHOP DUMPER
MAINTAINANCE.

I would like to acknowledge gratefully the kind help and full

cooperation rendered to us by the workshop staff.

I am thankful to dumper section staff for imparting the training to

us at full gratitude of valuable guidance

I am also thankful to my College DEI UNIVERSITY for their

constant guidance and taking initiative and encouraging us to do
well.
CONTENTS

1. Introduction
1.1 About the company
1.2 Project by company
2. Project specification
3. Mining machinery and its capacity
4.Introduction of Rear Dump truck
4.1 Parts of Dumper
4.2 Dumper measurement
4.3 Dumper specification
5. Drive train
5.1 Engine
5.2 Alternator
5.3 IGBT
5.4 WHEEL MOTOR
6.Hydraulic system
6.1 Steering system
6.2 Braking system
6.3 Hoist pump
7. Maintenance
8.Observation, Learning & Implementation
1. INTRODUCTION
1.1. ABOUT THE COMPANY
Reliance Power Limited is a part of the Reliance Group,
one of Indias largest business houses. The group
operates across multiple sectors, including
telecommunications, financial services, media and
entertainment, infrastructure and energy. The energy
sector companies include Reliance Infrastructure and
Reliance Power.

1.2. PROJECT BY COMPANY

MOHER & MOHER AMLOHRI EXTENSION Open Coal
mine was allotted to Reliance Power Ltd. (A subsidiary of
Reliance Anil Dhirubhai Ambani group under the
chairmanship of Mr. Anil Dhirubhai Ambani. The
project is an integrated project undertaken by the
company under the name of Sasan Power Ltd. (SPL).
This project named SASAN ULTRA MEGA POWER
PLANT (SUMPP) includes a thermal power plant. The
power plant is backed by high grade coal from its captive
coal mine the MMAE-OCP. The power plant is located at
a distance of about 25 Kms. from the coal mine. The coal
is transported by the help of conveyor belts.
2. PROJECT SPECIFICATION
o NAME OF THE MINE: Moher & Moher amlohri
extension opencast project
o ANNUAL CAPACITY: 20MT Coal
78 MBCM Overburden
o TOTAL AREA: 2131 Hectares
o GRADE OF COAL: G10
o COAL SEAMS: Purewa Seams & Turra Seams
o TOTAL RESERVE: Extractable 470MT
o MINE LIFE: 29 Years
o MINING METHOD: Front End Loader-Dumper
combination for
Coal
Shovel-dumper combination
for
Overburden
Dragline for inter-burden
o BENCH SIZE: OB benches 18-20 meters
Coal benches 15 meters
Dragline benches 55-60 meters
3. Mining Machineries AND ITS
CAPACITY

Name of the machine Capacity

Dragline 62 CUM bucket capacity
with 90 mm boom length
Electric rope shovel 42CUM
RBH Drill 250mm
Rear dumper 240 T
D 475 Dozer 850 hp
D375 Dozer 660 hp
4. INTRODUCTION OF REAR
DUMP TRUCK

It is used for hauling & dumping large payloads and transports

excavated material (Coal /Overburden) from one point to another
in mines.
Its major components are chassis, hydraulic system, one dump
body (240T), 2700hp v-type engine, and suspension with a proven
MTU engine, rear wheel AC electrical drive system & vehicle
information management system.
4.1. PARTS OF DUMPER
4.2. DUMPER MEASUREMENT
4.3. DUMPER SPECIFICATIONS
o Kerb weight- 450T
o Dump body capacity- 240T
o Bore- 170mm
o Stroke- 215mm
o Max. Speed- 64km/h
o Steer angle- 30 degrees
o Turning radius- 15.2m (4910)
o Engine- 16 cylinder v-type
o Drive system- Electrical drive
o Fuel tank capacity- 4500 Lts(diesel)
o Engine oil capacity- 260 Lts(15W40)
o Hydraulic tank capacity- 908 Lts(S2M68)
o Power train oil- S4CX30
o Coolant- MTU 1
o Wheel hub oil- 12 Lts(S4W680)
o Wheel motor oil- 40 Lts(S4W680)
o Tire- 50/80R57 radial
o Battery- 24V
5. DRIVE TRAIN
Engine Alternator IGBT
Wheel motor
5.1. ENGINE

INTURNAL COMBUSTION
ENGINE
The internal combustion engine is an engine in which the
combustion of fuel and an oxidizer (typically air) occurs in a
confined space called a combustion chamber. This exothermic
reaction creates gases at high temperature and pressure, which
are permitted to expand. Internal combustion engines are defined
by the useful work that is performed by the expanding hot gases
acting directly to cause the movement of solid parts of the
engine.

The term Internal Combustion Engine (ICE) is often used to refer

to an engine in which combustion is intermittent, such as a
Wankel engine or a reciprocating piston engine in which there is
controlled movement of pistons, cranks, cams, or push rods.
However, continuous combustion engines such as jet engines,
most rockets, and many gas turbines are also classified as types
of internal combustion engines. This contrasts with external
combustion engines such as steam engines and Stirling engines
that use a separate combustion chamber to heat a separate
working fluidwhich then in turn does work. For example, by
moving a piston.
 TURBO
-CHARG
ER OIL
COOLER
AFTER
COOLER
V-TYPE 16 CYLINDER ENGINE
(MTU)

In this dumper have used a v-type 16 cylinder v- type engine, this

type of engines, number of cylinders are uncommon in automotive
use.

A V16 engine is perfectly balanced regardless of the V angle

without requiring contra-rotating balancing shafts which are
necessary to balance engines with odd numbers of cylinders in-
line or those equipped with counterweighted crankshafts like the
90 V8. In addition V angles of 45 and 135 give an impulse
every 45, so are optimal solutions, for even-firing and non-split
bearing crankshaft journals.

V16 engines are rarely used in automobiles because V8s or V12s

of the same displacement typically produce just as much power,
and are much less expensive to manufacture and maintain. The
few V16s that have been produced were used in high-end luxury
and high-performance automobiles due to their smoothness (low
vibration).

This engine comprises, one turbocharger, radiator fan with float

clutch, after cooler and oil cooler

Turbocharger is work in an adiabatic process, one end of this

turbocharger is attached with the exhaust manifold and another is
after cooler. This is used for the increase the pressure and
temperature of air in an inlet manifold.

The process of cooling the turbocharger delivery of an engine is

called charge cooling and he cooler is known as after cooler. An
after cooler removes heat from the compressed air coming from a
turbocharger before it enters an engines induction system. this
increase efficiency by increasing he density of the air, making for
more air molecules.

5.2. ALTERNATOR
Alternator is used to generate a high voltage AC power. It is
drives from the engine crank shaft at flywheel side. It comprises
two windings stator and rotor with integrated blower. This
alternator is a three phase connected AC generator

an alternator generally consists of field poles placed on the

rotating fixture of the machine. Once the rotor or the field poles
are made to rotate in the presence of armature conductors
housed on the stator, an alternating 3 voltage represented by
aa bb cc is induced in the armature conductors thus resulting in
the generation of 3 electrical power.
It is give this high voltage AC current to IGBT (insulated-gated
bipolar transistor).
 5.3. IGBT (INSULATED GATE
BIPOLAR TRANSISTOR)
An insulated-gate bipolar transistor (IGBT) is a three-terminal
power semiconductor device primarily used as an electronic
switch which, as it was developed, came to combine high
efficiency and fast switching. It switches electric power in many
modern appliances: variable-frequency drives (VFDs), electric
cars, trains, variable speed refrigerators, lamp ballasts, air-
conditioners and even stereo systems with switching amplifiers.
Since it is designed to turn on and off rapidly, amplifiers that use
it often synthesize complex waveforms with pulse-width
modulation and low-pass filters.
In this dumper, This device carries high voltage AC current from
the alternator. Then this AC converts DC with the help of rectifier
then this DC converts AC with the help of invertor.
This conversion is used for make controlled AC at 60 HZ .then this
controlled AC give to AC wheel motor according to the operator, controlled by the
IGBT.
 5.4. WHEEL MOTOR
(TRACTION MOTOR)
Wheel motor also known as a traction motor. This motor is
directly connected with wheels.
this motor comprise that rotor or stator windings, sun and planet
gears & taper roller bearings.

CUT-SECTION OF WHEEL
MOTOR
IGBT supply a controlled AC directly to wheel motor stator
winding then EMF generate between rotor and stator winding
then rotor winding revolve and sun gear also revolve because
sun gear shaft is attached with the rotor spline then planet gear
also revolve with the help sun gear.

WHEEL MOTOR
A planetary gear system, also referred to as epicyclic gearing,
consists of three elements a sun gear, one or more planet gears,
and a ring gear. The sun gear is located at the center, and
transmits torque to the planet gears that orbit around it. Both are
located inside the ring gear. The tooth formation of the sun and
planet gears is external, while the ring gear is internal.
SUN & PLANET GEAR ASSEMBLY
In this motor, planet is revolve only own position and these help
to moves the ring and ring gear is attached with the disc. Planet
gear shaft away in inner side with external gears, these gear
helps to rotate the wheel hub and two bearings also used
between the wheel hub and stator.

6. HYDRAULIC SYSTEM
6.1. STEERING SYSTEM
The steering system is allows the driver to control the direction of
vehicle travel. this is made up by linkage that connects the
steering wheel to the steerable wheel and tires. The steering
system may be either manual or power. When the only energy
source for the steering system is the force driver applies to the
steering wheel, the vehicle has manually steering. Power steering
uses hydraulic system and electrical motor to assist the driver
efforts.
In this system use a power steering, it consist a steering pump,
hydraulic filters, amplifier, orbital valve and steering cylinders

STEERING PUMP
This steering pump drives by the hoist pump and alternator by
drive shaft. This pump supplies the hydraulic oil, hydraulic tank to
the hydraulic filters at very high pressure (3450-3550psi)
ORBITAL VALVE
Then this pressurized hydraulic supply to steering manifold
and then amplifier and orbital valve is control the direction of
wheel with the help valve.

6.2. BRAKING SYSTEM-

Braking system is used to stop and slow down the vehicle in the
shortest possible distance in according to the condition.

In this machine used two types of brakes:

POWER BRAKE
ELECTRICAL BRAKE
 POWER BRAKE
PARK
BRAKE
LOAD
BRAKE

SERVIC
E
BRAKE

Fig. Rear wheel

Disc-caliper assembly
o SERVICE BRAKE:- Service brake are the hydraulically, the
hydraulic brakes are applied by the liquid pressure. The pedal
force is transmitted to the brake shoe by means of a confined
liquid through a system of force transmission. The force applied to
the pedal is multiplied an transmitted to all the brake shoe by a
force transmission system. This system is based upon Pascals
principal. In this system, 12 caliper assembly used in the
machine.
8 caliper assembly in front
4 caliper assembly in rear.
This hydraulic pressure is also created by the steering pump and
control the equality of hydraulic at same pressure at all calipers.
o PARK BRAKE: - Park brakes also hydraulically, this brake
operated by hand and foot are used for parking and emergency
brake, this brake act on the rear wheel. 2 caliper assembly used in
rear wheel. At applied time, firstly apply park brake then the load
brake this load brake is 2 caliper assembly of service brake. This
is used for the load to disc at parking time with park brake.

ELECTRICAL BRAKE
o RETARDER: - Retarder is an external brake frequently used in
trucks. The purpose of the retarder is to assist in stopping the
vehicle, controlling vehicle downhill speed on a steep grade,
extending the life of the vehicle service brakes, and enhancing
vehicle control.
Retarder is the absorb the IGBT controlled high voltage AC by
rectifier, contactor tip and blower fan grid.
Rectifier is absorb the 550 voltage after that free voltage is
flow to grid by contactor tip then grid is very heat up so the
blower fan is cool down the grid, this fan is also rotate by this
heavy duty current.
In this system, have also an AUTO RETARDER SYSTEM; this
is used for the control speed limit of the vehicle. This system is
auto work after cross the speed limit.

BLOWER FAN
6.3. HOIST PUMP
Hoist pump is used for pressurizing the hydraulic and supply to
the hoist cylinder and hoist cylinder is used for raise and keeps
the dump body.

HOIST PUMP
This hoist pump pressure control by the control valve and this
control valve is attached with the hand lever and sensors.
 HOIST
CYLINDE
R

HOIST CYLINDER

7. MAINTENANCE
Maintenance is the process of preserving a condition or situation
of vehicle.
Maintenance has two types

PREVENTIVE MAINTENANCE
Preventive maintenance is the regular maintenance of the
vehicle. This is done at every 500 hour as recommended by OEM.
In this maintenance,
Check the leakage of hose in vehicle.
Check the grease pump, hoist pump, steering pump working
and leakage.
Check the leakage at brake caliper assembly.
Change the engine oil, front wheel hub oil at every 500 hours
(15W40).
Change hydraulic at every 6000 hours (S2M68).
 Change rear wheel motor oil at every 3000 hours (S4W680).
Change engine oil filter, hydraulic filter at every 500 hour.
Change return line filter at every 1000 hours.
Clean air filter, centrifugal at every 500 hours and change the
air filter at every 1000 hours.
Engine tappet setting at every 2500 hours.
Recover a payload data.
Check all electrical faults, sensor, horn, all lights of the vehicle.
Clean super structure, blower motor by air pressure.
Check window motor.

BRAKE DOWN MAINTENANCE

Brakedown maintenance is corrective maintenance, action as per
brakedown, mobilizing manpower, tools & support.
 8. OBSERVATION, LEARNING &
IMPLEMENTATION
I observe that the all workers knowing about own works.
I observed that the used scrap batteries at switching fluid lights
in inner side of dumpers for worker help.
Proper tools for each work in the workshop.
Fill the nitrogen in tires because
It is very light weight and cool gas.
It cant support the combustion.
Nitrogen gas escape the through the tires approximately
4 times slower than natural air.
Less heat=less wear=more mileage=less heat=better
safety
Nitrogen fill tires are approximately 2 times more than life.