Workshop on Technology Development for reaching 250 MT (19-20) Mahanadi Coalfields Limited

Estimated demand & Gap Demand of coal IN MT (at 100% satisfaction level) as per FSA/LOA Year Demand Prod Gap

Year UG1.50 OC TOTAL Coal production projection Year wise upto

Additional Shovel required to achieve 250 Mty by Capacity Total 34 Cum Cum Cum Cum Cum Grand Total115

Replacement of Shovel Existi ng Total 10 Cum Cum to 4.3 Cum

Capacity Total 35 T /60 T T T T Total1223 Additional Dumper required to achieve 250 Mty by

Replacement of Dumper Exist ing Total 50/60 T

Additional Dozer required to achieve 250 Mty by Capacity Total HP (with Ripper attachment) HP

Replacement of Dozer Existi ng Total 410 HP HP

Additional Drill required to achieve 250 Mty by Total 250 mm mm

Replacement of Drill Existing Total 250 mm mm

Additional Surface Miner required to achieve 250 Mty by Total mm

Additional Loading machine (Pay loader) required to achieve 250 Mty by Total >5 cum >10 cum

Replacement Loading M/C (Pay loader) Existi ng Total >5cum

Additional equipment required for UG upto Capacity Nos ExistingReplacement Continuous Miner 1.4 to 4.6 M2 SDL1 cum918 Low Height SDL 0.8 cum6 Low Height SDL 1 cum 3 LHD1.2 cum22920 LHD2.7 cum4 Roof BolterQuad bolter2 Shuttle Car15 Te6 ConveyorBelt Conveyor11800 m Roof Bolter15

Tube/pipe conveyorRequirement/Capacity Hingula5 Km Bhubaneswari3.5 km Other P&M ( other than HEMM) requirement to achieve 250 MT

Washery Jagannath washery10 Mty Hingula washery10 Mty Kulda washery10 Mty Basundhara washery10 Mty Siarmal washery10 Mty X 4 Lakhanpur integrated20 Mty & 10 Mty Other P&M ( other than HEMM) requirement to achieve 250 MT

Kaniha/Gopalji SILO30 Mty Lingaraj SILO16 Mty Bhubaneswari SILO20 Mty Ananta SILO15 Mty Bharatpur SILO15 Mty Hingula SILO15 Mty Gopalprasad SILO15 Mty Talabira-II &III SILO20 Mty Lakhanpur SILO 30 Mty Kulda SILO 10 Mty Siarmal SILO 40Mty Rapid Loading System including SILO requirement to achieve 250 MT

Technological Development & Mechanization of Mines Proposed Present technology Production level in SDL/LHD with Bord & Pillar in UG Man-riding system in UG 1.5 MT Dragline & Shovel-Dumper combination for OB removal, Loader-Tipper for coal production in OC Surface miner for blast free coal production in OC248.5 MT OITDS, GPS for better monitoring Future technology Continuous miner in UG Higher capacity Shovels & Dumpers Pipe conveyor for coal transportation Ripper dozer for blast free OB removal in OC RLS with SILO for faster loading of wagons

Award of Contracts SlProjectsKey Contracts for EPC, OB removal, coal removal etc. Timeline 1 Kaniha OCP Award of contract for MDOSep-17 2 Siarmal OCP Award of contract for MDO Dec-16

Issues with BEML (A) Delay in supply of spare parts. Spare parts of a module is not supplied in full rather it is supplied in piecemeal due to which repair of particular assembly and equipment is delayed. (B) BE-1600 Hydraulic Excavator 9.5 cum. 06 nos. supplied to MCL are going under frequent breakdown, due to Failure of engines, Hydraulic pumps & Hydraulic tubes, Cooling system and other components since its commissioning.

The performance of BEML : Year % Availability Model Present populat ion BE 1600 D BE 1000 D BE 1000 E

The performance of BEML : Year % Breakdown Model Present populat ion BE 1600 D BE 1000 D BE 1000 E

(C)The performance of BH-100 Ton Dumpers after warranty period is very poor due to failure of Engines, Transmission and other components. Performance is as below : Year % Availability Present population 29 Model BH-100 (100T)

(C)The performance of BH-100 Ton Dumpers after warranty period is very poor due to failure of Engines, Transmission and other components. Performance is as below : Year % Breakdown Model Present population BH-100 (100T)

(D) Recently, supplied BH-60 Ton Dumpers are giving problems like Cabin Vibration, Regular failure of suspension, Air Conditioning compressor mounting bolt loosening problem, Sensors are not working, Camera monitoring foundation bracket failure & Transmission pump failure etc. (E) Recently supplied BD-355 Dozers are also not performing to the mark and giving troubles like :  Automatic release of blades sometimes  Misalignment of cabin  Non functioning of Air Conditioner  Fuel Injection Pumping problem  Starting problem etc.

ISSUES WITH M/S.H.E.C., RANCHI There is general delay in supply of equipment as well as spare parts. As HEC is facing financial constraints, they are demanding advance payment for supply of equipment for recently ordered 10 cum. Electric Rope Shovel

ISSUES WITH M/S. PROMTRACTOR (JSC), RUSSIA Performance of 15 nos. 410 HP Dozers are very very poor due to abnormal failure of engine & transmission even in warranty period. The performance is as below : M/s. Promtractor (JSC), Russia has no Indian service provider for supply of spare parts and maintenance and also not supporting well for supply of spare parts and services. Year CompanyM/s. Promtractor (JSC), Russia % Availability Model Present Populati on Promtractor T CB % Breakdown Model Promtractor T CB

Thank you

 All HEMM should be supplied with Guaranteed Spare Parts Supply (GPS) or Maintenance and Repair Contract (MARC) for life time. SUGGESTIONS FOR SUPPLY AND MAINTENANCE OF EQUIPMENT

 Guarantee for initial 2-3 years is meaningless as machine will perform initially better than when it gets older after 03 years. Hence, guarantee for later period is more important.  Cost of equipment quoted is very less but spare parts are very costly which ultimately result into higher cost of production. If life cycle cost is adopted this can be eliminated.  Buy back system is to be incorporated in case of spare parts which are not consumed during warranty period. Some manufacturers are reluctant for life time guarantee due to uncertainty in foreign currency fluctuation. This problem can be sorted out by incorporating currency escalation/de- escalation clause. SUGGESTIONS FOR SUPPLY AND MAINTENANCE OF EQUIPMENT

 4-5 years satisfactory performance may be introduced instead of one year as per existing standard NIT.  At least 30-40% of the tendered quantity may be considered for meeting the prove ness criteria instead of at least one number as per existing standard NIT.  Tender finalization should be 60/40 basis as per earlier system to have a check on L-1 bidder both in price as well as performance.  The equipment which are not having base in India should not be given chance for participation in open tender as there is also problem of spare and service support because of non availability of India Agent. There should be a provision of consignment store having major population nearer to the project. Modification in Proveness criteria