1. Om Prakash Chairman-cum-Managing Director SECL
4/12/2017 2:32 PM
MISSION MT IN TECHNOLOGICAL REQUIREMENTS, DEVELOPMENT & ADOPTION SECL’s PERSPECTIVE
Om Prakash
Chairman-cum-Managing Director
SECL
© 2007 Microsoft Corporation. All rights reserved. Microsoft, Windows, Windows Vista and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries.
The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation. MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.

2. ABOUT SECL
ESTABLISHED : (As a subsidiary of Coal India Ltd)
Largest Coal Producing subsidiary of CIL.
A Mini Ratna PSU
HEAD QUARTER : Bilaspur (CG)
COAL PRODN. : MT in
MT in
NO OF MINES : 86 {UG – 64, OC - 21 & Mixed – 1}
MANPOWER : Around 69000

3. SECL COMMAND AREA

4. Subsidiaries & Operational Areas DANKUNI COAL COMPLEX (W.B)
SECL
CIC COAL FIELD
KORBA & RAIGARH
COALFIELD
DANKUNI COAL COMPLEX (W.B)
SUBSIDIARIES
OPERATIONAL AREAS
1-Baikunthpur
2-Bhatgaon
3-Bisrampur
4-Chirimiri
5-Hasdeo
6-Jamuna-Kotma
7-Johilla
8-Sohagpur
9 -Gevra
10-Dipka
11-Kusmunda
12-Korba
13-Raigarh
Coal Carbonization Plant Producing
1-Coal gas
2-Coal fines
3-Coke Products
4-Dehydated Coal Tar.
1-Chhattisgarh East Railway Limited (CERL)
2-Chhattisgarh East- West Railway Limited
(CEWRL).

5. SECL - Growth since inception
4/12/2017 2:32 PM
SECL - Growth since inception
© 2007 Microsoft Corporation. All rights reserved. Microsoft, Windows, Windows Vista and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries.
The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation. MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.

6. Coal/OBR – the coming years
4/12/2017 2:32 PM
Coal/OBR – the coming years
© 2007 Microsoft Corporation. All rights reserved. Microsoft, Windows, Windows Vista and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries.
The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation. MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.

7. Estimated Quantum of Excavation (2019-20)
Sl. No.
Details
(Target)
(Projections) 1
Total Coal Production (MT)
131
250 2
UG Coal Production (MT) 17 22 3
OC Coal Production (MT)
114
228 4
OBR (MM3)
164
720 5
Composite Excavation (OC Coal + OB) (MM3)
234
860

8. EST. ADDL. LAND REQUIRED FOR MAJOR PROJECTS (NEXT 5 YRS)SL
NO.
NAME OF
PROJECTS
Tenancy
Govt.
Forest
Total 1
Gevra OC Expn.
38.790 2
Dipka OC Expn.
24.411 3
Kusmunda OC Expn.
4.071 4
Pelma 5
Rai 6
Chhal
95.543
24.590 7
Durgapur 8
Madannagar 9
Rampur-Batura
12.874 10
Jampali
69.213 11
Chira Group, Syang Group
PR under preparation
Sub total 12
Total Land Requirement
10500
2200
11500
24200

9. Under Ground Capacity Expansion
UG Coal Production ( ) : MT
Expected Coal Production in : MT
By Intermediate technology (SDL+LHD) MT
By Mass Production Technology (MPT) MT
(Continuous Miner (CM)- 4 sets)
Highwall (HW)- 1 set MT
UG Production level planned in : MT
By Intermediate technology (SDL+LHD) MT
By Mass Production Technology (MPT) MT
(Continuous Miner – 13 sets)
Highwall (HW)- 4 sets MT
The UG coal production enhancement will include additional contribution from 9 sets of CM and 3 sets of HW.

10. MAJOR CONTRIBUTING UG PROJECTS IN INCREMENTAL PRODUCTION (MT)

11. UG mines in SECL - Next 5 years perspective
Modest growth is envisaged from UG mines.
LHDs & UDMs will find their place for replenishment & additional requirement.
SDLs will be gradually phased out.
More number of Man-riding systems to be introduced in large mines.
Extended use of multi utility vehicle for transport of materials, existing labour oriented haulages to be phased out.

12. UG Safety Equipment - Way forward
Safety items/equipment likely to witness wider application :
Strata control equipment
Light weight cap lamps
Light weight self-rescuers.
Refuge chambers.
Gas chromatographs.
Instrumentation for detecting hidden strata disturbances
Mechanized drilling.
Fast constructing ventilation stoppings.
Innovations in belt technology for UG mines.

13. Open Cast Capacity Expansion – Next 5 years
PRIORITY - I:
Sanction of Expn. PRs for Gevra OC (40-70 MTY) & Kusmunda OC (15-50 MTY) Major share of OBR is planned to come from high capacity HEMMs (40-55) Cum shovels, T Dumpers, mm Drills, HP Dozers etc.).
(i) Huge handling of OBR.
(ii) Huge requirement of land.
(iii) Slope stability management as mines progress to greater depths.
PRIORITY - II:
Development of Mand-Raigarh Coalfield: Planning of high capacity mines with high stripping ratio and greater depth.
PRIORITY - III:
Many of the new projects are being planned envisaging OB removal and Coal production by Departmental Equipment as well as through outsourcing.
Application and deployment of Surface Miners is likely to spread to yield sized coal and facilitate selective mining, if required.
Wide scale use of In-pit and Surface Belt conveyors.

14. Technological up-gradation planned in OC mines
Deployment of high capacity HEMM at mega OC mines
Transportation of coal by Belt (In-pit / Surface)
Introduction of Slope Stability Radar
3D Laser Scanner for mine surveying
High angle Belt conveyor for deeper & steep mines.
Skip Hoist system for deeper mines.
Introduction of 3D simulation for Mine planning with real time traffic simulation
Introduction of advanced technology in blasting :
Fragmentation analysis & continuous monitoring
Use of Electronic Detonator and Gas Bags
Use of Laser Profilers for face mapping and blast design

15. Future Challenges Counter Measures
Increasing environmental awareness & sensitivity.
Heavy blasting in the vicinity of human settlements.
Management of large traffic inside the mine.
Disposal of hazardous waste.
Counter Measures
Use of In-pit crushing/ conveying of coal through Belt.
Transportation of coal in form of slurry to pit head/ neighboring consumers.
Introduction of modern conveying equipment i.e. High angle / Flexible / Piped conveyor, Skip Hoist System etc.
OB conveying through Belt after crushing.

16. Requirement of High Capacity HEMM and related Infrastructure

17. Existing High Capacity HEMM in Mega Projects of SECL
Description
Gevra
(35 MTY)
Dipka
(25 MTY)
42 CuM Electric Rope Shovel
03 Nos.
02 Nos.
240 T Rear Dump Truck
16 Nos.
06 Nos.
850 HP Dozer
08 Nos.
05 Nos.
500 HP Motor Grader
04 Nos.
381 MM Drill
10 CuM Front End Loader
01 No.

18. HEMM to be inducted as per already approved PRs
Description
Gevra
(35 MTY) by
Dipka
(25 MTY)
Kusmunda
(15-50 MTY) by
42 CuM Electric Rope Shovel
02 Nos.
05 Nos.
240 T Rear Dump Truck
24 Nos.
08 Nos.
52 Nos.
850 HP Dozer
10 Nos.
06 Nos.
09 Nos.
500 HP Motor Grader -
381 MM Drill
10 CuM Front End Loader
20 Nos.
Surface Miner
05-10 Nos.

19. PROBLEMS IN PROCUREMENT OF HEMM
Limited sources available globally for high capacity HEMM.
PSU are constrained through systemic guidelines – When choice of technology / optimizing equipment is concerned.
It is difficult to formulate suitable specification to ensure quality equipment / technology.
Absence of indigenous capability / manufacturing base.

20. ON-LINE EQUIPMENT HEALTH & MAINTENANCE MONITORING SYSTEM
On-line pay load monitoring (PLM) for high capacity equipment is in vogue in mega projects of SECL.
High capacity HEMM are being monitored continuously by downloading of data through ECM relating to their health and operational parameters.
To enhance the productivity of the high capacity HEMM it is planned to incorporate on-line health monitoring system such as :
Daily Engine & Transmission health parameters with alarm system for abnormities such as Oil pressure, temperature, payload, air filter clogging, Oil level warning etc..
Health parameter of Motor & Generator such as winding & bearing temperature monitoring & warning and control circuit parameters with warning.
Auto generation of maintenance schedule based on the actual health of sub- assembly.
Exploring the possibility to interface ECM with OITDS.

21. Technology Absorption in Maintenance & Operation
Existing: High capacity HEMM (Shovels, Dumpers & Dozers) have been procured with MARC of 12/17 years to absorb the state-of-art technology.
Future outlook : All high capacity HEMM will be procured without MARC. Faster absorption of technology would be possible if the equipment are maintained in-house with necessary support of OEM.
Anticipated Training Requirements:
Operators are to be trained by manufactures at site and on simulators.
Maintenance personnel are to be trained at manufacture’s works and at site.
Existing departmental training center will be upgraded as per the technology of latest equipment.
Condition Based Monitoring : Facilities such as Wear debris analysis with spectroscopy, vibration analysis are planned to be upgraded.

22. INFRASTRUCTURE SET-UP FOR EQUIPMENT REPAIR / MAINTENANCE & REBUILDING OF MAJOR SUB-ASSEMBLIES
Presently Central Workshops are equipped with facilities matching up to 120T Dumpers & 10 Cum Shovels.
To meet the anticipated requirement, infrastructure is being upgraded in workshops of all the mega projects incorporating facilities like :
High capacity bay lubrication systems,
Washing plants,
Diesel Bowsers,
Mobile workshop equipped with latest facilities &
Tyre mounting and dismounting equipment
Central Workshops are being equipped with appropriate capacity/ technology for higher capacity Shovels & Dumpers.

23. INVENTORY & SPARES MANAGEMENT
MARC : Presently spares management for high capacity HEMMs are being done under MARC. To ensure the guaranteed availability, the MARC holder generally keeps the floats of major assemblies as per their assessment.
Forecasting of spares requirement being difficult, the inventory cost is unpredictable, hence float management appears to be the only logical solution.
The down time cost being comparatively high, a methodology for speedy procurement needs to be adopted for smooth running of HEMM.
Consignment store concept : Spares and floats of the HEMM to be maintained by manufacturer at our premises or nearby location which can be obtained after requisition by project, duly vetted.
Networking of Mega projects having high capacity HEMM for various details viz., availability of spares, consumption pattern etc. along with company HQ for clubbing the requirement, disbursement of spares and for monitoring at HQ level.

24. INVENTORY & SPARES MANAGEMENT
Present Practice:
Inventory for fast moving spares based on its annual off-take.
Quarterly procurement of consumables.
Minimum floats of sub-assemblies are being maintained.
Procurement of spares due to breakdowns.
Challenges for high capacity Equipment not under MARC:
Absence of consumption pattern.
Sourcing constraint - only source being the OEM.
High Prices - Difficulty in price justification.
High/Non-moving inventory due to above.
Long lead time / Currency fluctuation for imported equipment.

25. Long Term Perspective-I
INVENTORY & SPARES MANAGEMENT
Long Term Perspective-I
Search of reliable alternatives.
Care during procurement to negotiate long term supply of spares.
Preparation of drawings/specifications through reverse engineering to develop local sources.
Value engineering to develop alternate cheaper and better substitute.
Long Term Perspective-II
Pooling arrangement for high value-Insurance spares with similar manufacturing unit.
RC with OEM/Alternate sources for reduction of lead time and other benefits.
Structured periodical interaction between engineering and material function for course corrections to obtain targeted results.
Support for calculated risk taking.

26. Extending IT applications
Effective communication, efficiency and safety can be achieved in an OC mine by installation of following systems :
Already working :
OITDS – (In Mega OC Projects)
Video surveillance (at some locations)
Planned for deployment
Wireless video for industrial security
Proximity detection system.
Vehicle health monitoring system.
Collision warning systems.
GPS based vehicle tracking system, Boom Barrier, Weighbridge centering and integration to monitor coal transport and avoid pilferage:
Trial run being done in 6 Operational Areas.
To be inducted in all Operational Areas.

27. COAL HANDLING & EVACUATION

28. Coal Handling & Evacuation Plan (MT)
4/12/2017 2:32 PM
Coal Handling & Evacuation Plan (MT)
© 2007 Microsoft Corporation. All rights reserved. Microsoft, Windows, Windows Vista and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries.
The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation. MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.

29. Challenges in Coal Handling & Evacuation
Substantial infrastructure upgrade is to be done i.e., CHPs, Silos, Roads, Cross -Country conveyor belts etc.
System of electric loco passing under silos.
Requisite arrangement of internal transportation of coal is to be established.
Existing system (predominantly by road) may not be appropriate to handle such large quantity of coal.
Timely completion of East & East-West Rail Corridors are crucial for coal evacuation from Korba & Raigarh coalfields of SECL.
Requirement of massive Railway capacity augmentation.

30. COAL HANDLING FACILITIES (CHP / SILO)
(A) WORKS IN PROGRESS
SL No.
Name of Work
Remark
(1)
2 Nos. Silo 4000 MT at Gevra Area
Likely commissioning during
(2)
In Pit Conveyor System Area at Gevra Area
(B) CONSTRUCTION WORK TO COMMENCE SHORTLY
SL No.
Name of Work
Remark
(1)
20000 Over Head Bunker with CHP (Phase-I) at Kusmunda OCP (15-50 MTY).
Likely to start in
(C) ENGINEERING PLAN UNDER PREPARATION
SL No.
Name of Work
(1)
Main CHP with 4 Nos. Silos of 4000 MT capacity at Kusmunda OCP (15-50 MTY)
(2)
Over Head Bunker of MT with 2 Nos. Silo of 4000 MT capacity at Pelma OCP (15 MTY) of Raigarh Area.
(3)
Over Head Bunker of MT with 1 No. Silo of 4000 MT capacity at Chhal OCP (6 MTY) of Raigarh Area.

31. New Technologies likely to find future application:
New Technologies recently introduced for coal handling and evacuation system from OC mines:
Modification of Silo loading system
Silos with double discharge chutes
Provision of passing electric locos under the silos
Controlled Start Transmission (CST) Drive.
Plough Feeders for reclamation of coal from bunkers.
Shifting Belt conveyors.
New Technologies likely to find future application:
High Angle / Sandwich / Pipe Conveyors
Curved conveyor (Vertical & Horizontal)
Skip Hoist system
Dual Truck Mobile Sizer (DTMS)

32. Wagon Requirement
Since majority of coal evacuation is has been planned through Rail mode, the year-wise rake requirement per day will be as following:
Sl. No.
Year
Rake requirement 1 38 2 40 3 46 4 53 5 75 6
109
Increase in Rail traffic and requirement of wagons needs to be addressed.

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