Post on 03-Apr-2018
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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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