Transcript Slide 1

NCL
NCL – At a Glance
NCL
NCL was formed in 1985 bifurcating CCL
Has about 3% of the Total Geological Coal Reserves of India
Coal Reserves : India (01.04.14) : 301.56 BT
NCL (01.04. 14) : 9.66 BT
Digs out more than 12% of the National Coal Production
which fulfills about 13% of the coal based power houses
NCL produces only power grade coal from ten mechanized
opencast mines spreading over 100 Sq.Km
Unique Features of NCL
NCL
Handles highest volume :
Company
Total Volume
(Deptt+Outsourced)
Departmental Volume
(Mcum)
Actual
2013-14
Target
2014-15
Actual
2013-14
Target
2014-15
MCL
161.46
195.35
55.50
80.30
SECL
222.54
241.65
86.92
73.20
NCL
253.07
289.87
123.76
129.87
Produces 100% Coal departmentally
Largest fleet of Draglines : 21 out of 41 in CIL
>90% coal supply to Pit-head Power Plants
A typical cross sectional view of an opencast Mine in NCL
Surface
30-120M
Departmental/Outsourced OBNCL
Removal by Shovel+Dumper
Coal Production Shovel + Dumper combination
30-35M
PUREWA BOTTOM SEAM: 8-10 M
OB removal by Shovel + Dumper
Coal Production Shovel + Dumper combination
45 -55 M
TURRA SEAM: 15-22 M
Coal Production Shovel + Dumper combination
4
Mining Strategy
NCL
Top Overburden (A) by Outsourcing
A
Inter-burden (C+E) by Departmental
Shovel-Dumper & Draglines
B Coal
C Interburden
D
Coal (B+D+F) by
Departmental Shovel-Dumper
Top
OB
E
F
Coal
Interburden
Coal
Production & Despatch - Last Five yrs
Coal in Mt & OB in Mcum
250
200
150
Coal
100
Deptt OB
50
0
2009-10
Coal
67.67
Deptt OB 102.28
OS OB
75.16
Total OB
177.98
Despatch 66.67
OS OB
2010-11
66.25
100.04
82.14
182.18
64.21
2011-12
66.4
86.87
114.8
201.66
63.61
2012-13
70.02
83.98
111.72
195.71
67.29
2013-14
68.64
79.47
129.32
208.79
72.11
Total OB
Despatch
Production Projection for Five years
Particulars
Coal
Departmental
OB
Departmental
Composite
Outsource OB
(HoE)
Total Composite
Unit
2015- 2016- 2017- 2018- 201916
17
18
19
20
Mt
80
82
90
99
110
Mcum
112
139
153
156
175
Mcum
165
194
213
222
248
Mcum
158
195
215
244
261
Mcum
323
389
428
466
509
HEMM Required
(Existing Plan + Additional for 1 Bt Plan)
HEMM
Dragline:
24 cum
Shovel:
10 cum
20 cum
Dumper:
100T
190T
2015-16
201617
2017-18
201819
2019-20
Total
Total
Total
Total
Total
2
4
2
6
4
7
9
39
60
18
44
30
29
22
50
5
18
6
28
30
ADDITIONAL CAPACITY (M Cum) FOR
WHICH HEMM TO BE PROCURED
HEMM
NCL
2015-16 2016-17 2017-18 2018-19 2019-20
Dra gline
24cum &
above
18.9
Shovel
10 cum &
Above
86.71
20.12
11.87
23.74
10.84
25.24
42.24
9.68
11.30
7.90
Dumper
100T &
above
OVERVIEW OF HEMM IN NCL AS ON 01.01.2015
NCL
S.No
HEMM
ON ROLL
SURVEYED OFF BUT
WORKING
TOTAL
1
DRAGLINE
18
3
17%
21
2
SHOVEL
84
20
24%
104
3
DUMPER
448
94
21%
542
4
DOZER
160
30
19%
190
5
DRILL
133
19
14%
152
6
PAY LOADER
13
1
8%
14
7
GRADER
46
0
-
46
8
WATER
SPRINKLER
40
15
38%
55
9
CRANE
52
21
40%
73
10
TYRE
HANDLER
15
2
13%
17
TOTAL
1009
1214
Major Suppliers of HEMM
HEMM
DRAGLINE
NCL
Total-Nos.
Supplier
21
CATERPILLAR (CAT), HEC, BEML, URALMASH,
NKMZ
SHOVEL
104
P&H, HEC, BEML, CAT,
TATA-HITACHI , L&T, EKG ( RUSSIAN)
DUMPER
542
CAT, KOMATSU, BEML
DOZER
190
BEML, KOMATSU, CAT
DRILL
152
RECP, ATLAS COPCO, SBSH (RUSSIAN)
PAY LOADER
14
KOMATSU, KAWASAKI, CAT, LEIBHERR
GRADER
46
BEML, CAT
WATER
SPRINKLER
55
BEML, CAT
CRANE
73
TIL, ESCORT, ACE
TYRE HANDLER
17
BEML
Major Suppliers of HEMM
SUPPLIER
HEMMs SUPPLIED TO NCL
NCL
BEML
DRAGLINES, ER SHOVELS , HYDRAULIC SHOVELS (FRONT
END & BACKHOE ), DUMPERS , DOZERS, GRADER, WATER
SPRINKLER, TYRE –HANDLER
CATERPILLAR
DRAGLINES, ER SHOVELS, HYDRAULIC SHOVELS (FRONT
END & BACKHOE ), DUMPERS, DOZERS, GRADER, WATER
SPRINKLER, PAY LOADER
HEC
DRAGLINES, SHOVELS
KOMATSU
DUMPERS, PAY LOADER, BACKHOE
P&H
ER SHOVELS
URALMASH
DRAGLINES
NKMZ
DRAGLINES
TATA
HYDRAULIC SHOVELS(FRONT END & BACKHOE)
OMZ
ER SHOVELS
NCL
DRAGLINES
DRAGLINES IN CIL SUBSIDIARIES
ECL
BCCL
NCL
WCL
SECL
MCL
QTY
1
2
21
3
9
5
41
% OF
POPULATION
2.5%
5%
51%
7.5%
22%
12%
100%
% CAPACITY
3.1%
4%
60.5%
6.7%
17.8%
7.9%
100 %
% POPULATION BASIS
% CAPACITY BASIS
CIL
NCL
POPULATION OF DRAGLINES IN NCL
SNo
MODEL
MAKE
COLLOBARATOR
DRAGLINES PRESENTLY ON ROLL
QTY
NCL
21
1
W2000 24/96
HEC
R&R/BUCYRUS
(CATERPILLAR)
10
2
W2000 24/96
BEML
BUCYRUS
(CATERPILLAR)
3
3
W2000 33/72R
BEML
BUCYRUS
(CATERPILLAR)
1
4
ESH 20/90
URALMASH
4
5
ESH 15/90
URALMASH
1
6
ESH 10/70
NKMZ
2
DRAGLINES UNDER ERECTION
1
W2000 24/96
HEC
TOTAL
R&R/BUCYRUS
(CATERPILLAR)
2
2
23
AGE PROFILE OF DRAGLINES
NCL
Capacity
Survey-off Norms
Years
Hours
10 cum
25
100000
15-20cum
30
140000
24 cum &
above
30
140000
5
4
3
4
3
2
20/90- 3
33/72-1
24/96-1
0
0
20/90-1
24/96-3
24/96-2
24/96-2
15/90 -1
24/96-4
10/70 -2
24/96-1
< 1 year 1 to 5 years5 to 10 years
10 to 15 years
15 to 20 years
20 to 25 years
25 to 30 years>30 years
76% Draglines crossed 50% of life
DRAGLINES
NCL
AVERAGE
CMPDIL
AVAILIBILITY
NORMS
2014-15
Sl.
No.
MAKE
NOS
AVERAGE
HOURS
1
HEC
10
135600
58.43%
85%
2
BEML
3
79798
74.94%
85%
3
RUSSIAN D/L
5
145194
45.24%
85%
* The availability data is for the period from 1.4.2014 to 31.12.2014
NCL
SHOVELS
SHOVELS IN CIL SUBSIDIARIES
NCL
ECL
BCCL
CCL
NCL
WCL
SECL
MCL
CIL
QTY
13
7
10
52
0
19
3
104
% OF
POPULATION
12
7
10
50
0
18
3
100
SL. No
Model
Make
NCL
Cap.(Cum)
Total
ELECTRIC ROPE SHOVELS
A
20 Cum Shovels
1
295 HD
BEML (Bucyrus)
20.0
3
2
P&H 2300 XP
P&H ( surveyed off)
20.0
2
SUB-TOTAL
5
B
10 -20 Cum Shovels
2
P&H 1900AL
P&H
10.0
35
3
RB/BE 195B
HEC
10.0
17
4
182MHR17 MARIAN
BEML
10.0
5
5
EKG 10/12.5
HEC
10/12.5
4
6
MARIAN 182ACM
BEML
10.0
2
SUB-TOTAL
C
8 Cum Shovels
7
EKG 8
RUSSIAN
SUB-TOTAL
63
8.0
1
1
SL. NO
Model
Make
Cap.(Cum)
Total
HYDRAULIC EXCAVATORS
10 – 12 Cum Shovels
8
PC 2000
KOMATSU
12.0
2
9
EX 1900V
TATA HITACHI
11.0
2
10
RH 90C
BUCYRUS
10.0
1
SUB-TOTAL
NCL
5
5.5 – 9.5 Cum Shovels
11
BE – 1600
BEML
9.5
6
12
BE – 1000
BEML
5.5
3
13
H – 135S
DEMAG
9.5
1
14
LIEBHERR RE 982
LIEBHERR
5.5
1
TOTAL
11
1.2 – 3.2 Cum Shovels
15
L&T 300 CKD-II
L&T
3.0
7
16
TATA EX 600V
TATA
3.0
2
17
L&T 300CK
L&T
3.2
0
18
PC-650 [D]/[E]
BEML
2.8
4
19
H-40 (DEMAG)
DEMAG
2.8
4
20
PC-300
BEML
1.2
2
TOTAL
19
GRAND TOTAL
104
AGE PROFILE OF ER SHOVELS
NCL
(Total 69 nos including surveyed off)
SURVEY OFF NORMS
(in yrs)
SHOVELS
AGE
NOS
Electric Rope Shovel
>15
54
10-15
4
<10
11
8 Cum
10 Cum
15
20
12.5 Cum
15
20 Cum
22
33
21
8
4
3
0-5
5-10
10-15
YEARS ->
15-20
85% Shovels crossed 50% of life
20 & ABOVE
SHOVELS
NCL
AVERAGE
AVERAGE
CMPDIL
AVAILIBILITY
YEARS
NORMS
‘14-15’
Sl.
No.
MAKE
NOS
AVERAGE
HOURS
1
HEC
14
41023
18.5
46.93%
80%
2
BEML
5
37398
10
48.93%
80%
3
BEML
5
19144
4.4
70%
80%
26
62635
20.4
55.53%
80%
4
(UNDER MARC)
P&H
• The availability data is for the period from 1.4.2014 to 31.12.14
NCL
DUMPERS
DUMPERS IN CIL SUBSIDIARIES
NCL
ECL
BCCL
CCL
NCL
WCL
SECL
MCL
CIL
QTY
79
56
105
449
0
167
77
933
% OF
POPULATION
9
6
11
48
0
18
8
100
POPULATION OF DUMPERS
BEML MAKE
Sl No.
1
2
3
4
5
MODEL
DRESSER 170-D
BH-120
BH-100
BH-85
HD-785-2
TOTAL =
CAPACITY
170 T
120 T
100 T
85 T
85 T
POPULATION
7
37
75
90
13
222
CATERPILLAR MAKE
Sl No.
1
2
3
4
MODEL
CAT 777D- 100T
CAT-785 C
CAT 777 C/D
UR-120T
TOTAL =
CAPACITY
100 T
120 T
85 T
120 T
POPULATION
78
5
77
90
250
KOMATSU MAKE
Sl No.
MODEL
1
HD 785-7
2
445E
TOTAL =
CAPACITY
100 T
120 T
POPULATION
58
11
69
NCL
AGE PROFILE OF DUMPERS
Hour wise(Including surveyed-Off )
NCL
180
156
160
120 T
40000
170 T
50000
DUMPER
85 T
100 T
120 T
140
85 T
Survey off
Norms
(Hours)
24000
170 T
120
100
80
55
60
69
64
40
20
0
27
0 0
0-15000
63
9
0
15000-24000
59 0
0
24000-40000
Progressive Hours ->
32 0
7
40000 & ABOVE
NCL
EXPERIENCE OF NCL
WITH HEMMs
Problem Area : Spares parts Management
NCL
76% Draglines & 84 % ER Shovels covered more
than 50% of life
Due to ageing, need of spares & sub-assemblies
considerably increased
Non-availability of spares - increased down time
OEM/OPMs located overseas are major sources of
supply
Known indigenous OEM/OPMs and other sources
do not supply in time due to various reasons.
Problem Area : Spares parts Management
Even after completion of long delivery period of 6-12
months materials are not supplied by OEM/OPM
These qualified known suppliers do not submit offer for
many spares
Non-availability of spares was one of the major reason
towards non-adoption of Longwall and Continuous
Miner in U/G mining. Similar scenario is emerging for
large size HEMMs in opencast mining
Mechanical spares such as forged gears /pinions, shafts
etc. and other casting items are required by NCL on
regular basis to meet our replacement needs.
Problem Area : Spares parts Management
NCL
Explored some reputed
and quality indigenous
manufacturers who can supply in the event of nonsupply by OEM, similar type of items are used by
Railways , Shipping and steel industry etc.
Identification and enlistment of reliable and reputed
sources for supply of quality spares is essential
Overseas suppliers should develop manufacturing units
in India with the spirit of “Make in India”
Request august gathering to enlighten us
in finding solutions
DRAGLINES
NCL
Long lead time in Supply & Commissioning of
Equipment:
Supply Equipment
18 months
Erection & Commissioning
18 months
Delay in supply in supply of spares:
OEM are not supplying spares even after expiry of long
delivery period of 6-12 months
• Spares worth Rs 70 Crores (Approx.) are pending even after expiry
delivery of period. (Details)
DRAGLINES
NCL
Difficulties in service & supply of spares due to takeover/merger and discontinuance of collaboration of
OEMs.
• BEML supplied 3 no 24/96 draglines with collaboration of
Caterpillar, now they are NOT submitting offer for spare parts
• BEML has supplied 33/72 draglines, its maintenance & operation
is under trouble.
Electrical control systems becomes obsolete before the
machine completes its life time
Structural failures begin to appear after 15 years
whereas draglines are expected to render service for 3040 years
DRAGLINES
NCL
Do not have spare part & service depot in India
Competent technical persons not posted for training, spare part
support etc.
Do not provide complete drive software and training required for
maintenance & operation of Draglines, specially in electrical systems
as it is normally outsourced by OEMs.
Sufficient alternate sources are not available in the country to meet the
requirement of spares
Resorting to quote abnormally high prices for spare parts
Routine Training is not provided to Engineers
support maintenance & operation
& technicians to
DRAGLINES
NCL
CATERPILLAR
CAT has authorized GMMCO for their service in India,
but GMMCO do not have sufficient and competent
service people, service centre and spare parts in India.
CATERPILLAR has supplied draglines with ESCO,
HENDRIX & MARION buckets, but do not submit offer for
supply of bucket spares
HEC
DRAGLINES
NCL
Inordinate delay in Erection & commissioning of Draglines
(schedule)
Details
Performance of 24/96 Dragline supplied at Amlohri
project is not upto the desired level
Do not submit offer for Electrical, lubrication, Air system &
Esco bucket spares
The lead time of supply for some of the main parts of the
dragline is too high. For eg. Lead time for main gear is 20 months ,
bucket assy for 22 months, and for live ring assembly it is 12 months.
DRAGLINES
URALMASH
Affected due to break-up of the company during
disintegration of USSR
No spares depot in India. Thus the lead time for supply
of spares is very high
Non availability of technical experts causes delay in
attending critical breakdowns specially electrical
Recently authorized M/s SRB for service support in
India, but do not have sufficient infrastructure &
competency to support Draglines
NCL
DRAGLINES
NCL
BEML
BEML is not submitting offer for spare parts of Dragline
Performance of 33/72 dragline may be affected due to
discontinuance of tie up with Bucyrus (Caterpillar) has
ended
SHOVELS
NCL
HEC
Poor performance of BE-195 shovels
Total value of pending orders for BE-195 shovels
(10 cum) is Rs. 2.50 crores (approx)
SHOVELS
BEML
NCL
Performance of 5 nos Shovels (20 Cum-3 nos, 10 Cum -2
nos) which are under MARC for 17 years with BEML is
under trouble due to their problem with collaborator
Bucyrus/Catterpilar
Required inventory of spares and floats not being
maintained by BEML
Technical support for critical electrical problems is not
readily available
2 nos BE1600 9.5 Cum shovel under MARC with BEML
met with fire accident, yet to be re-commissioned by
BEML
SHOVELS
P&H
Sufficient service experts are not posted to
support the maintenance of shovels specially for
electrical systems.
P&H does not submit offer for supply of spares in
case of Limited/ Open Tender.
Lead time for supply of spares is very high (12
months in case of Imported Spares). No spares
depot in India.
NCL
DUMPERS
NCL
Does not even quote for all the tendered items
even being OEM /OES for BH-120 and 445E
dumper
Quotes much higher price against STE/DA and
drastically lesser price against OPEN TENDERS
Service support for Cummins engines fitted on
BEML equipment is poor.
DUMPERS
NCL
Change of authorized dealers for Unit rig dumpers
( Avg. working Hours: 41228) has resulted in
inordinate delay in finalization of depot agreements .
TEREX
(UNIT RIG)
1999-2010
• Dealer Voltas
BUCYRUS
2010-12
• Dealer –Voltas
retained upto
2014
CATERPILLAR
2012 onwards
• Dealer –
GMMCo from
2014
TECHNOLOGICAL UPGRADATION
NCL
Pay load monitoring system
Vehicle health monitoring system
Proximity working device to detect objects in close proximity of the
equipment and generation of alerts in case of presence of any object
Tail gate protection/ Anti collision device to provide additional
protection to the Operator
Extensive use of condition monitoring & NDT
T
TECHNOLOGICAL
UPGRADATION
NCL
Higher capacity Draglines, Shovels, Dumpers for better health monitoring,
reliability, productivity & safety
2 no 24/96 Draglines in place of 10/70 Draglines , 20 Cum Shovels & 190 T
Dumpers
Procurement of Draglines & Shovels with AC drive systems
24/88 Draglines & 20 cum shovels with AC Digital drives
procurement
in future
GPS based machines for monitoring location and working on real time basis
from anywhere.
GPS option is included in 190 T dumpers, 20 cum shovels & draglines.
Replacement of Some ER Shovels with Sate of the art Hydraulic Shovels
11 no hydraulic shovels have been tendered in place of 10 cum rope shovels
TECHNOLOGICAL UPGRADATION
NCL
Mandatory air-conditioned operator cabin to increase
productivity
Simulator Training for dumper operators
Planned for simulator training for Dragline & Shovel operators
Planned for creation of NDT facility at CWS for ensuring
structural stability of HEMM
Auto lubrication system in all HEMMs
Suggestions
NCL
Reliability improvement by technology uogradation for
existing equipment with help of OEMs
Procurement of only proven and performing equipment
based on life cycle cost
Insurance coverage for fire prone equipment like
hydraulic shovels
Suggestions
NCL
Foreign OEM’s to establish spares part depot & service
centers in India
Depot Agreement /Rate contract with OEM for Shovels
& Draglines spares also(both for Indigenous &
Imported)
Dependable indigenous sources need to be developed
for fast moving parts and those of wear and tear nature
Suggestions
NCL
OEMs may be asked to deploy their service personnel at
mine premises for long period
Comprehensive training(class room & on job) by OEM
for maintenance & operation personnel
Pool of manpower(skilled & Unskilled) for deployment
from a man power resource centre formed for the
purpose to fulfill the manpower requirements.
NCL
THANK
YOU.
Production Projection for 1 Bt Plan
Particulars
Coal
Departmental
OB
Departmental
Composite
Outsource OB
(HoE)
Total Composite
Unit
NCL
2015- 2016- 2017- 2018- 201916
17
18
19
20
Mt
80
82
90
99
110
Mcum
112
139
153
156
175
Mcum
165
194
213
222
248
Mcum
158
195
215
244
261
Mcum
323
389
428
466
509
SHOVELS IN CIL SUBSIDIARIES
WCL
SECL
MCL
CIL
56
NCL
53
39
40
22
271
14
21
20
14
15
8
100
11
18
27
9
18
6
100
ECL
BCCL
CCL
QTY
22
39
% OF
POPULATION
8
% CAPACITY
11
% POPULATION BASIS
SECL15%
MCL8%
ECL8%
% CAPACITY BASIS
BCCL14%
NCL20%
WCL14%
CCL21%
SECL18%
MCL6%
ECL11%
BCCL11%
NCL27%
WCL9%
CCL18%
Name of
Dragline
Project
Model
MAKE
Cap
Unit
Date of
Comm.
Abhimanyu
AML
24/96
w2000
HEC
24
Cum 05-09-14
PRG.W/Hr as
on 25.08.2013
2406
Project
Balram
NGH
24/96 w2000 BEML
24 Cum
EXC15-04-03
2270
75869
Krishna
NGH
24/96 w2000 BEML
24 Cum
EXC13-04-02
2233
83206
Pawan
DCH
24/96 w2000 BEML
24 Cum
EXC10-10-01
2354
80319
Model
MAKE
Cap Unit CIL NO
Date of
Comm.
PRG.W/Hr
as on
25.08.2013
Name of
Dragline
Project
Model
MAKE
Cap
Unit
Jwala
DCH
24/96
w2000
HEC
24
Cum EXC-2156 26-12-99
Vindhya
DCH
24/96
w2000
HEC
24
Cum EXC-1918 15-08-95 112021
Ural mash
20
Russian
Cum EXC-1849 26-06-95 123594
Vishwanath KHD ESH 20/90
CIL NO
Date of
Comm.
PRG.W/Hr
as on
25.08.2013
Name of
Dragline
80523
Name of
Dragline
Projec
t
Model
Matang
NGH ESH 20/90
Akshay
AML
24/96
w2000
Baidyanath KHD ESH 20/90
Bajrang
Jyoti
NGH ESH 20/90
DCH
24/96
w2000
MAKE
Cap
Ural mash
20
Russian
HEC
Unit
CIL NO
Date of
Comm.
PRG.W/Hr
as on
25.08.2013
Cum EXC-1761 25-03-94 133770
24
Cum EXC-1725 01-07-93 126689
Ural mash
20
Russian
Cum EXC-1698 02-10-92 137623
Ural mash
20
Russian
Cum EXC-1721 01-04-92 132137
HEC
24
Cum EXC-1393 01-09-91 117198
Project
Model
MAKE
Cap
Unit
Saraswati
JNT
24/96
w2000
HEC
24
Cum EXC-1065 08-03-89 170308
Saurav
BIN
24/96
w2000
HEC
24
Cum EXC-1455 06-04-87 173210
Gaurav
BIN
24/96
w2000
HEC
24
Cum EXC-1454 10-03-86 174750
Yamuna
JNT
24/96
w2000
HEC
24
Cum
CIL NO
Date of
Comm.
PRG.W/Hr
as on
25.08.2013
Name of
Dragline
EXC-655 02-03-85 196277
Name of
Project
Dragline
Model
MAKE
Cap
Unit
CIL NO
Date of
Comm.
PRG.W/Hr
as on
25.08.2013
Ganga
JNT
24/96
w2000
HEC
24
Cum
Shyam
BIN
10/70
ESH
NKMZRussian
10
Cum EXC-1457 08-05-79 210019
Vijay
JNT
15/90
ESH
Ural mash
Russian
15
Cum
Ram
BIN
10/70
ESH
NKMZRussian
10
Cum EXC-1456 15-05-78 205939
EXC-554 01-10-83 202937
EXC-245 01-04-79 194158
Supply of spares pending with OEMs/OPMs
Whose delivery period has expired
FIRM
VALUE IN Rs.Crores
HEC
39.3
CATERPILLAR
ARGO(GE)
TOTAL
14.9
16.4
70.6
As 20.12.2014
NCL
BACK
EXPERIENCE & ISSUES WITH DUMPERS
• There are 48 nos. of BH-120 Dumpers(Out of 450 Dumpers on
roll in NCL).The OEM concerned(BEML) does not even quote
for all the tendered items. This leads to difficulty in repair and
maintenance of BH-120 Dumpers.
• It is observed that BEML generally quotes higher price against
single tender enquiry and drastically less price against open
tender.
• The quality of spares provided by BEML is not up to the mark.
• Quality of service support provided by Cummins is on a
decline.
• CATERPILLAR has authorized GMMCO to provide service
support. GMMCO does not have adequate infrastructure to
cope up with service requirement for large fleet of CAT
Dumpers in NCL.
%
ECL
BCC
L
CCL
NCL
WCL SEC
L
MCL CIL
8
7
9
49
0
3
8.4
7.7
9.8
53.4 0
ECL
BCC
L
CCL
NCL
WCL SEC
L
47
303
159
74
16
17.4 3.3
92
100
MCL CIL
49
632
ECL
BCC
L
CCL
NCL
WCL SEC
L
MCL CIL
30
57
88
117
17
80
88
477
EXPERIENCE & ISSUES WITH DUMPERS
• Quality of technical support staff posted by OEM at NCL mines
is not up to the mark.
• Delay took place in finalization of DA due to takeover of Unit
Rig by Caterpillar.
• Operator’s dislike for operating 85 T dumpers due to
discomfort & inferior technology.
AGE OF DUMPERS
Age-wise(including surveyed-off)
140
85 T
126
100 T
120
120 T
105
170 T
100
Equipment
Survey off
Norms
85 T
9 yrs
120 T
12 yrs
170 T
15 yrs
85
80
60
BH100=33
BH-120=11
KOMATSU HD785-7=
58
CAT777D
100 T=35
40
UR-120=42
HD785-2=2
CAT777D
100 T=43
42
BH100=42
34
20
0
0-4
4-9
47
CAT777D=1
25
CAT777C=7
18
CAT777D=17
BH85=14
BH120=37
CAT777C=3
CAT-785=5
Years ->
9-12
53
HD785-2=13
BH85=8
CAT777D=41
BH85=64
CAT777D=1
33-11 D/E=3
170-D= 7
CAT777C=4
UR-120=47
12-15
7
BH85=4
15 & ABOVE
Sl No.
1
2
3
4
5
6
7
8
9
10
11
12
MAKE
MODEL
BEML
445E/BH-120
BEML
BH-100
BEML
BH-85
CATERPILLAR
CAT 777D- 100T
CATERPILLAR
CAT-785 C
CATERPILLAR
CAT 777D
CATERPILLAR
CAT 777C
KOMATSU
KOMATSU 785-7
BEML
HD-785-2
UNIT RIG
UR-120T
TEREX
33-11-E
TEREX
33-11-D
TOTAL ON ROLL DUMPERS=
SURVEYED OFF BUT WORKING
1
DRESSER
170-D
2
UNIT RIG
UR-120T
3
CATERPILLAR
CAT 777D
4
CATERPILLAR
CAT 777C
5
BEML
HD-785-2
6
BEML
BH-85
TOTAL =
CAPACITY
120.0 T
100.0 T
85.0 T
100.0 T
120.0 T
85.0 T
85.0 T
100.0 T
85.0 T
120.0 T
85.0 T
85.0 T
POPULATION
48
75
76
78
5
44
7
58
8
48
2
1
448
170 T
120 T
85 T
85 T
85 T
85 T
7
42
20
6
5
14
94
AGE OF DRAGLINES
Working hour wise
Survey-off
Norms
Capacity
7
Hours
10 cum
100000
15-20 cum
140000
24 cum & above
140000
20/90 -4
4
33/72-1
24/96-1
5
24/96-3
15/90 -3
24/96-4
2
24/96-3
0
0
0
3
10/70 -2
24/96-1
AGE OF ER SHOVELS of 10 cum capacity
Hour-wise (Including surveyed-off)
HOURWISE AGE OF 10 cum SHOVELS
16
14
SURVEY OFF NORMS
(IN HRS)
14
12
10
10 Cum
10
8
8
7
6
5
4
2
Electric Rope Shovel
12
3
2
0
PROGRESSIVE HRS->
75000
HEMM Procurement as Per Existing Plan: OC
HEMM
Dragline
24 cum
2015-16
Add
Repl
2
3
2016-17
Add
Repl
2017-18
Add
2018-19
Repl
Add
Repl
2
2
2019-20
Add
Repl
Shovel
10 cum
18
2
2
20 cum
6
3
2
100T
28
39
190T
30
54
4
3
Dumper
10
8
8
14
16
5
17
5
3
HEMM Required for enhancement of
Production to 1 Bt Plan Projections: OC
Sl. No.
Projections (1 Bt Plan)
1
Coal
2
Unit
2015-16 2016-17 2017-18 2018-19 2019-20
Mt
80.00
82.00
90.00
99.00
110.00
Departmental OB
Mcum
112.00
139.00
153.00
156.00
175.00
3
Composite Departmental
Mcum
165.33
193.67
213.00
222.00
248.33
4
Total Equipment Capacity*
Mcum
200.12
190.74
195.54
210.03
224.89
5
Variance (3-4)
Mcum
34.79
-2.93
-17.46
-11.97
-23.44
No.
1
4
3
6
No.
6
35
24
47
6
7
Additional Shovel Required
(20 cum)
Additional Dumper Required
(190 T)
* Existing Capacity+Capacity of HEMM as per existing procurement plan-survey off
Experience with Draglines :OEM/OPM
• Minimum Lead time for supply and commissioning of
Dragline :
Supply of spares
18 months
Erection of machine
18 months
Thus total time for commissioning of Dragline is 36
months after placement of order.
• Status of Draglines under erection/commissioning in NCL
Dragline Order
Detail placed on
HMB-13
HMB-14
M/s HEC
HMB-15
33/72
M/s BEML
Date of
commissioning
(As per supply
order)
27.03.2013
28.03.2014
Actual/Expected date
of commissioning
09.05.2014
May’15
28.03.2015
May’16
31.03.2013
Under testing
Delay
(Till date
Approx.)
1 year 2 months
10 months
Process yet to
commence
1 year 10 months
Experience with Draglines :OEM/OPM(contd)
• Electrical system becomes obsolete before the machine completes
its life of 30 years
• OEMs are not able to supply spares on time. Spares amounting to
Rs 70.6 crores are pending with HEC & Caterpillar even after the
expiry of delivery period. DETAILS
• Difficulties in supply of spares due to take-over/merger and change
of collaboration of OEMs.
• BEML supplied 3 no 24/96 draglines with collaboration of
Caterpillar, now they are NOT submitting offer for many items.
• OEMs sometimes quote abnormally high prices for spare parts.
• Structural failures begin to appear after 15 years whereas
draglines are expected to render service for 30-40 years
• Do not provide complete drive software and training required for
maintenance & operation of Draglines, specially in electrical
systems as it is normally outsourced by OEMs.
HEC
D/L
• The lead time of supply for some of the main parts of
the dragline is too high. For ex. Lead time for main gear
is 22 months & Lead time for live ring assembly is 20
months.
RUSSIAN
D/L
• No spares depot in India. Thus the lead time for supply
of spares is very high.
• Non availability of technical experts at Singrauli causes
delay in attending critical breakdowns specially
electrical.
CAT
D/L
• CATERPILLAR has supplied draglines with ESCO,
HENDRIX & MARION buckets, but do not submit offer
for supply of spares.
BEML
D/L
• Abnormal delay, of 1 yr 9 months, in erection of 33/72
Dragline at Krishnashila project due to improper liaison
between Caterpillar & BEML. The scheduled date of
commissioning was 29/03/2013. But the Dragline was
ready for marching on 01/12/2014.
• Even the proper maintenance of 33/72 dragline
supplied BEML cannot be guaranteed due to tie up
problem with Caterpillar .
ISSUES WITH SHOVELS of BEML
• Non availability of
critical spare parts & inadequate
serviceable floats.
• Performance of 5 nos Shovels (20 Cum-3 nos, 10 Cum -2 nos)
which are under MARC for 17 years with BEML is grossly
under trouble due to their problem with collaborator
Bucyrus/ Caterpillar.
• Sufficient service experts are not posted to support the
breakdown maintenance of shovels.
ISSUES WITH SHOVELS of P&H
• Sufficient service experts are not posted to support the
maintenance of shovels specially for electrical systems.
• P&H does not submit offer for supply of spares in case of
Limited/ Open Tender.
• Lead time for supply of spares is very high (12 months in case
of Imported Spares). No spares depot in India.
ISSUES WITH SPARES MANAGEMENT
• As per the manufacturers, the manufacturing time of critical items
is very high, as such it is becoming very difficult to make the
machines reliable as all failures are not predictable .
• Supply of critical spare parts against supply orders placed on OEMs
was not done even after completion of stipulated delivery period.
• OEMs do not submit offers for many of the critical items of
draglines.
• Some of the critical wear and tear parts could not be procured
because of lack of proven sources.
• High dependency on OEMs for the supply of spare parts has
resulted in monopolistic approach in some cases.
• Present CIL Policy for procurement of HEMM spares confines the
procurement of spare parts from OEM, OES, OPM & proven sources
who have previously supplied to CIL only.
• Development of sources by trial tendering is time consuming
activity as declaring the items proven takes a long time. Provision
for developing the items on trial for only 10% of the indented
quantity is a limiting factor.
DESIRED SOLUTIONS
• To overcome the crisis it is prudent to go for vendor
development immediately who can manufacture quality
spares at reasonable price and can deliver it within shortest
possible time.
• It should be appreciated that there are manufacturing firms in
the country who are highly capable and competent to
manufacture spare parts for HEMMs, but they don't have the
credentials as per our Purchase Procedures and so are not
eligible to supply.
• Therefore it is imperative to have additional provision in the
procurement policy for HEMM spares to procure spare
parts from alternate manufactures who have sufficient
infrastructure, R&D & workshop facilities but have not
supplied to CIL previously. This will also encourage “Make in
India" Policy of Government of India.
• The matter to be taken up with all OEMs & OPMs for reducing
the delivery time of Equipment as well as spare parts.
SOURCE DEVELOPMENT
Parts which are essential to develop sources will be identified
equipment model wise
RFQ meeting will be called for the capable firms
Senior executives team will visit their workshop, if required
Supply order will be placed on Shortlisted firms through limited
tender enquiry
Performance of the items supplied by these firms will be
monitored on continuous basis which will decide the Proven
Status of firm for supply of the parts in future and accordingly
Vendor registration can be done.
TECHNOLOGICAL UPGRADATION
• Some rope shovels are being replaced with hydraulic excavators
because of efficient & speedy work action and greater flexibility of
its use.
• Most of the new machines are coming with AC drives as AC motor
generators require less maintenance in comparison to DC motor
generators. Further, the DC motor generators are complicated &
costly as compared to AC.
• GPS based machines can tell its location and working condition on
real time basis from anywhere through internet.
ACTIONS TAKEN
• 11 no hydraulic shovels have been tendered in place of 10 cum rope
shovels. Delivery may be expected in 2015-16
• We are going to tender 24/88 draglines & 20 cum shovels with AC
drives only.
• GPS option is included in 190 T dumpers, 20 cum shovels &
draglines.
TECHNOLOGICAL UPGRADATION
• Some rope shovels are being replaced with hydraulic excavators
because of efficient & speedy work action and greater flexibility of
its use.
• Most of the new machines are coming with AC drives as AC motor
generators require less maintenance in comparison to DC motor
generators. Further, the DC motor generators are complicated &
costly as compared to AC.
• GPS based machines can tell its location and working condition on
real time basis from anywhere through internet.
ACTIONS TAKEN
• 11 no hydraulic shovels have been tendered in place of 10 cum rope
shovels. Delivery may be expected in 2015-16
• We are going to tender 24/88 draglines & 20 cum shovels with AC
drives only.
• GPS option is included in 190 T dumpers, 20 cum shovels &
draglines.
HEMM Required
(Existing Plan + Additional for 1 Bt Plan)
HEMM
Dragline:
24 cum
Shovel:
10 cum
20 cum
Dumper:
100T
190T
201516
201617
201718
201819
201920
Total
Total
Total
Total
Total
5
18
6
TOTAL
COST
Rs. Crores
approx
1000
2
4
2
6
28
39
18
30
60
44
TOTAL APPROX COST
4
7
9
30
29
22
50
NCL
910
2240
480
3195
7825
HEMM Procurement Plan: Departmental NCL
HEMM
Dragline
24 cum
2015-16
Add
Repl
2
3
2016-17
Add Repl
2017-18
Add
2018-19
Repl
Add
Repl
2
2
2019-20
Add
Repl
Shovel
10 cum
18
2
2
20 cum
6
3
2
100T
28
39
190T
30
54
4
3
Dumper
Add : New addition
10
8
8
14
16
5
Repl: Against replacement
17
5
3