Side discharge loader

A
MAJOR PROJECT ON
“A CASE STUDY ON PERFORMANCE OF SIDE DISCHARGE
LOADER”
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY,
HYDERABAD, TELANGANA STATE.
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
By
M. KALYAN (15QT1A2515)
N. PRADEEP (15QT1A2516)
O. ANILKUMAR (15QT1A2517)
U. SURENDAR (15QT1A2524)
V. PARAMESH (15QT1A2525)
S. SAITEJA (16QT5A2523)
UNDER THE GUIDANCE OF
Mr. G. DHAMODARA RAO
Assistant Professor
Head of the Department
DEPARTMENT OF MINING ENGINEERING
KLR COLLEGE OF ENGINEERING & TECHNOLOGY
(Approved by AICTE New Delhi, Affiliated to JNTUH, Hyderabad)
BCM Road, Palvoncha, Khammam – 507115, Telangana, INDIA
2015 – 2019

A
MAJOR PROJECT ON
“A CASE STUDY ON PERFORMANCE OF SIDE DISCHARGE
LOADER”
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY,
HYDERABAD, TELANGANA STATE.
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
By
UNDER THE GUIDANCE OF
Mr. AJAY KUMAR
MINE MANAGER OF SRP 1 INCLINE
2015– 2019

CERTIFICATE
This is to be certified that this project “A CASE STUDY ON PERFORMANCE OF
SIDE DISCHARGE LOADER” entitled is a bonafide work done by M. KALYAN
(15QT1A2515), N. PRADEEP(15QT1A2516), O. ANILKUMAR(15QT1A2517),
U. SURENDAR (15QT1A2524) , V.PARAMESH(15QT1A2525) , S. SAITEJA
(16QT5A2523), in partial fulfillment of the requirements for the award of the
BACHELOR OF ENGINEERING in MINING ENGINEERING from J.N.T.U.H ,
Hyderabad , during the year 2018 – 2019
M.BHARATH Dr. M. SURENDRA KUMAR
Assistant Professor Principal
Internal Guide
EXTERNAL EXAMINER

DECLARATION
We hereby declare that the PROJECT entitled “A CASE STUDY ON PERFORMANCE
OF SIDE DISCHARGE LOADER” is done by us, submitted in partial fulfillment of
requirements for the award of the degree in BACHELOR OF TECHNOLOGY IN
MINING ENGINEERING for the year 2015 – 2019.
DATE:
PLACE: Palvoncha

ACKNOWLEDGEMENT
With immense pleasure, I would like to express our indebted gratitude to my guide,
N.RAMESH, DEPUTY MANAGER OF SCCL IN SRIRAMPUR AREA, who has guided
throughout and encouraged me in every step of project work. Also, his valuable moral support
helped me to a great extent.
I would also like to thank Mr. AJAY KUMAR Manager of SRP 1 INCL for their
cooperation throughout this work.
We wish to express our sincere thanks to Dr. M. SURENDRA KUMAR, principal for
providing us all the necessary facilities for the project.
We place on record, our sincere thanks to Mr. G. DHAMODARA RAO, lecturer, Head
of the Department, for continuous encouragement and indebted to him for sharing expertise and
valuable guidance and encouragement extended to us.
Last but not least I sincerely express our thanks to all those who directly or indirectly
extended their help for the successful completion of my major project.
M.KALYAN (15QT1A2515)

ABSTRACT
With the changing scenario of the modernization it has become necessary to modernize coal
mining in SCCL. Improvement of productivity has become an important goal for today’s coal
industry. SDL’S are introduced in SCCL as intermediate technology in the year 1985 for
improvement in production and productivity. To reduce the physical fatigue of the coal fillers
who are being exposed to the freshly exposed faces, it is proposed to introduce intermediate
technology. SDL is one answer. SIDE DISCHARGE LOADER is a track mounted
electro hydraulically operated side discharging bucket loaders with smooth control system,
excellent maneuverability. It is a low-profile high output machine. SDL’S are now used as a
dominant loading machine to work in underground coal faces to scoop and load runs of mine
coal into transport equipment. In here to identify the various factors and problems affecting the
productivity of underground coal mines adopting the bord and pillar method of mining and to
propose suitable measures for improving them. The various key factors affecting productivity,
namely the cycle of operations, manpower deployment, machine efficiency, material handling
and management of manpower resources

CONTENT
S.NO TOPIC P.NO
CHAPTER 1
INTRODUCTION
1.1 Loader 1
1.2 Side Discharge Bucket 1-3
1.3 Technical Specifications 4-5
CHAPTER 2
OPERATION
2.1 To operate the machine 6
2.2 Traction control 6
2.3 Bucket and Hydraulic arm control 6
CHAPTER 3
MAINTENANCE
3.1 Daily Examination 7
3.2 Weekly Examination 7
3.3 Monthly Examination 8
3.4 Safety Features 8
CHAPTER 4
PROBLEMS EFFECTING THE PRODUCTIVITY OF MINE
4.1 Factors 9-10
4.2 Environmental Issues 10
4.3 Technical Issues 11
4.4 Accidents due to SDL 12-14
CHAPTER 5
EXPERIMENTAL STUDY
5.1 Mine Introduction 15-20
5.2 Variation in production through years in SRP 1 INCL 21

5.3 Representation of production rate 22
5.4 Field 23
5.5 Readings of cyclic time of SDL 24-26
5.6 Factors influencing bucket fill factor 27-28
CHAPTER 6
DETAILED ANALYSIS ON PERFORMANCE OF SDL
6.1 Loading time 29
6.2 Travelling time with load to discharge point 29
6.3 Discharging time 30
6.4 Travelling time without load from discharge point to loading point 30
6.5 Impact of SDL performance on productivity 31
CONCLUSION 32
REFERENCES 33

LIST OF FIGURES
S.NO NAME PAGE.NO
1 Side Discharge Loader 2
2 Panel Development with SDL 24
3 SDL with load 30
LIST OF TABLES
S.NO NAME PAGE.NO
1 Seam Details 18
2 Depth of workings and status 19
3 Variations in production through years is SRP 1 INCLINE 21
4 Readings of cyclic time of SDL (day 1) 25
5 Readings of cyclic time of SDL (day 2) 26

1
Chapter 1
INTRODUCTION
1.1 LOADER: A self-propelled crawler machine with an integral front mounted bucket
supporting structure and linkage which loads or excavates through forward motion of the
machine and lifts, transports and discharges material/coal.
1.2 SIDE DISCHARGE BUCKET: A bucket which loads through forward motion of
the machine and can discharge to the side from any end of the bucket.
The SDL is a electro hydraulically operated high output machine. The latest development in
the fields of hydraulics and fabrication and underground work are considered while designing
loaders and they are developed to offer maximum benefit to the mining industry. Flame proof
electrical make them suitable for operation in gassy mines. The electro-hydraulic crawler
mounted side discharge loader is a low profile
Side discharge loaders as loading system has made possible major breakthroughs in
increasing and production and productivity. Side discharge loaders is now used dominant
loading for intermediate face mechanisation in underground coal mines. The SDL with cable
realer with side discharge bucket of around 1.1M3
capacity suitable for 1 in 4 gradient. The
bulk density of coal is to be taken as 0.86 T/Cu. M. The SDL shall have DGMS approval to
work the machine in underground gassy mines.
The machine shall be compact, low profile, narrow base and crawler mounted, highly
manoeuvrable and stable with sufficient ground clearance. The engineering design shall
ensure low centre of gravity, heavy-duty construction, easy maintenance and inspection.
Ground pressure shall not exceed 1.0 Kg/Cm² Machine shall require a crew of one man only
for operation.
The machine shall be modular construction and designed for easy maintenance and
replacement of the loader components /sub-assemblies in underground is easier. The machine
is required for drivage of gallery headings in coal, shale coal, clay and stone having high
compressive strength in gassy UG coal mines. The machine shall be able to take sharp right
angle turns in the galleries without repeated manoeuvring. It shall be able to operate in
slushy floor with gradient of 1 in 4 at places, and cross gradient of 1 in 6 and with water up to
200 mm at some places. The coal face will be 4 to 4.5 Mts. in width. The ambient

2
temperature at the place of working will be around 35 Degree C with relative humidity of
98%, both occurring at the same time.
FIG:1 SIDE DISCHARGE LOADER
The machine shall be electro-hydraulically powered so as to ensure smooth control of the
machine. All electricals shall be conforming with Indian Flame proof regulations with
approval from DGMS DHANBAD for using in Indian gassy mines. All electricals shall be
suitable for voltage 550V, 3 -phase, 50Hz. The machine shall be designed to operate on
DGMS –approved Fire-Resistant Hydraulic Fluid (FRHF) HFB-68 and all hydraulic
components shall be compatible for the fluid.
The machine shall be equipped with loading boom and bucket for collection of coal from the
face, carry and unload on to a coal tub / Chain or belt conveyor. The height of the boom shall
be suitable to unload coal into tubs up to a height of 1.5 M. The side discharge chain bucket
shall be sturdy and bi-directional, suitable to unload coal from either side of the machine.
The chain shall be double out board, fitted with suitable flights, hydraulically powered with
suitable hydraulic motor.

3
Tensioning arrangement of Chain shall be such a way that it shall be rigid and easily operated
within short time. The attachment and detachment of the bucket for changing the direction of
unloading shall be quick and easy. It shall be carried out easily at the coal face. The boom
shall be fitted with suitable heavy-duty hydraulic cylinders for lifting and rolling back. The
mounting shall be sturdy and easily detachability.

4
1.3 Technical Specifications:
1. Overall length, carry position - 5509mm
2. Overall length, bucket down - 5855mm
3. Bucket width - 1800mm
4. Bucket height -1103mm
5. Width over track - 1770mm
6. Max convenient discharge height - 1454mm
7. Min convenient discharge height -224mm
8. Height over canopy -1425 to 1575mm
9. Digging depth -189mm
10. Ground clearance -150mm
11. Track centre -1755mm
12. Track shoe width -330mm
13. Breakout force -4854Kg
14. Bucket capacity -1.1M3
15. Machine weight - 9700Kg
16. Machine speed -0 to 3.5Kmph
17. Electric motor power -65HP
18. Trailing cable -Type FT7,25Sq.mm
19. Radiator Fan Speed -2200Rpm
20. Filter rating -10Micron
21. Alarm voltage -12V
22. Lighting voltage -24V
23. Required voltage -550V (3 phase)

5
24. Lifting time for bucket -4Sec
25. Lowering time for bucket -4Sec
26.Track width -300mm

6
Chapter 2
OPERATION
2.1 TO OPERATE THE MACHINE:
 There are 6 control levers in front of operator.
 In this 2 levers are used for the traction of the machine (movement of machine) and 4
levers are used for the bucket movement and hydraulic power take off.
2.2 TRACTION CONTROL:
 To move forward; push both levers front.
 To move backward; pull both levers rear.
 To slow turn; move one lever only.
 To spin turn; move one lever front another rear.
2.3 BUCKET AND HYDRAULIC ARM CONTROL
(4 levers):
 One lever for roll back
 Another for raising and lowering the bucket and arms
 Discharge the bucket
 Additional lever (in case of failure of above lever)

7
Chapter 3
MAINTENANCE
3.1 DAILY EXAMINATION:
 Inspect the breaks of SDL for effectiveness.
 Inspect the crawler chain and their looseness.
 Lubricate bearing and brake mechanism, inspect, adjust and lubricate chains where
fitted.
 Check that the driver seat is kept secured.
 Ensure that the headlamps are securely attached to the frame of SDL and that the
glasses of lamps and instruments are clean and unbroken.
 Check that the canopy is well secured in its position and the SDL is clean from dust.
 Check and refill hydraulic oil tank and radiator.
 Check water level and refill radiator.
 Check that –
All operating levers are functioning correctly.
There are no external indications of over
Heating on any accessible part of the electrical equipment
 Check fire extinguisher and audible warning devices.
3.2 WEEKLY EXAMINATION:
 Examine the power transmission equipment.
 Check brake levers and oil filters.
 Check radiator and inspect for any leakage, choking and damage.
 Inspect linkages between the drive and hydraulic pump.
 Check the brake by conducting de-acceleration test and stand still test.
 SDL shall be examined, tested and if necessary repaired or tests shall be carried out
after each repair.
 Check the crawler chains, pins bushes etc.
 Check cable rear and its limiting point for its safe operation.

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3.3 MONTHLY EXAMINATION:
 Check the oil levels in the gear box.
 Check the power transformer and its accessories.
 Check the contamination of lubricating oil and hydraulic oil.
 Examine and test the safety devices.
3.4 SAFETY FEATURES:
Canopy: It is situated on the top of the operator which protect the operator from the dangers
of the roof strata and also obstructions hitting his head while operation of SDL.
Audio visual alarm: This alarm is used when the machine is going to start. It gives audio
and visual alarm while moving forward as well as backward. This audio-visual alarm gives
blinking light in red color when the SDL is in operation.
Foot switch/Dead man switch: It is the switch provided at the foot of the operator. Machine
runs only when the operator presses the foot switch with his foot. In case of anything happen
to the operator and he gets out of his control, then he gets unable to press it longer then
machine stops automatically.
Head light: This safety feature helps operator to see the surroundings of the SDL due to
illumination of head light, which present front and rear side of the SDL.
Parking brake: The machine does not move by applying the parking brake but other
operation will run.
Cable releasing drum switch: If the cable finishes winding till end it gives indication. This
safety feature may be lead to the disconnection of power supply cable which is connected to
the GEB. So, when the trailing cable has minimum 6 rounds on reeling drum then SDL stops.
Temperature switch: This gets activated when the temperature of the oil reaches 65degrees
machine will trip.
Oil level switch: When the oil level in the oil tank gets reduced to minimum level then SDL
which is in the operation will get stops automatically.
Emergency switch: It is located at the backside of the radiator. If any person stands at back
of the machine, he applies switch to turn off the machine.

9
Chapter 4
PROBLEMS AFFECTING PRODUCTIVITY OF THE MINE
4.1 FACTORS:
In search of a critical problem affecting the productivity of an underground coal mine, the
problems identified are listed below:
 More travelling time of the transportation equipment: time needed to be optimized in
order to save both time and production cost.
 Poor pull
 Improper blast round design
 Inaccurate wedge cut formation
 Improper direction of holes
 Improper length of shot holes
 Improper spacing between the holes
 Improper charging
 Inadequate stemming
 Excessive stemming
 Improper delay mechanism
 Improper connection
 Presence of shale bands or other deformities on the face
 Improper fragmentation
 Breakdown of SDL
 Breakdown of chain conveyor
 Breakdown of belt conveyor
 Breakdown of drill machine
 Improper lead distance
 Improper ventilation
 Improper maintenance
 Electric faults and power tripping
 Roof problems
 Availability of water

10
Out of these, the major problems affecting productivity are: poor pull, improper lead
distance, machine breakdown and roof bolting time.
The productivity of SDL can be affected by some other factors like:
1. ENVIRONMENTAL ISSUES
2. TECHNICAL ISSUES
The SDL remains a major constraint in achieving desired mine output. Reasons for low
availability, poor working performance and alternatives at the mine to improve machine
performance are given below.
4.2. ENVIRONMENTAL ISSUES
a) Humidity: High humidity causes moisture deposition, accumulating dust is the reason for
machine getting heated and electrical failure due to short circuiting. Solution for the problem
is by air flushing to washout the sticky dust.
b) Water Seepage: There is no problem when operating the SDL on the dry floor. But where
seepage of water is there, the floor becomes mucky with the movement of the SDL. The
crawler gets submerged in the muck. This resulted in an extra load on the machine. This
problem has been partly solved by arresting the seepage water collecting in ditch formed at
the rise side.
c) Temperature: It was observed that the hydrostatic unit of the machine would get
overheated in continuous operation. It was found that when oil temperature rose beyond
65°C, the machine would start losing output power, causing difficulties in coal loading,
hauling load on the up gradient. For the above problem, the machine had to keep idle and the
oil is to be changed frequently. It was found that the hydrostatic pump performance improved
considerably.
d) Dust: Coal dust at the face creates problems due to the frequent choking of the shuttle
valves; pipes vents etc. Air flushing at regular interval to get rid of the dust was done.
Visibility Operators face the problem of haziness caused due to dust and humidity. This is
sorted out by cap lamps in clusters placed at strategic points.

11
4.3. TECHNICAL ISSUES
a) Cable reeling: The cable reeling device fails frequently. These would break and snatch
cable, causing cable damage. The cable is handled manually.
b) Articulation: The articulation chassis bolts broke frequently. This results in strain on the
chassis and hairline cracks developing along the row of bolt holes. The holes also get larger
causing loosening and breakage.
c) Gear box: The gear box mounting bolts in the chassis gets loosened frequently, causing
damage to threads in the gearbox.
d) Gate end box: The failure in the gate end box is due to contactor switch dysfunction by
overload causing tripping of the supply.
e) Hydraulic hoses and seals: Hydraulic hoses and seals failure occurs now and then
requires replacement.
f) Bucket: Bucket lift cylinder pin fail due to wear in regular succession. Conveyor of
bucket gets clogged when large sized lump is encountered.
g) Crawler chain: Crawler chain fasteners wears for specific run hours, need scheduled
replacement.

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4.4. ACCIDENTS DUE TO SDL:
1.Skidding of SDL: When working in the steep gradient exceeding 1 in 5, an effective
contrivance to prevent the machine running back shall be provided and used.
2.SDL movement at junctions: Formulate transport rules and implement them.
3.Obstacles in SDL roadway (steel ropes, rails etc..): All the obstacles should be removed.
4.Inadvertent entry of persons in SDL plying area:
a) Ensure no person are in the vicinity of SDL moment particularly in blind spots and
take help of guard to prevent any one approaching the vehicle while maneuvering, if required
b) Audio visual alarm should be provided and maintained in the machine which shall
confirm to the standards and parameters
5.Brusting of hydraulic hose: Thehigh pressure hydraulic hoses supplied with the machine
shall conformed to the standards and parameters as prescribed in DGMS, DHANBAD
6.Failure of brakes: All brakes should examine thoroughly before starting the vehicle
7.Tippling of SDL: In consultation with the manufacturer, COP should be framed for the
control andGuidance of persons employed for the installation, operation and maintenance of
SDL and associated equipment, as well as for prevention of accident and to provide safety,
health, convenience and discipline of persons.
Ensure not to exceed the maximum load indicated on the vehicle, the load is secured and
speed is not exceeded the stipulated speed limit.
8.Ejection from loose coal/stone run over by SDL: overloading of buckets should be
avoided and roadways should be maintained clear of loose coal/stone/other objects.
9.Hitting of trailing cables: Anticipate the swing of the SDL and movement of its trailing
cable. Display caution boards.
10.Dislodgement of supports by SDL: Anticipate the swing of the SDL and maintain
obstruction free roadway.

13
11.Run away of parked SDL: Before parking the SDL ensure
1.Rest the bucket on the floor.
2.Point the bucket against the roadway.
3.Put on the parking brake.
4.Do not park on the rise side of a working.
5. Do not leave the vehicle when parked on a gradient exceeding 1 in 15.
6.Use stoppers when SDL is idle.
12.Working under the raised SDL bucket: Formulate and implement SOP for operation of
SDL.
13.Persons working by standing in the bucket: Formulate and implement SOP for
operation of SDL.
14.Maintenance and repair:
1.Ensure proper maintenance of SDLs
2.Formulate SOP for use of maintenance and inspection of SDLs.
15.Failure of safety features: Ensure all required safety features are provided and
maintained in working condition in the SDL in compliance with the statue.
16.Electrocution: The relevant provisions of the Central Electricity Authority
Regulations,2010 shall be complied with in all Matter relating to the installation, operation
and Maintenance of the equipment.
The electrical equipment associated with the machine shall be checked by checked by
Electrical Supervisor of the mine for their flame proofers. The condition of cables in the
machine shall be checked at the beginning of each working shift and the findings thereof
entered a bound-paged book maintained for that purpose, which shall be signed by the
Electrical Supervisor with date
.

14
17.Failure to provide ergonomically designed seat: The cabin or seat of the operator
should be ergonomically designed and should be such that the operator has clear line of sight
in front as well as at rear of the machine without involving any constraint or strain.
18.Presence of cables, hoses in close proximity of plying SDL: Roadways and SDL should
be equipped with adequate lighting.
19.Failure to provide canopy: SDL should be provided with substantially constructed roof
canopies or cabs which shall give adequate protection against falling of ground from the roofs
or sides.
20.Non-functioning of CRD: Functioning of CRD shall be in order.
21.No Guard for CRD chain: Guard shall be provided to CRD chain.
Keeping this in mind, a cycle time study of various operations at the coal face was
performed during a study at Srirampur 1 Incline, in order to assess and interpret the issues
relevant to productivity. Thereafter, the average time taken for each operation was
calculated. The analysis of time study results revealed that the travelling time of SDL,
which is directly related with productivity is quite high and as a result impedes the
productivity of the mine.

15
Chapter 5
EXPERIMENTAL STUDY
This study has been carried out in SRIRAMPUR 1 incline, an underground coal mine
belonging to the SCCL, MANCHERIAL DISTRICT, state of TELANGANA, India. This
mine consists of 8 seams. This case study is carried out in 3 Seam. Employed in the BORD
AND PILLAR METHOD. It should be mentioned here that the bord and pillar mining
method comprises two phases, i.e. development and depillaring. In the development phase, a
series of narrow headings known as “bords” or “galleries” are driven into the coal seam
parallel to each other along the dip direction which are cut across at right angles by another
series of headings driven along the strike and thus forms the pillars simultaneously for
subsequent extraction during depillaring. Coal extraction in SRP 1 is done by drilling and
blasting, and SDL is used as the main work horse for coal production. SDL dumps the coal in
to the tubs which bring the coal to the surface.

16
5.1 MINE INTRODUCTION
BRIEF HISTORY OF SRP 1 INCLINE
1. Name of the mine : SRP 1 INCLINE
2. Name of the area : srirampur
3. Name of the owner : SRI BHASKAR RAO
4. Mine opened on : 02-09-1976
5. Production started on : 1978
6. Total mine take area : 160. 2 Hectors
7. Total acquired area : 3. 0 Hectors
8. Total private land : 79. 2 Hectors
9. Total Govt. Land : 3. 0 Hectors
10. Total forest land : 5. 0 hectors
11. Location : The mine is situated by
the side of MANCHERIAL
& CHENNUR, PWD NH16 & about
9Km away from
MANCHERIAL Railway station
12. Seam existing : 1, 2, 3B, 3A, 3, 4, 5 & 6 Seam.
13. Rate of full dip of seams : 1 in 2.5, N580
30min 13sec
14. Mine openings
Length of main Incline & Gradient : 355 m, 1 in 4
Length of Manway & Gradient : 343m, 1 in 4
Dia and Depth of Air shaft : Dia-5.5 m, Depth-69 m

17
15. Mines & villages around the mine : South side-SRP OCP
East side-SRP 3&3A Inc
North side- Gandhi Nagar huts
& permanent houses.
West side-Kattakommu huts and
Srirampur village.
16. Present of major fault : A 250 m up throw fault present at the
dip side of SRP 1
Property separated SRP 1 Incline &
SRP 3 &3A Incline.

18
17. Seam details
S NO. Seam Thickness
(m)
Working
thickness
section (m)
Partition
(m)
RMR Grade
1 1 6.4 2.5 ..... 64.0
Good
D
2 2 3.5 3.0 17.7 61.0
Good
G
3 3B 2.1 2.1 42 63.0
Good
D
4 3A 2.8 2.8 12 52.2
Fair
C
5 3 5.5 to 7 3.0 16 58.5
Good
D
6 4 1.5 1.5 15.5 68.4
Good
E
7 5 1.8 1.8 15.5 51.76
Good
D
8 6 1.8 to 2.8 1.8 to 2.8 12 63.0
Good
D & E
18. Important surface features Nallah No. 1 Nallah No. 2, NH. 16 Road, ShyamNagar
Huts & Permanent houses, Sangamalliahpalli Village,
Gandhinagar, Kattakommu huts & Permanent houses
And Srirampur Village.
19. Projected life of mine : 11 years

19
20. So far panels extracted bysand stowing 3 Seam-6 No S
4 seam-1 No S
5 Seam-2No S
6 Seam-6 No S
21.Depth of workings and status
Seam sl. No Depth minimum(m) Depth maximum(m) Status of workings
1 30 108 Discontinued
2 27 110 Discontinued (Non-
endible)
3B 40 150 Discontinued
3A 38 169 North property
standing on pillars
3 33 180 Working
4 33 95 North property
standing on pillars
5 40 160 North property
standing on pillars
6 45 195 working
22. Average Men on Roll : 1200
23. Average output per day :560 Tonnes
24. Technologies sand stowing :a) Depillaring by Hydraulic In 3 seam
by sand stowing
b) Double lift method hydraulic height
5.5 (Extraction Mt)
25. No of Drills projected (2010-11) :4 Drill

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26. Ventilation : By 2 Lakh Cu. Ft/Min Capacity 200HP Axial
flow fan Exhaust fan capacity : 2 Lakh Cu. Ft/Min;
27. Extractable coal reserve : 2.6 M. T
28. Total developed area : 111.19 Ha
29. Total Depillared area : 43 Ha

21
5.2 VARIATION IN PRODUCTION THROUGH YEARS IN SRP 1
INCLINE:
S.NO YEARS
PRODUCTION
(U/G)
OVERALL
PRODUCTION
OMS FILLING
TOTAL
MAN
POWER
1 2009-10 361179 361179 0.81 2.49 1915
2 2010-11 362510 362510 0.84 2.62 1876
3 2011-12 350320 350320 0.90 2.75 1760
4 2012-13 357025 357025 0.89 2.59 1682
5 2013-14 350000 350000 0.92 2.65 1585
6 2014-15 312014 312014 0.90 2.67 1467
7 2015-16 280000 285000 0.83 2.40 1352

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REPRESENTAION OF PRODUCTION RATE ON PIE CHART
[CATEGORY NAME]
15.22%
2010-2011
15.27%
2011-2012
14.76
2012-13
15.044%
2013-14
14.74%
[CATEGORY NAME]
13.14%
[CATEGORY NAME]
11.79%
PRODUCTION
2009-10
2010-11
2011-12
2012-13
2013-14
2014-15
2015-16

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5.4 FIELD
LOCATION OF SDL WORKING:
SOUTH OF 25th
DIP
7 ½ LEVEL
2nd
PANNEL
3 SEAM
SRP 1 INCLINE
DETAILS OF WORKING PLACE:
Thickness of seam: 5.5 – 7m
Depth in Mt min 33 max 180
Gradient of seam: 1 in 2.5
Height of extraction: 3m along stone roof
Working method: BORD AND PILLAR method DEPILLARING
With SAND STOWING method

24
FIG:2 PANEL DEVELOPMENT WITH SDL

25
5.5 Readings of cyclic time of SDL
The readings of cyclic time of SDL are taken from SRP 1 Incline on 14.02.2019-16-02-2019.
DAY 1
No of cycles 1 2 3 4 5 6 7 8 9 10
Spotting
time
10 - - - - - - - - -
Loading
time
21 23 24 20 15 25 33 47 61 115
Travelling
time with
load to
discharge
point
54 61 56 59 68 52 67 57 181 55
Discharge
time
45 26 44 142 25 30 33 21 24 26
Returning
time to
loading time
39 40 44 38 52 35 64 67 49 98
Total cycle
time
169 150 168 259 160 142 197 192 315 294

26
DAY 2
No of
cycles
1 2 3 4 5 6 7 8 9 10
Spotting
time
14 - - - - - - - - -
Loading
time
25 28 12 18 38 20 87 90 36 22
Travelling
time with
load to
discharge
point
64 47 57 42 59 74 72 66 116 91
Discharge
time
23 22 18 19 72 23 10 22 167 29
Returning
time to
loading
point
48 49 44 46 39 225 57 54 42 51
Total
cycle time
174 146 131 125 208 542 226 232 361 193

27
5.6. FACTORS INFLUENCING BUCKET FILL FACTOR:
Decreasing in bucket fill factor leads to decreasing in production
FILL FACTOR is the percentage of an available volume in a hauler body, bucket or bowl
that is actually used.
Bucket fill factor =
𝑡ℎ𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑏𝑢𝑐𝑘𝑒𝑡
𝑜𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑐𝑘𝑒𝑡
*100
As per the mine records of SRP 1 INCLINE the average bucket fill factor is
B.F.F =
1000
1105
∗ 100
= 90.49%
i.e. the amount of material loaded in bucket is 1000kg, and the bucket fil factor is 90.49%

28
BUCKET FILL FACTOR:
As per our case study the bucket fil factor is
The number of buckets filled in particular one blast is 17 and it leads to the production is 14
tonnes. But as per the mine records the 17 buckets of muck lead to 17tn of production. So,
there is a decreasing in bucket fil factor.
The material loaded in single bucket =
𝑡ℎ𝑒 𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑏𝑙𝑎𝑠𝑡 𝑖𝑛 𝑘𝑔𝑠
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓𝑏𝑢𝑐𝑘𝑒𝑡𝑠
=
14000
17
= 823.52kgs
The average bucket fill factor =
823.52
1105
∗ 100
= 74.52%
The decreasing in bucket fill factor = the avg B.F.F as per mine records – the avg B.F.F as
per case study
= 90.49-74.52
= 15.97%
As we conclude that the percentage of bucket fill factor is decreasing to 15.97%. It majorly
effects on the production.

29
Chapter 6
DETAILED ANALYSIS ON PERFORMANCE OF SDL
The following factors affect the performance of SDL which impacts on the production of
mine. Factors effecting on different cyclic times as follows:
6.1 LOADING TIME:
 One of the major reasons on loading is improper muck formation
 The muck forms like boulders due to improper blasting due to this the SDL takes
more time while loading
 The gradient of the seam is so high due to this reason while loading the lower side of
the muck it takes more time
 It takes long time to load the bucket since the left over at the bottom is of irregular
shapes and should be gathered so that bucket can be filled
 Driver negligence
6.2 TRAVELLING TIME WITH LOAD TO DISCHARGE POINT:
 There are a lot of disturbances in roadway so it takes more time while travelling with
load.
 The distance from loading point to discharging point increases while discharging the
muck in series of tubs.
 Due to high gradient of the seam it takes more time while adjusting the bucket at the
discharging point

30
FIG:3 SDL WITH LOAD
6.3 DISCHARGING TIME:
 Due to boulders the discharge time increases
 While adjusting the muck into tubs with suitable amount
 While adjusting the bucket more time consumes due to steep roof at lower side
6.4 TRAVELLING TIME WITHOUT LOAD FROM DISCHARGING
POINT TO LOADING POINT
 Improper road ways
 Increase in distance while loading the series of tubs

31
6.5 IMPACT OF SDL PERFORMANCE ON PRODUCTIVITY
 Due to improper blasting it results in formation of boulders it causes problem while
loading.
 Due to boulders the formation of spaces so the bucket cannot be filled properly.
 Due to uneven surface tilting of bucket may occur so that the slipping of ore from
the bucket occurs.
 Due to improper maintenance the small fragments coal samples drop from closing
side of bucket.
 While adjusting the sufficient muck into the tubs the bucket gives tilting action due
to this coal fragments drops from the tub and bucket too.
 Due to insufficient tubs.
 While lifting and lowering bucket the coal samples may fall down.
 While adjusting the bucket due to the steep roof the samples slips down.

32
CONCLUSION
The productivity of an underground coal mine is affected by several factors. There is always
scope for improvement regarding productivity. This study shows certain parameters affecting
the productivity of mine such as the cycle of operations, machine efficiency. The overall
reliability of the SDL system drops significantly with time. As we have seen above, have
resulted in overall decreasing in productivity. This study also demonstrates productivity
improvement of the case study of the mine through the enhancement of SDL productivity.
So, to overcome those issues, we have to make sure that the SDL run at optimum available
conditions. Many of the changes suggested in this can be implemented with minimal effort
and could have a profound effect on improving productivity at a minimal cost.

33
REFERENCES
Devi prasad Mishra, Mamtesh Sugla, Prasun Singha. (2013), productivity improvement in
underground coal mines. journal of sustainable mining. volume: 12. ISSN:2300-3960, pp:48-
53.
Sankha Sarkhel and U.K. Dey. (2015), a critical study on availability and capacity utilization
of side discharge loaders for performance assessment. IJRET, volume: 04
issue:07|eiSSN:2319-1163 | piSSN :2321-7308, pp. 251-258.
The singareni collieries company limited. Technical specifications of side discharge loaders.

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