Basic calculations for hauler capacity, man riding, pumping, Main mechanical ventilator, shearer, AFC, BSL, Conveyor belts,OPENCAST, drills, Graders, dumper capacity, power calculations, HEMM Survey-off norms etc

1. EQUIPMENT CAPACITIES
CALCULATIONS IN PLANNING
-A.V.REDDY

2. • Estimates capacity (KW/HP) of machines,
Electric power, Power cost/ton of coal or
OB , For OCs Capacities of shovels
dumper combination, capital required for
Plant and machinery etc, of New
Projects to in corporate in Feasibility
Reports. (FRs)
• Estimates P&M for Revised Feasibility
Reports of projects.
• Estimates P&M requirement of completed
projects and on going projects.

3. Technology adopted
a) Hand section
b) Mechanised mining
a) Hand Section :
Equipment required :
Haulers (DH,EH), Pumps, Drill M/Cs, Main
mechanical ventilator, Auxiliary fans
connected Electricals

4. • Gradient (1:3.5 or 1:4) Approx= 57/gradient
• Weight to be pulled
Calculation :
Pull = Pull due to rope(w) + Pull due tubs(W)
(kgs)
Pull due to rope= Resistance against gradient (w)
+ Rope rolling resistance(f)
= w x Gradient (Sin O) + w/10
( w is weight/mtr of rope)
=w/3.5+ w/10 (10% weight of rope)

5. Pull due to tubs/(man riding cars)
= Resistance against gradient (W) + Rolling
resistance of tubs (F)
= W x Gradient + W/40 (W/20)
where W is the total weight of tubs
= W / 3.5 + W/40 (W/20)
Total Pull = w/3.5+w/10 +W / 3.5 + W/40
(W/20) Kgs
Based on pull, rope is selected.
Breaking load of rope as per IS 1570 =352 KN for
26 mm rope dia
Factor of safety =9

6. Breaking Load = 350 x1000/9.81 Kgs
=35678 Kgs
Safe load =35678/9
=3964 kgs
HP =Total Pull x speed(mps)/75
KW =Total pull x speed(mps)/102
Peripheral speed of rope= 3.14xN
xD/60x1000 m/sec D is Drum Dia, in mm
N is RPM

7. Total Length of Installation,L in mtrs. 2200
Max. Lift,H in mtrs 134
Distance between two chairs m 16
Max. Travelling Speed,V m/s 3
Man Riding Capacity,C Nos. 675
Weight of person,Mper
in kgs 80
Weight of Chair,Mchair
in kgs 13
Weight of Rope,Mrope
in kg/m 1.6
Drive&Return wheel Dia,D in mtrs 1.5

8. Power required to raise mass of persons,Ppers
in W
= C x H x 9.81 x 80/3600 = 675x133.52x9.81x80/3600 =19647 W
Power to overcome Frictions,PFriction
Line Friction,PFriction1
Chair Spacing ,X chair
in mtrs 16
Total Continuous Rope length,LRope
in mtrs
=2 x L + 3.14 x D = 2x 2200 + 3,14x1.5 = 4404.71
Total no. of chairs, X
=L rope / Chair spacing = 4404.71/16 = 275.29
Total no.of persons on one side only,Y =275/2 = 134
PFricion1
= 0.09((Lrope x Mrope) +( Y*Mper) +X * Mchairs)) V = 5304 W

9. Friction included by vertical&horizontal curve stations,
PFriction2
P Friction C=
K*(Ppers
+PFriction1
)
where K is a constant that increases with angle
of deflection
Angle of Deflection % Value of K
5°To10° 1 0.01
10°To20° 2 0.02
20°To30° 3.5 0.035
30°To40° 5 0.05

10. Three curve stations are there
Sl.No Horizontal Angle Vertical Angle
1 33° 2.34°
2 37° 2.04°
3 33° 1.00°
At 1st Station,PFrictionCH1
= 0.05 x (19647 +5304) = 1247.57 W
PFrictionCV1
= 0.01 x (19647 +5304) = 249.51
At2nd Station,PFrictionCH2
= 1247.57w
PFrictionCV2
= 249.51W
At3rd Station,PFrictionCH3
= 1247.57W
PFrictionCV3
= 249.51W
Total PFriction2
= 3 * (1247.57+249.51) =4491W

11. Friction induced by Return sheeve
Wheel,PFriction3
0.02x(Ppers
+PFriction1
+PFriction2
)
0.02x(19647.468+5304.0042+4491.
27)
=588.854844
Therefore ,PFriction
=(5304+4491+588)
= 10384.12904
Total Power at the Driving Wheel,P Ppers
+PFriction

12. Efficiency of the System 0.76
Therefore,Input Power 39515.25927
Taking5%extra,Required Power will be 41491.02223
Standard Available Power,KW 45
Rope Pull Calculation
Power at Driving Wheel
= 30 KW =30/0.746=40HP
HP=2NT / 4500
So, T=HPX4500 / 2N
= (40*4500*7)/ (2*22*19.1)
= 1499.286054
= 15kN

13. Power = QxHx Sp.gravity/75x Efficiency HP
= Qx Hx Sp.gravity/102 x Efficiency KW
Q = Ltr/sec
H = Head in mtrs
Sp.gravity = 1.03 gms/cc
one gallon =4.54 Ltrs
Generally GPM of pump is taken
Say 2250 LPM = 2250/4.54 = 495 GPM or
500 GPM

14. Generally in SCCL mines single, Double,
multistage centrifugal pumps are being
used for pumping water from under
ground to surface.
7.5 HP to 500 HP.
• Depending upon depth and sump capacity
pumps are deployed.

15. Air Power in KW =
Air Discharge (Cu.m/sec)x water gauge in
mm/ 102
Fan efficiency = Air power in KW / brake
shaft Power in KW
Brake shaft power = Transmission efficiency
x motor efficiency x Measured input power
in KW
Overall efficiency = Air power KW x100/
Measured power in KW

16. Auxiliary fans of 20 KW is deployed in
galleries where the flow is less than
requirement
High water gauge fans of 90 KW (200 to
500mm water gauge) are deployed in
Road header drivages.
In SCCL mines1 to 3 lakh CFT/min i.e
(3000 to 9000 Cu.m/min) are working with
blade angle 14 to 22 deg
For Adriyala shaft 15000Cu.m/min fan is
required.

17. Mechanised mining :
To increase the production and safety
mechanised mining is adopted with
following technologies.
a) Long wall :
Shearer is the deciding factor

18. 1 Determine the mining rate, TPH
Assume
Cutting height,H mtrs 3.0
Web depth,D mtrs 1.0
Max. cutting speed,Vs mt/min 12.0
Coal density(solid), T/Cu.m 1.5
TPM= H*D*Vs
* T/min 54
TPH 3240

19. Drum Dia. mtrs 1.8
Web mtrs 1
Cutting speed, Vs mt/min 12.0
Density of coal (solid) T/m3
1.5
Q(Mining rate in tonnes per hour by one drum) TPH 1944
K is Specific energy consumption factor in HP-hr/Ton
Normally K is 0.5 for hard coal and 0.25-0.35 for soft coal
P(HP) = QK HP 972
There fore, for 3mtr extraction, the other drum requires only
a power of
(3-1.8)*1*12*1.5*0.5 HP 648
But, in practice, both drums will require equal power for bi-
directional
operation
KW 725.112

20. • (Assumed 1TPH=1KG)
• For 1000 TPH,
• S1 = 1000 Kg.
• S1 - Tension
• gc1 – Gravitational resistance on slack side (weight
component acting along the bottom for chain)
• gc2 - Gravitational resistance on tension side
• RC1 - Frictional resistance on slack side
• RC2 - Frictional resistance on tension side
• gc1 = qc x L x Sinø
• Where qc = Wt. of chain/mt.
• L = Length of chain in mt.
• Ø = Inclination

21. • RC1 = qc x L x fc x Cosø
• Where qc - Wt. of chain/mt.
• L - Length of chain in mt.
• fc - Frictional co-efficient of
chain with pan
• ~ 0.35 to 0.4 for
soft chain
• ~ 0.45 for shaking
& watering
• S2 = S1 + gc1 + RC1 or S1 + qcL (Sinø + fc
Cosø)
• (S1, S2 are in the opp. Direction)
• S3 > S2 and there will be some loss
• Thus S3 = 1.05 S2
• S4 = S3 – Gc2 + RC2

22. • Where
• gc2 = (qc x L x Sinø) + (qy x L x Sinø)
• RC2 = (qc x L x fc Cosø) + qy x L x fy x Cosø
• qy = Q/3.6V (Q = TPH, V = Velocity m/s)
• Fy = Frictional co-efficient of material conveyed
• 0.45 to 0.8 for dry soft coal,
• 0.8 for silica, rock etc, normally 0.7
• Now S4 = S3 – gc2 + RC2
• Or S4 = S3 – (qc L Sinø + qy L Sinø) + (qc L fc Cosø +
qy L fy Cosø)
• = S3 + qc L (fc Cosø – Sinø) + qy L (fy Cosø
– Sinø)
• Power (P) = (S4 – S1) KW
• 102
• Motor Power - P/h h = 0.8 to 0.9

23. Based on shearer capacity AFC,BSL, Gate
Belts, Trunk belts are designed.
The supports are designed by taking load
coming to supports / Sq.m area as per
finite element method.
The connected electricals are designed
basing on the above capacities
Power pack is designed on the design of
support load.

24. In SCCL Long wall technologies produced 4
to 7 lakhs per annum
BG technology the following equipment is
deployed
a) Jumbo Drills
b) LHDs
c) Hydraulic props
d) Power pack
SDL Low height are deployed in hand
section mines to increase productivity,
safety and decrease in man power

25. Based on production No. of LHD,SDL are
deployed
For CTX,811 Eimco LHDs annual
production = 50,000 T
For 912 Eimco LHDs = 60,000 T/ annum
For Low height SDLs = 45,000 T/ annum
Connected Electricals like GEBs, HT/LT
switches, transformers are calculated on
the No. of SDLs / LHDs deployed

26. a) Power to move load horizontally
=2.72 x L x F x (C+46)/1000 kW
b) Power to move empty belt
= 9.81 x F x G x (C+46) x S/1000 kW
c) Power to elevate load
=2.72 x L x H/1000 kW
Total Power P = (a) +( b) +(c)

27. Taking safety factor as 1.1 to 1.2 Total
power requirement is calculated
C = Centre distance in mtrs
F = Friction factor (0.03)
G = Inertia factor
H = Change in elevation in mtrs
L = Peak load in Tonnes/Hour
S = Belt speed in mtrs/sec

28. L= B x D x S/1000 Tonnes/Hr
L = Peak load
B =Belt capacity Factor
D = Material density Kg/Cu.m
S = Belt speed in mtrs/sec
• Selection of belt
T = K x P/S kN
P is power required, K = Belt Drive factor
S = speed mtrs/sec
= kN/1 m = kN/m Taking Factor of Safety as
10:1 for PVC F.S 7:1 for steel cordvalue from
table can be used for selection PVC/ Steel cord

29. Based on coal production, OB removal and
depth of the mine No. of shovels( Coal,
OB), Dumpers, RBH Drills (Coal, OB),
Dozers, Graders,Pumps and water
sprinklers and other common equipment
are calculated

30. Sl.No Particulars 3cu.mShovel
along with
35T Dumper
1 No. of Annual working days 330
2 No. of duty shifts 3
3 Duration of shift in Hr 8
4 Total No. of Annual shift hrs 7920
5 Annual utilisation of shift hrs 61%

31. 6 Annual working hr 4831.2
7 Shovel bucket capacity (m3) 3
8 Material density - Tes/BCM 2.2
9 Swell Factor 0.732
10 Bucket fill factor 0.905
11 Swell cum fill factor 0.662

32. 12 Material quantity per shovel bucket (T) 4.3722
13 Pay load capacity of dumper (T) 31.5
14 No. of passes per dumper load 7.204
15 No. of passes adopted 7
16 Adopted Pay load capacity of dumper (T) 30.605
17 Bucket cycle time (Minutes) 0.6

33. 18 Loading time per dumper (Minutes) 4.2
19 Spotting time of dumper 0.5
20 Shovel time for loading dumper (Minutes) 4.7
21 Hourly shovel capacity Cum/hr 177.595
22 Factor for travelling positioning etc. 0.85
23 Annual shovel capacity (Cum) 729300
M.Cum 0.73

34. Sl.No DESCRIPTION 0.5
1 Shovel loading time for dumper ,min 4.70
2 Spotting for unloading ,min 0.5
3 Unloading time ,min 0.6
4 Travelling time ,up ,min 1.20
5 Travelling time, down, min 1.00

35. 6 Dumper cycle time. min 8.00
7 Dumper waiting time 1.40
8 Cycle time adopted 9.40
9 No. of trips per hour 6.382979
10 Dumper utilisation hours 2376
12 No. of trips per annum 15165.96

36. 13 Dumper capacity,Cu.m 14.43182
14 Corrected dumper capacity 14.03093
15 Annual Dumper capacity,M.cum 0.212793
16 Calculated capacity of shovel, M.cum 0.73
17 No.of Dumpers required per shovel 3.524559
18 Rounded no. 4

37. Assessment of volume of water to be
pumped
Q = A x H x Run off coefficient
A = Catchment area in Sq.m
H = Maximum daily precipitation in m
Run off coefficients
For mined out area = 0.60
Area beyond excavation =0.10
For internal dump area =0.15

38. Maximum capacity of pump is determined
on operating time 20 Hrs for 10 days i.e
200 Hrs as per CMPDI
In SCCL 20 Hrs for 6 days i.e 120 hrs
Add 10% seepage for attaining total make
up
Peak pumping capacity = /120
No of pumps is determined from above
depend on pump capacity Cu.m/Hr

39. For coal based on coal & OB No. of Drills is
calculated
Drilling pattern for coal = 5 x 5 x 6/5
Height of bench =5 m
Spacing =5 m
Burden =5 m
Volume of coal exposed/ mtr drilling =30 Cu.m
Annul working hrs =2112
Annual meterage = 42000
Volume of coal exposed by one drill =1.26 M.Cu.m
Drill employed =150mm

40. For OB 250mm RBH drills are used
Depending on OB removal/ year No. of drills
calculated
Drilling pattern =8 x 8 x 9/8
Volume of OB exposed /mtr of drilling =72 Cu.m
Annual working Hrs =2112
Annual meterage = 40000
Volume of OB exposed M.Cu.m = 2.88

41. Road Length to be graded, Km 17
Road Width to be graded, Mtr 20
Area to be Graded, Sq.mtrs 340000
Speed of the Grader ,Mtrs / Hr 6100
Blade Length ,Mtrs 4.32
Blade overlap ,Mtrs 0.3

42. Width of Graded area/each pass ,Mtrs 4.32 SIN 600
3.74
Graded Area/hr,Sq,Mtrs((3.74-0.3)*6100) 20984
No of Hours required /day 16.20
No. of Graders available at GKOC 2
Working hours required / each Grader/Day 8.1
% of utilization on SSH 34

43. Dozers are 50% of shovel population
Water Sprinklers 28 kL -2 Nos
Common equipment
Cranes 10T to 70/100T
Diesel bouser
Maintenance van
Compact vibrator, Tyre handlers, Front end
loaders, Fire tenders etc, are provided

44. Power calculations
Connected load = kW
Active load = Connected load x demand factor kW
Demand factor = 0.6 to 0.9
kVA = Active load / Power factor
Power factor = 0.8
No. of annual working hrs = say 3000
Energy consumption/annum = Active load x No.of
hrs/annum
Unit cost =2.80 x kWH
Surcharge @ 0.06Rs/kWH
Maximum demand/ kVA= Rs.250

45. SURVEY OFF NORMS FOR HEMM
Sl.
Equipment
Existing(CMPDI) Proposed(SCCL)
No. Hours Years Hours Years
1 10 Cu.m Rope Shovel 80000 22 100000 25
2 4.6-5 Cu.m Rope Shovel 36000 12 40000 15
3 5-10 Cu.m Hydraulic Excavators 20000 9 40000 15
4 2.2-3.5 Cu.m Hydraulic Excavators 20000 9 35000 15
5 85 T Rear Dumpers 22000 10 35000 15
6 35 T Rear Dumpers 12000 9 20000 15
7 Water Sprinklers 12000 9 25000 15
8 420&310HP Dozers 14000 9 20000 12
9 250mm RBH Drills 20000 9 35000 15
10 150mm RBH Drills 10000 9 25000 15
11 Motor Graders 10000 9 20000 15
12 Front End Loader 16000 9 25000 15