Northern Coalfields Limited Training report on Heavy Earth Moving And Mining Equipment

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A
Summer Internship Report
On
“Heavy Earth Moving & Mining Equipment”
At
Base Work Shop (BWS)
Northern Coalfields Limited
(A subsidiary of Coal India Limited)
Submitted By:-
Saurabh Tripathi
Roll No:-0820me121098

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CERTIFICATE
This is to certify that Mr. Saurabh Tripathi a student of Lakshmi Narain College of
Technology, Indore course B.E, 6 Semester , has completed his summer Internship
at Northern Coalfields Limited (NCL) under the guidance of Mr. V.M. Dwivedi,
designation Chief General Manager
The period for which he was on training was starting from 05/May/2014 to
30/June/2014. This Summer Internship report has the requisite standard for the
partial fulfillment of the requirements for the award of B.E Degree prescribed by
the Lakshmi Narain College of Technology, Indore which is affiliated by RGPV,
Bhopal. This Report is the result of his own work and to the best of my knowledge
no part of it has earlier comprised any other report, monograph, dissertation or
book.

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DECLARATION
I hereby undertake and declare that this submission is my original work and to best
of my knowledge and belief, it contains no material previously published or written
by another person or material which has been accepted for the award person of any
other degree of any institute or other university of higher learning, expect where
due acknowledgment has been made in the text.
Name of student : Saurabh Tripathi
University : Rajeev Gandhi Technical University
Enrolment : 0820ME121098
Course : B.E, 6th Semester,
(Signature)

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ACKNOWLEDGEMENT
I express my sincere gratitude to my industry guide Mr. V.M. Dwivedi (Chief General
Manager) Northern Coalfields Ltd (NCL) for his guidance, continuous support and
cooperation throughout my project,
My faculty guide Ms. Astha Gupta has been constantly guiding and supporting me by
providing the right direction.

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PREFACE
The report below gives a brief profile of Coal India Limited and Northern
Coalfields Limited with their corresponding organizational structure.
It further describes different methods of coal mining, common activities performed
for opencast mining and different types of Heavy Earth Moving Machinery
(HEMM) used for the same.
It further elaborates about HEMM, basic definitions involved with it, following its
classification on the basis of operating mass and operator control configuration.
Then it briefly describes each member of classified HEMM family with their
corresponding labeled dig.
The end of report provides attention towards some of basic components of HEMM.

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Content
1. C.I.L at a Glance
1.1. C.I.L’s Mission
1.2. C.I.L’s Organizational structure
2. N.C.L profile
2.1. N.C.L’ s area of operation
2.2. N.C.L’s organizational structure
3. Types of Coal Mining Methods
3.1. Common activities undertaken in open-pit mining
4. Heavy Earth Moving Earth Moving Machinery
4.1. Basic definition
4.2. HEMM classification on the basis of controlconfiguration
4.3. HEMM classification on the basis of operating mass
4.3.1. Dozer
4.3.2. Loader
4.3.2.1. Swing loader
4.3.2.2. Skid steer loader
4.3.3. Backhoe Loader
4.3.4. Excavator
4.3.4.1. MSXR
4.3.4.2. Walking Excavator
4.3.4.3. Cable Excavator
4.3.5. Trencher
4.3.6. Dumper
4.3.6.1. Rigid-frame Dumper
4.3.6.2. Articulated-frame Dumper
4.3.6.3. Swing Dumper

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4.3.7. Scraper
4.3.7.1. Towed –scraper
4.3.8. Grader
4.3.9. Roller
4.3.9.1. Towed Roller
4.3.10. Horizontal Direction Drill
4.4. Some Important of HEMM
4.4.1. Engine
4.4.1.1. Air Intake System
4.4.1.2. Cooling System
4.4.1.3. Fuel System
4.4.1.4. Lube oil System
4.4.2. Torque Convertor
4.4.3. Tires of HEMM

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Coal India Limited (C.I.L) – A Maharatna Company
C.I.L at a Glance
To take care of energy requirements of India, the Central Government of India did
a nationalization of coal industry in the 1970s. By 1972, it acquired most of the coking coal
mines in India (226 coking coal mines) through Bharat Coking Coal Limited (BCCL). Similarly,
it acquired all 711 non-coking coal mines in India through Coal Mines Authority Limited
(CMAL). To consolidate the businesses of both coking and non-coking coal under one entity, a
formal holding company in the form of Coal India Limited was formed in November 1975 to
manage both the companies. Government of India held 100% of its shares from 1975 till 2010.
Coal India Limited (CIL) is an Indian state-controlled coal mining company headquartered
in Kolkata, West Bengal, India. It is the largest coal producer company in the world and
contributes around 81% of coal production in India
Operations:-
 CIL is the largest coal producing company in the world and operates through 81 mining
areas in eight states in India.
 It has 470 coal mines out of which 164 are open cast, 275 are underground and 31 are
mixed mines. Underground mines contributed to 8.35% of production
 CIL further operates 17 coal washeries, out of which 12 are for coking coal and 5 are for
non-coking coal. It also manages 200 other establishments like workshops, hospitals etc.
 Subsidiaries: Coal India produces coal through seven of its wholly owned subsidiaries.
It’s another wholly owned subsidiaryCentral Mine Planning and Design Institute,
CMPDIL carries out the exploration activities for other subsidiaries. CMPDIL also
provides technical and consulting services to it and to third party clients for coal
exploration, mining, processing and related activities.
 CIL also has a wholly owned subsidiary in Mozambique, Coal India Africana Limitada
(CIAL) for pursuing coal mining opportunities in that country.

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CIL’s Mission
To produce and market the planned quantity of coal and coal products efficiently
and economically in an eco-friendly manner with due regard to safety,
conservation and quality.
CIL’s Organizational Structure

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Northern Coalfields Limited (N.C.L) – A Mini Ratna
Company
Northern Coalfields Limited was formed in November 1985 as a subsidiary company of Coal
India Limited. It’s headquarter is located in Singrauli, Dist. Singrauli (M.P).Singrauli Coalfields,
covering total area of about 2201 sq.km attracted little attention earlier and remained
undeveloped on account of lack of communication, even though coal appears to have been
discovered, as early as 1840, and its mining was done near Kota, Parari and Nawanagar
sometime before 1857. The coal was then transported by bullock carts and camels to Mirzapur
for use in steamers on the Ganges. North-eastern part of the coalfield was selected for detailed
geological survey in 1958 during second plan period in independent India. Initially Geological
Survey of India and later Indian Bureau of Mines drilled bore holes to explore this region.
The exploration carried out by GSI/NCDC/CMPDI has proved abundant resource of power grade
coal in the area.
Operation:-
 The area of Singrauli Coalfields is about 2202 Sq.km. The coalfield can be divided into
two basins, viz. Moher sub-basin (312 Sq.km) and Singrauli Main basin (1890 Sq.km).
 Coal is produced through opencast mining.
 Coal resources from NCL in conjunction with easy water resource from Govind Ballabh
Pant Sagar make this region an ideal location for high capacity pithead power plants. The
coal supplies from NCL produce about 10515 MW of electricity from pithead power
plants of:-
1. National Thermal Power Corporation (NTPC).
2. Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd. (UPRVUNL).
3. Renupower division of M/s. Hindalco Industries.
The region is now called the "power capital of India". The ultimate capacity of power
generation of these power plants is 13295 MW and NCL is fully prepared to meet the
increased demand of coal for the purpose.

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 In addition, NCL is also supplying coal to power plants of
1. Rajasthan Rajya Vidyut Utpadan Nigam Ltd.
2. Delhi Vidyut Board (DVB).
3. Haryana State Electricity Board.
 NCL is engaged in mining activities, which has got unified Integrated Management
System (IMS) complying with Standard ISO 9001:2008, ISO 14001:2004 and OHSAS
18001:2007 for simultaneous management of economic, environmental and occupational
health and safety.

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NCL’s Organizational Structure

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Types of Coal Mining Method
Open Cast Mining-Open-pit or open-cast mining is a surface mining technique of
extracting rock or minerals from the earth by their removal from an open pit or borrow. Open-pit
mines are used when deposits of commercially useful minerals or rocks are found near the
surface; that is, where the overburden (surface material covering the valuable deposit) is
relatively thin or the material of interest is structurally unsuitable for tunneling (as would be the
case for sand, cinder, and gravel). For minerals that occur deep below the surface—where the
overburden is thick or the mineral occurs as veins in hard rock—underground mining methods
extract the valued material.
Ideal conditions for Opencast Mining are:-
 Thickness of coal seam -5m
 Coal without stone bands
 Free from surface structures or features
 Availability of perfect place for dumping
 Preferably no forest land
Coal is produced through opencast mining (Method of Work is Dragline-cum-Shovel Dumper
combination mining) in Northern Coal Fields Limited because of following mining and geology
condition:-
 OB thickness : 10m (at outcrop) 180m (N-E part)
 Avg. Stripping ratio : 2:60
Coal Mining
Method
UNDERGROUND
Methods
OPENCAST
Methods
SPECIAL
MINING
Method
Hydraulic
Mining
Gassification

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 Over Burden: 90% is medium and coarse grained sand stone.
Common activities Undertaken in Open-pit Mining
Above fig. reveals the use of different types of Heavy Earth Moving Equipment (HEMM)
used in coal mining activities.
These earth movers play a vital role in surface mining process, primarily to move earth and
minerals in large earthmoving and mining projects. Some of this equipment finds it place in other
applications, however, and the use of bulldozers and articulated trucks on road and highway
projects are just a couple of examples.
Common Machinery used for Opencast Mining are-
 Shovel, Dumper,
 Dragline,
 Surface miner, Bucket Wheel Excavator, In-pit crushing & Spreader.

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Heavy Earthmoving and Mining Equipment
Earth-moving machinery is a self-propelled or towed machine on wheels, crawlers or legs,
having equipment or attachment (working tool), or both, primarily designed to perform
excavation, loading, transportation, drilling, spreading, compacting or trenching of earth, rock
and other materials.
Basic Definition:-
 Base Machine-
It’s a machine with cab or canopy and operator-protective structure if required, without
equipment or attachments but possessing necessary mountings for such equipment and
attachments.
 Equipment-
A set of components mounted on the base of machine that allows an attachment to
perform primary design function of the machine.
 Optional equipment-
Optional component mounted onto base machine or equipment to increase, for example
capacity, flexibility, or enhance comfort.
 Operating mass(OM)-
It is mass of the base machine, with equipment and empty attachment in the most usual
configuration as specified by the manufacturer, and with the operator (75 kg), full fuel
tank and all fluid systems (i.e. hydraulic oil, transmission oil, engine oil, engine coolant)
at the levels specified by the manufacturer and, when applicable, with sprinkler water
tank(s) half full
Note 1 to entry: The mass of an operator is not included for non-riding machines.
Note 2 to entry: Ballast mass at delivery can be included if specified by the manufacturer

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 Rated Payload(PL)-
It is mass that can be carried by the machine, as specified by the manufacturer
 Rated Ballast Mass(BM)-
It is maximum mass of ballast that can be added to the machine, as specified by the
manufacturer
 Attachment-
Assembly of components that can be mounted on base machine or equipment for specific
use.
Key-
1. Attachment
2. Equipment
3. Base machine
4. Backhoe portion
5. Loader portion
 Gross Machinery Mass(GMM)-
maximum machine mass as approved by the manufacturer, which combines the operating
mass (OM) of the machine with the heaviest combination of equipment and attachments,

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the heaviest combination of optional equipment, the rated payload (PL), as specified by
the manufacturer, the rated ballast mass (BM) and, when applicable, full sprinkler water
tank(s)
Earth-moving machinery can be of a type either directly controlled by an operator riding or not
riding on the machine, or can be remotely controlled by wired or wireless means with or without
direct view on the working area.
Earth Moving Machine Operator Configuration
1 Direct control Machine
It is self-propelled earth-moving machinery where the machine is controlled by an operator
in physical contact with the machine.
1.1 Ride-on machine
It is self-propelled direct-control machine where the control devices are located on the
machine and the machine is controlled by a seated or standing operator.

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1.2 Non-riding machine
It is self-propelled direct-control machine where the control devices are located on the
machine and the machine is controlled by a pedestrian operator (neither seated nor
standing on the machine
2 Remote-control machine
It is self-propelled earth-moving machinery where the machine is controlled by the
transmission of signals from a control box (transmitter) that is not located on the machine to
a receiving unit (receiver) located.
Note-The remote control can either be wireless or by wire
2.1 Wire-controlled machine
It is a self-propelled remote-control machine where the control of the machine is
accomplished by signals transmitted through wires from an operator control device distant
from the machine.
Note-The remote control can either be wireless or by wire.
2.2 Wireless-controlled machine
It is self-propelled remote-control machine (3.3) where the control of the machine is
accomplished by signals transmitted through the air from an operator controlled device
distant from the machine
Note- A wireless controlled machine is operated with or without a direct view on the
working area.

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Classification of HEMM
HeavyEarthMoving
Machinery
Dozer
Loder
Skid steer loader
Swing loader
Excavator
MSRX
Walking excavator
Cabel excavatorBackhoe Loader
Trencher
Dumper
Rigid-frame
dumper
Articulated-frame
dumper
Swing dumper
Scraper Towed scraper
Grader
Roller Towed roller
Horizontal
Direction Drill

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1. Dozer
It is a self-propelled crawler or wheeled machine with equipment having either a dozing
attachment which cuts, moves and grades material through forward motion of the machine or a
mounted attachment used to exert a push or a pull force.
2. Loader
It is a self-propelled crawler or wheeled machine which has front-mounted equipment primarily
designed for loading operation (bucket use) and which loads or excavates through forward
motion of the machine.

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NOTE-A loader work cycle normally comprises filling, elevating, transporting and discharging
of material.
2.1.Swing loader
It is a loader having a swing type lift arm which can rotate to the left and the right of the
straight position.
NOTE-A swing loader working cycle is similar to a loader cycle, but additional work can
be done with the equipment offset from the longitudinal axis of the machine.
2.2.Skid Steer Loader
It is a loader which normally has an operator station between attachment-supporting
structures and which is steered by using variation of speed, and/or direction of rotation
between traction drives on the opposite sides of a machine having fixed axles on wheels or
tracks.

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3. Backhoe Loader
It is a self-propelled crawler or wheeled machine having a main frame designed to carry both
front-mounted equipment and rear-mounted backhoe equipment (normally with outriggers or
stabilizers).
NOTE 1 -When used in the backhoe mode, the machine is stationary and normally digs
below ground level.
NOTE 2 -When used in the loader mode (bucket use), the machine loads through forward
motion.
NOTE 3 -A backhoe work cycle normally comprises excavating, elevating, swinging and
discharging of material. A loader work cycle normally comprises filling, elevating,
transporting and discharging of material.
4. Excavator
It is a self-propelled machine on crawlers, wheels or legs, having an upper structure capable
of a 360° swing with mounted equipment and which is primarily designed for excavating
with a bucket, without movement of the undercarriage during the work cycle.

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NOTE 1- An excavator work cycle normally comprises excavating, elevating, swinging and
discharging of material.
NOTE 2 -An excavator can also be used for object or material handling/transportation.

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4.1.Minimal Swing Radius Excavator MSRX excavator
It is designed for operation in a confined space, having an upper structure with a short
swinging radius and with its equipment and attachment swinging within 120 % of the
width of the undercarriage.
4.2.Walking Excavator
It is excavator with three or more supporting legs, which can be articulated, telescopic or
both, and which can be fitted with wheels.
4.3.Cable Excavator
It is excavator having a wire-rope-operated upper structure designed primarily for
excavation with a dragline bucket, front shovel or grab, used for compacting material
with a compaction plate, for demolition work by hook or ball, and for material handling
with special equipment and attachment.

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5. Trencher
It is a self-propelled crawler or wheeled machine, having rear- and/or front-mounted
equipment or attachment, primarily designed to produce a trench in a continuous operation,
through motion of the machine
NOTE- The attachment can be a digging chain, wheel, disk, plough blade or similar.
6. Dumper
It is a self-propelled crawler or wheeled machine with an open body, which transports and
dumps or spreads material, and where loading is performed by means other than the dumper
NOTE- A compact dumper can have integral self-loading equipment.
6.1.Rigid-frame dumper
It is a dumper having a rigid frame and wheel or crawler steering.
6.2.Articulated frame dumper (wheeled machine)
It is a dumper with an articulated frame which accomplishes the steering of the dumper.

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6.3.Swing dumper
It is dumper having a 360° swing upper structure, whose upper structure consists of a
rigid frame, the open body and the operator's station, and whose undercarriage consists
of a track type or wheeled unit.
7. Scraper
It is a self-propelled or towed crawler or wheeled machine which has a bowl with a cutting
edge positioned between the axles, and which cuts, loads, transports, discharges and spreads
material through its forward motion.
NOTE- The loading through a forward motion can be assisted by a powered mechanism
(elevator) fixed to the scraper bowl.

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7.1.Towed scraper
It is a scraper that is not self-propelled but which is propelled instead by a towing
machine on which the operator's station is located.
8. Grader
It is a self-propelled wheeled machine with an adjustable blade positioned between the front
and rear axles, which can be equipped with a front-mounted blade or scarifier that can also be
located between the front and rear axles
NOTE- The machine is primarily designed for grading, sloping, ditching and scarifying of
materials through its forward motion.

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9. Roller
It is a self-propelled or towed machine having a compaction device, consisting of one or
more metallic cylindrical bodies (drums) or rubber tyres, which compacts material such as
crushed rock, earth, asphalt or gravel through a rolling and/or vibrating action of the
compaction device.
9.1.Towed Roller
It is a roller that is not self-propelled but which is instead propelled by a towing machine
on which the operator's station is located.

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10.Horizontal directional drill
It is a machine that uses a steerable cutting head attached to the end of a drill string for
creating a bore through the earth in a horizontal direction
NOTE 1 Drilling can include fluid injection through the drill string to the cutting head,
tracking of the bore by use of sensors or a transponder near the cutting head and subsequent
enlargement of the bore by back reaming.
NOTE 2 These machines typically apply force to the drill string using a drill frame parallel
to, or inclined up to, 30° relative to the operating earth surface.

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Some Important Parts of HEMM
1. Engine
An engine is a device which transforms the chemical energy of a fuel in to thermal
energy and uses this energy to produce mechanical work.
Heat engines can be classified into two types:-
a) External combustion engine - In an External Combustion Engine the product of
combustion of air and fuel transfer heat to a second fluid which is the working fluid
of the cycle. Example: - Steam Engine, Steam Turbine Plant.
b) Internal combustion engine - In an Internal Combustion Engine the product of
combustion are directly the motive fluid. Example:-Petrol, Gas, Diesel Engines, Jet
engines & Rockets are also internal Combustion Engines.
Above Fig. shows some of major components of HEMM’s engines

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Engine Specifications of different HEMM used in Northern Coal Fields Limited are given
below:-
Engine is the prime mover of equipment. Utmost care is hence required to keep the
engine in Order so as to roll the equipment on the road.
 Air
 Cooling
 Fuel
 Lube Oil
Synchronized functioning of all these systems will lead to Optimum output and life of the
engine.

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Air Intake System
A well designed air intake system provides cool, clean air for combustion while minimizing inlet
air pressure drop to the turbocharger. Normally, this can be accomplished by using engine-
mounted air cleaners, but some applications require intake air to be brought in through ducts
from outside the engine room. There may also be requirements for special filtration and ducting
due to fumes, dust, airborne mists, ambient temperature or even altitude. These requirements
should be carefully considered because the inlet restriction that accompanies increased filtration
and ducting can cause the
engine to be derated and
turbocharger life reduced.
Components of Air System
• Air filter & housing
• Air inlet piping
• Turbocharger
• CAC (Charged Air
Cooler)
• Intake manifold
• Cylinder
components

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Cooling System
All internal combustion engines produce heat as a byproduct of combustion and friction. This
heat can reach temperatures up to 1925°C (3500°F) and can have catastrophic affects on engine
components. Pistons, valves and cylinder heads must be cooled to reduce the risk of detonation.
Cylinder temperatures need to be controlled so lubricating oil can maintain a protective film on
the cylinder surfaces and the lubricating oil should be cooled to ensure its integrity. In addition to
overheating, overcooling can have negative effects on the engine. Overcooling can reduce engine
performance and shorten the engine’s service life.
The basic components are:-
 The coolant
 Water pump
 Engine oil
 Cooler
 Coolant
temperature
regulators
 Radiator fan and
the radiator

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Fuel System
The fuel system is a major component of the diesel engine. According to the requirement of the
diesel engine working condition modes, its function is to gush out the right amount clean fuel the
combustion chamber within regular hours, with the proper atomized state, causing the advantage
of mist to form and burn.
The complete fuel-injection system is comprised of:
• Fuel tank
• Valve
• Primary fuel filter
• Water separator
• Fuel pump
• Secondary fuel filter
• Fuel line kit
• Nozzle assembly
• Fuel cooler

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Lube Oil System
An internal combustion engine would not run for even a few minutes if the moving parts
were allowed to make metal-to-metal contact. The heat generated due to the tremendous
amounts of friction would melt the metals, leading to the destruction of the engine. To
prevent this, all moving parts ride on a thin film of oil that is pumped between all the moving
parts of the engine.
Function of lubricating system:-
 One purpose is to lubricate the bearing surfaces.
 The other purpose is to cool the bearings by absorbing the friction generated heat.
Above Fig. shows flow of oil in Lubrication System

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2. Torque convertor
A torque converter is mounted on the input side of the transmission gear train and
connected to a drive plate. The drive plate is used to connect the converter to the
crankshaft flywheel flange of an engine. The torque converter is filed (from 50% to 80%)
with an automatic transmission fluid, and transmits the engine torque to the transmission.
Functions of flywheel are as follows:-
 It can either multiply the torque generated by the engine or function as a fluid
coupling.
 It also serves as the engine flywheel to smooth out engine rotation as its inertia
helps to maintain crankshaft rotation between piston power pulses.
 It tends to absorb torsion vibration from the engine and drive through the fluid
medium since there is no direct mechanical connection through the converter.
The torque converter has three major components: the pump impeller; the turbine runner;
and the stator. The impeller is integrated with the converter case, many curved vanes
being radially mounted inside. A guide ring is installed on the inner edges of the vanes to
provide a path for smooth fluid flow.
Sectional view and installation of Torque Convertor

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3. Tires of HEMM
Charles Goodyear invented vulcanized rubber in 1844 that was later used for tires. In
1888, John Dunlop invented the air-filled or pneumatic tires; however, his were for
bicycles. In 1895, André Michelin was the first person to use pneumatic tires on an
automobile, however, not successfully.
A tire is a composite, in other words, an inseparable assembly of materials with very
different properties, whose manufacture demands great precision
Tire Cross-Section

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1- A layer of airtight synthetic rubber.
This layer is found inside the tyre and functions as the modern equivalent of the inner
tube.
2 – The casing ply.
This casing is composed of fine textile fiber cords, laid down on straight lines and
sandwiched in rubber. These cords are a key element in the structure of a tyre and enable
it to resist pressure. In each ply of a car tyre, there are about 1400 cords, each of which
can resist a force of 15 kg.
3- The lower bead area.
Its role is to transmit engine and braking torque from the rim of the tyre through to the
contact patch.
4 – The bead wires
They help to hold the tire onto the rim. They can bear a load of up to 1800 kg without the
risk of breakage.
5 – The supple rubber sidewalls
They help protect the tire from shocks that could damage the casing, e.g. Minor shocks
against pavements, potholes, etc. There is hard, protection rubber where the tire joins the
rim.
6- Bracing plies.
Reinforced with very fine, very resistant steel cords, they are crossed obliquely and stuck
together. The cords cross the casing cords to form rigid triangles. This is known as
triangulation and makes the crown rigid. The plies encircle the entire crown of the tyre
and perform a very complex role:
They must be sufficiently rigid around the tyre’s circumference so that they aren’t
stretched by centrifugal force, thus controlling the diameter of the tyre under all
conditions.
7 - The radial plies.
These plies help to retain a stable profile under the effect of speed and also help to reduce
heating up. They are armed with cords, generally of nylon, fitted in single strands or in
bands perpendicular to the bracing plies around the tyre’s circumference so as not to
stretch under centrifugal force.

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8 - The tread
It is laid over the bracing plies. This is the patterned part of the tyre which will be in
contact with the road. The tread in the contact patch must be able to resist very significant
stresses. The treat compound must grip on all types of surface; resist wear and abrasion
and heat up as little as possible.

Northern Coalfields Limited Training report on Heavy Earth Moving And Mining Equipment

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