EQUIPMENT CAPACITIES CALCULATIONS IN PLANNING

-A.V.REDDY

• 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.

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

• 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)

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

Breaking Load = 350 x1000/9.81 Kgs =35678 Kgs Safe load =35678/9 =3964 kgs

HP =Total Pull x speed(mps)/75KW =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

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

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

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

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

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

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=2NT / 4500

So, T=HPX4500 / 2N = (40*4500*7)/ (2*22*19.1)

= 1499.286054

= 15kN

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

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.

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

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.

Mechanised mining :

To increase the production and safety mechanised mining is adopted with following technologies.

a) Long wall :

Shearer is the deciding factor

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

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

• (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

• 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

• 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

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.

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

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

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)

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

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

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

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%

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

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

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

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

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

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

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

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

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 mSpacing =5 m Burden =5 mVolume of coal exposed/ mtr drilling =30 Cu.mAnnul working hrs =2112Annual meterage = 42000Volume of coal exposed by one drill =1.26 M.Cu.mDrill employed =150mm

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

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

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

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

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

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