Project Report on Industrial Training

OVERVIEW OF MINING COMPONENTS

TATA STEEL LIMITED, JHARIA DIVISION

(BHELATAND A. COLLIERY)

Project Duration: 01-06-2017 to 31-07-2017

SUBMITTED BY:ASHISH KUMAR

REF. N0.:-SGR/BAC/24A/866/17
UNIVERSITY :-ICFAI UNIVERSITY,
JHARKHAND,RANCHI
DEPT.:-MINING Engineering

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 CONTENTS
PREFACE 3
.....................................................................................................................

ACKNOWLEDGEMENT .............................................................................. 4
AN INTRODUCTION TO TATA STEEL LIMITED
&BHELATAND A.
COLLIERY .............................................................. 5
BRIEF ABOUT MECHANICAL EQUIPMENTS ON
BHELATAND A. COLLIERY ,TATA STEEL LIMITED,
JHARIA DIVISION
1. AIR COMPRESSOR .................................................... 11

2. SIDE DISCHARGE LOADER (SDL) ......................................................17

3. CONVEYOR BELT ..................................................................................................20

4. WINDER MACHINE .................................................. 22

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 5. PUMP ......................................................................................... 25

6.VENTILATION29

7.SUPPORT...31

8.MINING METHOD33

PREFACE
As a part of B. TECH it is outmost essential to take
a practical training related to subject of matter. For
this purpose , one has to associated for a
period.TWO MONTH

The objective of this project work is to provide an

opportunity to the student to get acquainted with
various problems in the field of technical subject
and also know how to solve them.

The various situations which has to be solved in the

industries like breakdown, allotting various
employees in a particular job to combat critical
situations, to have good look after the co workers
regarding their safety and to look after that the
whole production unit would be continuous,
smooth and flawless.

It should be made sure that whatever the situation

may arrive, the safety of the co workers should be
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the primal task and should not be compromised.

ACKNOWLEDGEMENT

It gives me a great pleasure to submit the project report

of training which I have undergone at Bhelatand
A.colliery , TATA STEEL LIMITED, Jharia Division.
Through this acknowledgement, I sincerely acknowledge
my indebtedness & gratitude to all those who have
assisted me during my training.

I am thankful to training division, Mr. Barun Kumar

Banerjee (Head,BAC) & Mr. Aman (Sr. Mgr,maint) who
had allowed me undergo the training at Bhelatand A.
colliery for their benevolent guidance , kind co-operation
throughout my training & for completing this project
report. Their guidance has helped me to gain much
required practical knowledge about the plant. I am also
thankful to Mr. Vinod Prasad sir who gave me the
knowledge about the mining components in the firm.

I extend my thanks to all instructors of Bhelatand

A.colliery, TATA STEEL LIMITED, Jharia Division for
their valuable support.
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This respect is the result of cooperation and coordination
of the entire member mentioned above.

INTRODUCTION
TO
TATA STEEL LTD.
FOUNDER: JAMSHETJI NUSSERWANGJI TATA

(1893-1904)

Jamshetji Nusserwanji TATA ranks among the greatest

visionaries of industrial enterprise of all time. Gifted with the
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most extraordinary imagination and prescience, he laid the
foundations of Indian industry, contributed to its consolidation,
and became a key figure in Indias industrial renaissance.

The first stake for the steel plant

was driven on a forest-covered plateau in Sakchi on 27th
February 1908. The dream had come alive, but the dreamer
himself was no more for. Jamshetji had died at Nauheim in
Germany in 1904 after his successors to preserve the family
name. His spirit continued to inspire his sons to carry their
fathers dreams of fruitionwell after his death.
Jamshetji TATA won himself an enduring
place in Indias history with his unique courage, commitment .

JEHANGIR RATANJI DADABHAI TATA

(1904-1993)

JRD TATA has been one of the greatest builders and

personalities of modern India in the twentieth century. He

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assumed Chairmanship of TATA Sons Limited at the
young age of 34; but his charismatic, disciplined and
forward-looking leadership over the next 50 years and
more, led the TATA Group to new heights of achievement,
expansion and modernization. Under his stewardship, the
number of Tata ventures grew from 13 to around 80,
encompassing steel, power generation, engineering,
hotels, consultancy services, information technology, art
and culture, consumer goods, industrial products, etc.

Introduction to TATA STEEL

LIMITED, JHARIA DIVISION
(BHELATAND A. COLLIERY):-
S. Lease Existing Manpower
no Hold production (Nos)
1. Bhelatan 630 (ton/day) 650
d A.
colliery

Name Of Agent: Mr. Jasbir Singh

Name of Manager: Mr. Barun Kumar Banerjee

Introduction:-
Tata steel, limited, operates five underground coal
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 mines at Jharia,Dhanbad for captive
supply of coking coal to Jamshedpur plant.

Jharia Division comprises five collieries and

two coal processing plants spread over two
groups viz Sijua and Jamadoba group.

Bhelatand A. colliery falls under Sijua

group of collieries of Tata steel ltd.

Bhelatand A. colliery, is working underground mine.

Location and Access:-

LOCATION :- District Dhanbad
State - Jharkhand

Nearest Railway Station:-Katras- 6km

Dhanbad- 12km

Nearest Airport:- Ranchi- 150km

Topography: - flat to undulating

Altitude: - 170 M to 188 M

Above MSL

Location:-

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 Bhelatand A. Colliery is a part of jharia
coalfield and surrounded by BCCL Coal Mines
& Tata Steel Bhelatand A. Mine.
The colliery office about 11km from
Dhanbad railway station between
Loyabad & Katrastownship.
NH32 is about 5km from the colliery office.
IMPORTANT SURFACE FEATURE:-
Main J-C railway line is passing EastWest
of the south side of the property.
Abandoned Railway siding is passing East-
West of the North side of the property.
Status of coal seams:-
Status of coal seams above XII seam working
including XI seam:-Bhelatand A. colliery being an
old workingmine, most of the seams upto XI seam
is exhausted. Presently, working areas are
confined to XIV E,XIIIE,XIIIW,XIVWSeam.

INDUSTRIAL SAFETY:-

SAFETY & HEALTH POLICY STATEMENT

If a job represents a potential safety or health threat, every effort will be

made to plan a safe way to complete the task in a safe manner. Every
procedure must be a safe procedure. Shortcuts in safe procedures by
management and all other associates will not be tolerated. If a worker
observes any unsafe or unprotected exposure, which may pose a potential
threat to their safety & health, he or she must inform management
immediately.

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SAFETY & HEALTH GOALS

The following goals have been established for Tata Steel Manufacturing
Company:

(1) Provide workers with a safe work environment.

(2) Conduct routine/regular workplace inspections.

(3) Provide Personal Protective Equipment.

(4) Develop and implement safe work procedures and rules.

(5) Provide on-going safety training

(6) Enforce safety rules and appropriate discipline.

(7) Provide on-going property conservation practices.

NEW EMPLOYEE ORIENTATION:-

All new employees must attend our Safety Orientation Session prior to
starting work within their assigned area. This session will be
conducted under the direction of the Safety Director and in
coordination with Human Resources.

The following topics will be covered in the Safety Orientation Session:

Company History
Safety Program/Policy & Work rules
Responsibilities
Safety Education/Training
Safety Audit/Inspections
Accident Reporting/Investigation Requirements
First Aid & Blood borne Pathogens
Personal Protective Equipment
Tool & Equipment Use
Material Handling

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Lockout-Tagout
Machine Guarding
MVR Requirements
Hazard Communication
Emergency Action
Return-to-work & Light Duty Assignments

PERSONAL PROTECTIVE EQUIPMENT

Personal Protective Equipment (PPE) includes all clothing and

accessories designed to protect against workplace hazards. In some
situations the only available protection for employees will be the use of
PPE and often in emergencies, PPE will be required for the safety of the
workers. As required by federal and state regulations, personal protective
equipment is essential for the protection of eyes, ears, face and other
body parts when working around hazardous machinery and equipment.

SAFETY RULES

All safety rules must be obeyed. Failure to do so will result in

strict disciplinary action.

All injuries must be reported as soon as possible.

No horseplay, alcohol, or drugs allowed on premises.

No alcohol usage allowed during lunch break.

PPE must be worn as prescribed by management.

All tools/equipment must be maintained in good condition.

Only appropriate tools shall be used for specific jobs.

All guards must be kept in place.

No spliced electrical cords/wiring allowed.

Only authorized personnel can operate forklift vehicles.

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 1. AIR COMPRESSOR

Advantages of Air Power

a. Air Power versus Electric Power
b. Air Power versus Hydraulic Power

Types of Air Compressors

a. Reciprocating Type
1. Single-Stage
2. Two-Stage

b. Rotary Type
1. Rotary Sliding Vane Type
2. Rotary Helical Screw Type

Accessories
a. Air Receiver
b. Belt Guard
c. Diagnostic Controls
d. Intake Filter

Selection of an Air Compressor

a. Industrial Type Tools
b. Automotive Service Shops
c. For Use with Air Cylinders
d. Air Flow Through Orifices

INTRODUCTION:-
The normal state of air, barometric, is called atmospheric
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pressure. When air is compressed, it is under pressure greater
than that of the atmosphere and it characteristically attempts
to return to its normal state. Since energy is required to
compress the air, that energy is released as the air expands and
returns to atmospheric pressure.

WHERE IS COMPRESSED AIR USED?

Compressed air powers many different kinds of devices. It can

go through a small air turbine to turn a shaft, as in a dental
drill; or it can be expanded through a nozzle to produce a high-
speed jet, as in a paint sprayer. Compressed air provides torque
and rotation power for pneumatic tools, such as drills, brushes,
nut runners, roof bolting, riveting guns, and screwdrivers.

ADVANTAGES OFAIRPOWER
When there are a dozen or more forms of energy to
choose from, what advantages does air power
offer? Here, compressed air stacks up against two
of its competitorselectricity and hydraulics.

AIR POWER VERSUS ELECTRIC POWER:-

Flexibility: Air tools can be operated in

areaswhere other power sources are unavailable,
since engine-driven portable compressors are
their source of air power. Electric power
requires a stationary source.
Safety: Air-powered equipment eliminates
thedangers of electric shock and fire hazard. Air
tools also run cooler than electric tools and have
the advantage of not being damaged from
overload
or stalling.

AIR POWER VERSUS HYDRAULIC

POWER:-

Flexibility: Compressed air systems offer

simplerinstallation than hydraulics, particularly
where tools are frequently interchanged.
Compressed air systems also offer better
adaptability for automation and flexibility for
changing or expanding operations.

Maintenance: Air systems have less

downtimethan hydraulic systems because they
have less complex controls. Less preventative
maintenance is required with air, whereas
hydraulic fluids must be monitored and replaced
periodically.

Safety: Hydraulic devices operating near

openflame or high temperatures present fire
hazards, unless fire-resistant fluids are used.

RECIPROCATING SINGLE ACTING

COMPRESSORS:-
Reciprocating single acting compressors are
generally of one-stage or two-stage design.
Compressors can be of a lubricated, non-lubricated
or oil-less design. In the single-stage compressor,
air is drawn in from the atmosphere and
compressed to final pressure in a single stroke. The
single-stage reciprocating compressor is illustrated
in Single-stage compressors are generally used for
pressures of 70 psi (pounds per square inch) to 135
psi. In the two-stage compressor, air is drawn in
from the atmosphere and compressed to an
intermediate pressure in the first stage. Most of the
heat of compression is removed as the compressed
air then passes through the intercooler to the second
stage, where it is compressed to final pressure. The
two-stage reciprocating compressor is illustrated in
Figure 2. Single and two-stage reciprocating
compressors are frequently used in auto and truck
repair shops, body shops, service businesses, and
industrial plants. Although this type of compressor
is usually oil lubricated, hospitals and laboratories
can purchase oil-less versions of the compressors as
illustrated in Figure.

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ROTARY SLIDING VANE TYPE

The rotary sliding vane compressor consists of a

vane-type rotor mounted eccentrically in a housing
As the rotor turns, the vanes slide out Against the
housing. Air compression occurs when the volume
of the spaces between the sliding vanes is reduced
as the rotor turns in the eccentric cylinder.
Single or multi-stage versions are available.
ACCESSORIES
Standard accessories are available to help ensure
reliable and trouble-free compressor operation.
Some special purpose devices also are available
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to meet unusual requirements. Below is a list of
commonly used accessories.

AIR RECEIVER
A receiver tank is used as a storage reservoir for
Compressed air. It permits the compressor not to
operate in a continuous run cycle. In addition, the
receiver allows the compressed air an opportunity
to cool.

DIAGNOSTIC CONTROLS
Protective devices designed to shut down a
compressor in the event of malfunction. Devices
may include high air temperature shut down, low
oil level shut down and low oil pressure shut
down, preventative maintenance shut down, etc.

INTAKE FILTER
The intake filter eliminates foreign particulate
matter from the air at the intake suction of the
air compressor system. Dry (with consumable
replacement element) or oil bath types are
available.

SPECIFICATION:
TWO STAGE RECIPROCATING
COMPRESSOR
L.P. DIA=220mm
H.P. DIA-130mm
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 NO. OF INLET VALVE=2
NO. OF OUTLET VALVE=2
WORKING TEMP.=50deg C
INTERCOOLED BY AIR COOLING
MAX. AIR DELIVERY
PRESSURE=8.6kg/cm(sq.)
WORKING AIR PRESSURE=7kg/cm(sq.)
Lubrication by oil

2. Side Discharge Loader

(SDL):-

The side discharge loader is a low profile high output

machine. The largest development in the fields of
hydraulic and fabrication and underground work are
considered while designing the loader and they are
developed to offer maximum benefit to the mining
industry. Flameproof electrical make them suitable
for operation in gassy mines.
The M412 crawler mounted side discharge loader is a low
profile high output machine. The latest development in the fields
of hydraulics and fabrication and underground work are
considered while designing the loaders and they are developed
to offer maximum benefit to the mining industry. Flameproof
electrical make them suitable for operation in gassy mines.

SPECIAL FEATURES

Outstanding power/weight ratio; Low heat generation; Low

center of gravity; Low specific base pressure; Fail safe parking
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brake; Track aligning guards; powerful flood lights; emergency
stops; dead man switch; heavy duty construction; Protection of
sprocket from ingress of dust. The manufacturer reserves the
right to change the specifications and design, of this machine at
any time without notice.

The other variants of Side Discharge Loaders

available are:-
Extra Low Height - 1.0 cum bucket capacity.
Standard Height with CRD arrangement - 1.0 cum bucket
capacity. All the above machines are approved by DGMS,
India for use in underground coal mines.

General information and general requirements

of SDL:-
No SDL shall be worked with hydraulic fluids
which is not fire resistant and specially approved
by the component authority for the purpose.
No SDL shall be constructed with materials
namely aluminium, magnesium, etc. incentive to
sparking.
The manufacturer/ suppliers of SDL shall provide
the necessary information to the user in
accordance with IS 11114 & IS 11249. The
manuals as specified in IS 10280 shall also be
supplied along with equipment.

Hydraulic system:-
Following checks shall be carried out for
hydraulic systems

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 Bring the hydraulic temperature up to operating
temperature Celsius prior to hydraulic system
checking.
Check the flow and pressure using flow meter and
pressure gauge respectively.
Change fire resistant hydraulic fluid (FRHF) at
every 1500hr.
The operating temperature of the hydraulic fluid
shall not exceed 65 degree Celsius in any case.

Mechanical system:-
following checks shall be carried out:-
Check all fasteners of crawlers, gears boxes,
motor base and pump flange. Tighten them with
torque wrenches as per recommendation.
Check the tightness of crawler chain. Low tensioned
chains result in slipping the sprockets and
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 extensively tensioned chains results in high wear
and load on crawler parts and drives.
Electrical system:-
Flame proof feature of all the electrical
equipment shall be maintained.
Insulation resistance of the trailing cable should
be above 1 M(ohm) when tested by 500V.

3.Conveyor Belt:-

APPLICATION

RO-PLY has a wide field of application for the transport of

moderately to very abrasive materials such as cement,
coal, coke, earth, flint, grain, gravel, ore, phosphate, slag,
stone materials and timber.

CONSTRUCTION AND PROPERTIES

RO-PLY is a 2-ply belt construction with cut edges and

a carcass of synthetic EP fabric (polyester/polyamide).
Between the fabric plies is an innerply of ROULUNDS patented
STIFLEX - a rubber and textile fibre compound.
The fibres are orientated lengthwise in the belt. This carcass
combined with covers of standardized thicknesses and qualities
adapted to the field of application provide the following good
properties:

1 High wear resistance

2 Small elongation at highest working tension
3 High impact resistance
4 Excellent directional stability
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5 Good trough ability
6 Good weather resistance

TECHNICAL DATA:-

Max. material temperature 100 Celsius

Ambient temperature Max. 50 Celsius, min -30celsius
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Nature Antistatic according to ISO284
Maximum recommended trough 45 Celsius
angle for three sectioned carrying
idlers.
Angle of wrap 240-270(degree)
Coupling Tyre (motor-gear), Flange
(drum-gear)
Specification:
Drive /discharge pulley
Snub pulley
Tension pulley
Tail end pulley
Return idler
Through idler
Safety units:-
V scrapper
Pull cord
EVA

AVAILABILITY

Open or endless lengths - Max. length unit 400 m/roll

or according to agreement.
Max. belt width 1500 mm.

4. WINDER MACHINE:

INTRODUCTION

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Transport developments followed two distinct routes
in each of the major coal, persons, materials and
equipments.
Coal transport has either been by locomotive-hauled
mine cars, belt conveyors or rubber tired trucks. The
transport of persons, materials &equipments has
either been by rail mounted track system vehicles.

The advantage of drift transport system

over shaft system are as follows:-
1. The lowering and raising of all materials and
equipment without dismantling and reassembly.
2. The compatible use of drift for person and
Materials transport and coal haulage by
conveyor without any operational
interference of one with the other.
Technical specification:-
1 pit winder

Motor AC induction
Depth of Coal 376m
Brake Hydarulic
Balance Rope 3*36mm
Winding rope 6*25mm
Guide rope 8*41mm
Drum 2.2(m)
Speed 10(m/s)
Capacity of winder 1050kw
Weight of main tower 300ton

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Weight of stock tower 80ton
Weight of shaft fitting 100ton
Skip capacity 8ton

2pit winder(man winder)

Motor Slip ring (300kwA)
Tail rope 36mm
Head rope 25mm
Maximum Speed 7m/s
Depth of winder 412m
Capacity of winder 300kw
Wieght of winder 3014kg
Winder rope 4*25mm
Guide rope 6*41mm
Balance rope 2*36mm
Dia of shaft 4.8m
Drum dia 2.4m
Brake Pneumatic

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winder machine is useful in loading of coal, materials
inside the mines which are connected to the conveyer belt
and consequently discharging the same on the surface
which is again loaded to the conveyer belt to discharge in
the washeries. Generally man winder is used to carry
employees in the mines.

5. Pump:-

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 A pumpis a device that moves fluids , or sometimes
slurries, by mechanical action. Pumps can be classified
into three major groups according to the method they
use to move the fluid: direct lift, displacement, and
gravity pumps.
Pumps operate by some mechanism (typically
reciprocating or rotary), and consume energyto perform
mechanical workby moving the fluid. Pumps operate
via many energy sources, including manual operation,
electricity, engines, or wind power, come in many sizes,
from microscopic for use in medical applications to
large industrial pumps.
Mechanical pumps serve in a wide range of applications
such as pumping water from wells,aquarium filtering,
pond filteringand aeration,in the car industryfor water-
coolingand fuel injection,in the energy industry for
pumping oiland natural gasor for operating cooling
towers. In the medical industry,pumps are used for
biochemical processes in developing and manufacturing
medicine, and as artificial replacements for body parts,
in particular the artificial heart and penile prosthesis.
Single stage pump When in a casing only one
impeller is revolving then it is called single stage pump.
Double/multi-stage pump When in a casing two or
more than two impellers are revolving then it is called
double/multi-stage pump.
centrifugal or roto-dynamic pump

The centrifugal or roto-dynamic pump produce a head and a

flow by increasing the velocity of the liquid through the
machine with the help of the rotating vane impeller. Centrifugal
pumps include radial, axial and mixed flow units.

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Centrifugal pumps can be classified further as

end suction pumps

in-line pumps
double suction pumps
vertical multistage pumps
horizontal multistage pumps
submersible pumps
self-priming pumps
axial-flow pumps
regenerative pumps

Positive Displacement Pumps

A Positive displacement pump operates by alternating filling a
cavity and then displacing a given volume of liquid. A positive
displacement pump delivers a constant volume of liquid for each
cycle independent of discharge pressure or head.
The positive displacement pump can be classified as:

Reciprocating pumps - piston, plunger and diaphragm

Power pumps
Steam pumps
Rotary pumps - gear, lobe, screw, vane,
regenerative (peripheral) and progressive cavity.
specifications

Type High tension pump

Motor AC induction type
Input power 400kw
Current 84 amp
Voltage 3300v
Efficiency 94.5(percent)
Phase 3

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Weight 3900kg
Stage Multistage
Working temperature 50deg c
Rpm 1490
Motor Power 82 HP
Discharge capacity 218.2 m^3/hr
Relubrication 5000hrs.
Frequency 50Hz
Types of pump:

Type Shaft GPM Head (feet)

I 45 250.3 75
II 55 400 100
IIA 65 500 125
III 75 800 150

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