The Singareni Collieries Company Limited (A Government Company) KOTHAGUDEM COLLIERIES Khammam District, Andhra Pradesh, (India)

Transcription

1 The Singareni Collieries Company Limited (A Government Company) KOTHAGUDEM COLLIERIES Khammam District, Andhra Pradesh, (India) TENDER DOCUMENT For Procurement of Continuous Miner Equipment for Shanti Khani, Mandamarri Area ENQUIRY NO. C0111G0154 Dated: TENDER CLOSING DATE: at AM TENDER OPENING DATE: at AM 1

2 THE SINGARENI COLLIERIES COMPANY LIMITED (A GOVERNMENT COMPANY) Technical Specifications for SHANTHI KHANI CONTINUOUS MINER Package SL. Item Description Total Qty No A Continuous Miner 1 nos B Shuttle Cars 2 Nos C Feeder breakers 1 nos D Roof Bolter 1 No E Electricals (Power centre) 1 set A Continuous Miner 1.0 The Continuous Miner should be of Approved by DGMS, Dhanbad,India, as a unit, including all its components like Hoses, Electricals, cable adopters, AV alarms and other safety requirements etc to operate in Indian Coal Mines 2.0 The machine should have the following cutting and conveying capacities. 2.1 Should be able to cut and convey the coal of compressive strength of Kg/Sq.cm with continuous cutting capacity of around 200 TPH and loading capacity of minimum of 600 TPH 2.2 The cutter head should be fitted on ranging type arm. The cutter head should be drum type fitted with replaceable cutter picks and powered with electrical motor. The KW rating of the cutter motor should be around 175KW. 2.3 The cutter heads should be equipped with powerful water spray and flooded bed dust collector for suppression of dust while cutting and also to control dust in the machine vicinity. Water interlocking system should be provided with cutter head. 2.4 The cutter head should be operative when only water spray with sufficient quantity and required pressure is made available for dust suppression by providing suitable inbuilt pump. 2.5 The conveyor should have provision of slewing 45 0 on either sides and also provision to raise or lower for unloading the coal into Shuttle cars. 2.6 The machine should be crawler mounted with Electric or Hydraulic drive with Wider grouser pads so that the ground pressure shall be around 1.2 kg/sq.cm. 2.7 Should be able to cut coal for continuous production in a coal seam of varying thickness from 2.2 M to 3.6 M. should be able to travel in the gallery of 4.0 M wide and 2.1 M height. Dinting (Floor) capability of machine to be mentioned. 2.8 Should have good maneuverability and stability with minimum ground clearance of 220 mm 2.9 Should be able to negotiate gradient up to 1 in 4, cross gradient up to 1 in Should have adequate braking capacity to stop rolling down on slope while in working or when parked. The brakes should be Fail safe type The machine should be designed to operate on Fire Resistant Hydraulic Fluid (FRHF)-HFDU-68. All the hydraulic components should be fully compatible with FRHF used. The capacity of hydraulic tank should be of adequate capacity for system requirement and cooling. Adequate capacity cooler/radiator should be provided and system designed temperature should be around 70 Degree Centigrade. All hydraulic hose assemblies should have DGMS approvals. Suction/Pressure line/return line filters should be provided in the circuit to maintain clean hydraulic fluid. Hand / Powered Pump should be provided with self sealing couplings for topping / replenish hydraulic fluid pressure gauge, temperature gauges should be provided at a convenient place near to operator plat form. Hour meter should be provided to record the machine working hour (cutting hours) 2.12 The machine should be provided and fitted with suitable lights at both front and rear ends to ensure good lighting and visibility. Entire lighting arrangements should be suitable for 12/24V. all electrical fitting used should be FLP IS Type and approved plug and sockets for motors and control panel. Suitably sealed glands should be provided for other apparatus. 2

3 2.13 The machine should be operated with local controls as well as Radio Remote control system. The continuous Miner should be able to be operated from a distance of around 20 mt with the help of Radio Remote control 2.14 All electricals should be Energy efficient The machine should be fitted with stabilizer cylinders so that with the help of stabilizer cylinders the whole machine can be lifted for maintenance purpose Centralized lubrication system should be provided to lubricate all the points automatically. 3.0 Technical Data : enclosed in Annexure A B Shuttle Cars 1.0 The Shuttle Cars should be of Approved by DGMS, Dhanbad,India, as a unit, including all its components like Hoses, Electricals, cable adopters, AV alarms and other safety requirements etc to operate in Indian Coal Mines 2.0 The Shuttle Cars should have the following capacities: The Shuttle Cars should be able to collect the coal produced by continuous Miner and unload on to the mobile feeder breaker/belt conveyor Should have volumetric capacity min 10 Tonnes of loose coal (one Cu. M = 0.8 tonnes) The conveyor boom should have elevating and lowering arrangement facilities discharging the coal 2.3. on to feeder breaker or belt conveyor The Shuttle Cars should have tramming speed around 6.0 Km/H. 2.5 The Shuttle Cars should be a tyre mounted machine, the tyres should be available in Indian market and are of rubber insert with four wheel drive & power steering. One set of spare tyres & other accessories to be supplied along each machine 2.6 The Shuttle Cars Should have good maneuverability and stability with sufficient ground clearance. 2.7 The Shuttle Cars should be able to travel in the galleries of 4 M wide and 2.2 M, height, and to negotiate gradient up to 1 in 5 and cross gradient of 1 in CHAIN; The life of the chain and sprocket should be not less than 0.8 Million Tons for conveying the coal. 2.9 FLIGHTS: Heat treated Forged steel should be used for flights. 3.0 Electricals 3.1 The Shuttle Cars shall be operated on electrical supply and are suitable for operating voltage of 1100 V AC, 3 phase, 50 Hz. 3.2 The machine should have Torque balancing cable reel to wind and unwind the cable automatically as per the tramming speed and direction. It should accommodate the suitable cable (Type FT 10 as per IS:14494 or equivalent) with DGMS approved cable of around 220 Mtrs. 3.3 The machine should be provided and fitted with suitable lights at both front and rear ends to ensure good lighting and visibility. Entire lighting arrangement should be suitable for 12/24V 3.4 All electrical fitting used should be FLP & IS Type, and approved by DGMS(India). All cable entry boxes should be provided plug and sockets for motors, and control panel. Suitably sealed glands should be provided for other apparatus. 4.0 Technical Data : enclosed in Annexure B Feeder breaker C 1.0 The feeder breaker should be of Approved by DGMS, Dhanbad,India, as a unit, including all its components like Hoses, Electricals, cable adopters, AV alarms and other safety requirements etc to operate in Indian Coal Mines 2.0 The Crawler Mounted Feeder Breaker should consist of the following three main elements. i). The intake or receiving hopper. ii). The onboard conveyor system. iii). The breaker The hopper should be of robust design and construction. The hopper should be suitable for discharging the coal from rear end of the machine Chain conveyor should be provided to convey the coal received in the hopper for crushing & loading into the belt conveyor. The chain conveyor should be reversible The Breaker should be mechanically driven through gear reducer. The breaker should be designed for minimal generation of fines. 3

4 2.4. Should be able to crush coal at -150 mm size (with adjustment of - 100mm to mm) and convey at the rate of around 40 T/Min; where the compressive strength of coal is about Kg / sq. cm The crusher head should be drum type and fitted with replaceable cutter picks and powered with suitable rated motor and gear reducer 2.6. The crusher heads should be equipped with water spray of adequate capacity for Suppression of dust while crushing and also to control dust. Mist spray system should be provided at the crushing point for effective suppression of dust. The spray system should be inter locked with crusher. The crusher should be operative, when only water spray system with sufficient flow and pressure is available for dust suppression. 2.7 CHAIN: The life of the chain and sprocket should be not less than 0.6 Million Tonnes for crushing and conveying the coal. 2.8 FLIGHTS: Heat treated Forged steel should be used for flights 3.0 CRAWLER: 3.1 Forged Steel Wider grouser pads should be used so that the ground pressure does not exceed 0.9 to 1.2 kg/ Sq.cm. High ratio gear box and high torque Electric / hydraulic motor should be used for crawler for high tractive force. 3.2 Electrically / Hydraulically operated crawler track units should be provided for tramming the machine. The Machine should be mounted on hydraulic cylinders for providing ground clearance and leveling of the machine 3.3 Should be able to work in the galleries varying height from 2.2 M to 3.6 M and should be able to travel in the gallery of 4 M wide and 2.2 M height. 4.0 Technical Data : enclosed in Annexure C D Twin Roof Bolter 1.0 The Twin Roof Bolter should be of Approved by DGMS, Dhanbad,India, as a unit, including all its components like Hoses, Electricals, cable adopters, AV alarms and other safety requirements etc to operate in Indian Coal Mines 2.0 The machine should have the following drilling & bolting capacity 2.1 Should be able to drill the hole, anchor the bolt and tighten the nut to the required torque, in sand stone roof and also to drill holes at different centers and angles. The Machine also should be able to drill min 2 holes, anchor the bolt and tighten the nut in a cycle. 2.2 Should have the provision of wet drilling as well as dry drilling for installation of bolts in roof & slides at different angles. 2.3 Should be able to drill holes of dia 27, 35 & 43 mm in Sand stone having compressive strength up to 500 kg/sq. cm to a depth of 2.4 mt in a single pass. 2.4 The drilling unit should be wet drilling as well as dry drilling type, semi /full automatic, wear resistant, and vibration should be as minimum as possible 2.5 The Machine should be able to drill holes of 2.4 mtrs depth with roof of gallery having height of 4.5 Mtrs. 2.6 The machine should be Electro-Hydraulic type. 3.0 The machine should be a crawler mounted one with the following feature 3.1 Winder grouser pads so that the ground pressure shall be around 1.0 kg/sq.cm. 3.2 Should be able to travel in a gallery of 4 Mtrs. Wide and 2.2 Mtrs. Height 3.3 Should have good maneuverability and stability with sufficient ground clearance 3.4 Should have independent controls for Right hand and left hand drivers 3.5 Should be able to negotiate gradient up to 1 in 5 and cross gradients up to 1 in Should have adequate braking capacity to stop rolling down on slope while working or parked. The brakes should be of Fail safe type 3.7 The machine should have automatic cable reel system in compatibility with the tramming speed and direction 3.8 It should accommodate the suitable cable (Type FT 10 as per IS or equivalent) around 220 M length 4

5 4.0 Technical Data : enclosed in Annexure D E ELECTRICALS : Enclosed In Annexure E 5.0 General terms and conditions: 5.1 Centralized lubrication system should be provided to lubricate all the points automatically in all the equipments 5.2 The life of individual components like Gear Boxes, Crawler/Track chain, conveyor chain, Hydraulic components etc., shall be furnished. 5.3 All the equipments in the system should be guaranteed for a minimum of 12 months from the date of commissioning or 18 months from the date of supply whichever is earlier. 5.4 All the equipments in the system, shall be designed and manufactured to the norms/recommendations and standards currently in force in India. 5.5 Availability of the system should be 80% on SSH 5.6 Training on Operation & Maintenance should be provided for a period of 3 months on all equipments in the system at site Nos of Operational & maintenance & spare parts manuals of hard & Soft copies shall be provided 5.8 All Hoses should be routed & clamped properly and tagged at both ends for easy identification & replacement 5.9 The Equipment supplied, shall be designed and manufactured to the following norms/recommendations and standards currently in force in India DGMS, India, approval should be submitted before dispatch of the machine Electrical - IEC standards/indian Electricity Rules Mechanical - ISO Standards 6.0 MONITORING SYSTEM i An hour meter should be provided to each equipment to record the working hours of the machine. ii Specific energy consumption per tonne of coal produced, crushed and conveyed should be specified to each equipment. iii Required Pressure gauges, temperature gauges and meters etc should be provided to each equipment at a convenient place near to operator. 7.0 SAFETY FEATURES. I The machine starting arrangements should be through pilot operated switches which are provided with the machine keeping the Gate End Box at far end. II Low level fluid cut off in the hydraulic tank and high fluid temperature cut off switches should be provided and fitted on the machine to set at required / designed temperature. III Emergency stop buttons should be provided at strategic points to stop the machine power supply to the machine from various points. IV Fire extinguishers should be provided on each machine. V Fail safe brake to prevent rolling down the equipment either in cutting or in parking condition. VI Programmable Methane gas monitor with audible alarm and power supply cut off. VII Audio Visual alarms for pre start warning and while reversing. VIII Storage arrangement for bolting material like drill rods, resin capsules, tools etc to be provided on the Roof Bolter machine. IX The machine should be provided and fitted with suitable lights to ensure good lighting and visibility. Entire lighting arrangement should be suitable for 12 /24 Volts. X All Electrical fitting used with the equipment shall be FLP/ IS type, and approved by DGMS (India). All cable entry boxes should be provided with suitable plug and sockets for motor and control panel. Suitable sealed glands should be provided for other apparatus. XI Automatic cable reeling indicator to ensure the rotation of drum should be provided at the sight of operator. 8.0 SPARES. I The spares and consumables (except oils, lubes, tyres and picks) required during the warranty period of 12 months shall be supplied along with the machine. 5

6 Over and above the spares required (supplied along the machine) during the warranty period shall be supplied by the firm at free of cost at site. II The machine should be suitable for oils and lubricants of Indian makes like IOC, etc. and the list of Indian equivalents shall be submitted along with offer. The tyres required for Shuttle cars should be available in Indian Market. III a) Initial fill of oils, Lubricants Picks, Tyres, flight bars, Chains, filters etc, should be supplied along with the machine. b) The quantity of oils, Lubricants, picks, tyres etc for 6 months consumption to be supplied along with equipment. c) The drawings/ specifications for the consumables like picks, pick holders, chains, flight bars, Tyres etc shall be submitted along with machine. IV Spares required for smooth operation for 2 years after warranty for maintenance and consumables (except oils, lubricants, picks & tyres), should be offered separately, which is added to the landed cost of the equipment, to decide the commercial status and the same will be purchased by sccl. Any spares required over and above the quoted spares should be supplied free of cost during the 2 years period. Any spares consumed during the warranty period from the above supplied items, the same shall be replaced free of cost within 4 weeks time. 9.0 Hydraulics: I All the machines should be designed to operate on Fire Resistant Hydraulic Fluid HFDU-68. The hydraulic fluid temperature should be maintained below 70 C even after working for full shift. II All the hydraulic components should be fully compatible with FRHF used. III IV V VI VII VIII IX The capacity of hydraulic tank should be of adequate capacity for system requirement and cooling Adequate capacity cooler/radiator should be provided keeping in view of ambient temperature of 45 C and system designed temperature. The FRHF temperature should be limited to 70 degrees when the machine is continuously working. Pressure gauge, Oil level indicating gauge and temperature gauges should be provided on tramming and drilling platforms at a convenient place so that operator can read the pressure and temperatures of operating circuits Powered Pump should be provided with self sealing couplings for topping / replenish hydraulic fluid All the machines should be fitted with stabilizer cylinders so that with the help of stabilizer cylinders the whole machine can be lifted for maintenance purpose. Suction / Pressure line / Return line filters should be provided in the circuit to maintain clean hydraulic fluid 6

7 Annexure A TECHNICAL PARAMETERS Of CONTINOUS MINER: Sl.No Description Unit Approximate Dimension 1 Over all Chassis height. mm To be specified. 2 Over all width. mm around Over all length mm Around Cutting Height 5 a). Minimum mm b)maximum mm Cutter dia mm Around 950mm. 8 Cutter Width mm Around Cutting capacity(continuous) TPH Cutter motor rating KW Around Ground clearance mm Minimum Machine weight Kgs. To be specified. 13 Crawler chain width mm -do- 14 Ground pressure Kg/Sq cm Gathering head loading method -- To be specified 16 Gather head Drive -- Dual drive is preferable 17 Rating of conveyor TPH Around Conveyor width mm To be specified 19 Conveyor motor rating KW -do- 20 Tramming speed KMPH To be specified Annexure B TECHNICAL PARAMETERS of SHUTTLE CARS: Machine dimension & Important data. Sl.No Description Unit Approximate dimensions 1 Overall length mm Overall width mm Overall all height mm Overall weight Kgs To be specified 5 Ground clearance mm Conveyor width mm To be specified 7 Carrying capacity Tonnes 10 8 Conveyor discharge rate Tonnes/Min Tram speed Km/H Tyres --- Details to be furnished. 11 Power required (minimum) Traction KW To be specified Conveyor KW To be specified Hydraulic Pump KW To be specified 7

8 Annexure C TECHNICAL PARAMETERS OF FEEDER BREAKER Sl.No. DESCRIPTION UNITS APPROXIMATE DIMENSIONS. 1 Tramming Height (Max) mm Over all height at Max. discharge mm 1900 clearance 3 Over all width (max) mm Over all length ( max) mm Weight of the machine Kgs To be specified 6 Ground clearance mm Height setting Minimum mm Maximum mm Bits Replaceable type picks with TC tips. 10 Type and size of the gear box To be specified 11 Breaker Motor rating KW Min 75 Conveyor 12 Capacity around TPM Chain (Double out board) Breaking Ton 85 strength per strand 14 Flight solid, alloy steel forged Heat treated Forged steel 15 Tramming Speed variable Mts/Min Crawler chain size mm To be specified 17 Groused Pad Width mm -do- 18 Low oil level cut off switch To be provided 19 High Fluid temperature cut off switch Shut down switches to be provided. 20 Operating voltage V ph, 50 Hz. 21 Power rating of Motor for power pack KW To be specified. 8

9 Annexure D 3.0. TECHNICAL PARAMETERS TWIN ROOF BOLTER : 3.1 Machine Dimensions UNITS APPROXIMATEDIMENSIONS Minimum height mm Around Minimum operating height mm Around Maximum operating height mm Maximum Roof bolter reach mm To be specified Minimum rib bolting height from floor mm To be specified Maximum rib bolting height from floor mm To be specified Roof bolt centre mm 800 to Maximum operating width mm Minimum Ground clearance mm Length overall mm To be specified Weight of the machine Kgs To be specified WET DRILL UNIT Drill Chuck 1 square drive Hole size mm 27,35 and Feed speed Drilling To be specified Feed speed Bolt Insertion & Retraction To be specified Penetration rate in sand stone having To be specified compressive strength of 500 kg/sq.cm TRACK SYSTEM Unit / Approximate Track pads Forged steel with by-directional grouser s, width to be specified Ground pressures Kg/sq.cm Tractive effort KN 250 KN Brake system Fail safe/emergency brake pack and hydrodynamic brake valves Maximum tram speed(high) KMPH To be specified Gross vehicle mass(unladden) KG to be specified Power rating of motors KW to be specified II. ADVANCE TEMPORARY ROOF SUPPORT APPROXIMATE DIMENSIONS a. Collapsed height mm Less than 2000 b. Extended height mm 4500 c. Maximum setting load Tons Around 15 d. Maximum Yield load Tons Around 20 9

10 Annexure E E ELECTRICALS The Continuous Miner district comprises of the following machines for which the electrical equipment are to be offered. Sl.No. Description Approximate KW each at Quantity (Nos.) 1100V 1. Continuous Miner Shuttle Cars Twin Roof Bolter Feeder breaker The electrical system (A Combined Power Centre) consisting of H.V. Circuit breaker, Transformer, Cables, Gate End Boxes and couplers etc., suitable for above equipment. The electrical power system should be of Restricted Earthed Neutral System. All the electrical equipment offered for the continuous miner district should be Flame proof and DGMS approved. The Power centre consists of 1500 KVA, 3300/1100 V Transwitch should have a neutral grounding resistance monitoring relay which is fail safe. The relay should trip the primary (3.3 KV) breaker of Transwitch in the event of open circuit in the neutral to earth path including the Neutral grounding Resistor (NGR). Load centre should have 2 nos of 400A (One service & One spare), 6 nos of 200A (Four service & Two spare) of 1100 V 4 nos of 200A 550 V ( for auxiliary equipment) out lets, One feeder for Twin Bolter (3 KVA) one feeder for lighting transformer (5 KVA) 10 Nos ( 5 service & 5 Spare) of Trailing cables 220 mts length of type FT-10, IS or equivalent with plug & Sockets of DGMS approval for reeling and unreeling purposes. IS communication equipment SCCL will provide 3.3 KV supply up to incoming of the Tran switch / the Power center. 10