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RO: Kothagudem Collieries – 507 101 “EXPRESSION of INTEREST

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RO: Kothagudem Collieries – 507 101 “EXPRESSION of INTEREST The Singareni Collieries Company Limited (A Government Company) RO: Kothagudem Collieries – 507 101 “EXPRESSION OF INTEREST “(EoI)” Supply, installation and maintenance of Hardware & Software with proven technology for Software solutions for Tracking of coal grade from shovel loading point to customer discharge point for coal grade accuracy and enhancing control measures for the improved customer satisfaction in coal grade supply system. About SCCL: Singareni Collieries Company Limited (SCCL) is situated in southern part of India and having its operations in six districts of northern Telangana i.e., Kumuram Bheem Asifabad, Mancherial, Peddapalli, Prof. Jaya Shankar Bhoopalpalli, Bhadradri Kothagudem & Khammam Districts. SCCL has been supplying coal to most of the customers situated in Telangana and to some extent in southern parts of India and some parts in Maharashtra. SCCL has produced 64.40 Million tonnes of coal during 2018-19 and has dispatched 67.66 Million Tonnes of coal to various categories of consumers during 2018-19 and has set production target of 70.00 Million Tonnes for the year 2019-20. SCCL has been operating 30 underground mines and 18 Opencast mines to meet the linkage requirements of major power, Cement, Captive Power, Sponge Iron and other customers. SCCL is a Pioneer in introduction of various state of the art underground technologies in its mines such as Longwall, Thick seam working by Blasting Gallery and Continuous Miner technologies etc and opencast technologies such as Dragline, Highwall Mining, In-pit Crushing & Conveying, Surface Miner, etc. Though SCCL is mainly engaged in mining of coal and its business, as a part of diversification, the company has entered into power generation and presently operating 2x600 MW Singareni Thermal Power Plant (STPP). Other major business is manufacturing of explosives for internal consumption and generation of POB (sand) for stowing purpose internal use to maintain the ecology. In OC mines, coal of different grades is transported from working benches of OC to the dispatch points at surface by the Dumpers. These Dumpers are to be tracked and alerted for dumping the at designated points as per the grade of the coal. It is necessary to establish a suitable IT based system for executing the work properly. The system will be implemented initially at JVR OC-II Project as pilot project to establish the technology for achieving the project. Objective of Current “EIO’:- In open cast mines Coal is extracted from different Seams (A seam refers to a particular layer of coal). The quality of coal differs from one seam/section to the other seam/section and is measured/ identified based on the GCV (Gross Calorific Value) into different Grades such as G1, G2…….G17 and is priced differently. The Coal is excavated from the coal seams/section by Excavators (Shovels) and is loaded into Dump Trucks and unloaded into the various Crushers/Bunkers through which coal is dispatched. Hence, the coal excavated will be of different seams with seam or section specific grades based on the working location of the shovels deployed for coal excavation. Thus, coal grade dispatched is based on the conformity of coal movement from shovel location/ grade to unloading point to customer’s trucks. Hence, the grade of the coal produced or dispatched varies dynamically based on the deployment of shovels and the coal dumped into the respective bunker and belt and pre-weigh bin While it is essential to monitor and control the grade of the coal being dispatched for the satisfaction of the customer and marketing , the manual systems had their own limitation. It is proposed to establish a RFID & GPS based system to meet the above requirement as brought out in detail in this document. It is intended to take up a pilot project at one of the project i.e., JVROC-2, on the success of which it shall be extended to other mines. Tentative scope of work The broad scope of work include : o Establishing a suitable communication wireless network in the Project duly considering the current workings and dump yards as well as future projections which may create Blind Zones. o Providing GPS and RFID equipment to all the mobile machinery like shovels and dumpers. o Establishment of RFID readers for all excavating equipment (Shovels), and dump yard locations, crushers, belts and pre-weigh bin are to be connected to the network. o A Central Server to receive the required data from the said systems with required software licences for real time auto capturing capturing and storage of the data and hosting application software. o Development and Hosting of the application software and customer support for training , maintenance and enhancements as may be required. Functional Scope o At JVR OCP-II , Coal is excavated from the following seams with the following grades of coal and thickness : S.NO Seams GCV Grade 1 B seam top section (B4 to B7) 3099 G15 2 B seam bottoms section (B1 to B3) 3606 G13 3 A seam top section 3657 G13 4 A seam bottom section 4951 G8 5 Index seam 5190 G8 o About four shovels and thirty dump trucks are deployed by company for coal production at a time. In addition, about two Shovels and 15 Dumpers of contractor are also deployed on coal. o The excavated coal is moved along the indicated path. Seam/ section ( grade 1) . Seam/ section (grade 2) this is fixed coal grade. Seam/ section ( grade 3) . Shovel 1 . Shovel 2 . Shovel 3 . Shovel 4 . Shovel 5 . Pay Loader1 . Pay loader 2 . Dumper 1, dumper 2------so on up to 50 dumpers . Crusher 1 . Crusher-2 . Crusher-3 . Criusher-4 . Coal stock yards -1 . Coal stock yards -2 this is fixed coal grade. Coal stock yards -3 . Dump yard-3 . Belt one . Belt two . Belt three . Pre weigh bin 1 . Pre weigh bin 2 . Pre weigh bin 3 o Except coal stock yards and seams and sections, all the above indicated systems will carry/hold coal grade so dynamically. The operating grade capturing system shall be established in real time basis o The coal dumped at the dump yards also is lifted when ever required and possible by SCCL owned or Hired Loaders. About 2 two or three loaders are deployed for re-handling of the dumped coal. o The collected coal is dispatched to the outbye trucks from the following bunkers…… . There are three coal stock yards of different grade and 500TPH crushers (3nos +2nos spare) with two streams of belts to defined pre weigh bin bunkers of 2nos with 150 T capacity and 300T capacity for dispatch of coal. o Each bunker is designated for a particular grade of coal at a point of time.. The planned grade of the coal may change from one working shift to the other. o SCCL will provide periodically an autocad map showing the status of the mine where the location of each coal seam at that time and dump locations will be available. o The working location of the shovels will be changing from time to time. The system must be able to track the working seam and the GCV / Grade of the coal based on the working plan, GCV/Grade of the seam from master data and the location of the shovel obtained by the fitted GPS equipment. o The system shall also obtain the grade of the coal loaded into the trucks from the GPS location fitted on to the trucks and the shovel from which the coal is loaded for each trip. o From this data the estimated GCV / Grade of the coal collected / dispatched between a given time hour / shift / day based on the average grade of the total coal as below. Mine is being worked 24 hrs with 8hrs each shift. In each shift HEMM (shovels and dumpers) will be allotted to operators. o The firm also shall develop reports and also a proper interface to port this data to existing SAP data where ever required. The application software to be developed accordingly. SCCL will provide required inputs. Here, grade of coal seam/section---- shovel mapping ----dumper mapping----- dump yard mapping----- crusher mapping ---- belt mapping and pre weigh bin mapping. As per mapping, the coal shall flow from shovel to truck loading system. Any variations shall prompt an alert and report. Here all the system of coal flow shall be mapped so dynamically. The requirement may be as under: o Shovel shifting from one grade to other grade due to exhaustion of blasted coal, demand of the coal grade and break down of the equipment o If there is requirement of shifting a shovel from one grade to other grade/ dumper to shovel grade and crushers/stock yards to belt stream and pre-weigh bin is aligned to single grade and the flow is monitored with software solutions. Any variations in the flow shall be reported with specific alerts. Software solutions are required for map the equipment, coal movement from loading of coal benches in a quarry to unloading points of coal customer with specific coal grade. Every time mapping of the equipment in the system and real time data storage of equipment tracking in the mine take area is very much critical to resolve the issue 1. Establishment of Connectivity network : a. The firm shall supply and install the back bone data communication for tracking of dumpers and real time storage of data by RFID tags or any other suitable technology. b. The data from the RFID readers shall be communicated to the surface control room by network. The firm shall make suitable system for conversion of the signal & protocol. c. The system requires the usage of RF (Radio Frequency) active readers d.
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