Mono Rail System of Transportation Preamble: SCCL proposes to introduce Longwall Technology at KTK-5 Incline mine of Bhupalpalli area. The bulk production technology from Longwall calls for faster, safer and hassle free transportation system. Worldwide for bulk production technology either monorail system or FSVs and FBLs with different attachments to transport different materials are being used. FBLs are not suitable in this project as the gradient is not favorable. Hence SCCL proposes to use MONORAIL system for transportation of men and material by off-loading the design, supply, installation and commissioning and train the SCCL crew in operation and maintenance. Brief Description of the Mine: Kakatiya Khani-5 (KTK-5) Incline is an operating mine in Bhoopalpalli Area of SCCL. Tunneling work at KTK 5 Incline was started in September 1993 and producing coal since January 1995. Tunneling at KTK 5A Incline was started in July 1997 and producing coal since July 2000. There are three working coal seams in the project and liquidated from top to downwards (I, IIB and III seams). Initially the mine was developed with conventional bord & pillar with manual mining and later switched over to semi-mechanization i.e. loading operations are mechanized with SDLs. At present 12 No’s of SDLs are working in this mine. As a means of faster rate of extraction and dispensing with drilling and blasting of coal face in underground mines for improved safety and productivity, SCCL is studying the feasibility of introducing cutting technologies like Longwall mining, Continuous Miner and extraction of developed pillars by Longwall Mining, wherever feasible.

It is proposed to Introduce Longwall technology by annexing the dip side property to the extent of 2.0 Sq.Km. It is proposed to liquidate south side property (Phase-II property under forest land) of No1 seam, 2 Bottom seams of existing KTK-5 Incline Mine and to develop and liquidate all the three seams i.e. No.1 seam, 2 Bottom seam and 3 Seams in the Dip side extension property with Longwall technology. Proposed Method of Extraction by Longwall : The extraction proposed under the scope of this Project is entirely by LONGWALL CAVING METHOD. The sequence of extraction in caving method should be in descending order. Hence initially extraction in No.1 Seam is taken up followed by extraction in 2 Bottom seam beneath the de-coaled areas of 1 Seam. Finally 3 Seam will be extracted beneath the settled goaf of 1 Seam and 2 Bottom Seams. The strategy would be to introduce the Longwall technology in the 1 Seam property of the present working boundary of the mine to achieve production to the tune of 0.80 MTPA followed by 2 Bottom seam. Then to shift the Longwall equipment sequentially to 1 Seam, 2 Bottom Seam and 3 Seam of the expansion area.

The method of work involves the preparation of Longwall panel by driving gate roadways and extraction of coal by Longwall method. The extraction sequence is in descending order. Coal from the three seams i.e. 1 Seam and 2 Bottom Seam and 3 Seams is proposed to be extracted by Longwall mining. Total 31 numbers of panels are considered for Longwall mining in all the three seams i.e., No 1 Seam, No 2Bottom seam & No 3 Seam as shown in Table 3.

Table 3. Seam wise proposed number of Longwall panels

Sl. No. Seam Virgin Area Developed Pillars

1 1 12 1

2 2B 11 1

3 3 6 0

Total 29 2

The length of panels varies from 345 meters to 1110 meters. The face length (panel width) varies from 100 meters to 134 meters. The gate roads of the panels are kept slightly raising to facilitate self drainage. Face dip shall be driven preferably in full dip / apparent dip of the seam for operational convenience subjected to maintaining the minimum support resistance to be maintained as per the statute and also maintaining the optimum obliquity of the Longwall face so as to achieve the guaranteed production from Longwall.

Longwall panels are formed by development of Gate Roadways from trunks up to the boundary line. At the end Tail gate and Main Gate are joined together with face dip and Long wall equipment is installed in this chamber. Extraction of panel commences from boundary towards trunk roadways (retreating with caving).

The operating chock height ranges from less than or equal to 1.8m and up to a maximum height of more than or equal to 3.4 m. While forming the panels and deciding the face lengths due consideration was also given for superimposition of panel barriers of two seams.

Phasing of Longwall panels at KTK-5 Incline Longwall is as follows:

Table 4 .Sequence of Development and extraction of seam wise Long wall panels in the Mine. Description LW Panel Numbers Seam wise extraction Phase-1 IS_PANEL No-1 to IS_PANEL No-5 1seam (Existing property )

Phase-2 IIBS_PANEL No-1 to IIBS_PANEL No-5 2B seam (Existing property )

Phase-3 IS_PANEL No-6 to IS_PANEL No-12 1 seam (Expansion property )

Phase-4 IIBS_PANEL No-6 to IIBS_PANEL No-11 2B seam (Expansion property )

Phase-5 IIIS_PANEL No-1 to IIIS_PANEL No-6 3 seam (Expansion property)

• Panel wise sequence of operation is shown in development plans of No.1, 2B and 3 seams are enclosed as Plate No.1, Plate No.2 and Plate No.3 respectively.

• Gallery dimensions :

The minimum dimensions in trunk/gate/face dip roadways proposed for monorail for men and material transportation are 4.8 m width and 3.5 m height. The

Minimum dimensions in Trunk Roadways, Gate Roadways and face dips proposed for Mono Rail system for men and material transportation is given in Annexure-1.

• Gradient of Monorail system route:

i. Gradient along Trunk Roads : 1 in 3.6 to 1 in 4.5 ii. Gradient along gate roads : Raising 1 in 30 to 1 in 40 iii. Gradient along Face dip : 1 in 2.5 to 1 in 4

• Geo-Engineering studies:

The roof and floor rocks and all the coal seams of BH.No-482 & 577 were referred to Regional Analytical Lab, Kothagudem apart from the RQD studies. National Institute of Rock Mechanics (NIRM) conducted “Hydro fracture” studies in two boreholes viz. BH.No.501 & 502. PMP details of roof and floor strata are given in below table 1.

Table 1. PMP details of Roof and Floor strata

Strata Roof of I Seam

Floor of

I Seam

Roof of II Bot Seam

Floor of II Bot Seam

Roof of III Seam

Floor of III Seam

Density (gm/cc) 2.02-2.30 2.15-2.29 2.28-2.32 2.19-2.32 2.12-2.34 2.22-2.29

Tensile Strength (kg/cm2) 12.23-33.78 15.03-29.71 23.67-50.28 14.64-43.27 11.30-

42.40 14.31-34.43

Compressive Strength (kg/cm2) 144-384 142-316 257-388 166-457 164-492 194-431

Young's Modulus X 105 (kg/cm2) 0.36-0.91 0.36-0.69 0.58-1.26 0.41-0.96 0.40-1.09 0.09-0.91

Shear Strength (kg/cm2) 30.41-81.77 33.47-70.21

56.95-127.63 35.7-101.2 34.64-

100.53 38.81-90.01

Impact Strength Index 48.18-52.47 48.15-51.25 50.20-56.62 48.58-53.77 48.54-

55.02 45.61-53.31

Proto dyaknov Strength Index 0.54-1.65 0.52-1.36 1.07-2.85 0.63-2.05 0.71-2.40 0.77-1.62

RQD % 43-100 52-96 76-93 71-100 63-100 42-99

Requirements of the Monorail Transportation System are as follows: • Shall be suitable for installation and operation in galleries of size 4.8 m (width) and

3.5 m height and suspended to the roof. • Shall be able to carry upto 40 tonnes of load (Longwall Powered Roof Supports/

Shearer) in the gradients upto 1 in 2.5. (22.8 degrees). • Shall be able to carry the equipment having a length of 8-12 m and heights up to 2.0 m. • Shall be able to transport 300 workmen (150 in and 150 out) within two hours during

shift change hours. Suitable number of drives and number of men carriers shall be considered to meet this requirement.

• Shall have provision for extension and retreat of the system as per the requirement. • Provision shall be available to work the system at varying speeds depending upon

DGMS permission and weight of the loads being transported. • Shall be provided with effective and foolproof service and parking brake system as

per the requirement to stop the system on steep gradients up to 1 in 2.5 ( 22.8 degrees).

• The system shall be suitable for movement of the locomotives in both the directions on the same monorail with intermittent crossing stations (passing places) and should have suitable operator cabins.

• Load lifting devices and load tying devices provisions shall be included in the part of supply.

• Shall be provided with all safety devices as necessary for transportation of men and material in underground mine and as per the DGMS approvals/permissions.

• Number of Intermediate Stations may vary from panel to panel and seam to seam with minimum and maximum horizontal deflections are in the range of 2°- 98° and minimum and maximum vertical deflections are in the range of 0°- 27°. Details for design of the system are given in

• Necessary permissions from DGMS and other statutory bodies required from time to time. • Two way communication system with driver should be available from each of the cabin and to

the surface control room. Provision shall be made so that the locomotive can be stopped from any of the cabin in case of emergency.

• Provision shall be made to prevent running back of the locomotive when stopped midway and also prevent over speeding when moving down a incline. Effective parking brake and interlocking shall also be provided to prevent movement of the locomotive at the time of embarking and dis-embarking.

• Blinking lights and audio alarms system shall be provided to alert the persons about the movement of the system.

• All electrical equipment used for mono rail transportation shall be either FLP (Flame Proof) or intrinsically safe as the case may be and must be approved by DGMS for use in underground mine.

• Separate drives with rack and pinion arrangements for a length of about 500 m for salvage from old face and erection on new face shall be included in scope of supply.

• Required number of junction points and passing places shall be considered in the design of the system. Data for design is given as below:

The minimum and maximum horizontal deflection in No.1 Seam is in between 4°- 97° and corresponding vertical deflection is in between 0°- 27° with minimum and maximum length in meters is in between 1150 m-2100 m. The minimum and maximum horizontal deflection in No.2B Seam is in between 2°- 75° and corresponding vertical deflection is in between 0°- 14° with minimum and maximum length in meters is in between 1700m-4800m. The minimum and maximum horizontal deflection in No.3 Seam

is in between 12°- 98° and corresponding vertical deflection is in between 0°- 16° with minimum and maximum length in meters is in between 2500 m-2700 m. Required range of seam wise horizontal and vertical flexibilities in each seam along with minimum to maximum lengths are given in below table 2. : Table 2. Seam details for monorail installation

Seam Horizontal Deflection

Vertical Deflection Length in metres

No. Min Max Min Max Min Max 1 4° 97° 0° 27° 1150 2100

2B 2° 75° 0° 14° 1700 4800 3 12° 98° 0° 16° 2500 2700

I. Design Drawings along with horizontal and vertical deflections in No.1

Seam is enclosed as Plate No.4. II. Design Drawings along with horizontal and vertical deflections in No.2B

Seam is enclosed as Plate No.5 III. Design Drawings along with horizontal and vertical deflections in No.3

Seam is enclosed as Plate No.6. Tentative length of Monorail System: Tentatively there is about 10 km distance of monorail at a time needs to be installed and operated at KTK-5 Incline for Longwall.

The approximate phasing of monorail system consists of the following:

i. Along gate roads: about 5 Km

ii. Common length in 2B Seam along trunks: about 1.5 Km

iii. Face dip: about 500 m

iv. Trunks length in 1, 2B and 3 Seams : about 3 Km

Scope of Supply: Design, Engineering, Manufacture, Testing, supply of equipment to site, site fabrication, erection, installation of equipment, and commissioning, training of the complete system of Suspended Mono rail transportation system for transportation of men and material at KTK-5 Incline Longwall Underground Mine on TURN KEY BASIS including DGMS permissions and other statutory permissions and performance guarantee test along with Comprehensive AMC for a period of three years which starts after 24 months warranty period from the date of commissioning of the system.

Scope of the Successful bidder for Monorail : i. Design, Engineering, Manufacture, Testing, supply of equipment to site, site fabrication,

erection, installation of equipment, and commissioning of the complete system of Mono rail transportation for accommodating men and material transportation.

ii. Comprehensive maintenance (along with spares) for a period of 3 years which starts after 2 years warranty period from the date of commissioning of the system. iii. Operation of the Monorail for initial 2 years after the installation and extend the necessary

training to SCCL personnel. iv. DGMS permission for the monorail transportation and any other statutory

approvals/permissions required for working monorail system from time to time is in the scope of the successful bidder. v. All the safety devices required to be maintained as per the DGMS permission shall be in the

scope of successful bidder. vi. Necessary training should be provided to SCCL personnel involved in the operation and Maintenance of the monorail system by the successful bidder. vii. The firm is responsible to obtain field trial and permanent permissions from DGMS and any other statutory approvals/permissions for operation of the system from time to time in underground mines. Scope of the SCCL for Monorail :

i. Required manpower for mono rail installation and transportation of the equipment including extension of mono rail.

ii. Preparation of gallery dimensions suiting for mono rail installation in the mine.

iii. Roof and side supports along the mono rail route.

iv. Necessary lighting along the mono rail route.

v. Necessary ventilation all along the mono rail route.

vi. Water shall be provided by SCCL on free of cost basis.

vii. Mine preparation works shall be carried out by SCCL.

vii. Grouting of Roof bolts, brackets shall be done by SCCL.

viii. Surveyor assistance will be provided to mark centre line, grade line etc.,

ix. All civil foundations and roof bolt grouting work, embarking and disembarking station civil works will be done by SCCL. All the steel structural posts shall be supplied and installed by SCCL including civil/other foundations wherever necessary.

viii. Power shall be provided by SCCL on free of cost.

ix. Required surface infrastructure like sheds, cranes etc., shall be provided by SCCL.

Comprehensive Maintenance Contract (CMC): The successful bidder shall enter into a CAMC for a period of 3 years which starts after two years warranty period from the date of commissioning of the system as per following terms: i. The firm has to check up all components/systems and mechanical structures like machinery

and equipment periodically.

ii. The AMC is for service and maintenance and required spares will be arranged by the firm.

iii. Prices shall be on " FIRM PRICE " basis till completion of the Annual Maintenance Contract.

iv. The firm should prepare and submit the maintenance schedules for proper maintenance.

v. Authorised Engineers are required to visit once in a month for thorough check up and to take up the rectification jobs.

vi. The firm has to attend the problems within 24 hours, as and when informed in emergencies.

vii. Approvals and calibration of the system to be arranged by the firm and the any cost incurred is to be borne by the firm.

viii. For carrying out the maintenance, required manpower will be provided by SCCL.

ix. The firm has to attend breakdown calls as and when required in addition to the regular visits of once in a month during AMC period. The firm should depute their technical personnel and rectify the problem within 24 hours, otherwise, penalty @1% per day of the contract amount of that quarter will be levied beyond 24 hours.

Specific terms and conditions :

• The bidder shall clearly indicate the specifications of all equipment proposed to be utilized along with sketches and diagrams wherever required.

Other Terms & Conditions:

i. The tenderers must inspect the mine and location of proposed Monorail system to ascertain the parameters prior to attending pre-bid vendor meet and submitting the offer.

ii. Tenderer shall confirm to submit DGMS approval/Field trial permissions for monorail system before commencement of supply, installation and commissioning.

iii. In case of field trial permission, tenderer shall confirm to obtain permanent approval from DGMS for monorail on successful field trial and to get renewal of the same from time to time.

iv. The Monorail System is guaranteed for a period of 24 months from the date of commissioning or 30 months from the date of supply.

v. Tenderer shall confirm to submit 3 sets of operation, maintenance, and spares manuals (hard and soft copies) along with supplies.

FLOOR FLOOR

1 in 4.04.80

2.402.40

2.68

3.88

1 in 4.3

4.80

3.86

2.74 3.

30

GALLERY SECTIONS AT GATE ROADWAYS

GALLERY SECTIONS AT TRUNK ROADWAYS

1 in 2.7

4.80

4.29

2.51

1 in 3.0

4.80

2.60

4.20

2.40

GALLERY SECTION AT FACE DIP

Annexure - 1

3.28

ROOF

FLOOR

MonoRailOperationalArea

ROOF

FLOOR

MonoRailOperationalArea

2.40

2.40

ROOF

MonoRailOperationalArea

2.402.40

ROOF

MonoRailOperationalArea

2.40

3.50

4.80

3.50

ROOF

FLOOR

MonoRailOperationalArea

ALL DIMENSIONS ARE IN METRES

2.40 2.40

DEPARTMENT OF PROJECT PLANNING

THE SINGARENI COLLIERIES COMPANY LIMITED( A GOVERNMENT COMPANY )

(ISO - 9001:2008 Certified)

S.O.MD.JANARDHANA REDDY

Sr.SurveyOfficerDy.G.M.B.KISHAN RAOGeneral Manager

BHUPALAPALLI AREA

PROJECTION PLAN OF 1 SEAM

PLATE No : 1

PROJECT REPORT FOR EXPANSION OF KTK No.5 INCLINE WITH LONGWALL

M.VENKATESWARLU

Date : Oct 2015RF= 1:5000

K.SAIBABU

DEPARTMENT OF PROJECT PLANNING

THE SINGARENI COLLIERIES COMPANY LIMITED( A GOVERNMENT COMPANY )

(ISO - 9001:2008 Certified)

S.O.MD.JANARDHANA REDDY

Sr.SurveyOfficerDy.G.M.General Manager

BHUPALAPALLI AREA

PROJECTION PLAN OF 3 SEAM

PLATE No : 3

PROJECT REPORT FOR EXPANSION OF KTK No.5 INCLINE WITH LONGWALL

K.SAIBABU M.VENKATESWARLU

RF= 1:5000

B.KISHAN RAO

Date : Oct 2015

DEPARTMENT OF PROJECT PLANNING

THE SINGARENI COLLIERIES COMPANY LIMITED( A GOVERNMENT COMPANY )

(ISO - 9001:2008 Certified)

SOMD.JANARDHANA REDDY

Sr.SurveyOfficerDy.G.M.B.KISHAN RAOGeneral Manager

BHUPALAPALLI AREA

MONORAIL LAYOUT IN 1 SEAM

PLATE No : 4

PROJECT REPORT FOR EXPANSION OF KTK No.5 INCLINE WITH LONGWALL

M.VENKATESWARLU

Date : Oct 2015RF= 1:10000

K.SAIBABU

DEPARTMENT OF PROJECT PLANNING

THE SINGARENI COLLIERIES COMPANY LIMITED( A GOVERNMENT COMPANY )

(ISO - 9001:2008 Certified)

BHUPALAPALLI AREA

PLATE No : 6

PROJECT REPORT FOR EXPANSION OF KTK No.5 INCLINE WITH LONGWALL

SOMD.JANARDHANA REDDY

Sr.SurveyOfficerDy.G.M.B.KISHAN RAOGeneral Manager

MONORAIL LAYOUT IN 3 SEAMM.VENKATESWARLU

Date : Oct 2015RF= 1:10000

K.SAIBABU