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CENTRAL WORKSHOP JAYANT ANNUAL PERFORMANCE REPORT (2019-20)
Central Workshop Jayant Annual Performance Report
PREFACE Mechanization of mine needs technical expertise & systems, We at Central workshop support our coal producing projects & allied support systems by repairing & maintaining floats of sub-assemblies for all the HEMM’s (like Dragline , Shovel ,Dumper , Dozer etc.), Coal handling plants, Dewatering/pumping system of Mines & IWSS, Electrical substations of Mines & colonies etc. ,We extend our onsite technical services for restoring complicated technical problems & also provide for proactive preventive maintenance via condition monitoring cell situated in our campus, all these activities have righteously earned us the honor of being ‘Backbone of NCL’.
We as team Central workshop are always thankful to the commendable vision of the people back in 1990’s who saw through the requirement for decades to come & established this state-of-art highly mechanized central workshop comprising of 10 repair sections like Engine shop, Electrical shop, Machine Shop etc.
We are also thankful to the current NCL Management headed by our Dynamic CMD Sri P.K Sinha, Director (Tech/oprn) Sri G. Pandey, Director (Tech/ p and p) Dr. Anindya Sinha, Director (finance) Sri. N. N. Thakur, CVO Shri A. K. Srivatava & last but not the least our HOD Sri S.C Vats who all have guided us to achieve what is expected of us.
With great pride here I present to you the Annual Performance report of FY19-20 for necessary information & further needful guidance and suggestions.
Thanking You, SUDHIR KUMAR SRIVASTAVA GENERAL MANAGER CENTRAL WORKSHOP
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Central Workshop Jayant Annual Performance Report
INDEX PREFACE…...........................................................................................................01 ENGINE SHOP…………………………………………………………………………………………..…….03 TRANSMISSION SHOP…………………………………………………………………………………….08 ELECTRICAL SHOP…………………………………………………………………………………………..13 MACHINE SHOP………………………………………………………………………………………………21 WHEEL MOTOR SHOP…………………………………………………………………………………….27 WELDING SHOP……………………………………………………………………………………………..30 RECLAIM SHOP……………………………………………………………………………………………….33 BER AND SURVEY OFF DETAILS……………………………………………………………………...40 CONDITION MONITORING CENTER…………………………………………………………….....42 INVENTORY STATUS……………………………………………………………………………………….50 TAKSHSHILA BHAWAN……………………………………………………………………………………53 CSR ACTIVITIES……………………………………………………………………………………………….55
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Central Workshop Jayant Annual Performance Report
ENGINE SHOP
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Central Workshop Jayant Annual Performance Report PERFORMANCE OF ENGINE SHOP AT A GLANCE a. Engine Production : Target Actual
2018-19 208 214
2019-20 218 219
(166-O/H+48-S/R)
(167-O/H+52-S/R)
b. Engine Receipt VS Delivery: 2018-19
Received Delivered
2019-20
223 179
228 178
c. Inventory : Inventory
2018-19(31/03/19) 11.25 Cr.
Material Receipt Material issued
2018-19 49.61 Cr. 49.92 Cr.
2019-20(31.03.2019) 10.4 Cr.
Reduction 7.55 %
d. Special achievement :
i.
Cat C-32 engine of D11T Dozer and repaired, tested and delivered to Amlohri Project without any special training for the first time at CWS. Cummins QSC8.3L engine of Crane of Jayant Project repaired without any special training for the first time at CWS. Cummins QSX15C engine of BE1600 application first time successfully tested at CWS and delivered to Kakri Project. 1 no. SAA12V140E3 of WA800 Pay loader application and 1 No. QST30C of BH100 Dumper application delivered to Central Coalfields Ltd., Barkakana. CWS Overhauled engine clocked remarkable Hours & received at CWS in FY 2019-20
ii. iii. iv. v.
vi.
ENGINE MODEL
ENGINE S/N
PROJECT
LOH
16VS2000 3508 BEUI KTA3067 KTA38C (120T) QST30C
5362002649 C8T00299 25205807 25320523 37242948
NIGAHI NIGAHI AMLOHRI NIGAHI KRISHNASHILA
19950 17700 14409 12266 11553
CWS overhauled engine clocking extraordinarily & still operational in project: ENGINE MODEL
CAT 3508 BEUI CAT 3508 BEUI CAT 3508BEUI SAA12V140E-3 DDC16V2000
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ENGINE S/N
C8T00312 C8T00353 C8T00300 502775 5362000248
PROJECT
EQ. No.
NIGAHI NIGAHI NIGAHI JAYANT JAYANT
FKR00554 FKR00555 FKR00556 N10276 Tx-42
Present LOH
19092 18219 18035 13446 11814
Central Workshop Jayant Annual Performance Report
MONTHWISE TARGET VS ACHIEVEMENT OF ENGINE OVERHAUL FY 2019-2020 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
22 19
18
17
APR'19
18 16
MAY'19
18
21 18
20 18
16
ACHIEVEMENT JUN'19 TARGET JULY'19 AUG'19
SEP'19
ENGINE TARGET VS ACHIEVEMENT FY 2019-2020
NO OF ENGINES
2
1
0
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Central Workshop Jayant Annual Performance Report
OVERHAULING COST (SPARES) OF MAJOR ENGINES 60.00
54.20
54.96
50.00
COST IN LAKHS
40.39
40.24
38.00
40.00 32.69
FY 1819
30.00 20.00 11.95
12.98
10.00 0.00 QST-30C
S6D-170
3508 BEUI
SAA12V-140
ENGINE MODEL
ENGINE RECEIVED VS DELIVERY 250 223 215 200 178
179
150
RECEIVED DELIVERY 100
50
0 APR-18- MAR-19
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APR'19-MAR'20
Central Workshop Jayant Annual Performance Report
LIFE IN HOURS
AVERAGE OVERHAULED LIFE OF MAJOR ENGINE MODELS 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0
FY 18-19 FY 19-20
3508 BEUI
KTA 38-C
NTA-855
ENGINE MODEL
***
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S6D-140
Central Workshop Jayant Annual Performance Report
TRANSMISSION SHOP
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Central Workshop Jayant Annual Performance Report Report on Transmissions at CWS Jayant Sl No 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22
MODEL
Application
BH100TM BEML BH100 DUMPER BH100TC BH85TM BEML BH85 DUMPER BH85TC CAT777 C/D TM CAT 85/100 DUMPER CAT777 C/D TC BD355 Elect TM BD355 Mech BEML BD355 DOZER TM BD355TC CLT754,CLBT754 WS28 CAT D11 R/T TM CAT DOZER D11R/T CAT D11 R/T TC CAT 988HTM CAT 988H PAYLOADER CAT 988HTC CAT 14M TM CAT 14M GRADER KAWASAKI PL KAWASAKI TM PAYLOADER HD785-7TM KOMATSU 100T DUMPER HD785-7TC BG825TM BEML BG825 GRADER CAT785C TM CAT 120T DUMPER CAT785C TC
4500 4500 5000 5000 12000 11000 4800
Approx OH Cost(in Lakh) 18 4.5 18 4.5 17 4 11
Approx Cost New(in Lakh) 45 10 45 10 110 30 55
7500 8000 4500 24000 24000 9000 9000 7000
4800 4900 2600 NA NA 5000 5000 6000
23 2 5 22 4 22 5 23
55 5 22 80 20 80 20 100
7 21 15 1 1 1 1 1
24000 22000 22000 6000 12000 12000
NA NA NA 3500 NA NA
30 45 8 26 22 5
120 150 50 55 120 30
1 15 15 6 0 0
New TM Life
OH TM Life
8000 8000 8000 8000 16000 16000 7500
Annual Target
Breakdown analysis of failed transmissions received during the year 2029-20: Sl. No
Failure Reasons
%age of Total Failures
1
Gear Shifting Trouble(GST) & Metal Found in Strainer (MFS)
75
2
Not Taking Load (NTL)
14
3
Normal Wear & Tear (NWT)
11
Breakdown Analysis of BH100 Transmissions: An Interactive session was organized at Vocational training center (VTC) of CWS Jayant on Dated: 06/12/2019 to improve the performance and reduce the pre-mature failure of BH100 Transmission. Representatives from projects (Executives, Foreman, and Fitter) and Service engineers from the OEM have attended the program. 9|Page
18 18 13 13 35 30 15
Central Workshop Jayant Annual Performance Report In BH-100 transmissions the major problem is the Oil leakage from PTO Lubrication tube (Cross Tube) and in many cases it is the cause of Pre-mature failure due to Oil Starvation. The matter was also discussed with M/S BEML and they appraise that replacing the PTO lubrication tube with PTO lubrication Hose Assy (Part No.953TC02027), frequent tube failures can be avoided .
IMPROVEMENT IN SAFETY ENVIORNMENT 1. Use PPE was strictly adhered for both departmental and contractual workers. 2. Due to the construction special dismantling zone, oil spilling due to dismantling of transmissions of BH100 and HD785-7 were avoided which eliminated the possibility any unsafe occurrence. 3. Burnt oils during dismantling were properly collected for disposal at an outside tank constructed near the dismantling zone. This reduced the environmental impact of the toxic burnt oils. 4. A total of 111.65 Ton Scrap (81.7 Ton Iron & Steel, 22.2 Ton BER Transmission Assay, 5.3 Ton Aluminium, 0.45 Ton Aluminium Mix and 2 Ton Bearings) deposited at Regional Store. This resulted in creating a safety working environment as well as cost benefits to the company from the scrap sale. NEW INITIATIVES & SPECIAL ACHIEVEMENT 1. Modification on D355 Electronic transmission to make it compatible with BD355 Mechanical Model Dozer which led to OH Cost Saving, Reduction in Overhauling Time as well as Inventory. 2. Repairing and reclamation work of Pump Wheel Gear (Part No: 1951311143) applicable in BD355TC was done successfully which eliminated the delay in Overhauling Work due to delay in supply of the Spare. Special Dismantling zone was successfully constructed outside the transmission shop to carry out dismantling activities which will subsequently improve cleanliness, scrap management and reduces cycle time of transmission overhauling activity.
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Central Workshop Jayant Annual Performance Report
PRE-MATURE FAILURES OF TRANSMISSION SHOP Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
MODEL BH100TM TC BH85TM TC CAT777 C/D TM CAT777 C/D TC BD355 TM(MECHANICAL) BD355 TC CLT754/CLBT754 TM CAT D11R/T TM CAT D11R/T TC CAT 988HTM CAT 988HTC CAT 14M TM KAWASAKI PL TM HD785-7 TM TC BG825TM TOTAL 11 | P a g e
2019-20 3 NIL NIL NIL 1 NIL NIL NIL NIL NIL NIL NIL NIL NIL 3 7
2018-19 5 2 1 NIL NIL NIL NIL NIL NIL NIL NIL NIL NIL 1 1 10
Central Workshop Jayant Annual Performance Report AVERAGE LIFE OF TRANSMISSIONS & TC Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
MODEL CAT777DTM CAT777DTC CAT -785C TM CAT -785C TC CAT988HTM D11R TM D11R TC CAT WD834B TM HD785-7TM HD785-7TC D355TM D355TC BH 100 T/M BH100 TC BH85-1 TM BH85-1 TC BG825 CLT-754 TM CLBT754TM AVERAGE TM AVERAGE TC
2017-18 11225 11340 8055 5691 NA NA NA NA 24345 25650 3277 4871 3355 3013 4921 4225 6914 3676 2597 7596 9132
2018-19 11316 10687 NA 10685 7282 NA NA NA 16902 16902 5910 4702 3974 4030 4883 4322 1925 2326 NA 6815 8555
***
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2019-20 14305 11096 NA NA 2389 13586 32203 8331 27436 22834 5525 5081 6026 6444 5300 5300 2412 2019 1691 8093 13826
AVG LIFE OF LAST 03 YEARS 12282 11041 8055 8188 4836 13586 32203 8331 22894 21795 4904 4885 4452 4496 5035 4616 3750 2674 2144 7501 10504
Central Workshop Jayant Annual Performance Report
ELECTRICAL SHOP
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Central Workshop Jayant Annual Performance Report Electrical Shop Target Total Job Delivered Target Achievement % Total Job Receipt Target Achievement against Receipt Jobs Total Item receipt Total Electrically premature failure items % Pre-Mature failed items against receipt KVA Target Total KVA KVA %Achievement Total Costing (As per Job card) Avg. Costing per job
FY2019-20 520 515 99.04 514
FY2018-19 496 473 95.36 486
100.19 816
97.33 706
76
48
9.31 240 285.14 118.81 392995615.62
6.799 240 297.11 123.80 358100121.14
763098.2828
757082.7085
Target-520 Achievement-515
Target v/s Achievement for FY 2019-20 60
56 52
50 42 40
44
51 42
46 44
42
44
36
30
4444
37
36
24
20 10 0
Target
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44
Achievement
4445
44
45 42
4443
Central Workshop Jayant Annual Performance Report Receipt-514 Delivery-515
Receipt v/s Delivery for FY 2019-20 70
61
60
60
56 52
50 40
48
45 36
46
4544 3736
35
30
37
24
20 10 0
Receipt
45 33
20
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55
51
Delivery
39
45
43 36
Central Workshop Jayant Annual Performance Report
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Central Workshop Jayant Annual Performance Report
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Central Workshop Jayant Annual Performance Report
Fault Analysis for 24/96 D/L for FY 2019-20 N.Qty
. Row Labels 24/96 D/L Electrical Mechanical Overhauling Grand Total
Amlohri 8 3 2 3 8
Bina 3 1 2 3
Dudhichua 21 13 2 6 21
Jayant 41 22 16 3 41
Fault Analysis for 24/96 D/L for FY 2019-20
15, 19% 44, 54% 22, 27%
Electrical
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Mechanical
Overhauling
Nigahi 8 5 3 8
Grand Total 81 44 22 15 81
Central Workshop Jayant Annual Performance Report Special achievements by Electrical Shop
1) Installation of transformer testing panel : for electronically conducting all the vital tests like short circuit ,open circuit & high voltage test of transformer windings.
2) Installation of DVDF test set : it helps in ensuring almost 100 % performance reliability of the repaired transformers by testing transformers at double supply voltage and double frequency.
3) Procurement of transformer turns ratio meter : it is a very modern & vital electronic tool which can help in avoiding life threatening transformer blasts by detecting winding faults(that cannot be detected by simple insulation testers like megger etc) without dismantling a transformer.
4) Installation of induction Bearing heater : to help increase the life of bearing by avoiding primitive flame heating technique. 5) Dismantling & refurbishing commutator of hoist/Drag motor 20/90 DL : NCL is a user of very huge capacity DC motors (used in Draglines) some of the parts in these DC motors specially 19 | P a g e
Central Workshop Jayant Annual Performance Report commutators is very costly(approx. 28 lakhs) & has to be imported from Russia which would take around 5 - 6 months after placement of order. In the current incidence as there was no motor ready due to lack of commutators & the dragline would have been made to stand for atleast 6-7 months, so a motivated team of Electrical shop took up the challenge of completely dismantling the commutator of 1120 KW & then reassembled it successfully . This was a very critical task & has never even been tried in other subsidiary of CIL, but the hardwork paid well the motors was ready in just 20 days.
6) Highest number of main motos rewinded in an year i.e 12 motors.
***
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Central Workshop Jayant Annual Performance Report
MACHINE SHOP
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Central Workshop Jayant Annual Performance Report Initiatives: 1. Conversion of Lathe Machine to Special purpose Horizontal boring machine:Need: Heavy load of de-shafting of armature on single horizontal boring machine. Conversion Process: removal of tool post of lathe machine and installed attachment at that position for holding of armature/job keeping in view of centre height of job. i) Tool Post Removal ii) Fabrication of attachment iii) Attachment Installation iv) Manufacturing of socket for drill and boring bar v) Final Assembly
Fig: FINAL ASSEMBLY
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Central Workshop Jayant Annual Performance Report Special achievement: 1. Fabrication of multi patient ventilator attachment: Machine shop fabricated multi patent ventilator attachment of copper tube and Bakelite material with the help of electrical shop. Dr NSC tested it and working satisfactorily.
2. Machine shop developed 02 Nos. New Motor Pinion shaft of 24/96 D/L delivered to DCH project against WO/DUD/CWS/19-20/000734/MAC/MC and WO/DUD/CWS/19-20/2677/PRE on 24/06/2019 and 04/02/2020 respectively in FY 2019-20.
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Central Workshop Jayant Annual Performance Report 3. In F.Y. 2019-20, Machine Shop repaired 06 Nos. motor pinion shaft and delivered to projects of NCL.
S.No. 1 2 3 4 5 6
Work Order WO/AML/CWS/1819/003266/MAC/MRE WO/BIN CWS/1819/003409/PRE WO/NIG/CWS/1920/837/PRE WO/DUD/CWS/1920/1314/PRE WO/NIG/CWS/1920/1359/PRE WO/JAY/CWS/1920/002371/MAC/MC
HEMM Sub Assembly 24/96 DL MOTOR PINION SHAFT 24/96 Motor pinion shaft D/L 24/96 Motor pinion shaft D/L 24/96 Motor pinion shaft D/L 24/96 Motor pinion shaft D/L 24/96 DRAG MOTOR PINION DL SHAFT
Qty 1
Gate pass 13670
Del Date
Project
01.04.19
AML
1
13668
01.04.19
BIN
1
14266
9-072019
NGH
1
14522
25.08.19
DCH
1
14561
31.08.19
NGH
1
15231
18-01-20
JNT
4. In F.Y. 2019-20, Machine shop repaired 02 Nos. intermediate pinion shaft of 24/96 D/L by inserting a new shaft.
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Central Workshop Jayant Annual Performance Report
Fig: Intermediate pinion shaft of 24/96 D/L
16
15.1
14 12
11.5 11.5 11.5
12
12
12.9 12 11.5 11.5 11.5 11.5 11.5
12
10.1
10
9.9 9.1 8.5
7.8
8
7.2
6.9
6
5.4 4.3
4 2 0 Apr
Jun
Aug
Oct
Dec
Feb
Re-Repair Target V/s Achievement in the year 2019-20
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Target 6.3
Achiev.
Central Workshop Jayant Annual Performance Report
350 300
300 244
250
199 201
200
175
Target
141
150 90
100
129 95 9510095 95 82 69
9086 90
90
90
Achiev. 90
90
90 77
50 0 Apr
Jun
Aug
Oct
Dec
Feb
Repair Target V/s Achievement in the year 2019-20
12 9.8
10 8.1
8 6
7.9
7.5 6
6
6
6
6
6 4.9
4.3 3.6
3.5
Apr
Jun
4
6
6
6
6
6
4.5 3.6
2 0 Oct
Dec
HT Target V/s Achievement in the year 2019-20
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Target Achiev.
3.5 3.5
Aug
6
Feb
Central Workshop Jayant Annual Performance Report
WHEEL MOTOR SHOP
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Central Workshop Jayant Annual Performance Report Highlights 2019-20 : At a Glance 1. Achievement of Target 2019-20 Item/Assembly Wheel Motor Armature Blower Motor Alternator Total
Target 76 24 20 20 140
Achievement 52 45 23 12 132
% Achievement 68% 188% 115% 60% 94%
## As per directives received from HQ, assemblies applicable to BH-120/UR-120 Dumpers, were to be repaired according to instant demand only, so that any pile up of inventory/WIP can be avoided. Because of lower demand, AAP Target was not achieved for Wheel Motor/Alternator. ## Demand satisfaction has been 100% for entire year.
2. Average Life of sub-assemblies w.r.t. previous year FY 2018-19
FY 2019-20
64 9552
69 13024
No. of Wheel Motor Received Average LOH
% Increase in Avg Life 36.35%
3. No. of Premature Failures w.r.t. Previous Year
Year 2019-20 % of Total Motors Received
Total Wheel Motor Received 69
2018-19 % of Total Motors Received
64
Improvement w.r.t. Previous Year
3 4.35%
Motors < LOH 2000 4 5.80%
Motors < LOH 3000 9 13.04%
5 7.81%
9 14.06%
10 15.63%
3.46%
8.27%
2.58%
Motors < LOH 1000
4. Cost of Repair (Material Only) w.r.t. Previous Year
No. of Wheel Motor Delivered Average Repair Cost (Material Only) in ₹
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FY 2018-19
FY 2019-20
63 764192.13
55 558410.12
% Reduction in Average Repair Cost 26.93%
Central Workshop Jayant Annual Performance Report 5. Inventory Reduction Inventory As on 01.04.2017 (in ₹) Inventory As on 01.04.2018 (in ₹) Inventory As on 01.04.2019 (in ₹) Inventory As on 31.03.2020 (in ₹) Reduction during FY 2019-20
12,328,645.21 11,438,087.94 234,909.32 NIL 100%
## Zero Inventory figure has been achieved through reducing the same gradually over a period of 03 years. 6. Special Achievement 30 Nos. Unserviceable Wheel Motors were lying in shop for long. Competent approval was obtained for declaring the same as BER. Thereafter, BER Motors were deposited to Store for disposal, resulting into generation of revenue to company of around 70 Lacs. 7. Improvement in Safety Environment High quality, Polymer Handle Hammers was procured in Wheel Motor Shop, to improve safety of workmen during repair job.
***
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Central Workshop Jayant Annual Performance Report
WELDING SHOP
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Central Workshop Jayant Annual Performance Report PERFORMANCE REPORT OF WELDING SHOP FOR THE FY 2019 – 2020
NOTE: In case of Dipper handle, we have received only 7 work orders from different projects and delivered 10 Dipper handles in FY 2019-20.
Performance report of repaired Dipper Handle.
20 18 16 14 12 10 8 6 4 2 0
TARGET ACHIEVEMENT
ACHIEVEMENT 2019-20
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TARGET
Central Workshop Jayant Annual Performance Report Performance report of repaired sub-assemblies of HEMM and CHP
620 600 580 560 540 520 500 480 460 440 420 400
TARGET ACHIEVEMENT
ACHIEVEMENT TARGET
2019-20
Average life of repaired sub-assemblies at different projects: 1. Average working hour of a Dipper handle of P& H 1900AL Shovel is 5000hrs in FY 201819 and 5500hrs in FY 2019-20. 2. Average working hour of a lower roller of P& H 1900AL Shovel is 3800hrs in FY 2018-19 and 4000hrs in FY 2019-20. 3. Average working hour of a Idler of P& H 1900AL Shovel is 6000hrs in FY 2018-19 and 7000hrs in FY 2019-20. NOTE: Above working hours is approximate figure, data taken from different projects. Cost of repair at Welding shop: 1. Average cost of repair of Dipper handle is Rs.1650000 in FY 2018-19 and Rs.1825000 in FY 2019-20. New initiatives undertaken by Welding shop are followings: 1. In FY 2019-20, we started repairing of the size segment of Crusher (CHP) and the rope drum of the Dragline. 2. We are planning to procure MIG/MAG semi -automatic welding machine to improve the quality and the quantity of repaired jobs. Capital scheme initiated. 3. We are planning to procure automatic optical profile cutting machine for quick and precise cutting according to our requirement. Capital scheme to be initiated in FY 202021. For improvement in safety environment, we are going to procure the smoke arrestor for welding shop floor to make this shop a smoke free zone. Indent to be initiated in FY 2020-21.
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Central Workshop Jayant Annual Performance Report
RECLAIM SHOP
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Central Workshop Jayant Annual Performance Report Performance Report of FY 2019-20 1. Achievement of target i.e, Production against Target: For FY 19-20 Target for Repair = 38 No’s; Actual Repaired job against demand= 24 no’s Note: Less failure of job compared to FY 18-19. For FY 18-19 Target for Repair = 31 No’s; Actual Repaired job against demand= 37 no’s 2. Average life of respective sub-assemblies concerning to their shop against average life achieved last year: For FY 18-19=2522.58 Hrs For FY 19-20=3820.27 Hrs 3. Number of premature failures in FY 19-20 against FY 18-19: For FY 18-19=07 nos For FY 19-20= 04 nos 4. Breakdown analysis:
KAKRI (18-19)=06 Nos
KAKRI (19-20)= 03 Nos
NTL 1
OHG
Mech. (Key Way)
1 1
Shaft Brg Sz. 3
1
Rotor Assy failed Dust Deposition
Rotor Assy failed
DCH (18-19)= 16 Nos
NTL
1
DCH (19-20)= 15 Nos
NTL
Shaft Brg Sz.
Shaft Brg Sz.
Rotor Assy failed Pinion Brg Fail F.Assy Earth
Rotor Assy failed Pinion Brg Fail OHG
2 1
5
4 1
3
Overheating Shaft Broken
Overheating
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1
Mech.
1
1 1 1 4
2 3
2
Central Workshop Jayant Annual Performance Report
NGH (18-19)= 03 Nos
NGH (19--20)= 05 Nos
NTL
OHG Other Reason Oil Leakage Shaft Brg Sz. Pinion Brg Fail
Shaft Brg Sz. Rotor Assy failed
1
1
1
1
1 2 1
1
Other Reason: 1. FA & RA touches during Oper. 2. Fan mounting Bolt broken during Oper.
JNT (18-19)= 04 Nos
JNT (19-20)= 02 Nos
NTL
Assy Jam
Other Reason
Shaft Brg Sz.
1
1
1
3 Other Reason: 1. Due to entrance of the foreign material , Magnetorque Assy failed.
AML (19-20)= NIL
AML (18-19)= 02 Nos Other Reason
Other Reason
Rotor Assy failed
Rotor Assy No Failure report is received from failed 1
1
Other Reason: 1. Coupling side slip ring free & connection lead found broken of field assembly.
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AML Project in FY 19-20
Central Workshop Jayant Annual Performance Report
JRD (18-19)= 02 Nos
JRD (19-20)= NIL
Shaft Brg Sz. Shaft Broken 1
1
No Failure report is received from JRD Project in FY 19-20
SECL, KUS (18-19)= 01 Nos
SECL (19-20) = NIL
Field Assy Ground 1
No Failure report is received from SECL, KUS in FY 19-20
Note: Partial spares fitted & returned due to shortage of 01 no Field Assembly.
MCL, Balram (18-19) = NIL
MCL, Balram (19-20)= 01 Nos Field Assy failed Rotor Assy failed
No Failure report is received from
Shaft Brg Sz
1
1
1
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Central Workshop Jayant Annual Performance Report
BREAKDOWN ANALYSIS IN % AGE FOR MAGNETORQUE ASSY IN NCL
OHG (Overhauling) 6%
FY 18-19 Other Reason 3%
Shaft Brg Sz. 23% NTL 29% Rotor Assy failed 12% Field Assy Ground 3%
Pinion Brg Fail 12% Assy Jam 3% Shaft Broken 3%
Overheating 6%
FY 19-20 Mechanical Oil leakage 3% 7% Dust Deposition 3% OHG (Overhauling) Other Reason 3% 10%
NTL 4%
Shaft Brg Sz. 24%
Rotor Assy failed 14%
Field Assy Ground 10% Pinion Brg Fail 14% Shaft Broken 4%
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Overheating 4%
Central Workshop Jayant Annual Performance Report
5. New initiatives undertaken by their respective shops: a) During field visit for preventive inspection / checking , for improvement maintenance practices is demonstrated by CWS team to maintenance crew during greasing in magnetorque assembly for P&H 1900AL shovel “It has been advised for grease toping in all four quadrants of shaft bearings, by manually rotating the shaft of magnetorque in all four quadrants step by step and charge the grease in the points provided in the rotor assembly on both side for more reliability of magnetorque assembly (during daily maintenance).” b) Induction heater has been used for bearing fitment. In prevailing practice oil bath heating was done. c) One rejected shaft is successfully repaired by undercut, welding and then machining. The said shaft was loose at the filed assembly fitment area. Precise and slowly welding was done by dividing the welding area in the four quadrants for less chance of shaft bend. Repaired job was delivered to Dudhichua Project for P&H-07.
6. Special achievement: a) Remove the bend in the core of the field assembly poles which have been occurred during operation in the machine at P&H-01 (05-segment) of Nigahi Project due to failure of shaft and pinion bearing of NDE. By using 100T hydraulic press and some attachment bend is completely removed. This type of failure generally has not been observed. b) Less production in 19-20 due to less failure of job as compared to the last year Repaired Job 18-19 = 36 nos. Repaired Job 19-20= 24 nos. c) Modification in old repairing practices for quality work during repairing of magnetorque assembly.
Hammer
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Central Workshop Jayant Annual Performance Report Figure-A
Figure-B
Figure-C
Figure-A: Old practice for fitment of oil seal and retainer. Retainer was push fitted by applying force through hammer. Figure-B: New & safe practice for fitment of oil seal and retainer by using in-house developed puller. Figure-C: New & safe practice for removal of oil seal and retainer by using same puller.
7. Cost of repair / output, if tangible, in comparison to last year: Cost of repair / output in FY 18-19 = Rs 8,82,85,785.00/Cost of repair / output in FY 19-20 = Rs 2,52,06,794.00/8. Improvement in safety environment of respective shops: • New method of job dismantling process is developed for such jobs which are not dismantled by normal method. By adopting this method safety environment of manpower is enhanced. For dismantling of such jobs in which there is the chance of puller rod thrown-off during job dismantling process, this new method is applicable. As this method does not required puller rod.
Puller Rod
Figure-A
Figure-B
Figure-A: With the use of two puller road and one center hole jack, job is dismantled in horizontal position. Figure-B: with the use of 02 jacks job is dismantled in vertical standing position. Advantage: More safe practice as there is no risk of puller rod to hit any person during excess load.
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Central Workshop Jayant Annual Performance Report
BEYOND ECONOMICAL REPAIR DETAILS List of assemblies declared BER in FY 2019-20 Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Model DDC 16V 2000 QST-30C (BH-100 (100T) DDC 16V 2000 SAA12V-140E-3 SAA12V-140E-3 SAA12V-140E-3 CAT C11 KT-2300 KTA-38C CAT 3508 BEUI S6D-170 D-355 Transmission. Assembly of D-355 Dozer. CAT-777C (85T) Transmission applicable for CAT777C/D dumper. BG825 Motor Grader BG825 Motor Grader CAT777C/D 85T BG825 Motor Grader transmission BD355 Mech. Trans. CAT-C11 Main motor (550 HP) of DMH Drill Clutch Shaft Assy 04 Segment, P&H 1900AL Clutch Shaft Assembly 04 segment P&H 1900AL 469563 Drag Motor BG825 Motor Grader Main motor(550 HP) of DMH Drill Wheel Motor 776 Total
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Quantity
Order No.
19 3 3 1 1 1 1 22 11 16 14
GM/CWS/55/2019/109 dtd. 18/07/2019 GM/CWS/55/2019/200 dtd. 01/10/2019 GM/CWS/55/2019/199 dtd. 01/10/2019 GM/CWS/55/2019/315 dtd. 04/12/2019 GM/CWS/55/2019/317 dtd. 05/12/2019 GM/CWS/55/2019/318 dtd. 06/12/2019 GM/CWS/55/2020/360dtd. 07/01/2020 GM/CWS/55/2020/402 dtd. 07/02/2020 GM/CWS/55/2020/ 402 dtd. 07/02/2020 GM/CWS/55/2020/402 dtd. 07/02/2020 GM/CWS/55/19-20/164 dtd. 07/02/2020
8
GM/CWS/55/2019/96 Dtd. 07/07/2019
7
GM/CWS/55/2019/116 Dtd. 24/07/2019
1 1 4 1 6 1 1 1
GM/CWS/55/2019/272 dtd 07/11/2019 GM/CWS/55/2019/365 dtd 29/11/2019 GM/CWS/55/2020/365dtd 11/01/2020 GM/CWS/55/2020/439 dtd 13/03/2019 GM/CWS/55/2020/38.dtd 17/04/2020 GM/CWS/55/2020/360 dtd 07/04/2020 GM/CWS/55/2020/440 dtd.13/03/2020 GM/CWS/55/2019/ 187dtd 26/09/2019
1
GM/CWS/55/2020/363 dtd 09/01/2020
1 1 1 30 157
GM/CWS/55/2019/250 dtd 22/01/2019 GM/CWS/55/2019/303dtd 29/11/2019 GM/CWS/55/2020/440dtd 13/03/2020 GM/CWS/55/2019/ 331 dtd. 17/12/2019
Central Workshop Jayant Annual Performance Report
SURVEY OFF ITEMS DETAILS List of Plant & machineries surveyed off during FY 2019-20 Sl. No.
Model
Quantity
1
Trailer Actross 3348
1
2 3 4 5 6 7
Mini truck Mini truck School Bus (MP 17 A 4608) Truck MP53H0147 Truck MP53H0146 630T Hydraulic Press Universal M P Armature Machine DC testing Panel Total
1 1 1 1 1 1
8 9
NCL/SGR/Excv/36/19-20/H-551 Dt:29/02/2020 NCL/SGR/E&M/2020/603 dt:30/01/2020 NCL/SGR/E&M/2020/602 dt:30/01/2021 NCL/SGR/E&M/2020/599 dt:30/01/2022 NCL/SGR/E&M/2019/387 dt:31/10/2019 NCL/SGR/E&M/2019/448 dt:27/11/2019 NCL/CWS/S-Off/20/06 dt: 02/04/2020 NCL/SGR /Excv/36/19-20/D-434 dt: 02/09/2019 NCL/CWS/S-Off/20/07 dt: 02/04/2020
1 1 9
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Order No.
Central Workshop Jayant Annual Performance Report
CONDITION MONITORING CENTER Annual Performance Report of CMC for FY 2019-20
Oil Analysis
Bearing Inspection (As per demand of project)
Electronic Card & Subassemblies Repair
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19
5492 6262 5992 5634 5777 5740 5705 5184 4695 3864
156 125 90 29 10 11 3 17 56 28
44 141 213 243 257 294 346 482 404 366
25 27 28 29 29 30 31 32 34 34
10 37 19 6 17 47 48 69 83 131
Achieved
4623
22
361
35
97
Annual Target
4300
Need based
360
34
60
% Achievement
107.5
--
100.3
102.9
161.7
CBM Inspection of Draglines
Year 2019-20
Need based services in shovels & Draglines
Achievement of CMC from year 2009-2010 to 2019-20
CBM team of CMC has completed its planned CBM target for the year. In addition to that, it has also met the demand of ‘need based services in Shovels & Draglines’ of different projects completely, which has been 161.7% of its annual target. Bearing inspection has been done as per demand of the projects. All the received bearings were inspected for proper dimensional accuracy. Oil analysis lab has provided help in monitoring health of different HEMMs by analyzing oil samples collected from sub-assemblies. With the help of Spectrometer, the lab has been able to successfully surpass its target with better analysis of oil samples. Electronics Lab has been able to fulfill demand of different projects within time. 42 | P a g e
Central Workshop Jayant Annual Performance Report Planned CBM Activities of CMC done in FY 2019-20
Sl. No.
1
2
3
4
5
6
Project
Amlori
Name of Dragline
Model
Akshay
24/96
Abhimanyu
24/88
Ajay
24/88
Ram
10/70
Shyam
10/70
Gaurav
24/96
Saurav
24/96
Pawan
24/96
Jwala
24/96
Vindhya Vijay
24/96 15/90
Yamuna
24/96
Saraswati
24/96
Ganga
24/96
Somnath
33/72
Baidyanath
20/90
Bajrang
20/90
Krishna
24/96
Balram
24/96
Matang
20/90
Bina
Dudhichua
Jayant
Khadia
Nigahi
Total CBM inspections done
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Inspection Sl. No. 525 541 526 547 527 523 551 518 550 524 539 521 540 528 543 531 542 535 533 522 538 529 544 536 530 545 534 520 548 519 537 532 546 517 549
Date of start of CBM inspection 01.07.19 17.12.19 12.07.19 23.02.20 16.07.19 12.06.19 15.03.20 11.04.19 13.03.20 02.06.19 03.12.19 10.05.19 05.12.19 25.07.19 20.01.20 11.09.19 03.01.20 04.11.19 28.10.19 26.05.19 25.11.19 21.08.19 23.01.20 08.11.19 01.09.19 30.01.20 31.10.19 03.05.19 29.02.20 18.04.19 11.11.19 21.09.19 11.02.20 08.04.19 05.03.20
35 Nos.
Central Workshop Jayant Annual Performance Report Some important fault detection and preventive actions suggested by CBM Team, which helped in reducing the breakdown of HEMMs in the year 2019-20
Sl. No.
1.
2.
3.
4.
Date of Inspection
03.12.2019
27.12.2019
02.02.2020
06.01.2020 & 07.01.2020
Machine
Gaurav Dragline (24/96)
Akshay Dragline (24/96)
Somnath Dragline (33/72)
Ganga Dragline (24/96)
Project
Bina
Amlohri
Khadia
Jayant
Problem or observations of CMC team
Action taken by CBM team
Major crack detected in AFrame RHS rear leg, during our CBM inspection. Insp. (Sl.No. 539, Dt.03.12.19.)
Brought to the notice of Dragline I/C and got it rectified with utmost priority.
Compensating winding of Drag motor -0 is very High (145° C) during our CBM check. (Insp. Sl.No.541 , Dt.27.12.19)
Recommended to immediately replace the slip joint sets, after which the temperature has come down under control.
1. RHS boom foot pin crack & also DGB housing cracks were observed in our CBM (Insp Sl.No.545, Dt.02.02.20 )
Our timely advice to the projects has avoided the major failure & also downtime.
2. Poor commutator surface Conveyed the seriousness of condition of Hoist Motor-01 motor condition & got it was observed which might rectified by sending for CWS. caught fire due to sparking. High Vibrations in MG set -02 Provided continuous by repeated (Ref: CMC/CWS/DL/2020/08 assistance checking of vibration Dt. 07.02.20) readings enabling the localized point of fault detection during alignment.
Also in many cases, on request from projects, CBM team has measured the temperatures & vibrations of MG set bearings, Drag & hoist Gearbox bearings , Current & Voltage signatures in Load and No-Load of various sub-assemblies HEMM, thus helping in root cause detection.
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Central Workshop Jayant Annual Performance Report Some important Electrical fault detection and breakdowns attended by CMC Team in the year 2019-20
Sl.N o.
Date of Inspection
Machine
Project
1.
09.10.2019 To 22.10.2019
Saraswati Dragline (24/96)
Jayant
2.
03.01.2020
Saurav Dragline (24/96)
Bina
3.
03.09.2019
Krishna Dragline (24/96)
4.
09.11.2019 To 10.11.2019
Ganga Dragline (24/96)
5.
28.02.2020
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Old CHP
Nigahi
Nature of failure
The root cause was identified by CMC team. “High voltage was being generated due to voltage drop in a Card Holder and associated circuit in the Hoist panel”. Failure of transfer of Problem traced in Drag-Walk operation from Drag to Transfer Contactor Latch Walk and vice versa. (DWTR). DWTR was repaired as per direction of CMC. Rate of DWTR is approx. Rs. 1 Crore and not easily available. Hoist Gen. & Hoist Motors – 02 nos. each failed and had to be replaced due to heavy sparking.
Heavy Vibration in DM-2 Drag Gen. armature lead was base and Drag Motor touching the main pole and very pinion-2. low voltage was observed in one of the Drag Gen. causing unbalance in voltage and hence high vibration. VCB problem
VCB was opened and coil spacing adjustment was done to rectify the fault.
Apron Feeder-2 was under breakdown for 02 months due to Electrical Fault in DC Drive. The feeder was not able to run the belt in loaded condition.
The output of DC drive used to dip in the loaded condition. Fault traced in rectifier panel of the DC drive and necessary tuning of the circuit was done to get the required output voltage level. Received “Letter of Appreciation” from Area General Manager, Nigahi for this effort.
Jayant
Nigahi
Corrective Action taken/ root cause findings by CMC team
Central Workshop Jayant Annual Performance Report ACHIEVEMENT OF ELECTRONICS LAB, CMC/CWS DURING THE YEAR 2019-20 Yearwise Electronic/ Electrical Control Cards and Sub- Assly Repairing Status of CMC,CWS Jayant
no. of assly successfully delivered
600 500
482 404
400 346 300
366
361
294 213
200
243
254
134
100 44 0 09-10
10-11
11-12
12-13
13-14
14-15
15-16
16-17
17-18
18-19
19-20
Year
361 nos. successfully repaired electronic control cards and sub-assemblies of different type of HEMMs, CHP and P&M has been delivered in the year 2019-20. There has been significant saving in terms of money and cutting down breakdown time by the repairing of control cards at CMC against the replacement cost of 361 nos. of new control cards/sub-assemblies during FY 2019-20. Equipment wise control cards delivered after successful repairing: Sl. No. 1 2 3 4 5 6 7 8
Equipment 24/96 Dragline BE / Marion 182M Shovel 120T Dumpers + 170T Dumpers 100T + 85T Dumpers BD355 Dozer Grader+ Drill Other P&M Grid Resistors TOTAL
No. of cards delivered 15 85 94 04 50 02 18 93 361
02 nos. SCR Package (Part No.- IC3605D080FP360/FGBY) of 24/96 Draglines of Dudhichua Project were repaired. The unit cost of a new SCR Package is approx. Rs. 53 Lacs. 46 | P a g e
Central Workshop Jayant Annual Performance Report Control cards of Marion 182 M Shovels, DC2000 and DOM II system of 24/96 Draglines and 170T dumper have become obsolete and are not being supplied by OEM anymore. These equipments are running by repaired control cards from CMC only. CMC lab has also successfully repaired 09 nos. LDCC Cards of DC2000 Drive and 10 nos. Analog I/O Cards – 17FB140 of 120T Dumpers. These cards are not easily available and are not being repaired anywhere else. CMC has been repairing Grid Resistors of 120Te Dumper for last few years and has delivered 93 nos. of repaired grid resistors to different projects of NCL in the year 2019-20. In the year 2018-19, CMC Lab has started repairing of Joysticks of BD355 Dozers as well. Different projects were facing crisis of this Joystick and CMC lab successfully repaired and delivered 50 nos. of Joysticks in the year 2019-20 to mitigate their problem. CMC lab has provided assistance to the other subsidiaries of CIL by repairing control cards of Marion 182M shovel and 120T Dumper.
Details of Electronic Control Cards repaired for other subsidiaries of CIL in the year 2019-20:
S.N. Subsidiary Area/Project
1
CCL
KDH
Eqpt.
Name of Card DCFB Card Marion 182M SBCA Card LTB Card Shovel 3TB Card Joystick 85T/100T Unified Electronic Dumper Control
Qty. 4 1 1 2 1 3 Total
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12
Central Workshop Jayant Annual Performance Report
Oil analysis through Spectrometer
Spectrometer : It is used for finding the HEMM machine health by testing the used oil for wear debris content, contamination, physical properties of the oil like viscosity, particle count with accurate results. We have tested 3113 nos. of used oils of different sub-assemblies of HEMM using this spectrometer since its commissioning in Nov. 2018. This spectrometer is extensively being used for : Oil testing during periodic maintenances of HEMM in 250Hrs, 500Hrs. for assessing sub-assemblies health Breakdown analysis of Engine block burst, suspicion of viscosity reduction due to fuel dilution or coolant leakage. Few case studies based on Oil Analysis Report: Case 1: Khadia Dumper (D-0897) CAT 777E Dumper of Khadia Project had toppled during OB dumping on 05/01/2020. The OEM service engineer checked and suggested for checking the engine after dismantling. The machine was inspected by CMC on 07/01/2020 physically and the engine was found rotating manually. Thereafter, Engine oil sample was collected for testing. Oil test report showed no abnormality (Sample Id - 11607). CMC suggested running the engine under strict supervision after cleaning and regular maintenance. The dumper is still running with the same engine. 48 | P a g e
Central Workshop Jayant Annual Performance Report Case 2: Dudhichua Dozer An engine oil sample of Caterpillar D11T (CAT-09) dozer was received for testing on 27/02/2020. Test report was of severe category (Sample Id - 12012). Iron and Silicon level was severely high. We suggested check for dirt filter blockage, power loss, blow-by, smoking as well as air induction system. After taking corrective actions by the project another sample (Id - 12024) was received after 56 hours of running and the report was showing no abnormality and the engine is still in running condition. Case 3: Kakri Dumper The engine oil of Dumper CN-12 was tested and found wear metals viz. iron, silicon in initial oil sample (Sample ID :11933) . Later after carrying out suggestions of CMC oil report a sample was again tested and all properties were found OK. (Sample ID: 12031) Some of the actions taken by Jayant Dumper section as suggested by the Spectrometer oil reports:
S.N.
Dumper No.
Comp.
Sample ID
Sample Date
LOH (Hrs)
Age of Oil (Hrs)
1
553
Engine
9975
10/28/2019 22728
260
2
2330
Engine
9976
10/25/2019
1733
287
3
550
Engine
10104
11/12/2019
2309
260
4
2329
Engine
10120
11/16/2019
3794
101
CMC comment
Action taken by Jayant Project
Abnormal iron & Engine replacement aluminium content 1. Engine tappet setting done after white smoke Abnormal iron, Al appearance. 2. Wear rates found normal & Si content in sample ID 10107 taken on 14/11/2019. 1. Four injectors replaced Abnormal Fe, Al & after investigation for cause Si content possibly of diesel dilution. due to viscosity 2. Engine oil & lube oil filters drop caused by replaced. Machine under diesel dilution observation. 1. Engine oil & lube oil filters replaced. Air intake system checked. Abnormal Cr, Al & thoroughly Si content 2. Wear rates found normal in sample ID 10169 taken on 26/11/2019.
Thus the Oil Analysis Lab is continuously helping the projects in detection of faults and assessment of sub-assemblies health before actual breakdown, thus saving down time & money.
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Central Workshop Jayant Annual Performance Report
INVENTORY STATUS
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Central Workshop Jayant Annual Performance Report Reduction in inventory by 15.07% over last Financial Year.
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Central Workshop Jayant Annual Performance Report
As on 01.04.2020:Non-Moving Spares Consumables Total Non-Moving Spares Consumables Total
5yrs 306.61 7.38 314.00 3yrs 431.81 13.37 445.18
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Central Workshop Jayant Annual Performance Report
TAKSHILA BHAWAN An endeavor towards engineering & human excellence………. In the esteemed motivation of our CMD sir Shri Prabhat Kr. Sinha who has always vouched for putting efforts to enhance the skills & Knowledge of our employees for the all-round development of company, Our team CWS has kick started this training center with new enthusiasm & focus to generate co-ordination between the repair activities /maintenance practices of CWS & projects, this will definitely help in building a team of excavation department across the length & breadth of NCL. Our courses are focused on specific machines & all the executives as well as the nonexecutives concerned with that machines are invited & also the OEM’s are invited for brain storming classroom sessions & thereafter practical demonstration & learning sessions are held in respective shop floors in the workshop.
Our first training session for Dumpers was graced by respective Director technical (Operations) Shri Gunadhar Pandey & GM(Excv.)HOD Shri S.C Vats, the initiative was lauded by the dignitaries for becoming the long awaited link between CWS & projects.
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Central Workshop Jayant Annual Performance Report
First inaugural technical lecture was given by the Director Technical sir himself & he also wished for a successful & vital role to be played by the Takshila Bhavan in times to come. Up till now we have trained: All 10 Projects representatives (Employees) on Engine repair & maintenance practices. All 10 Projects representatives (Employees) on Transmission repair & maintenance practices. 130 ITI apprentices of various trades trained for basic practices. 50 Employees trained on Knowledge about certified standing orders of coal india. It is our firm resolve to make this training center as useful as possible for our company & employees as well, thus training programs for physical & monetary health development for employees of CWS will also be taken up after the covid-19 crisis.
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Central Workshop Jayant Annual Performance Report
CSR ACTIVITIES
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Central Workshop Jayant Annual Performance Report
Thank You
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