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PROJECT EQUIPMENT PLANNING FOR RAILWAY EMBANKMENT

SUBMITTED BY:

Nishant Kamal (251074)

**Siddhartha Kamat (251075)
**

Gourav Kapoor (251076)

**Vaibhav Kapoor (251077)
**

Narendra Kashikar (251078)

1. Problem Data

Problem Question: A railway embankment of 15KM long and 1.5m height is to be constructed in two working seasons of 225 days each. The top width is 25 m and side slopes (H:V) is 2:1. The material for the embankment is ordinary earth available along the environment along the embankment with an average lead of 2km and moisture content of 8%. The fill is to be compacted at OMC (16% by weight) to 95% of MDD. Water is available at an average distance of 3Km. Assume suitable L section.

25 m

2:1

1.5 m

31 m

Figure: Assumed Section

2. Quantity Calculation

Bottom Width Given that Top Width is 25m and the side slope is 2:1 and the depth of the embankment is 1.5m. Therefore, the increase in the width of the embankment at the bottom is = 2(2 * 1.5m) = 6m Therefore the bottom width of the embankment = 25 + 6 = 31m

Area of the Cross section Area = (Top Width + Bottom Width)/2 * Height = (25 + 31)/2 * 1.5 = 42 Sqm.

Quantity of soil required for embankment of 15km Quantity = Length of road(in meters) * Area of cross section(in Sqm) = [15 * 1000 ] * 42 = 6,30,000 Cum.

Amount of Work to be Completed per day/hour Total project should be completed in two work seasons of 225 days each. Assuming that the 2 construction seasons of 225 days each do not include the mobilization period Therefore, available days for construction = 225*2=450 Days Assuming that the suitable length section for the construction of embankment is 1km, then the time available for construction of 1km of embankment is = 450/15 = 30 days. Quantity of work in term of Cum/day to be completed to ensure successful and timely completion in 450 days= 6,30,000/450=1400 Cum/Day As we calculated, 1Km of embankment must be completed in 30 days therefore the working shifts have been planned as 1 session of 12 Hrs. per day and assuming the 2 Hours of Non-Working Time, hence The Total Productive Time is 10 Hrs./Day .

3. Project Planning

Using the above data, A Microsoft Project (MSP) file was created in order to schedule the project. The project length of 15km was divided into packages of 1km each and resources including labor and equipment were assigned to each of these packages to estimate the total cost of the project. The Total Cost for the construction of the embankment including labour and equipment is 12.78 Crore.

The Labor Assumed for each package: 1 Project Manager, 2 Site Engineers, 8 Drivers, 15 Machine Operators, 2 Surveyors, 5 Supervisors, 8-10 Skilled Labor and 12-20 Unskilled Labor. The Equipment needed for each Package: Excavator, Dumper, Push Dozer, Motor Grader, Water Sprinkler and Compacting Roller.

**4. Equipment Planning-Productivity and Requirement
**

Equipment Name: LIUGONG 205C Hydraulic Excavator

S. No. Description 1 Output= QxEfficiencyx3600/C Bucket Capacity(Q) Heaped Capacity Bucket Factor Swell Factor Efficiency Cycle Time Productivity of Excavator Work to be completed in a day No. of Excavators Output Calculation for Excavator Quantity Units 82.3296 Cum/Hr 1.7152 Cum 2.68 Cum 0.8 0.8 0.8 60 Sec Remarks

Q=Heaped Capapcity*Bucket Factor*Swell Factor Rated Capapcity

Assumed Assumed

82.33 Cum/Hr 823.3 Cum/Day Assuming 10 Hrs working in a Day 1400 Cum 1.7004737 No. Say 2 Excavators needed.

**Equipment Name: TATA LPK 2516
**

S. No. Description 2 Rated Capacity Actual Capacity(80%) Density of Embankment Material Cycle Time(C) Lead Loading Time Travelling With Load Travelling W/o Load Spotting, Waiting and Turning Total Cycle Time No.of Cycles per Hour Output of Dumper Actual Dumper Capacity Output of Dumper Number of Dumpers/Excavators Output of 22T Dumper Quantity Units 22000 Kg 17600 Kg 1600 Kg/Cum Remarks

2 Km 8 min 6 min 4.8 min 5 min 24 min 2.52 No.

Assuming Travel speed=20kmph Assuming Travel speed=25kmph

11 Cum 23.562 Cum 3.49 4 No.

Assuming 85% Efficiency Productivty of Excavtor/Productivity of Dumper

**Equipment Name: BEML BD155 (324 HP)
**

Output of Push Dozer-BEML BD155(324HP) Quantity Units Remarks 160 Cum/Hr (loose volume handled /trip)* S*(60/t)*(efficiency)

S. No.

Description 3 Output of Push Dozer

Swell factor(S) Cycle time/trip in minutes(t) Loose valume handled / trip Blade width Blade height Blade factor Cycle time(t) D= haul distance F = forward speed R = reverse speed G = gear shift time in min No. of Dozer Per Day

0.8 2.5 min 10.44 Cum 4.13 m 1.59 m 1 2.5 min 100 m 4.25 kmph 8 kmph 0.2 min 1 No. t=(D/F)+(D/R)+G

**Equipment Name: Champion’s Motor Grader-120HP
**

Output of Motor Grader-Champion Motor Grader-120HP S. No. Description Quantity Units Remarks 4 Output of Motor Grader 194.666667 sqm/min Area graded per cycle/Cycle Time*(Efficiency=0.8) Cycle Time=Df/Vf + Dr/Vr Df Dr Vf Vr 1.5 mins 100 m 100 m 8 kmph 10 kmph Assumed back and forth method

Forward Speed Reverse Speed

Area graded per cycle Blade width Thickness graded in 1 cycle Area to be Graded in 1 Day No.of Passes Output per Pass

365 m2 3.65 m 150 mm 9333 sqm 6 1946 sqm/hr

Blade Width*Length covered in 1 pass

Work Per Day=1400Cum/0.15

No. of Grader per day

0.47 OR 1

9333/(1946*T), Where T=10 Hrs

**Equipment Name: Sheep Foot Roller-(Volvo SD200F)
**

S. No. Description 5 Output of Roller Output of Sheep Foot Roller-Volvo D77F Quantity Units Remarks 3360 sqm/hr Output=C*W*S*1000/P

W-Width of Drum S-Avg. Compacting Speed P-No. of Passes C-Efficiency Factor No. of Rollers needed per Day

2.1 m 8 Kmph 4 No. 0.8 1.11 Or 2

**Equipment Name: BEML Water Sprinkler-6000 Ltr. Capacity
**

Output of Water Tanker-6000 Ltr Quantity Units 29440 Ltrs/Hr (W*P*(A-O/100) 368000 Kg 160 Cum/hr 1.6 g/cm3 8% 16 % 6 Cum 2800 Lpm 2400 Lpm 3.79 No. 13.5 min 3 km 20 kmph 40 kmph 1.07 min 1.25 min 20.48 Cum/Hr No.of Trip/Hr*Rated Capacity*Efficiency Efficiency=90% 29440/20480=1.44 Nos. 60/Cycle Time Travelling+Filling+Emptying W P A O

S. No.

Description 6 Water to be Added Weight of Loose soil to be compacted Output of Dozer Density of Soil Available MC Optimum MC Rated Capacity of Tanker Filling Pump Capacity Emptying Pump Capacity No.of Trips/Hr Cycle Time Df,Db Vf Vb Filling Time Using 2 Pumps Emptying Time using 2 Pumps Output of Tanker

Remarks

No. of Tankers/Day

2 No.

Complete Equipment Planning: For the given project, all the equipment requirements are calculated. These details are as follow. ACTIVITY Earthwork excavation Transportation of Earth Dozing the Large Volumes of Earth Grading of earth over layers Compaction Water Sprinkling EQUIPMENT LIUGONG 205C Hydraulic Excavator TATA LPK 2516 Dumpers BEML BD155-324HP Champions Motor Grader-120HP Volvo SD200F BEML Water Sprinkler-6000 Ltr. Capacity NO. OF EQUIPMENTS 2 4 1 1 2 2

5. Vibratory Sheep Foot Roller-Evaluation and Selection

Figure: A Sheep’s Foot/Pad Foot Roller(Model: Changlin YZK 12HD)

Technical Parameters under evaluation 1. Operating Weight: Operating weight is selected as an important selection parameter. More the weight more is the efficiency. Hence the weightage given to this parameter is 20 out of 100. 2. Drum Details: This is the most important selection parameter because efficiency is entirely dependent on the various drum features listed below and accordingly are given weightage out of net weightage of 20. Drum width (mm) Diameter (mm) Drum thickness 8 7 5

3. Vibratory System: Combination of amplitude and frequency gives superior compaction and also reducing the no of passes, thereby improving the output. Hence this is also an important parameter and hence given the weight-age of 20 out of 100. Following sub-parameters are considered and given weightage out of 20Frequency (Hz) Nominal Amplitude (mm) Centrifugal force (KN) 4. Gross Power: The power required is the power needed to propel the machine & this power requirement is established by the output of the engine in terms of HP. The chart provided by manufacturer enables the equipment planner to analyse a machine’s ability to perform under given set of job and load conditions. Hence it comes under a technical selection parameter list. The weightage given to this parameter is 10 out of 100. 5. Speed: Speed consideration is of working speed in this condition. This speed, if is more, will give higher output in less time. Also for moving of equipment for longer distances the speed will play an important part. Hence this parameter is given weight-age of 20 out of 100. 6. Re-filling capacity: For longer work schedules and minimal operational delays better re-filling capacity is always advised. In re-filling capacity three major fuel capacities are considered Fuel tank capacity Hydraulic Oil Water tank capacity 6 4 10

The weightage given to this parameter is 10 out of 100.

The Technical Specifications for the given equipment from 4 different manufacturers are obtained and the details are tabulated as follows:

Sr. No.

PARAMETERS

CATERPILLAR

L&T

VOLVO

CHANGLIN

Model Name

CS533E

1107 PD

SD160F

SD200F

YZX12HD

1 2

Operating weight in Kg Drum details Drum width (mm) Diameter (mm) No. of pads Pad height (mm) Pad foot area (Sq. Cm)

11760

12300

16391

20536

13200

2134 1534 140 127 89.4

2150 1500 144 NA NA

2134 1600 120 127 125

2134 1651 136 127 125

2100 1702 135 80 126

3

Vibratory system Frequency (Hz) Nominal Amplitude (mm) Centrifugal force (KN) 31/34 1.8/.85 33 0.8 20.8-33.8 2.21/1.68 20.8-28.3 1.99/1.51 31/35 1.45/.7

234/133 130

114 112

339/257 160

359/273 200

274/171 110

4 5

Gross Power(HP) Speed(Km/hr) Maximum speed Minimum Speed

12 8

12 6

11.8 4.8

11.9 4.1

10.6 4.8

6

Refueling Capacity in Liters Fuel capacity Engine oil capacity Hydraulic oil capacity 200 NA 60 235 14 70 267.1 NA NA 267.1 NA NA 250 15 140

Output of Compactors: 1. Surface capacity: Output of the Compactor: Q = ( C * W * S * 1000) / P Where, Q = Output in sq.m/hr W = Drum width in meters S = Avg compaction speed in Km/hr P = Number of passes C = Efficient factor = 0.6 for fair, 0.7 for good, 0.8 for excellent conditions

2. Volumetric Capacity Output of the compactor Q = ( C * W * S * t * 1000) / P Where, t = Thickness of soil layer

Output Calculation: Assume that the considered equipment is used for compaction of a single layer of 300mm thick. Then the output of considered equipment will be as follows. CATERPILLAR Sr. No. 1 2 3 4 5 Parameters CS533E C W S T P Output Cum/hr. 0.8 2.134 8 0.15 4 512.16 L&T 1107 PD 0.8 2.150 8 0.15 4 516 VOLVO SD160F 0.8 2.134 8 0.15 4 512.16 SD200 F 0.8 2.134 8 0.15 4 512.16 CHANGLIN YZX12HD 0.8 2.100 8 0.15 4 504

Based on the output calculation of the 5 models, we can see that there does not exist much of a difference in the output values. As per this calculation though the L&T 1107PD shows best results but may not be the best alternative. Therefore a further evaluation is done based on technical specifications of the 5 models of Sheep’s foot roller.

Evaluation based on Technical Parameters Sr. No. Parameters MAX points out of 100 CATERPILLAR CS533E L&T 1107 PD VOLVO CHANGLIN SD160F SD200F YZX12HD

1 2

3

4 5 6

Operating weights Kg Drum details Drum width (mm) Diameter (mm) No.of Pads Pad Height Pad Foot Area Vibratory system Frequency (Hz) Nominal Amplitude (mm) Centrifugal force (N/cm) Gross Power (Hp) Speed (Km/hr) Refuelling Capacity L

20 25 6 6 6 3 4 20 6 4 10 10 20 5

57.26

MAX points out of 100 59.89 79.81 100

64.27

99.25 90.12 97.22 100 70.95 97.14 81.44 65.18 65 100 74.87

100 88.13 100 NA NA 94.28 36.19 31.75 56 100 87.98

99.25 94 83.33 100 99.2 96.57 100 94.42 80 100 100

99.25 97 94.44 100 99.2 80.85 90 100 100 100 100

97.67 100 93.75 62.99 100 100 65.61 76.32 55 100 93.6

Sr. No.

Parameters

MAX points out of 100

CATERPILLAR CS533E

1 2

3

4 5 6

Operating weights Kg Drum details Drum width (mm) Diameter (mm) No. of Pads Pad Height Pad Foot Area Vibratory system Frequency (Hz) Nominal Amplitude (mm) Centrifugal force (N/cm) Gross Power (Hp) Speed (Km/hr) Refuelling Capacity L Total Score Out of 100

20 25 6 6 6 3 4 20 6 4 10 10 20 5 100

11.45

L&T VOLVO CHANGLIN 1107 SD160F SD200F YZX12HD PD MAX points out of 100 11.98 15.96 20.00 12.85

5.96 5.41 5.83 3.00 2.84 5.83 3.26 6.52 6.50 20.00 3.74 80.3329

6.00 5.29 6.00 NA NA 5.66 1.45 3.18 5.60 20.00 4.40 69.5442

5.96 5.64 5.00 3.00 3.97 5.79 4.00 9.44 8.00 20.00 5.00 91.761

5.96 5.82 5.67 3.00 3.97 4.85 3.60 10.00 10.00 20.00 5.00 97.8604

5.86 6.00 5.63 1.89 4.00 6.00 2.62 7.63 5.50 20.00 4.68 82.6653

Therefore from the above evaluation we can deduce that the VOLVO SD200F is the most suitable option in terms of technical parameters and also has an output close to the L&T 1107PD.

**6. Owning and Operating Cost
**

The following Calculations for equipment costs have been calculated with reference the HCC EQP Norms, while on Summer Internship Training in the year 2012. The following values represent the costs to the certain degree of accuracy whose values may differ based on local and unforeseen conditions at the site or otherwise. The following calculation is for the Pad Foot Roller.

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