By: Allan Reeves

Use and Maintenance of Mobile Coal Handling Equipment

2004 PRB Coal Users Group Conference

Importance of Rolling Stock

Significant investment Reliability of fuel supply Each fuel operation is unique with an optimum mix of mobile equipment Productivity in operation Improper operation and maintenance can introduce a significant fire or safety risk

Our Experience
Transition to all PRB coal on all generating units Addition of new equipment and upgrades to existing equipment
Rolling stock, dust collectors, transfer points, dust suppression, control system, rail sidings

Consuming bituminous coal stockpile and building sub-bituminous coal stockpile, but still receiving bituminous coal. Total coal receipts of 10.4 MM tons.

2003 COAL RECEIPTS 1,200,000

1,000,000

800,000

600,000

Western

Eastern
400,000

200,000

0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Month

PRB coal being laid over remnants of bituminous coal. Note dust suppression during coal movement.

Track dozer dressing up the overlaid PRB coal. Track dozers were used to fill the central drainage ditch.

Three tractor scrapers and one rubber-tire dozer dedicated to stockpile management plan during transition period.

The water wagon is used primarily for dust control

However, on the top of the tank is a water cannon for fighting fires.

Fire extinguishing

Monitoring Mobile Equipment Performance

Individual machines are tracked as well as the entire plant fleet Machine costs are compared within the plant and across plants Mobile equipment availability can be above 95% (excluding routine maintenance)

Total Fleet Cost

1, 200, 000

1, 000, 000

800, 000

600, 000

400, 000

200, 000

0 1996 1997 1998 1999 2000 2001 2002 2003

HOURS
40,000

35,000

30,000

25,000

20,000

Series1

15,000

10,000

5,000

0 1996 1997 1998 1999 2000 2001 2002 2003

Cost Per Hour

45.00 40.00 35.00

30.00

25.00

20.00 15 . 0 0

10 . 0 0

5.00

0.00 19 9 6 19 9 7 19 9 8 19 9 9 2000 2001 2002 2003

SPECIFY BEFORE YOU BUY

Considerations when Specifying Equipment

Identify equipment uses and capabilities

Crawler tractors

Rubber-tired dozer

Wheel loaders
Productive at load and carrying coal over 400 ft. Equip machine with largest bucket available Compacts coal very well Compaction rate if coal is spread in thin layers 65-78 lb/ft Production rate at 400 FT. 750 TPH

Tractor scraper

Considerations when Specifying Equipment

Identify equipment uses and capabilities Write Specs to order the machine exactly how you want it equipped

Options mounted on a tractor-scraper

Air Pre-cleaner

Fire Extinguishers

Dual Headlights

Considerations when Specifying Equipment

Identify equipment uses and capabilities Write Specs to order the machine exactly how you want it equipped Include a solid fire protection system

Fire system manual discharge mounted on rear of tractor-scraper

Extinguisher

Plunger

Plunger and Control Box

Fire system nozzle position on the rear of a tractorscraper

Spray Nozzles

Protect-O-Wire

Protect-O-Wire

Considerations when Specifying Equipment

Identify equipment uses and capabilities Write Specs to order the machine exactly how you want it equipped Include a solid fire protection system For tractor-scrapers, include protective covers if you top load from a chute

Pre-Cleaner

Considerations when Specifying Equipment

Identify equipment uses and capabilities Write Specs to order the machine exactly how you want it equipped Include a solid fire protection system For tractor-scrapers, include protective covers if you top load from a chute Install automatic greasing systems on rubbertired machines

Preventive Maintenance
Follow OEM recommendations and add from your own experience Repair before failure We use OEM lubricants and filters With canopies over the rear engines of tractor scrapers, check engine air filters every half shift

Fire Prevention
Wash down equipment often

Wash the hide-out spots

Fire Prevention
Wash down equipment often Remove unnecessary shields and belly pans

Brake shields have been removed.

Belly pans had been installed here.

Final Considerations
Strategic partnerships Lease or Purchase? Consider operator comfort and convenience

Questions?