Completion of Major Bucketwheel Excavator Revamp for NLC India
TAKRAF Group has announced that its India division has successfully completed all orders for a significant upgrade of Special Mining Equipment (SME) for NLC India Limited (NLCIL).
This accomplishment reinforces the ongoing partnership between TAKRAF India and NLCIL, while also highlighting TAKRAF’s reputation for engineering excellence in supporting one of India’s largest power producers.
NLCIL, established in 1956, is a government-owned public sector company and stands among the country’s leading lignite and power producers. The company operates three open-pit mines at Neyveli, Tamilnadu, with a total installed capacity of 28.5 million tonnes per year.
Refurbishment Project Overview
In July 2024, TAKRAF India was awarded two major refurbishment contracts for 700-litre bucketwheel excavators (BWEs) at NLCIL’s Mine I and Mine IA. These contracts formed part of a broader package comprising four orders to revamp and maintain eight machines. After the recommissioning of the first 700-litre BWE in September 2025, the second unit was brought back into operation on 15 December 2025. BWE 1574 is now fully operational at Mine I, marking the completion of all four orders.
BWE 1574: Service Life and Refurbishment
Originally commissioned in 1989, the refurbished BWE 1574 has accumulated more than 170,000 operating hours over its 36-year service life. To ensure continued safe and efficient operation, NLCIL opted for a comprehensive major refurbishment, as outlined by TAKRAF.
Scope and Execution of the Project
TAKRAF India managed every stage of the project, from engineering through to recommissioning. The scope of work included replacing critical structural and mechanical components, with the entire refurbishment completed within the planned 12-month timeline.
Modernisation and Technological Upgrades
Under the modernisation programme, the bucket-wheel excavator was enhanced with a range of advanced technologies, including:
- Structural stability verification and design reassessment
- Upgraded drive power ratings
- Replacement of obsolete components with state-of-the-art systems
- Implementation of Programmable Logic Controller (PLC)
- Variable Voltage Variable Frequency (VVVF) drives
- Human-Machine Interface (HMI) systems
- Real-time operator interface
- Automatic Fire Detection and Quenching System (AFDQS)
- Wireless systems and cloud-based remote monitoring solutions
All upgrades fully comply with current Design & Manufacturing Safety (DMS) norms. TAKRAF anticipates that these enhancements will extend the operational lifespan of the machine by approximately 15 years.
Commissioning and Acknowledgements
Senior representatives from both NLCIL and TAKRAF India attended the recommissioning of BWE 1574, which was renamed KING CHOZHA BWE 1574 to mark its new operational phase. This achievement highlights TAKRAF India’s robust execution capabilities, bolstered by the technical expertise of TAKRAF Germany, and underscores its commitment to delivering tailored engineering solutions.
Rajagopalan Ramanathan, Managing Director of TAKRAF India, stated, “The successful completion of all four refurbishment projects for NLCIL reflects the trust our client places in our expertise and collaborative strength. We are honoured by this partnership and look forward to continuing our support for NLCIL’s mining operations with high-performance, reliable equipment.”