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Major Mechanical Modifications Done in Raw Material Area-Sp3

The document summarizes mechanical modifications made in the raw material area of SP-3. It describes: 1) A modification to use used shell plates as rubber windows for rod mills to prevent crack development due to impact of rods. 2) Linking the firefighting and process water pipelines to ensure uninterrupted water supply during repairs by installing valves and a fabricated water filter. 3) Replacing a vibrating feeder with a belt feeder to bunker 41 to prevent jamming during monsoon and ensure smooth hammer crusher operation.

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146 views50 pages

Major Mechanical Modifications Done in Raw Material Area-Sp3

The document summarizes mechanical modifications made in the raw material area of SP-3. It describes: 1) A modification to use used shell plates as rubber windows for rod mills to prevent crack development due to impact of rods. 2) Linking the firefighting and process water pipelines to ensure uninterrupted water supply during repairs by installing valves and a fabricated water filter. 3) Replacing a vibrating feeder with a belt feeder to bunker 41 to prevent jamming during monsoon and ensure smooth hammer crusher operation.

Uploaded by

sghane5674
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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MAJOR MECHANICAL MODIFICATIONS

DONE IN RAW MATERIAL AREA-SP3

A PRESENTATION BY:

TEAM MECHANICAL-
RMA(SP-3)
CONTENTS
1. RE-USE:
Rubber window modification – Rod Mill section

2. RE-THINK:
Linking process water and fire fighting pipelines –Lubrication Section

3. RE-ENGINEER:
Belt feeder 41 – Hammer Crusher Section
RE-USE
Rod Mill Window
Modification

ROD MILL SECTION – RAW MATERIAL AREA, SP-3


Rod Mills
Rod Mill: Specifications
Mill Size - 2700 (diameter) x 3800 mm (length)
Crushing capacity - 30 tph (rated) , 36 tph (designed)
Feed size - -10mm
Product size - -3mm
Material to be crushed - Coke
Bulk Density - 0.6 T/M3
Moisture Content - 5 – 12%
Mill Speed - 15.3 rpm
Rod Loading - 34% of the shell volume
Cooling requirement - 160 lph @ 2.5 kg/cm2
Rod Mill Window Modification
The Problem:
Non Availability Of Rubber Window
Shell Plates

Rods
Rod Mill Window Modification
The Rubber Window:
• Fixed inside the shell cavity at the discharge end of the
Rod Mill along the periphery

• Number Of Rubber Windows used : 14nos.

• Function : It cushions the impact action of the rods


against the Shell during operation

• Average Life : 8 to 12 months


Rod Mill Window Modification
Impact On Rod Mill
Crack development and propagation in Rod
Mill Shell
Rod Mill Window Modification

Reasons For Crack Development:

• Thinning of Shell due to wearing out action of Coke on


Shell over a long period of time

• Impact of the rods on the Shell directly due to damaged


rubber windows
Rod Mill Window Modification
Implications :
• Close to 90 hours of maintenance for repairing shell cracks
between May and September 2014

• Close to 540 man hours worth of labour spent on repairs

• 72 packets of welding electrodes used

• Decrease in reliability of equipment


Modified Rubber Window
Raw Material Used:
Raw Material Used:

Used Shell Plates


Rod Mill Window Modification
The Process:
1.Drilling the Shell Plate to accommodate Counter – sunk
holes:
Rod Mill Window Modification
2. Marking dimensions for cutting
Rod Mill Window Modification
2. Marking dimensions for cutting
Rod Mill Window Modification
3.Cutting the liners with the help of knife :
Rod Mill Window Modification
4.The Finished Product
Rod Mill Window Modification
5.Fixing the liner inside the Rod Mill
ROD MILL SHELL

COUNTER-SUNK
BOLTS
MODIFIED
RUBBER
WINDOW

REINFORCING
PLATE
DISCHARGE
WINDOW CAVITY
Rod Mill Window Modification

Rubber Window After fixing


Rod Mill Window Modification

Advantages
• Control over Crack development
• Control over Discharge Window Strip breakage
• Time saving in Maintenance

Shortcomings
• Limited life span
• High manpower consumption
• Limited stock of worn out Shell plates
RE-THINK
Linking fire fighting pipeline
with process water pipeline

LUBRICATION SECTION – raw material area


Linking Pipelines..

Background

• The Hammer Crushers' Oil coolers and Rod Mills’ bearings need
process water for cooling

• This requirement is met by the Process water pumps of


Machine-1
Linking Pipelines..

The Problem
• Repair in Process water pumps/pipeline of Pump house of Machine-
1 results in stoppage of process water to Package-2 and hence
equipment cannot function

• Resulting in shortage of crushed Coke and Flux


Linking Pipelines….

Solution
To link the firefighting pipeline and
process water pipeline at site
Linking Pipelines….
Pipeline Modification At Rod Mills : Overview
Linking Pipelines….
Work done
1. Arresting water leakage in the firefighting pipeline/process
water pipeline

2. Checking /Changing of de-functional Valves in both


Firefighting and Process water pipelines in the route

3. Flushing out the rust/trash etc. of firefighting pipeline

4. Laying of Pipeline in Rod Mill and Hammer Crusher area with


the appropriate fittings
Linking Pipelines….
Pipeline Modification at Hammer Crushers : Overview
Linking Pipelines....
A Problem faced:

• During change-overs, process pipeline frequently got clogged


Linking Pipelines..
In-House Fabricated Water Filter
Linking Pipelines….

In-House Fabricated Water Filter


Linking Pipelines..

Outcome:

• Uninterrupted supply of process water to Rod Mills and


Hammer Crushers

• Repair of process water pipelines can be carried out


without affecting operations
RE-ENGINEER
Bunker -41 belt feeder

HAMMER CRUSHER SECTION –SP-3


Hammer Crushers
Parts of a Hammer Crusher
Point Of Comparison Primary Hammer Crusher Secondary Hammer
Crusher
Equipment name Reversible Hammer Mill
Quantity 3
Capacity Rated - 250 tph , Designed - 300tph
Material to be crushed Limestone
Rotor size 1500*2300 mm
Rotor speed 700 rpm
Product size 15 mm -3 mm (90% )
Drive system Variable Speed Fluid Constant Speed Fluid
Coupling Coupling
Material of construction:

Body as per IS : 2062


Shaft EN 8/C45
Liners Mn Steel , IS : 276 Gr.4 (D)
Hammers GS 42 Cr Mn Mo V 12
Bunker -41 belt feeder
The Problem

Frequent jamming of the vibro-feeder during monsoon


leading to :

• Frequent stoppage of flux crushing

• Wastage of manpower and effort


Bunker -41 belt feeder
The solution
• Replacement of vibro-feeder-41 with belt feeder

• Increasing the slope of vibro-feeder body


Bunker -41 belt feeder

Work done

• The slope of the vibro-feeder body was increased by


providing packing so that the height increased by 36mm.
Bunker -41 belt feeder
Belt feeder 41 :work done

• It was designed to run a 1200mm belt with the capacity


of feeding 400 tons/Hr of flux material

• The belt feeder structure was pre-fabricated near the site

• The existing vibro-feeder was dismantled.


Bunker -41 belt feeder

Belt feeder :work done

• The pre-fabricated belt feeder structure was erected.

• The gear box and motor were fitted with the belt feeder
structure

• Conveyor belt was mounted


Bunker -41 belt feeder

Belt feeder :work done

• The mouth of the bunker-41 and The feed chute of the


Hammer Crusher were modified

• Trials were taken with load


Bunker -41 belt feeder
Before modification
Bunker -41 belt feeder
After modification
Bunker -41 belt feeder

Result
• Jamming problem solved

• The modification has helped in smooth running of


Hammer crusher
Bunker -41 belt feeder

Upcoming Project:

• Erection of Belt Feeder to remove stones seperated from


stone thrower in R-110 belt conveyor
Thank You!!

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