flsmidth-profile
TRANSCRIPT
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MY PROFILE AT
FLSMIDTH
MACHINE DESIGN AND
ENGINEERING
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CLIENTS & CONSULTANTS
WORKED WITH AT FLSMIDTH WORSLEY (Australia)
GROOTEGALUK (South Africa)
ADANI
VSP
VEDANTA
NALCO
UTKAL
IOCL
BMT-WBM (Australia)
MN DASTUR (Calcutta)
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Project Description Client Role Played
Team
Size
Man
Days
BWR 900TPH VSP Design Lead 4 384
BWSR 800TPH VSP Design Lead 4 384
Twin Boom Stacker VSP Design Lead 4 288
Transfer Car VSP Design Lead 2 96
BWSR 2750TPH Adani Preronet Design Lead 4 384
BWSR 2000TPH Adani Mundra Project Lead 10 720
BWR 1200TPH NALCO Project Lead 10 1008
BWSR 1000TPH UTKAL Project Lead 7 600
Stacker 5300TPH Grotegaluk Design Lead 2 144
Stacker 4000TPH Worsley Design Lead 3 480
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MACHINE DESIGN AND
ENGINEERING CAPABILITIES:
STACKER AND RECLAIMER Bucket Wheel Stacker cum Reclaimer
Bucket Wheel Reclaimer
Slewing and Non-Slewing Stacker
Twin Boom Stacker
SHIP UNLOADER Screw Type
COKE OVEN EQUIPMENTS Charging Car
Pusher Car
Quenching Station - Ram
Hot Coke Car
Compacting Box
Mobile Hopper
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Jaw Crusher
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Apron Feeder
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Design Process for Stacker,
Reclaimer and Ship Unloader
Design Basis (ISO, FEM, AS)
Input Design Document (Design
Specification)
Preliminary Calculations
FEA
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BWSR MACHINE
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Input Document
BASIC DATAS
ENVIRONMENT, DUTY & DESIGN PARAMETERS
STANDARDS, RULES & LOADS
LOAD CASES / COMBINATIONS
MATERIAL
MECHANICAL PROPERTIES
ALLOWABLE STRESSES
MATERIAL LOADS
LIVE LOADS ON BOOM CONVEYOR
INCRUSTATION (DIRT ACCUMULATION) ON BOOM
BELT TENSIONS
RESISTANCES DUE TO FRICTION AND TRAVEL
WIND LOAD
DEAD LOADS
LIVE LOADS
LATERAL COLLISION
SEISMIC LOAD
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Standards
ISO 5049 & ISO 5048
FEM Section II
IS 800
BS 2573 part 1 & 2
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CALCULATIONS
Slew Bearing Calculation
Wheel and Rail Calculation
Bucket Wheel / Screw Calculation
Drive Calculation (conveyor, Travel, Bucket Wheel, Slew)
Conveyor Calculation
Pin, Shaft, Bearing Calculation
Wheel Load Calculation
Stability Calculation
Cylinder Calculation
Guy and Boom Calculation
Splice Joint Calculation
Weld Calculation
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FEA Calculation
Structural Analysis
Buckling Analysis
Modal analysis
Fatigue Calculations
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WORSLEY STACKER
Australia
Review Consultant : BMT WBM
Australia
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Tech Spec
Material Handled : Bauxite
Stacking Capacity : 4100 TPH
Reclaiming Capacity: -
Boom Length : 36.5m
Stock pile : 35m
No of Wheels : 26
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LOAD COMBINATION-6: E+V+G+F+D+P+Ws [LUFF DOWN] [DEFLECTION]
Without Shift
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SLEW PLATFORM
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UNDER-CARRIAGE
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SIX WHEEL EQUILIZER 4 WHEEL EQUILIZER
BOGIE
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Tripper Car Structure
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IOCL Stacker
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Bucket Wheel Reclaimer
NALCO
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VSP BWSR
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Tech Spec
Material Handled : Coal
Stacking Capacity : 850 TPH
Reclaiming Capacity: 750 TPH
Boom Length : 32m
Stock pile : 30m x 8m
No of Wheels : 18
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Counter Weight Boom
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BUCKET WHEEL
BOOM
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Pylon
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UNDER CARRIAGE
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ADANI BWSR
DAHEJ
Review consultant : BMT WBM
Australia
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Tech Spec
Material Handled : Coal
Stacking Capacity : 4600 TPH
Reclaiming Capacity: 2750 TPH
Boom Length : 42m
No of Wheels : 32
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ADANI LUFF STRUCTURE AND
UNDER CARRIAGE
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UNDER CARRIAGE
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Wheel on Bridge
Reclaimer Structure
VSP
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Tech Spec
Material Handled : Iron Ore
Stacking Capacity : -
Reclaiming Capacity: 1000 TPH
Rail CRS : 35m
No of Wheels : 16
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Bucket Wheel Reclaimer
VSP
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Tech Spec
Material Handled : Iron Ore
Stacking Capacity : -
Reclaiming Capacity: 1200 TPH
Boom Length : 32m
Stock pile : 30m x 12.6m
No of Wheels : 18+2
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Ship Unloader
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Swept Area
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Ship Unloader
2500 TPH unloading Capacity
Vessel Handled : Cape Size 1,80,000 DWT
Horizontal Arm Length : 35m
Vertical Screw Length : 30m
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Luff Structure
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Slew Platform
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gantry
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Storage Bin
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Data
Material : Bauxite (2.1T/m3)
Largest Dia : 14m
Largest Length : 24m
Volume : 2000m3
Basis : DIN 1055
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Existing Design
Date : 29/9/2007
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Over all stress
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Third Modification
30 thk stiffners (red color)
20 thk (Magenta color) File Ref : storage-bin32
Date : 8/10/2007
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Introduction of 10
mm thk stifner
Increase the thk
to 20mm
Increase the thk
to 30mm
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Over all stress
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Redesign of Kiln Shell To Minimise
Brick Breakage
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20mm Thk Shell without
Flanges and Wrap plates
SHELL-final ang90_without-flange.PART
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With 75mm width and 25thk
flange (3 nos) outside shell
without wrap plate
Cut into 4 parts, cut equally away
from duct
SHELL-final ang90_R4-f-75split 45deg.PART
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3 Flange Plates
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Coupled Field Analysis (Thermal
and Structural Analysis) of Kiln
Shell
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Analysis Problem description
As the model and Loads is symmetric about its Axis, a Axisymmetric Analysis is performed there the Axis is Y axis.
A steady state Heat Transfer is simulated with 1200mm length in temperature of 600 and side walls having a convective heat transfer coefficient of 10W/m2C.
The Shell is of Material 1220.
The properties of the same has been applied to the shell.
A varying material properties wrt temperature has also been applied.
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Case 1
1200mm at 600 deg and 1200mm
with Air convection
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Thermal
Analysis
Stress Distribution
in N/m2
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Deformation in metre
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Case 2
1200mm at 600 deg and 1200mm
with Ideal Insulation on walls
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Conclusion
High stresses are observed in Case 1 at the
middle of the shell.
High Local Stress are observed in Case 2 near
the welding.
Compared to Case 1 the stress region has
moved down.
Hence a reducing insulation can be provided
along the length to arrive at a loW stress zone
some where in between the non heated length.
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LEAN
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LEAN IMPLEMENTATION PLAN
S.N
o Activities
Target
date Status
1 From History of Proposals arriving the spec of std machine
2 Meeting with engineers and finalize the milestones and CH &
CU's
3 Preparation of Manhour & Cycle time for various milestones
4 Analyzing & listing of various standardization activities & area
of Improvement
5
Prepare a schedule for implement the standardization
process and fix up the time & responsibility (also think-off the
optimization and efficiency)
6 Standardization process ( Date & Time will be finalized later)
7 Establishing the project monitoring system and monitor the
health of various projects
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Requirements in Boom Length
40m-45m
44%
36m-39m
13%
30m-35m
31%
56m-60m
6%
51m-55m
3%
25m-29m
3%
Requirements in Rail Centre
6m
3%
7m
31%
8m
25%
8.2m
22%
9m
1%
10m
11%
12m
7%
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Boom Length – 30m - 45m
Material – Coal & Iron Ore
Capacity – 500TPH to 3000TPH
Rail Centers – 7m,8.2m & 10
No. of Buckets – 8, 9 & 10
Bucket Wheel Dia – 7, 8 & 8.8m
Standardized
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MACHINES DEPARTMENT Team : GVKR/SARA Kaizen status: Completed
Objective: Reduction of engineering time (process time) & Cycle time for
Bucket Wheel Stacker & Reclaimer (BWSR) Machines of various clauses.
Initiatives
taken
Man hours
savings
cost savings
(INR) Implementation of
Hyper works to reduce
the Design time for
BWSR Machine
1500 hrs to 750 hrs 600000
Development of
Program for Design of
Bucket wheel Stacker
Reclaimer
700 hrs to 250 hrs 360000
Parametric Surface
model Generation of
complete structure
200 hrs to 90 hrs 88000
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Kaizen status
Parameter Current
status
Target status
Automate creation of Beam Element model
with loads in Hyperworks with optimization
to arrive at section sizes of Luff Structure.
Current BEA
time is 50 Hrs.
To accomplish within
5 Hrs.
Creation of database which provides all the
details regarding the implemented projects.
This includes the section sizes used, the
technical data and the actual weight. Using
which a program for applying loads and cg’s
to be developed
It consumes 27
Hrs.
To accomplish within
2 Hrs.
Program to Automate the assumption of
Loads, CG’s & Wind Area for Design of
BWSR
Time consumed
is 150 Hrs
To accomplish within
10Hrs
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Thank You