MY PROFILE AT

FLSMIDTH

MACHINE DESIGN AND

ENGINEERING

CLIENTS & CONSULTANTS

WORKED WITH AT FLSMIDTH WORSLEY (Australia)

GROOTEGALUK (South Africa)

ADANI

VSP

VEDANTA

NALCO

UTKAL

IOCL

BMT-WBM (Australia)

MN DASTUR (Calcutta)

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

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

Jaw Crusher

Apron Feeder

Design Process for Stacker,

Reclaimer and Ship Unloader

Design Basis (ISO, FEM, AS)

Input Design Document (Design

Specification)

Preliminary Calculations

FEA

BWSR MACHINE

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

Standards

ISO 5049 & ISO 5048

FEM Section II

IS 800

BS 2573 part 1 & 2

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

FEA Calculation

Structural Analysis

Buckling Analysis

Modal analysis

Fatigue Calculations

WORSLEY STACKER

Australia

Review Consultant : BMT WBM

Australia

Tech Spec

Material Handled : Bauxite

Stacking Capacity : 4100 TPH

Reclaiming Capacity: -

Boom Length : 36.5m

Stock pile : 35m

No of Wheels : 26

LOAD COMBINATION-6: E+V+G+F+D+P+Ws [LUFF DOWN] [DEFLECTION]

Without Shift

SLEW PLATFORM

UNDER-CARRIAGE

SIX WHEEL EQUILIZER 4 WHEEL EQUILIZER

BOGIE

Tripper Car Structure

IOCL Stacker

Bucket Wheel Reclaimer

NALCO

VSP BWSR

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

Counter Weight Boom

BUCKET WHEEL

BOOM

Pylon

UNDER CARRIAGE

ADANI BWSR

DAHEJ

Review consultant : BMT WBM

Australia

Tech Spec

Material Handled : Coal

Stacking Capacity : 4600 TPH

Reclaiming Capacity: 2750 TPH

Boom Length : 42m

No of Wheels : 32

ADANI LUFF STRUCTURE AND

UNDER CARRIAGE

UNDER CARRIAGE

Wheel on Bridge

Reclaimer Structure

VSP

Tech Spec

Material Handled : Iron Ore

Stacking Capacity : -

Reclaiming Capacity: 1000 TPH

Rail CRS : 35m

No of Wheels : 16

Bucket Wheel Reclaimer

VSP

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

Ship Unloader

Swept Area

Ship Unloader

2500 TPH unloading Capacity

Vessel Handled : Cape Size 1,80,000 DWT

Horizontal Arm Length : 35m

Vertical Screw Length : 30m

Luff Structure

Slew Platform

gantry

Storage Bin

Data

Material : Bauxite (2.1T/m3)

Largest Dia : 14m

Largest Length : 24m

Volume : 2000m3

Basis : DIN 1055

Existing Design

Date : 29/9/2007

Over all stress

Third Modification

30 thk stiffners (red color)

20 thk (Magenta color) File Ref : storage-bin32

Date : 8/10/2007

Introduction of 10

mm thk stifner

Increase the thk

to 20mm

Increase the thk

to 30mm

Over all stress

Redesign of Kiln Shell To Minimise

Brick Breakage

20mm Thk Shell without

Flanges and Wrap plates

SHELL-final ang90_without-flange.PART

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

3 Flange Plates

Coupled Field Analysis (Thermal

and Structural Analysis) of Kiln

Shell

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.

Case 1

1200mm at 600 deg and 1200mm

with Air convection

Thermal

Analysis

Stress Distribution

in N/m2

Deformation in metre

Case 2

1200mm at 600 deg and 1200mm

with Ideal Insulation on walls

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.

LEAN

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

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%

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

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

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

Thank You