PROJECT WORK

ON
TO STUDY THE PROBLEM IN CC#13,14,15

CONVEYORS AND SUGGEST REMEDIAL MEASURES

By
T.PYDI REDDY
JUNIOUR OFFICER (103278)
CENTRAL MAINTENANCE MECHNICAL

Under the Guidance of

Sri S.SRIDHAR
Sr.MANAGER C.M.M.
What is belt conveyor ?
A mechanical system composed of suitable
• Head,
• Tail &
• Bend pulleys and
• Belt idlers or a slider bed

to handle bulk materials, packages, or

other objects placed directly upon it.
• Bulk Material Handling
• Uninterrupted & continuous material flow
• Automation
• Safety
• Easy to maintain
• Less skill for operating the system
• Long distance transmission irrespective of
Geographical location.
• Eco-friendly
• Most economical
 Pulleys
 Drive mechanism
 Tensioning mechanism
 Conveyor Belt
 Idlers
 Belt & Pulley cleaning system
 Discharge system
 Safety Devices
 Supporting structure
 Drive Pulley
 Snub Pulley
 Drive Snub
 Tail Snub
 Discharge snub
 Tail Pulley
 Take-up Pulley
 Discharge Pulley
 Bend Pulleys
 Pressure Pulley
 Deflection Pulleys
 Motor
 Gear Box
 Couplings
 Braking Device
 Hold Back mechanism
 Internal
 External
 Material transportation by conveyors in VSP
-- 80% of total transportation.
 Total installed length of conveyor belt –
148.56 km.
 Total number of conveyors -- 423.
Installed Conveyors
(Department wise)
Department Installed
length (m)
RMHP 70062
C&CCD 15113
Sinter Plant 26673
Blast Furnace 17364
CRMP 4706
SMS 2466
TPP 4728
Others 9448
 SALIENT FEATURES OF
CONVEYORS IN VSP

Longest conveyor : CK-1 (1260m, in Base-

Mix yard of SP)

Max. width of conveyor : 2000mm

(B1,B2,D1&D2 in BF)

Max. strength of Fabric Belt : 1400/4

Max. capacity Conveyor belts : 1400 tph

Steel cord conveyors : D1 & D2, main

charging
conveyors of blast
furnace
 Total length of belt replaced during the period 2012-
13 was 36359 meter and 38091 meter during 2011-12
 Conveyor belt replacement due to Through Cut was
12857 meter during 2012-13 & 10482 meter during
2011-12.
 Conveyor belt replacement due to Wear Out was
17398 meter during 2012-13 and 24823 meter during
2011-12
 Conveyor belt replacement due to Belt burnt was
1220 meter during 2012-13 and 1578 meter during
2011-12
 Conveyor belt replacement
 Conveyor belt shortening
 Pulley bearing changing
 Pulley lagging
 Pulley replacement
 Idlers replacement
 Mechanical maint. of drive mechanism and other
accessories
 Structural repairs
 Mechanical fasteners
 Vulcanizing
- Cold vulcanizing
- Hot vulcanizing
 Off-Centering of belt
 Belt Snap
 Longitudinal cuts
 Failure of pulleys
 Failure of lagging
 Failure of couplings
 Failure of Hold back
 Failure of internals of gear box
 Winding of belt on pulleys
 Belt elongation
 Belt Slippage
 Client jamming
 Pocket formation
 Ply Separation etc
 Transferring of material from Coal tipplers to
Stockyard. Conveys all materials like Boiler coal
and Coaking coal etc. Any stoppage of conveyors
lead to tippling delay causing huge demurrage
charges
 Joint failures & Through Cuts (Longitudinal,
Width Wise)
 1. Installation of belt scales.
2 Interlocking of belt scale adjustment to the GPL 1&2. 
 3. Narrowing of skirt board & GPL feed point.
4. Installation and deflection plates at GPL point.
5. Installation of high trough angle 30 deg at feed point.
6. Reviewing of counter weight and take up sheave pulley.
7. Better replacing existing sheave pulley with anti frictional
 ball bearing mounted sheave pulley.
8. Increase the diameter of the drive pulley from 500mm to
630 mm
 Idlers Jamming due to poor house keeping
 No lagging to the drums except drive tail pulley.
 TIS (Tramp Iron Separator) not working properly feeding Chute
Skirt board liver not in proper position.
 Zero speed meter sensor is not available after the feeding Chute.
 Counter weight ropes holding pulley jamming
 Take up trolley not in fee movement on rails due to material
pillager.
 Huge jamming drive snap pulley
 More belt pieces are invested for immediate belt running purpose;
it will cause more joint failures.
 Improper inspection of Idlers and Bad Joints.
 Clear the Idlers Jamming and maintain good house keeping
 Proper lagging to the all drums
 Good Maintenance of TIS (Tramp Iron Separator)
 Put Skirt board liners properly to feeding chute
 Arrange zero speed meter sensor
 Clear spillage material on counter weight hold pulleys
 Maintain take-up trolley in free movement
 Frequently maintain of the drive snub pulley.
 At the time of belt repair, Inserted long length pieces to reduce
the no. of joints.
 Periodical inspection of Idlers and Bad joints
 Maintenance of good house keeping to surrounding
area is very neat and clean.
 Reduce conveyor and mechanical Break downs.
 Machine availability is Improve more.
 Utilization of less man power.
 Transport to more material through this CC# 13, 14,
15 conveyors.
 Follow good safety conditions.
 No accidents less break downs.
 Spare parts, cost very less for competitive production
cost..
 Spillage cleaning is the main cost factor in running of these
conveyors. The cost incurred for cleaning of conveyor can be
saved by taking preventive measures such as avoiding spillage,
running belt in centre etc. 
 Savings by avoiding spillage in these conveyors: 
 No. of workers engaged for daily Cleaning: 4 
 Labour component for each worker : Rs 330/- 
 Labour component per day: Rs.330*4 = Rs1320 
 Labour component per year= Rs 1320*365 = Rs 4.81 lakhs
=Rs 4.81 lakhs perannum
 CONCLUSION

 To reduce failures of Belts in the identified streams i.e.,

CC#13,14, 15 ,and this project is taken up mainly to
reduce maintenance cost, labor cost, down time and to
increase availability and reliability of the equipment for
production.
 It is possible with the collective efforts of both CMM
and shop mechanical people. CMM department seek
help from shop people for recommendations action
plan.