STATE POLYTECHNIC JAKARTA - PT. SOLUSI BANGUN INDONESIA
ANALYSIS CAUSES OF BROKEN BELT IN BELT
CONVEYOR 51B-BC4
CASE STUDY
ILHAM PRAYOGA MUKHTAR
1802315020
MUHAMMAD RAKA MASTADI
1802315026
D3 ENGINEERING STUDY PROGRAM
COOPERATION PROGRAM
JAKARTA STATE POLITECHNICS WITH PT. SOLUSI BANGUN
INDONESIA
MECHANICAL ENGINEERING DEPARTEMENT,
MECHANICAL ENGINEERING STUDY PROGRAM,
CEMENT INDUSTRIAL ENGINEERING CONCENTRATION
NAROGONG - 2020
ANALYSIS CAUSES OF BROKEN BELT IN BELT
CONVEYOR 51B-BC4
This case study is ready to be implemented in the case study exam
written by:
Ilham Prayoga Mukhtar
1802315020
Muhammad Raka Mastadi
1802315026
Lecture Adviser,
Hamdi,S.T.,M.Kom.
NIP 196004041984031002
Adviser,
Slamet Priyo Pranoto
NIK: 62102380
TABLE OF CONTENTS
Thing
TABLE OF CONTENTS ......................................................................................... i
LIST OF PICTURE ............................................................................................... iii
LIST OF TABLES ................................................................................................. iv
CHAPTER 1 ........................................................................................................... 5
INTRODUCTION .......................................................................................................... 5
1.1.
Background ......................................................................................................... 5
1.2.
Formulation of the problem ................................................................................ 6
1.3.
Scope of problem ................................................................................................ 6
1.4.
The purpose of making Case Study .................................................................... 6
1.4.1 Specific Purposes ............................................................................................... 6
1.5 Location .................................................................................................................... 7
CHAPTER II ........................................................................................................... 8
INTRODUCTION OF DEPARTMENT AND LITERATURE REVIEW ..................... 8
2.1
Department Description ...................................................................................... 8
2.2
Organizational structure ...................................................................................... 9
2.3
Job description .................................................................................................... 9
2.4
Conveyor Belt.................................................................................................... 12
2.5
Belt Conveyor Function .................................................................................... 12
2.6
Conveyor Belt Type .......................................................................................... 12
2.7
Belt Conveyor Type .......................................................................................... 16
2.8
Belt Conveyor supporting components ............................................................. 18
2.9
Problems With Belt Conveyor .......................................................................... 19
2.10
Water spray system ........................................................................................... 23
2.11
Classification and Pipe Material ....................................................................... 23
2.12
Joints (Fittings) ................................................................................................. 27
CHAPTER III ....................................................................................................... 29
METHODOLOGY ....................................................................................................... 29
3.1.
Problem Solving Methodology ......................................................................... 29
3.1.1 Identification of problems ................................................................................. 30
3.1.2 Discussion Method............................................................................................ 30
3.1.3 Literature review ............................................................................................... 30
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
3.1.4 Design Method .................................................................................................. 30
3.1.5 Analysis Method ............................................................................................... 31
CHAPTER IV ....................................................................................................... 32
RESULTS AND DISCUSSION ................................................................................... 32
4.1
Consumer needs analysis .................................................................................. 32
4.2
Belt Performance on the 51B-BC4 Belt Conveyor ........................................... 32
4.3
Conditions on 51B-BC4 Conveyor Belt ........................................................... 34
4.3.1 Belt Conditions ................................................................................................. 34
4.3.2 Waterspray Conditions .................................................................................... 36
4.4
Problems that occur........................................................................................... 37
4.5
Root Cause Analysis ......................................................................................... 39
4.6
Root Problem Analysis ..................................................................................... 40
4.7
Solution offered ................................................................................................ 40
CHAPTER V......................................................................................................... 42
CONCLUSIONS AND RECOMMENDATIONS ....................................................... 42
5.1
Conclusion ........................................................................................................ 42
5.2
Recommendations ............................................................................................. 42
BIBLIOGRAPHY ................................................................................................. 43
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
LIST OF PICTURE
Figure 1. 1 Equipment Location.............................................................................. 7
Figure 2. 2 Abrasion Resistant Belt ...................................................................... 16
Figure 2. 3 Flame resistant belt ............................................................................. 16
Figure 2. 4 Heat Resistant Belt ............................................................................. 17
Figure 2. 5 Oil Resistant Belt ................................................................................ 17
Figure 2. 6 Belt Conveyor Supporting Components ............................................. 18
Figure 2. 7 High elevation..................................................................................... 19
Figure 2. 8 Uncentric Loading .............................................................................. 20
Figure 2. 9 Carry Roller ........................................................................................ 20
Figure 2. 10 Impact Roller .................................................................................... 21
Figure 2. 11 Return Roller .................................................................................... 21
Figure 2 12 Connection Mechanical Method Belt ................................................ 22
Figure 2. 13 Belt Splicing Hot Splicing Method .................................................. 22
Figure 2. 14 Broken Cleaning Belt ....................................................................... 22
Figure 2. 15 Belt due to high temperature............................................................. 23
Figure 2. 16 Elbow Joint ....................................................................................... 27
Figure 2. 17 Tee Connection ................................................................................. 27
Figure 2. 18 Reducer Connection.......................................................................... 28
Figure 2. 19 Stamp Connection ............................................................................. 28
Figure 2. 20 Flock Shocket Connection ................................................................ 28
Figure 4. 1 Belt layer ............................................................................................. 33
Figure 4. 2 51B-BC Temperature Trend 4 ............................................................ 33
Figure 4. 3 belt conditions exposed to high temperatures ..................................... 34
Figure 4. 4 Re-joint Belt ....................................................................................... 34
Figure 4. 5 Belt due to Bubble .............................................................................. 35
Figure 4. 6 Condition Bubble in Belt is quite severe ............................................ 36
Figure 4. 7 Condition after change New Belt ....................................................... 36
Figure 4. 8 Waterspray Conditions 51B-BC4 ....................................................... 37
Figure 4. 9 Sensor Display Waterspray................................................................. 37
Figure 4. 10 Temperature Trend Clinker .............................................................. 38
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
LIST OF TABLES
Diagram 1. 1 Organizational Structure of the Production Department ................... 9
Diagram 1. 2 Organizational Structure of Finish Mill Production.......................... 9
Diagram 3. 1 Flow Chart ....................................................................................... 29
Diagram 4. 1 FishBone Diagram .......................................................................... 39
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
CHAPTER 1
INTRODUCTION
1.1.
Background
PT. Solusi Bangun Indonesia is part of the Indonesian cement
company. Semen Indonesia has a commitment to become a leading
company with the best performance in the building materials industry in
Indonesia. Semen Indonesia is stepping up to meet the needs of
development in Indonesia with a production capacity of 15 million tons of
cement per year.
The presence of Semen Bangun Indonesia in Indonesia is marked by
the operation of four factories in Lhoknga - Aceh, Narogong - West Java,
Cilacap - Central Java and Tuban - East Java. Broadly speaking, there are
seven areas in PT.Solusi Bangun Indonesia Narogong Factory, namely:
Quarry, Crusher, Reclaimer, Raw Mill, Kiln, FinishMill and Pack House.
Finish Mill is the last area before Pack House. One of the equipment in this
area is the Belt Conveyor which acts as the Clinker transport material before
going to the final mill, Ball Mill. The ball mill is fed by the Pre-grinder.
But it cannot be denied that every equipment has a case. Just as if
the material in the form of a clinker carried by the Belt Conveyor with
optimal capacity but the temperature of the material exceeds the optimal
temperature, this can damage the Belt Conveyor.
Belt tearing often on the Belt Conveyor can result in fatal events if
not handled immediately or allowed to occur repeatedly will cause a break
that can hamper the production process. This can be avoided by proper belt
maintenance and preventing potential damage to the belt, thereby extending
the belt lifetime to the conveyor belt. So we took the title "Analysis of the
Causes of Belt Damage in Belt Conveyor 51B-BC4".
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
1.2.
Formulation of the problem
Based on the background and objectives that have been explained,
the formulation of the problem that must be resolved is as follows:
a. What is the process of transporting material from Clinker Storage
Narogong 2 ?
b. What are the supporting components of a Belt Conveyor?
c. What are the causes of Belt Conveyor damage?
d. What are the benefits after analyzing?
1.3.
Scope of problem
a. Checking the condition of the Belt can only be done when the Repair
or Operations Stop
1.4.
The purpose of making Case Study
1.4.1 Specific Purposes
a. Determine the cause of Belt damage to the 51B-BC4 Belt Conveyor by
analyzing
b. Cost Saving add Lifetime to the 51B-BC4 Belt Conveyor
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
1.5 Location
Figure 1. 1 Equipment Location
Figure 1.1 Shows the Location of Equipment that is the main
problem, 51B-BC4 is one of the Conveyor Belt that serves to deliver
combustion material in the form of Clinker, through Clinker Storage Silo
(494-3S1). Before heading to Pre-Grinding, the Clinker is distributed
through several Belt Conveyors, such as; 51B-BC1 or 51B-BC2 or 51BBC3 then continue through 51B-BC4.
Of course, the material in the form of Clinker still has a high
temperature of 180-185 ° C. This is the reason why 51B-BC4 often
experiences repairs or changes, in other words, it is not in accordance with
the duration of the replacement or repair.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
CHAPTER II
INTRODUCTION OF DEPARTMENT AND LITERATURE REVIEW
2.1
Department Description
Production is part of the Directorate Manufacturing Organization.
The production department is tasked with keeping the production process
running according to the targets set by management. It is expected that with
the control and supervision carried out well by the production department,
the cement manufacturing process at PT. Solusi Bangun Indonesia Tbk, has
no problems and runs smoothly.
The production department consists of several sub-departments,
including Raw Kiln Mill Production, Finish Mill Production, Production
Support, and Planner Production. Production Patroller has the following
tasks:
a. Inspection Running
- Listening - Seeing - Touching - Smelling
b. Lost Elimination
- Over Production
- Over Processing- Waiting
- transporting
- Inventory
- motion
- Re-work
c. House Keeping
d. Trouble Shooting
e. Unsafe Elimination
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
2.2
Organizational structure
Production Department Organizational Structure
Production
Manager
Support
Administration
Production
Planning SI
Raw Mill &
Kiln NAR 1
Area
Manager
Raw Mill &
Kiln NAR 2
Area
Manager
Finish Mill
NAR 1 Area
Manager
Finish Mill
NAR 2 Area
Manager
Production
SI
Diagram 1. 1 Organizational Structure of the Production Department
b. Organizational Structure of Production of Finish Mill and Pack
House Nar 2
Finish Mill and Pack
House NAR 2
Pack House
NAR 2
Superintendent
Finish MillNAR 2
Superintendent
Group A
Finish Mill NAR 2
Superintendent
Group B
Finish Mill NAR 2
Superintendent
Group C
Finish Mill NAR 2
Superintendent
Group D
Diagram 1. 2 Organizational Structure of Finish Mill Production
2.3
Job description
The production department is responsible for plant operations during the
cement production process. The target is:
1. Production stability
2. Good quality cement
3. Amount of production reached
4. Operate the factory with due regard to safety and the environment.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
The production department is led by a manager who oversees two parts,
namely the Raw Mill and Kiln production areas, and the Finish Mill production.
The tasks of each part of the production:
1. Finish Mill production manager
a. Set and validate target operation parameters
b. Entitled to ask panelists or operators to turn off Finish Mill
c. Coordinate and take corrective actions with relevant departments to solve
problems or disruptions in equipment or processes that can affect product
quality, environment and safety.
2. Superintendent Shift Finish Mill production
a. Oversees the operating system at Narogong NAR 2 Finish Mill and other
supporting facilities
b. Provides recommendations for improving operating conditions to the
panelman or operator when there is a problem with the machine or the
production process
c. Coordinate and take corrective actions with relevant departments to solve
problems or equipment disruptions that affect product quality,
environment and safety.
d. Report to the Finish Mill area manager in an emergency
e. Ensure that security requirements are met during operation at Finish Mill
3. Panelman or Operator of Finish Mill production
a. Control the process at Finish Mill and maintain stability of optimal
operating conditions
b. Record operating parameters and faults
c. Reports to superintendent shifts when problems occur during operations
d. Take corrective action if a problem occurs
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
4. Patroller Finish Mill Production
a. Oversee and maintain the smooth operation process
b. Fill out the checklist and record if a problem occurs
c. Report immediately to the superintendant shift if a problem occurs
d. Has the right to stop equipment in an emergency situation
e. Maintain equipment performance and equipment safety
5. Students on the Job Training at Finish Mill Production
a. Identify potential hazards and work according to SOP
b. Study the flow of material in the Finish Mill process
c. Study the parameters and control variables in Finish Mill
d. Perform troubleshooting when a problem occurs
e. Housekeeping in the work area
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
2.4
Conveyor Belt
Conveyor Beltis a means of transporting materials in large volumes
that generally transport in the horizontal direction. The device consists of a
belt that is resistant to the transport of solid objects. The belt used is made
of various types of materials. For example from rubber, plastic, leather or
metal that depends on the type and material to be transported. For
transporting hot material, the belt used is made of heat-resistant material.
2.5
Belt Conveyor Function
1. As a means to transfer goods or products from one place to the next.
2. As a means for cooling the hot products resulting from the production
process.
3. As a tool to enter materials or product materials into the machine for
the production process.
4. To send material from suppliers to material storage or storage and so
on.
2.6
Conveyor Belt Type
1. Conveyor Belt Cotton
Conveyor Beltcotton is a conveyor belt made from cotton. There
are several types of cotton conveyor belts that have different
thicknesses, some have 2 ply cotton and some have 3 ply depending on
the needs in the production machine.
The characteristics of the use of cotton-based conveyor belts in
industrial plants are as follows:
a. Conveyor Belt Made from cotton is used to supply product
ingredients or dry materials.
b. Conveyor Belt made from cotton resistant to material or product
ingredients that heat below 50 ° C.
c. Conveyor Belt made from cotton can not be a medium for
supplying direct liquid tangible goods.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
d. Conveyor Belt cotton has a non-slippery surface.
e. Conveyor Belt Made from cotton can change color if used to supply
products that are still hot.
f. Conveyor Belt made from cotton is usually used as a line transfer
of goods or light and small workpieces.
Examples of parts or goods that use cotton conveyors in industrial
factories are as follows:
a. Dry objects or items such as yarn, shoes, cloth, etc.
b. Objects or material products such as raw rubber, wooden blocks,
Teflon, etc.
2. Conveyor Belt Rubber.
Conveyor Belt made from rubber has the characteristics of use in
industrial plants as follows:
a. Conveyor Belt made from rubber can be used as a line supply of
hot products.
b. Conveyor Belt made from rubber can be used in the watery work
area.
c. Conveyor Belt made from rubber can also be used to supply goods
or products that are dry.
d. Conveyor Belt made from rubber is used to transfer goods or
objects that are heavy and large.
Examples of goods or product materials that commonly use
rubber-based conveyors are as follows:
a. Product materials are still hot and require cooling of water after
going through a processing process, such as hot rubber, hot plastic,
and others.
b. Product materials that have heavy and large sizes such as rubber
sheets, fabric sheets, pelg unit products, and others.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
3. Conveyor Belt Habasit.
Conveyor BeltHabasit is a Conveyor Belt made of Pvc, Pu and
Plastic. The characteristics of the use of Belt Conveyor Habasit usually
used by industrial plants are as follows:
a. Conveyor Belt habasit can be used as a transfer line for powder
chemical and chemical goods.
b. Conveyor Belt habasite can be used as a line weighing or final
weighing for product results.
c. Conveyor Belt habasite can be used to transfer objects or products
that use a little water as cooling.
d. Conveyor Belt habasit can be used to transfer the type of material
products or goods that are thin and slippery.
e. Conveyor Belt habasite can be used fatherly transferring products
or solid objects which have hot temperatures.
f. Habasit Conveyor Belt can be used to transfer product materials or
goods with the media area that is rising up or down.
g. Conveyor Belt habasite can be used to transfer product materials or
goods with horizontal area media.
Examples of product materials or goods that use a Habasit Belt
Conveyor for the transfer are as follows:
a. Material or product material that comes out of the dozing process
such as rubber material for loading sandals, shoes, tires and others.
b. Material or thin and slippery product materials such as rubber
films, fabric liners, etc.
c. Material or product material made from chemical powder or
chemical.
4. Conveyor Belt Metal.
Conveyor Belt Metal Conveyor Belt is made of a composition of
metal materials such as stainless steel.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Characteristics of use Metal conveyor belts are usually used by
industrial plants in areas such as the following:
a. Conveyor Belt made of metal can be used to transfer material or
material products through chemical cooling water.
b. Conveyor Belt Made from metal can be used to transfer material or
material products through the cooling liquid heat.
c. Conveyor Belt made of metal can be used to transfer product
materials or goods that are still hot.
d. Conveyor Belt made of stainless steel metal can be used to transfer
product materials or goods with a media area that is rising up or
down.
e. Conveyor Belt made of stainless steel metal can be used to transfer
product materials or goods with horizontal area media.
Examples of product materials or manufactured goods that use
stainless steel metal conveyor belts are as follows:
a. Material or product material in the form of rubber sheets which are
still hot to be cooled through chemical water cooling such as
Compd for shoes, sandals, tires and others.
b. Material or product material in the form of solid objects that are
still hot to be cooled through cooling water such as metal parts,
plastic parts, and others.
5. Conveyor Belt Teflon or Modular Rollers.
Conveyor BeltTeflon or modular roller is a Belt Conveyor
made of Teflon material. Teflon-shaped conveyor belts usually have
characteristics for use in industrial plants such as the following:
a. Conveyor Belt Teflon rollers can be used to transfer product
materials or goods that require slippery lines.
b. Conveyor Belt Teflon rollers can be used to transfer product
materials or goods that require transfer by slidding.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
c. Conveyor Belt Teflon rollers can be used in watery areas that
contain chemicals such as chemicals that are used so that the
product material is not sticky.
d. Conveyor Belt Teflon roller can be used as a medium for slidding
for large and heavy product yields.
e. Conveyor Belt Teflon rollers can be used to transfer goods or
product materials with horizontal conveyor lines.
2.7
Belt Conveyor Type
1. Type A (Abrasion Resistant Belt)
Figure 2. 2 Abrasion Resistant Belt
Conveyor Belt This type A has a high energy impact resistance
with a maximum working temperature at 70 oC. Type A conveyor belts
are also resistant tooxygen, ozone, impact and abrasion but not
recommended for oily, acidic and basic media.
2. Type F (Flame Resistant Belt)
Figure 2. 3 Flame resistant belt
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Conveyor Belt This type F has a resistance with a maximum
working temperature at 100 oC. Usually this type of Belt Conveyor is
used in underground mining tunnels.
3. Type T (Heat Resistant Belt)
Figure 2. 4 Heat Resistant Belt
Conveyor Belt This type T has a resistance with a maximum
working temperature at 100 - 400 oC. T type conveyor belts are also
resistant tooxygen, ozone, water and acids. Usually used to transport
materials with high temperatures.
4. Type O (Oil Resistant Belt)
Figure 2. 5 Oil Resistant Belt
Conveyor Belt This T type has a resistance with a maximum
working temperature at 90 oC and resistant to acids, oils and greases.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
2.8
Belt Conveyor supporting components
Chute
feed
Caring
idler
Impact
idler
Tail pulley
Head pulley
Return
idler
Belt
Bend
pulley
Snappulley
Discharge
chute
Gravity
take-up
Figure 2. 6 Belt Conveyor Supporting Components
a. Belt: One of the main elements of the conveyor. Belts are made of
various materials, such as: steel, nylon, cotton, rubber and others.
Belt must meet the requirements, namely the ability to absorb low
water, high strength, lightweight, flexible, small strain, high
resistance to separation of layers and long service life.
b. Head pulley : functions as the initial drive of a Belt Conveyor
system because the pulley is directly connected to the gearbox so
that it is directly connected to the drive
c. Tail pulley : usually as the end point of material transfer
d. Impact roll : roll with rubber on the outside which is usually
installed in the fall of the material so that there is a thrust back
e. Bend Pulley: connecting pulleys or bending belts to take up pulleys
or ballast pulleys. Where Bend Pulley works to adjust the balance
of the belt on the ballast.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
f.
Idler function: Serves to hold or support the Belt on the Carryin
and Return.
g. Take up Pulley function: Maintain and adjust the belt so it is
always tight so that there is no slip in the drive pulley and
compensate for changes in belt length
h. Belt Cleaner : removes the remaining charge from the belt surface
before exiting the last chute.
2.9 Problems With Belt Conveyor
In the Belt Conveyor, a very vulnerable part of the damage lies in
the Belt itself. That is because the Belt receives a direct impact from the
material. Especially if the belt is used to transport raw materials that are still
in the form of chunks and high temperatures. In addition, there are still
several other problems.
a. The angle of tilt is too high
This problem causes the material to be unbalanced so that the
material falls backward
Figure 2. 7 High elevation
b. The loading position is not centric
Can cause material mess after exiting the Hopper can even
damage the Impact Roller.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Figure 2. 8 Uncentric Loading
c. Carry Roller
Problems with the Carry Roller if it is damaged due to wear and even
holes will have an impact on the Belt on the Conveyor Belt. If the Carry
Roller is stuck, the friction if left unchecked can cause the whole Belt to
tear in the Belt Conveyor.
Figure 2. 9 Carry Roller
d. Impact Rollers
Similar to Carry Rollers, if the Impact Roller wears on the rubber
part, if left friction on the belt, can cause a belt tear on the Conveyor Belt
because it is exposed to the sharp inner side of the Impact Roller.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Figure 2. 10 Impact Roller
e. Return Roller
Problems in the Belt Conveyor one of them on the Return Roller.
If the Return Roller is worn and perforated even the Stuck, the Belt
Conveyor can tear.
Figure 2. 11 Return Roller
f. Belt Connections to the Belt Conveyor
Belt splicing is a problem in the conveyor belt. In belt splicing,
there are 2 methods, namely mechanical method (Mechanical Joint) with
one of them using SuperScrew and Endless Splicing Method, there are 2
types, namely Hot Splicing and Cool Splicing. If the splicing of the belt
is not good, it can result in the breaking of the belt connection on the Belt
Conveyor.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Figure 2 12 Connection Mechanical Method Belt
Figure 2. 13 Belt Splicing Hot Splicing Method
g. Broken Cleaning Belt
Damaged Belt cleaning can cause the belt and roller on the Belt
Conveyor to wear out, because the belt is not clean when protesting.
This causes a buildup of material under the Belt Conveyor
Figure 2. 14 Broken Cleaning Belt
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
h. Material that is too hot
Temperatures that are too high in the material can cause the Belt
to form lumps on its surface, and can even burn if the heat exceeds the
ability of the Belt base material.
Figure 2. 15 Belt due to high temperature
2.10
Water spray system
Water Spray System is a system with water spray that is connected
to the control valve manually or automatically. The water source is
connected to the installation pipe from the pump house as a supply of
pressurized water.
2.11
Classification and Pipe Material
Classification and pipe material can be stated as follows:
1. GIP pipe (Galvanized Iron Pipe)
This pipe is often called a galvanized pipe which is a kind of
iron pipe which is covered with a zinc protective layer which can
greatly reduce the tendency of the pipe to corrode. Galvanized pipe has
many benefits, one of which is the main distributor of gas, water, oil,
steam or gas so that the installation is strong, safe and durable. In some
other purposes, this material is also used as construction: for example a
support / pole and so on, depending on the needs of its users.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Galvanized Pipe Advantages:
a. Shatter resistant
b. Durable
c. The connection uses thread
d. Strong surface
2. PVC plastic pipe
PVC pipe, which is a type of plastic pipe, is generally used as a
conduit for cold water and light and heavy waste water, especially
chemical liquids because this pipe material is very good for liquid
materials which are characteristic of causing certain reactions with the
presence or absence of temperature changes.
PVC has the following advantages:
a. Chemical resistant
b. Very strong
c. Easy installation fee
d. Low heat conductivity
e. Easy installation
f. Almost maintenance free (virtually free maintenance)
g. Has corrosion resistance
3. Steel Pipe
Steel pipes function as pipelines for energy supplies, for
example: water, oil, gas and other flammable liquids. In the industrial
world, the use of pipes is very dominant. Among other things, as a
transportation system for various industrial products. Therefore
material selection is very important considering the fluid to be flowed
has different characteristics so that the media (pipe) will adjust.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
a. Carbon Steel
Carbon steel is the most common pipe material in the power
plant, chemical, process, hydrocarbon and pipe industry industries.
Mild steel is carbon steel with a carbon content of less than 0.30%.
Medium carbon steels have 0.30% to 0.60% carbon. High carbon
steel has carbon above 0.6%.
b. Alloy Steel
Alloy steel is one steel that contains a number of alloying
elements, such as 0.3% chromium (Cr), nickel 0.3% (Ni),
molybdenum 0.08% (Mo), etc. [ASTM A 941]. Low alloy steel is
alloy steel that contains less than the minimum percentage of alloy
defined. Alloy steel II-4 is generally used in high temperature and
high pressure operations such as in power plants, heat exchangers
and furnace tubes, and chemical reactors.
4. Copper Pipe
Copper pipe is a type of pipe that is strong and durable, and is
usually more widely used for hot water installations. Copper pipe can
be an alternative because it is more flexible and does not rust, as well
as heat and high pressure resistance. Copper pipe material is a mine
material from the earth as befits boksit, monel, tin or iron, but copper
has special properties: because it is strong, rust resistant, easily formed
and can be used in various purposes such as electronic kebel and so on.
5. Concrete Pipe
Concrete pipe is a composition of building materials made from
a mixture of cement or similar adhesives, coral, water and aggregates
with or without other additives that do not reduce the quality of the
concrete pipe. Used for sewage, tunnels and irrigation.
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Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
6. Brass Pipe
Brass is an alloy of copper and zinc metal with copper content
between 60-96% by mass. The color of brass varies from dark reddish
brown to light yellow silvery depending on the amount of zinc. Zinc
affects more the color of the brass. The main component of brass is
copper, so brass is usually classified as a copper alloy. Brass is very
easy to form in various forms, a good conductor of heat, and is generally
resistant to corrosion from salt water. Because of these properties, brass
is mostly used to make pipes, plumbing accessories, plumbing tools,
tubes, screws, radiators, musical instruments, marine applications, and
cartridge casings for firearms. Brass is stronger and harder than copper.
In trading there are 3 types of brass known, namely:
a. Brass wire (brass wire) copper content between 62-95%
b. Brass pipe (seamless brass tube) copper content between 60-90%
c. Brass plate (brass sheet) copper content between 60-90%
7. Cast iron pipe
Cast iron pipe is a type of pipe that is very hard compared to
similar iron pipes because with the results of cast, carbon (Ca) so that it
has carbon properties (hardening properties) and is resistant to rust.
Therefore it is very suitable to be used as a distribution of industrial
waste in a sanitation project (purification plan). However, quite a
number of entrepreneurs use this cast iron pipe material in small to
medium projects in commercial buildings.
26
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
2.12
Joints (Fittings)
Joints (fittings) are part of a piping installation that functions as a
connector between pipes and as the end of the piping or outlet fittings.
1. Elbow Joint (Ellbow)
Elbow joints (Ellbow) are types of fittings which are piping
components that function to change the direction of fluid flow. Ellbow
consists of 3 types that are most commonly used namely Ellbow 45o, 900
and 180o.
Figure 2. 16 Elbow Joint
2. Tee connection
Tee in fitting serves to divide the flow, usually this branch
has the same diameter with the diameter of the main pipe, with
another name straight tee for the same diameter, whereas if the size
is different then the name is reduser tee.
Figure 2. 177 Tee Connection
3. Reducer connection
Reducer fittings, as the name implies, these types of fittings
function to reduce fluid flow. Reducing here is not like a valve
27
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
(valve), but the size of the pipe is reduced. So that this reducer serves
to connect pipes of larger diameter to pipes that have smaller
diameters.
Figure 2. 18 Reducer Connection
4. Stamp connection
The cap function is to stop the flow at the end of the pipe.
These fittings are welded directly to the main pipe section.
Figure 2. 19 Stamp Connection
5. Flock Shocket connection
Flock Shocket connection serves to connect two pipes with
the same diameter.
Figure 2. 20 Flock Shocket Connection
28
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
CHAPTER III
METHODOLOGY
3.1. Problem Solving Methodology
Here is a flowchart of the case study implementation method:
A
Start
Identification of
problems
Analisa
Identification of
problems of
Discussion
Start
problems
Discussion of
problems
Literature Study
Perumusan
Masalah
Tidak
Hasil
Perumusan
masalah
Literature Study
Ya
Data search
`
Menentukan
Akar
Masalah
Data search
Data collection
Tidak
Diskusi
Solusi
Data collection
Ya
A
End
D
Diagram 3. 3 Flow Chart
i
a
g
Problem solving
methods are useful for solving problems that have
r
been formulated aand achieving predetermined goals with various stages of
m
1
29
.
Analysis of the Causes
of
Belt
Damage
in
the
51B-BC4
Belt
Conveyor
1
,
F
research and also data sources. The method used to solve the problem in the
Case Study is based on the flow chart above, namely:
3.1.1
Identification of problems
In this method, observations are carried out in Belt Conveyor
51B-BC4 in the Finish Mill Nar 2 area to determine the problems
that occur and find the root of the problem and how to handle it.
3.1.2
Discussion Method
Discuss existing problems with related parties such as the
field supervisor (FinishMill patroller area), FinishMill maintenance
area employees, and CBM (Condition Based Monitoring) to get
explanations and suggestions.
3.1.3
Literature review
Conduct a review of sources and literature related to this
Case Study. The information or theories collected will be used as a
guide or basis and consider solutions to overcome the problem.
3.1.4
Design Method
After the data is collected, the stages of case study report
design are carried out such as theory, discussion, conclusions and
recommendations.
30
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
3.1.5
Analysis Method
After the analysis phase is completed, the next step is to
determine the solution that will be given after the analysis results are
applied to the existing problem.
The data that has been obtained is then compared with the
theoretical basis to find conditions that are not ideal in the facts in
the area. That way the root of the problem can be analyzed with the
Root Cause Analysis method based on the conditions that are not
ideal. After finding the root of the problem, proposals submitted by
the NAR 2 Finish Mill department to be analyzed and considered in
accordance with the literature review obtained, to find the most
appropriate solution to resolve the case taken.
31
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
CHAPTER IV
RESULTS AND DISCUSSION
4.1
Consumer needs analysis
The needs analysis is based on the occurrence of high temperature
in the clinker in the transport clinker area 51A-BC02 when the clinker silo
indicates low level, and aims to reduce the clinker temperature.
The results of the needs analysis include:
1. High temperature on the clinker. So that with the water spray at 51B-BC4
the temperature can decrease.
2. Easy installation and re-installation process.
3. Easy maintenance process.
4. Tool components are easy to obtain and operate.
5. The price of each component of the tool can be reached.
4.2
Belt Performance on the 51B-BC4 Belt Conveyor
Belt performance on the 51B-BC4 Conveyor Belt can be known by
knowing the Belt Specifications. Here are the specifications:
Item Number: 300000093324
BELT; CONV; 1200 MMW; 4PLY; OE 4.8 MMTC; 2,4 MMBC; EP 200
The brand Belt: BANDO INDONESIA
Belt Type: HR-710
(Heat resistance No. 710)
Length with Fastener connection: 304 Meters
Length with Hot Splicing connection: 307 Meters
Width Belt: 1200 mm
32
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Figure 4. 21 Belt layer
Thick Top Cover Rubber
: 4.8 mm
Thick Bottom Cover Rubber : 2.4 mm
Number of Layers (Fabric)
: 4 Ply (Polyester Fabric)
Power
: EP-200 (200kgf / cm.ply)
Belt the 51B-BC4 Belt Conveyor is equipped with a special
compound Ethylene Propylene rubber, has exceptional heat resistance and
abrasion resistance. The maximum temperature of the material handled is
around 400 oC and the maximum surface temperature of the belt is 180 oC.
Suitable for starch materials such as cement products, because it is not
cracked.
Typical applications: hot clinker, hot powder, hot sintered ore, etc.
Figure 4. 22 51B-BC Temperature Trend 4
33
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
The temperature trend on 51B-BC4 can be seen in the TIS
(Technical Information System) located on the CCR Operator. If the graph
or trend decreases, it means that the temperature is low, whereas if it
increases it means that it is high. If we look at Figure 4.2s, the trend tends
to increase and shows temperatures reaching 180 ° C. Then it can be
concluded that the temperature at 51B-BC4 is very hot than expected
below 120o C
4.3
Conditions on 51B-BC4 Conveyor Belt
4.3.1 Belt Conditions
Belt conditions on 51B-BC 4 on November 23, 2019
experienced a 2.7 meter long bubble which was due to the high
temperature of Clinker material. In order to quickly return to normal
Cement Production, a belt splicing is done with 2 Mechanical methods
splicing using SuperScrew 127.
Figure 4. 23 belt conditions exposed to high temperatures
Figure 4. 24 Re-joint Belt
34
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
The belt splicing process causes Finish Mill lane 5 and Finish
Mill lane 6 to Stop.
3 months later, precisely on January 22, 2020 Conditions on
the Belt experience Bubble and cause the Rubber layer on the Belt to
tear. If this is left unchecked, it will be exposed to a layer of yarn /
carcas so that the Belt breaks easily. Then the condition condition is
checked and monitored.
Figure 4. 25 Belt due to Bubble
On March 23, 2020, the Belt Conditions returned to Bubble
with a pretty severe Belt condition. This is due to the high Clinker
temperature and the corner radius of the frame is too large so that
the heat in the belt that is transferred from the Clinker material
becomes concentrated in the indentation so the Belt is torn up to 4
layers.
35
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Figure 4. 26 Condition Bubble in Belt is quite severe
Due to the severe belt condition, a new belt was replaced
according to Belt 51B-BC4 specifications using the Hot Splicing
Splicing Method with a total Belt Length of 307 meters.
Figure 4. 27 Condition after change New Belt
4.3.2 Waterspray Conditions
On Belt Conveyor 51B-BC4, actually already has a
Waterspray that works to reduce high temperatures in the Clinker
(Material transported by the Belt). The waterspray turns on
automatically with the sensor when the temperature reaches
temperatures above 120 ° C. However, with only one Waterspray, it
36
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
is less effective and proven, Belt still often experiences Bubble or
can be called burnt. And cause help, so the Belt can be broken.
Figure 4. 28 Waterspray Conditions 51B-BC4
Figure 4. 29 Sensor Display Waterspray
4.4
Problems that occur
The problem that occurs in clinker material is temperature. The
temperature of the clinker is high when stored in the Clinker silo. Clinker
that is still hot goes into the silo without any provision for a long time
This problem results in Belt Conveyor 51B-BC4 often experiencing
tearing. Belt tearing if left unchanged will disrupt the process of cement
production because the conveyor belt carries the main material of cement,
37
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
which is Clinker, and if the belt replacement is frequent, it will result in
increased costs, and time to replace it, which will disrupt the production
process.
The temperature trend on 51B-BC4 can be seen in the TIS
(Technical Information System) located on the CCR Operator. If the graph
or trend decreases, it means that the temperature is low, whereas if it
increases it means that it is high. If we look at Figure 4.10 the trend tends to
increase and shows temperatures reaching 180 ° C. Then it was concluded
that the temperature at 51B-BC4 was hotter than expected below 120 ° C.
Figure 4. 30 Temperature Trend Clinker
38
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
4.5
Root Cause Analysis
Located Underground
The bend radius is too small
Troubled Carry, Impact
and Return Roller
Belt slope angle
Broken belt in Belt Conveyor 51B-BC4
Over Load
High Temperature
Diagram 4. 4 FishBone Diagram
39
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
4.6
Root Problem Analysis
Based on the Fishbone Diagram which outlines the root of the
problem. It can be concluded several things:
1. Equipment
From the problem about Belt Belt Curves Too Large, we have a
suggestion to reduce the Radius of the Belt, so that the
distribution of heat in the Belt can be evenly distributed.
2. Material
The problem of overheating material can be overcome by the
addition of pipelines at 2 points 51B-BC4. With the addition of
pipes flowing with water it is expected to reduce temperatures, at
least close to what is expected. So as to increase the Lifetime or
lifetime of the Belt
3. Environment
Environmental problems in Equipment 51B-BC4 also affect the
temperature drop, because the device is underground, there is no
environmental air that helps reduce the temperature of the
material carried by the conveyor belt.
4.7
Solution offered
From the discussion of root problem analysis that has been
presented, it can be concluded that Clinker material temperature is the
dominant problem. We can still deal with this problem in the way that has
been explained in the root cause analysis.
So the solutions we can offer are:
1. Modify Frame dimensions. These modifications include changes
in the high or low and the gap in the Idler Frame
2. Add and utilize Waterspray.
40
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
Adding Waterspray is expected to reduce the temperature of
Clinker or Material transported by Belt 51B-BC4, at least close to
the expected temperature. Because actually, Clinker's temperature
can still reach 180 ° C, resulting in the expected decrease in Belt
life.
41
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
CHAPTER V
CONCLUSIONS AND RECOMMENDATIONS
5.1
Conclusion
Conclusion from the Case Study made this is:
1. Causes of frequent belt damage on the 51B-BC4 Conveyor Belt
include: Radius Curves are too large and the angle of the belt tilt and
Clinker Temperature of the Silo are still too high.
2. The solution offered is to modify the gap between the Idler Frame and
the addition of one WaterSpray point
5.2
Recommendations
Suggestions from the Case Study made are:
1. Verification and further testing of the solutions offered is needed.
2. Required analysis of the estimated costs needed to realize the
solutions offered
3. Analysis is needed about the efficiency of spraying carried out by the
pipe to be applied.
42
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor
BIBLIOGRAPHY
Akbar,
F.
2012.
Types
of
Pipes
for
Industry.
Taken
from
https://fachrezakbar.wordpress.com/2012/03/22/memahami-dasardasarpemipaan1/. On February 17, 2020 at 19.37 WIB.
Duda, H. Walter.(1988).Cement Data Book 3 edition. Jerman: Bauverlag Gmbh.
PT.
Bando
Indonesia.
Conveyor
Belt.
Taken
from
https://www.bandoindonesia.com/conveyor.html On April 2, 2020 at 13.35 WIB.
Sugeng.
2014.
Types
of
Connections
Between
Pipes.
Taken
from
http://www.idpipe.com On January 12, 2020 at 13.35 WIB.
43
Analysis of the Causes of Belt Damage in the 51B-BC4 Belt Conveyor