Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
CILACAP, 2019
CASE STUDY REPORT
Advisor I Advisor II
Assessor I Assessor II
ii
PREFACE
Thank you, we pray to the presence of God Almighty, God who bestowed His
mercy and blessings on us all. Thanks to his gift, this Case Study entitled
"Mistracking Belt Conveyor on X92-BC2 " can be completed as well as possible
in order to fulfill EVE student assignments in semester 4.
This report contains information about the causes of hunting on the X92-BC2
Conveyor Belt at PT Solusi Bangun Indonesia.
Although it has been arranged to the fullest by us, we, as human beings, are
well aware that this report is very flawed and is far from perfect. Therefore we
really expect constructive criticism and suggestions from readers.
It is our hope that this report can be an inspiration or a means of learning aids
for students or the general public in finding theories about Belt Conveyors.
That is what we can say, hopefully the readers can benefit from and learn from
this report.
Writers
iii
LIST OF CONTENT
iv
3.2.6 Finish...................................................................................................... 30
CHAPTER IV .............................................................................................................. 31
4.2 Spesification Data Sheet................................................................................ 32
4.3 Parameter Operation X92-BC2 ..................................................................... 33
4.4 Equipment Peforment X92-BC2 ................................................................... 33
4.5 Data Analysis ................................................................................................ 33
4.5.1 Finding Item ........................................................................................... 33
4.5.2 Root Cause Analysis .............................................................................. 34
CHAPTER V ............................................................................................................... 40
5.1 Conclusion.......................................................................................................... 40
5.2 Recommendation:............................................................................................... 40
BIBLIOGRAPHY ........................................................................................................ 42
v
LIST OF FIGURE
vi
Figure 2. 32 Belt with Roller set-up............................................................................. 22
Figure 2. 33 Adding washer ......................................................................................... 22
Figure 2. 34 Ogoshi method for wear testing .............................................................. 23
Figure 2. 35 Wear adhesive method ............................................................................ 24
Figure 2. 36 Wear abrasive method ............................................................................. 26
Figure 2. 37 Wear fatique mechanism ......................................................................... 27
Figure 3. 1 Flow diagram ............................................................................................. 28
Figure 4. 1 Belt Conveyor ............................................................................................ 31
Figure 4. 2 Material spills ............................................................................................ 33
Figure 4. 3 Fishbone diagram ...................................................................................... 34
Figure 4. 4 Blocking tail pulley ................................................................................... 35
Figure 4. 5 Worn out tail pulley ................................................................................... 35
Figure 4. 6 Before after cleaner design ........................ Error! Bookmark not defined.
Figure 4. 7 Dimensioning of material load .................................................................. 40
vii
LIST OF TABLE
Table 2. 1 Maximum tilt angle to the belt conveyor for some types of materials ......... 8
Table 4. 1 Equipment specification of X92-BC2......................................................... 32
Table 4. 2 Operation parameter of X92-BC2............................................................... 33
Table 4. 3 Equipment perform of X92-BC2 ................................................................ 33
Table 4. 4 St41 Characteristic ...................................................................................... 36
Table 4. 5 Silica content 2018 - 2019 .......................................................................... 39
viii
CHAPTER I
INTRODUCTION
X92-BC2 is one of the main equipment in the Raw mill Area which is tasked
with transporting Raw Materials in the form of Silica and Iron Sand from the
reclaimer to the bin. In operation X92-BC2 works to serve two bin, namely bin
silica and iron sand.
1.1 Background
In the process of making cement at PT Solusi Bangun Indonesia Tbk there are
main equipment ranging from crusher, stockpile, raw mill, preheater, silo blending,
kiln, cooler, finish mill, and packer. Whereas on the other hand there are auxiliary
equipment such as transporters, storage, GCT, and others.
Transporter is a tool used to move bait from one place to another.
One type of transporter used at PT. Solusi Bangun Indonesia, namely Belt
Conveyor. This tool is used to carry different materials in each area. The Raw Mill
area has several Conveyor Belts as transportation equipment, one of which is X92-
BC2. This equipment is one of the important equipment because it is a transport
tool whose duty is to bring raw material in the form of Silica and Iron Sand from
X92-BCl to bin. If X92-BC2 has a problem or often experiences unscheduled stops,
it will cause considerable losses for the sustainability of production.
The conditions of X92-BC2 within one year 2018 experience a stop of 2 times
for 1.30 hours and 3.70 hours. Which caused a Raw Meal loss of 3000 tons. This
calculation is calculated based on the loss of all hourly production.
The problem that occurs in this equipment is that the belt on the X92-BC2 has
a mistracking so that a lot of Silica material is spilled along the Belt side. This
incident raises some suspicions related to the cause of the shift of the belt on the
X92-BC2. One of them is due to material overload and worn out tail pulley.
1
2
1.2 Problem
Based on the background and objectives that have been described, then the
formulation of the problem to be solved is as follows :
1. The cause of Mistracking Belt Conveyor on X92-BC2.
1.4 Purpose
Can analyze cause of mistracking belt on Belt Conveyor X92-BC2.
CHAPTER II
THEORY
3
4
Homogenisiersilo Elektrofilter
Kühlerentstaubung
Kohle
Roh-Mehl
Wasser
Kohlen-
Mühle
Zyklon- Rohmühle
Drehofen Wärme- Kühlturm
tauscher
Zumahl- Filter
Klinkerkühler Gips stoffe Loseverlad Packerei Palletisierer
Zement Zement
Klinker- Silo Silo
silo
Zementmühle
Grinding and separating drying material occurs in Raw Mill. PT Solusi Bangun
Indonesia uses Raw Mill with Vertical Roller Mill type with 4 rollers. The results
of Raw Mill are Raw Meal which is stored and homogenized in Blending Silo.
Next, the feed will enter the kiln for clinker combustion and processing.
Cilacap plant uses a dry process system. In the kiln the material is heated to reach
± 1450˚C. For lay-out heating the kiln uses IDO (Industrial Diesel Oil) after which
it uses coal. Products from kilns are clinkers containing C3S, C2S, C3A and C4AF.
The clinker is cooled in the cooler by using air from outside. Rapid cooling
occurs to maintain decomposition between C3S and C2S. it affects the quality, heat
recovery and security to be transported and stored. Cooled to ± 120˚C and stored
in clinker silos
After that, the clinker is pureed in the ball mill. Before entering the ball mill,
the clinker is grinding first in the pre grinder to make it easier to blend in the ball
mill. The clinker from the pre-cylinder is sent to the Ball Mill to be processed in
combination with gypsum and other additives such as dolomite, pozzolan and fly
ash. The product of the finish mill is cement. Cement is transported to cement silo
with water slides and bucket elevators. From cement silos packed in pack houses
and cement ready to be distributed.
Belt conveyor or conveyor belt is a transport plane that used to move cargo in
the form of units or spills, horizontal direction or an angle of slope / inclination of
a system operating one operating system to another in a line production process,
who use the belt as a conductor of cargo. Belt Conveyor on essentially a fairly
simple equipment. The tool consists of belts that are resistant to the transport of
solid objects. Belt use the conveyor belt can be made from various types of
materials eg : rubber, plastics, leather or metal depending on the type and nature of
the material to be transported.
6
Belt Conveyor has a main component in the form of belts which is above the
rollers fulcrum. Belt driven by the motor through a pulley, belt move in translation
with a flat pass or skewed depending on the needs and planning. Material placed
above belt and belts moving together towards unity. In operation conveyor belt use
in the form of an electric motor propulsion with intermediate wheel gear which is
coupled directly to the drive pulley. Which is above the belt rollers will move
across the rollers with the appropriate speed of rotation and pulley drive.
There are several considerations that underlie the best research transporter:
1) Usage characteristics, it involves the type and size of the material, material
properties, as well as the conditions of terrain or workspace tools.
2) The production process, transport hourly capacity of the unit, continuity
removal, material stacking method and duration of operational tools.
3) The economic principles, covering the cost of manufacture, maintenance,
installation, operating costs and depreciation costs of the initial price the
tool.
2.3.1 Working Principle of Belt Conveyor
The geometry of the conveyor belt can be seen in Figure 3 shows the
trajectory of the conveyor belt.
The main components of the conveyor belt can be seen in the picture
Feed
chute
6 Head
2.1 pulley
4 Drive
Carrying
idler
2.3 Impact
idler 2.2 Return Bend
6 Tail idler pulley Snap Dischar
pulley - ge chute
1 Belt
pulle
y
5 Gravity
take-up
1. Belt
Belt is one of the major components of the conveyor belt. Belt
usually consists of several layers (ply) for protective and
reinforcement of the belt itself. Upper and lower layer is a protective
layer of the collision and friction that will occur, and lining amid a
reinforcing layer of the belt. This layer is usually in the form of
special wire or fiber carcass. It’s not stand the collision and friction.
In general, two types of belt be distinguished items, namely:
2. Idler
3. Frame
Figure 2. 10 Frame
4. Drive
Figure 2. 11 Drive
12
5. Take Up
Take-up to make sure the voltage of the belt. Which serves to
maintain and adjust the belt to keep it tight so it does not slip on the
drive pulley and the offset when there is a change in belt length. Take-
up is usually applied in a long belt to make sure the voltage changes
due to load material. Several types of take-up often used in, among
others, screw conveyor belt take-up, take-up winch.
6. Pulley
7. Cleaner
1. Motion Detector
This tool is used to detect the movement of belt conveyor.
Motion detectors are usually installed in tail pulleys. If belt occurs or
even belt is disconnected, motion detector will get pulse signal per
minute less than setting. Because of that, eventually the motion will
turn off the conveyor belt due to an abnormal indication of conveyor
belt operation.
3. Metal Detector
This tool is used to detect the presence of metal materials that
come raw material.
4. Emergency Stop
An emergency stop is a breaker switch which, when activated
(pressed) will stop the device. The use of emergency stop installation
is to stop the equipment from the field in case of an emergency.
16
5. Belt Drive
This tool is used to detect conveyor is tilted or off track. If the
belt comes into contact with this tool, then there will be an alarm
signal in the CCR. And if not immediately handled it will make the
conveyor belt stops.
6. Material Level
Material level is used to indicate how much material there is in
the chute / bin area. The type of level material used is rotary. If the
material level is full (in bin) or blocking on the chute, the material
will touch the rotary blade causing the switch in the cut-level
material, and interlock with the conveyor belt system so that it will
turn off the belt conveyor.
1. Misalignment of Idlers
2. Translational Misalignment
The three possible translational misalign idler orientations are
shown in Fig. 2. Obviously, the misalignment in x- and z-direction
can be neglected. A misalignment in y-direction will shift the idler
station relative to the belt center line. Mistracking will occur as an
effect of the self-alignment of the conveyor belt. The belt tries to
follow the lowest points of the idler stations due to its self-centering
behavior caused by belt and bulk material mass.
If all stations are tilted, the belt will run with much more
stability but with a highly increased energy consumption because of
frictional effects on the contact points of the outer idlers. Tilting of
idlers stations increases the motion resistance.
5. Rotational Misaligned at z-Axis
A rotational misalignment around the z-axis is known as a
skewed idler station. The skewed station in the figure below will steer
the belt in the normal direction of the idler. The sideways movement
is directly proportional to the angle of skew, as long as the force
acting on the belt is smaller than the maximum frictional force
between the belt and idler. Otherwise the belt will slip above the idler.
The occurring steering effect can be used as an output value in a
controlled training idler.
2. Before carrying out any work, be sure to properly tag and/ or lock
out the conveyor system. You may also need to adhere to specific
site safety requirements.
Figure 2. 29 LOTOTO
3. Be sure to check all pulleys, tracking idlers, carry rollers and return
rollers are free from buildup and are rotating freely. Any worn or
seized components will cause belt misalignment.
Figure 2. 30 Pulley
4. Check to make sure adequate tension has been applied on all drive
and gravity take up pulleys. If a belt is under or over tensioned this
may cause belt misalignment. If you are unsure as to whether the
tension of your conveyor is correct, please consult your original
conveyor specs or conveyor supplier for more detail on belt tension.
5. Asymmetric loading such as the one below in figure 2. 31, of the
transfer point is one of the most difficult causes of belt tracking
issues to address, and causes the most problems. Belt tracking
devices are a must in this case as dry and wet running will not be
cared for by manual idler adjustment.
22
Start
Collecting
Data
Data
Analysis
NO
YES
Conclusion
Report
Finish
28
29
Case Study can be started if the title has been determined and the
proposal has been prepared.
1. Observation
Discuss the problems with the authority such as the field
supervisor, the Patrol Raw Mill area, the Maintenance Raw Mill area,
the PM Raw Mill area and the Raw Mill Engineer area to get an
explanation, validation data, and advice on problems that occur in Belt
Conveyor X92-BC2.
2. Literary Study
3. Experience
At this phase is used to find and collect information about Belt
Conveyor X92-BC2 starting from the work system of tools, processes
and designs related to the location of the project both from books,
journals, specifications data, vendors, internet, and manual books.
30
3.2.5 Report
3.2.6 Finish
31
32
X92-BC2 Coupling
05-03-2018 Mechanical 3.83
Broken
Friction
between Increased Silica
tailpulley for Rawmill
and cleaner feed
34
35
Worn
out of
tail
pulley
For this reason, design changes are needed and change the
cleaner material with ductile material.
Before After
310 RA cos α
F 260
W cos α W
𝑊 = 𝑚×𝑔
𝑊 = 9,1845 × 9,81
𝑊 = 90,099945 𝑁
𝐹 = 𝑅𝐴 cos ∝ × 𝜇𝑘
1
𝐹 = × W × cos ∝ × 𝑐𝑜𝑠 ∝ × 𝜇𝑘
2
𝐹
1
= × 90,099945 × cos 26 × 𝑐𝑜𝑠 31 × 0,57
2 𝐹 = 19,7831374 𝑁
38
RA
180 RA cos α
F
390
W cos α W
𝑊 =𝑚×𝑔
𝑊 = 5,86202 × 9,81
= 57,5064162 N
𝐹 = 𝑅𝐴 cos ∝ × 𝜇𝑘
1
𝐹 = × W × cos ∝ × 𝑐𝑜𝑠 ∝ × 𝜇𝑘
2
1
𝐹 = × 57,5064162 × cos 39 × 𝑐𝑜𝑠 18
2
× 0,57
𝐹 = 12,10112284804671 𝑁
The results of these calculations prove that the new design has
fewer styles compared to the previous design. Basically, wear cannot
be removed, but can still be reduced.
39
In these data, the quantity of silica is increase about 13,83% from 5%.
This data is the bigger quantity of silica sand in 2018.
3. Overload Material
We calculate the belt conveyor capacity with measurements
carried out directly in the field. So that data is obtained:
Actual in Field
Known :
• Belt length loaded (S) : 20000 meter
• The time needed to pour material (t) = 18 s
• Mound material height = 140 mm
• Material mound width = 480 mm
𝑔
𝜌𝑠𝑖𝑙𝑖𝑐𝑎 = 2,56 ൗ𝑐𝑚3 = 2,56 𝑡𝑜𝑛ൗ𝑚3
Calculation of cross-sectional area
1
𝐴= 𝑥 𝑎 𝑥 𝑡
2
1
𝐴= 𝑥 480 𝑥 140
2
𝐴 = 33600 𝑚𝑚2
Calculation of velocity
𝑆 =𝑣×𝑡
𝑆
𝑣=
𝑡
20
𝑣=
18
𝑣 = 1,154 𝑚Τ𝑠 = 4155,19 𝑚ൗℎ𝑜𝑢𝑟𝑠
Calculation of quantity
𝑄 =𝐴×𝑣 ×𝜌
5.1 Conclusion
Based on data and the results of our analysis, the causes of X92-BC2
conveyor belts experiencing mistracking are influenced by several factors, namely:
5.2 Recommendation:
1. Widening of conveyor belt, to overcome overload on conveyor belt X92-
BC2.
2. Replacement of cleaner material using a ductile cleaner material and
reposition of cleaner with new design.
40
BIBLIOGRAPHY
ATTACHMENT