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UJALA It Eliminates the Darkness

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Date of First Meeting: - 12/09/2008
Total no. of meetings: - 09



Mr. P. K. Gupta Leader
Mr. Chamanlal Dy. Leader
Mr. Saurabh Harne Member
Mr. M. K. Lakhani Member
Mr. U. P. Gupta Member
Mr. R. D. Maurya Member
Mr. Anil Dev Member
Mr. Madhukar Mishra Member
Mr. Shyamal Roy Member
Mr. A. K. Dixit Member

FACILITATOR
Mr. Balbir Singh

MEMBER STEERING COMMITTEE
Mr. A. Akhtar

Avg. Attendance of Group - 73%
Avg. Age of Group - 40 YEARS
Avg. Working Experience of Group - 17 YEARS



CIRCLE'S INTRODUCTION
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PROBLEMS COLLECTED BY
BRAIN STORMING

1. Spillage of urea prills from filled stitched bags.
2. Spillage of urea from bagging machines during lumps removing.
3. Failure of ET-06 belt conveyor due to cracking of bend pulleys.
4. Damaging of ET-01 belt conveyor and D-Shaping of transoms.
5. Uneven stitch length of stitches on urea filled bags.
6. Poor performance of bagging machines (Service air problem)
7. Rupturing of urea filled bags at portable conveyors.
8. Urea spillage at ET-07/ET-08 tail pulleys area.
9. Urea spillage due to jamming of TR-01/TR-02 at BH-03/BH-06.
10. Huge dust emission at ET-07/ET-08 belt conveyors.







PROBLEM SELECTED

Problem no. 3. Failure of ET-06 belt conveyor due to cracking of bend
pulleys is selected.



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SYSTEM
INTRODUCTION
ET-6 bend pulley is used to bend the conveyor belt, towards the
gravity take up pulley and counter weight to provide sufficient
tension in conveyor belt & keep it straight. The belt conveyor
system is used to convey the Urea prills from prilling section to
Bagging plant.
HEAD
PULLEY
CARRYING
IDLER
SNUB
PULLEY
BEND
PULLIES
RETURN
ROLLERS
TAIL
PULLEY
TAKE UP
PULLEY
BELT
Urea prills from
Prilling Tower
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PROBLEM
INTRODUCTION

ET-06 belt conveyor bend pulleys frequently cracked at hub as well as at drum. Whole bulk
conveyor system stopped time to time for repairing/replacement of the pulleys, Resulting in
the diversion of urea solution to V-5. Reclaiming of urea solution from V-5 incurred extra
cost.

REQUIREMENT

To find out ways so that Failure of ET-06 Belt Conveyor does not occur due to cracking of
Bend Pulley.

INITIAL DATA COLLECTION

1. Diversion time & date.
2. Recovery Lineup time.
3. Production rate before diversion.
4. Basic Design of Pulley.








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Cause & Effect Diagram
MEN
MACHINE
MATERIAL
Not Applicable
Not Applicable
Not Applicable
Low Design Capacity
No modification in basic
design since plant running
METHOD
Frequent
failure due
to
Cracking
of Bend
pulleys.
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0
10
20
30
40
50
60
70
80
90
100
A B C
Nature of Prob.
A = Design Limitation = 90%
B = Variation in Load = 5%
C = Regular Inspection = 5 %

PARETO DIAGRAM
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Development of Solutions
Possible Solutions Action Reason
Balancing Problem Discard Only vibration
observed.
Load Limit Discard As Urea flow is uniform
most of the time.
Material Fault Discard No material failure is
there.
Alignment Discard Alignment checked
found ok.
Counter Weights Discard As per original
Drawing.
Pulley Design Accepted No modification since
plant start up.
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Selection of Solution
Modification in Design of Bend Pulleys

Frequently facing the problem of cracking of bend pulleys of
ET-6 belt conveyor, our plant personnel had a visit at Indo-
Gulf Fertilizer to have comparative study regarding bend
pulleys. It was discovered after discussion that their pulleys
are designed for heavy duty and they have not faced same
problem since start up of the plant. There fore the drawing
of their pulleys were obtained and subsequently new heavy
duty pulleys were procured as per our requirement and
plant load. Those were installed during annual shut down.
Since than there has been no problem of cracking of
pulleys observed, even though we are running plant at
relatively higher load.
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OLD ET-6 BEND PULLEY
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NEW MODIFY ET-6 BEND PULLEY
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Cost Benefit Analysis
Cost of Modification
Unit Rs.
Bend Pulley 2 Nos. 96755
Bearing (With Sleeve) 4 Nos. 31245
Total Cost 128000

Average Loss per Year (Diversions Only) 113200
Pay Back Period 413 Days


Average Loss per Year (Diversions & Tripping) 3051200
Pay Back Period 15 Days

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BENEFITS
TANGIBLE BENEFITS

Savings per Year = Rs. 113140

INTANGIBLE BENEFITS

Shocks on related equipments (Other pulleys)
will be avoided due to subsequent start up of
Belt Conveyor.
A potential problem will be minimized.
Reliability of ET-6 will be improved.