1. MY PROFILE AT
FLSMIDTH
MACHINE DESIGN AND
ENGINEERING

2. CLIENTS & CONSULTANTS
WORKED WITH AT FLSMIDTH
 WORSLEY (Australia)
 GROOTEGALUK (South Africa)
 ADANI
 VSP
 VEDANTA
 NALCO
 UTKAL
 IOCL
 BMT-WBM (Australia)
 MN DASTUR (Calcutta)

3. 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

4. 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

6. Jaw Crusher

7. Apron Feeder

8. Design Process for Stacker,
Reclaimer and Ship Unloader
 Design Basis (ISO, FEM, AS)
 Input Design Document (Design
Specification)
 Preliminary Calculations
 FEA

9. BWSR MACHINE

10. 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

11. Standards
 ISO 5049 & ISO 5048
 FEM Section II
 IS 800
 BS 2573 part 1 & 2

12. 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

13. FEA Calculation
 Structural Analysis
 Buckling Analysis
 Modal analysis
 Fatigue Calculations

14. WORSLEY STACKER
Australia
Review Consultant : BMT WBM
Australia

15. Tech Spec
Material Handled : Bauxite
Stacking Capacity : 4100 TPH
Reclaiming Capacity: -
Boom Length : 36.5m
Stock pile : 35m
No of Wheels : 26

18. LOAD COMBINATION-6: E+V+G+F+D+P+Ws [LUFF DOWN] [DEFLECTION]
Without Shift

21. SLEW PLATFORM

22. UNDER-CARRIAGE

23. SIX WHEEL EQUILIZER4 WHEEL EQUILIZER
BOGIE

24. Tripper Car Structure

27. IOCL Stacker

28. Bucket Wheel Reclaimer
NALCO

31. VSP BWSR

32. 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

34. Counter Weight Boom

35. BUCKET WHEEL
BOOM

36. Pylon

37. UNDER CARRIAGE

38. ADANI BWSR
DAHEJ
Review consultant : BMT WBM
Australia

39. Tech Spec
Material Handled : Coal
Stacking Capacity : 4600 TPH
Reclaiming Capacity: 2750 TPH
Boom Length : 42m
No of Wheels : 32

40. ADANI LUFF STRUCTURE AND
UNDER CARRIAGE

41. UNDER CARRIAGE

42. Wheel on Bridge
Reclaimer Structure
VSP

43. Tech Spec
Material Handled : Iron Ore
Stacking Capacity : -
Reclaiming Capacity: 1000 TPH
Rail CRS : 35m
No of Wheels : 16

50. Bucket Wheel Reclaimer
VSP

51. 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

54. Ship Unloader

55. Swept Area

57. Ship Unloader
 2500 TPH unloading Capacity
 Vessel Handled : Cape Size 1,80,000 DWT
 Horizontal Arm Length : 35m
 Vertical Screw Length : 30m


61. Luff Structure

62. Slew Platform

63. gantry

64. Storage Bin

65. Data
 Material : Bauxite (2.1T/m3)
 Largest Dia : 14m
 Largest Length : 24m
 Volume : 2000m3
 Basis : DIN 1055

66. Existing Design
Date : 29/9/2007

67. Over all stress

68. Third Modification
30 thk stiffners (red color)
20 thk (Magenta color)
File Ref : storage-bin32
Date : 8/10/2007

69. Introduction of 10
mm thk stifner
Increase the thk
to 20mm
Increase the thk
to 30mm

70. Over all stress

71. Redesign of Kiln Shell To Minimise
Brick Breakage

72. 20mm Thk Shell without
Flanges and Wrap plates
SHELL-final ang90_without-flange.PART

75. 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

76. 3 Flange Plates

79. Coupled Field Analysis (Thermal
and Structural Analysis) of Kiln
Shell

80. 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.

81. Case 1
1200mm at 600 deg and 1200mm
with Air convection

82. Thermal
Analysis
Stress Distribution
in N/m2

83. Deformation in metre

84. Case 2
1200mm at 600 deg and 1200mm
with Ideal Insulation on walls

86. 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.

87. LEAN

88. 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

90. 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%

91. 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

92. 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

93. 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

94. Thank You