lri iligan audit report for finish mill & crusher area (02-20-15).pdf

Beta Equipment Sales Corporation

TECHNICAL REPORT(AUDIT REPORT)

for

FINISH MILL & CRUSHERLAFARGE REPUBLIC, INC. ILIGAN PLANT

February 20, 2015

Date of Report

Approved by:

Marlon B. Diokno

Chief Operating Offiicer

Report No.: LRI-ILI-JSM-100315

March 10, 2015

Prepared by:

Jose Roie S. Manaog

Technical Service Engineer

Checked by:

Elmer B. Ningas

Operation Head

Noted by:

Joseph M. Ascaño

Operation Manager

BO. KIWALAN, ILIGAN CITY, PHILIPPINES

Date of Inspection

F-PES-TR Rev-0

Precisely Right.

RUNNING STOP

SCOPE OF INSPECTION :

BELT CLEANER BELT TRACKER TAIL PROTECTION SKIRTING IMPACT BED

CONVEYOR BELT PULLEY ROLLER OTHERS: ______________

RECOMMENDATIONS

1

2

3 Install belt cleaning system for carryback and material build-up solution at pulley and rollers.

INSPECTION REPORT

CUSTOMER LAFARGE REPUBLIC, INC. ILIGAN PLANT INSPECTION DATE February 20, 2014

PICTURES/ILLUSTRATIONS

2

3

ITEM OBSERVATION AND FINDINGS ANALYSIS

1

MATERIAL CLINKER DATE INSTALLED N/ACLINKER WF

OPERATION SITE FINISH MILL 1 TYPE OF INSPECTION

BELT WIDTH 1000MM CONVEYOR ID

Penetration of dust and water from peel-off at joint

portion.

Inappropriate belt for transporting hot materials.

Ineffective belt cleaning system installed. Belt cleaners

primary function is to remove the material that stick on

the belt surface after unloading zone (as seen in Fig.3),

thus preventing the material loses and also to protect

the conveyor accessories specially its idlers.

Peel-off at the joint portion of belt observed.

Cracks on top cover rubber

Carryback materials build-up underneath the conveyor.

Replacement of Heat Resistance Conveyor Belt designed for specific condition.

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1 2

3

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RUNNING STOP





BELT WIDTH 650MM CONVEYOR ID

INSPECTION REPORT




GYPSUM WF

MATERIAL GYPSUM DATE INSTALLED N/A

RECOMMENDATIONS

Install belt cleaning system for carryback and material build-up solution at pulley and rollers.

3Material build-up at the face of return rollers.

1



the belt surface after unloading zone (as seen in Fig.1-3),



1Carry back materials sticked to the conveyor belt.

2 Carryback materials build-up underneath the conveyor.

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3

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INSPECTION REPORT

BELT WIDTH 800MM CONVEYOR ID ADDITIVES WF

MATERIAL ADDITIVES DATE INSTALLED N/A



1Excessive carry back materials beneath the conveyor and

reached the return rollers and conveyor belt.






2 Improper installation of conveyor belt.

Secondary cleaner can’t serve its purpose due to

improper installation of conveyor belt. The secondary

cleaner's blade should be below the installed conveyor

belt to scrape the carryback materials.



RECOMMENDATIONS

1 Install belt cleaning system for carryback and material build-up solution at pulley and rollers.

2 Re-install Conveyor belt or Reposition of Secondary Cleaner.

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1 2

Secondary Conveyor

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INSPECTION REPORT



BELT SPECS 750MM CONVEYOR ID COMMON CONVEYOR

MATERIAL CLINKER, GYPSUM & ADDITIVES DATE INSTALLED N/A

RECOMMENDATIONS

1Install Belt Tracker to provide immediate, powerful and continuous steering to correct belt's path, preventing

spillage, equipment damage and repairs.

2 Rubber lagging of Tail, Snub, Bend and Take-up pulleys.

1Worn-out rubber lagging of Tail Pulley and misalignment

of belt.

4 Worn-out rubber lagging of Take-up Pulley.

2 Worn-out rubber lagging of Snub pulley.

3 Worn-out rubber lagging of both Bend pulleys.

Worn-out rubber lagging will result premature damage

to the face of pulley, misalignment (as seen in Fig.1) and

slippage between the pulley and belt.

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4

2

3

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INSPECTION REPORT

BELT SPECS 750MM CONVEYOR ID COMMON CONVEYOR

MATERIAL CLINKER, GYMSUM & ADDITIVES DATE INSTALLED N/A


OPERATION SITE CRUSHER TYPE OF INSPECTION

1 Conventional skirting system.

Existing skirting system cannot control the escape of

fugitive material that lead to spillages on the side and

beneath the conveyor in the loading point area.

2 Belt mistracking observed along the Conveyor System.



RECOMMENDATIONS

1 Modification of skirting system and install rubber lining to achieve good sealing.



3 Multiple belt edge damaged along the conveyor belt.

4 Excessive carry back materials beneath the conveyor.






Misalignment entails other conveyor system problem if

not treated immediately. Those are like belt edge

damage, damaging conveyor strucure, excessive material

spillages and worst is unnecessary stop in operation.

3 Replacement of Conveyor Belt.

4 Install multiple belt cleaning system for carryback and material build-up solution at pulley and rollers.

1 2

3 4

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INSPECTION REPORT



BELT SPECS 1300MM CONVEYOR ID B04

MATERIAL LIMESTONE DATE INSTALLED N/A

3Without rubber lagging and excessive material build-up

at the face of both Bend Pulley.

1 Worn-out rubber lagging at the Head Pulley.

RECOMMENDATIONS

1Rubber lagging of Head, Bend and Take-up pulleys and remove fabricated scraper at the bend pulley to prevent

damage to the pulley.

2 Worn-out rubber lagging at the Take-up Pulley.



to the face of pulley, misalignment and slippage

between the pulley and belt.Ineffective belt cleaning system installed. Belt cleaners


the belt surface after unloading zone, thus preventing

the material loses and also to protect the conveyor

accessories specially its idlers. (as seen in Fig.3)

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1 2

3

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RUNNING STOP




INSPECTION REPORT

BELT SPECS 1300MM CONVEYOR ID B04

MATERIAL LIMESTONE DATE INSTALLED N/A



1

2



Conventional skirting system and belt misalignment in

the tail area.




RECOMMENDATIONS


3 Multiple belt edge damaged along the conveyor belt.



damage (as seen in Fig.3), damaging conveyor strucure,

excessive material spillages and worst is unnecessary

stop in operation.



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3

2

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2Worn-out rubber lagging at Snub Pulley with fabricated

scraper.

INSPECTION REPORT

BELT SPECS 1000MM CONVEYOR ID BC07



RECOMMENDATIONS



1Rubber lagging of Bend, Snub and Tail pulleys and remove fabricated scraper at the snub pulley to prevent damage

to the pulley.

3Worn-out rubber lagging and excessive material build-up

at Tail Pulley.

1 Worn-out rubber lagging at both Bend Pulley.

4 Conventional skirting system.






between the pulley and belt.


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damage (as seen in Fig.2), damaging conveyor strucure

(as seen in Fig.1), excessive material spillages and worst

is unnecessary stop in operation.


1 Conveyor belt hit the stucture.

2 Belt-edge Damage.


INSPECTION REPORT



BELT SPECS 1000MM CONVEYOR ID BC07

RECOMMENDATIONS



3 Tied-off carrying roller. (Self aligning frame & roller)Unequal distance and not aligned or damaged frame of

carrying rollers can cause belt mistracking.

4Excessive carryback materials build-up at the face of the

return rollers.






2 Supply and replacement of carrying rollers.


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BELT SPECS 1000MM CONVEYOR ID BC10A



INSPECTION REPORT

1,2Worn-out rubber lagging and excessive material build-up

at the Snub and Take-up Pulley.






RECOMMENDATIONS

Rubber lagging of Snub and Take-up pulley.


4 Vertical rollers installed at the carrying side.It will prevent belt edge damage but can't correct the

mistracking or misaligning of the conveyor belt.



3Excessive carryback materials build-up at the face of the

return rollers.






1

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2

3

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Rubber lagging of snub pulley.4

RECOMMENDATIONS


3Carryback materials build-up at the face of the return

rollers.





4 Worn-out rubber lagging at snub pulley.




1

Conventional skirting system.




2

Belt mistracking observed along the Conveyor System.



damage, damaging conveyor strucure, excessive material

spillages and worst is unnecessary stop in operation.


INSPECTION REPORT






BELT SPECS 1000MM CONVEYOR ID BC10B

1

4

2

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Summary:

For Clinker WF

1. Replacement of Conveyor Belt (Heat Resistance)

2. Installation of (1) Martin Compact Cleaner for 1000mm BW.

For Gypsum WF


For Additives WF


For Common Conveyor

2. Rubber Lagging of (1) Tail Pulley 400mm dia. X 850mm length.

3. Rubber Lagging of (1) Snub Pulley.

4. Rubber Lagging of (2) Bend Pulley 280mm dia. X 850mm length.

5. Rubber Lagging of Take-Up Pulley 400mm dia. X 850mm length.

6. Installation of (1) Martin HD QC#1 Primary Belt Cleaner for 750mm BW.

7. Installation of (1) Martin SC16 Secondary Belt Cleaner for 750mm BW.

8. Installation of (1) Martin® Torsion V-Plow for 750mm BW.

9. Install (1) Remaskirt with clamp.

11. Replacement of Belt Conveyor.

1. Installation of (3) Martin® Belt Tracker upper and (3) lower unit for 750mm BW.

10. Installation of (1) Martin® Trac-mount MD Impact Cradles for 750mm BW.

For BC04

1. Rubber Lagging of (1) Head Pulley 800mm dia. X 1450mm length.

2. Rubber Lagging of (1) Take-Up Pulley 600mm dia. X 1450mm length.


4. Installation of (1) Martin XHD QC#1 Primary Belt Cleaner for 1300mm BW.




For BC07


2. Rubber Lagging of (1) Tail Pulley 400mm dia. X 1200mm length.

3. Rubber Lagging of (1) Snub Pulley 300mm dia. X 1200mm length.


7. Installation of (1) Martin HD QC#1 Primary Belt Cleaner for 1000mm BW.



10. Checking and replacement of carrying rollers.

8. Installation of (1) Martin® Trac-mount HD Impact Cradles for 1300mm BW.




For BC10A

1. Rubber Lagging of (1) Snub pulley.

2. Rubber Lagging of (1) Take-up Pulley.




For BC10B





7. Rubber Lagging of Snub Pulley




PROPOSAL

Item No. Particular Qty U/M Part No. Price (Php) Total amount (Php)

1 Conveyor Belt Bridgestone NF315/2 1000 x 3.0 x 2.0 x 10m SF-180 (Endless) for Clinker WF 10 Mts n/a - -

2 Martin® Compact Cleaner (Green) for 1000mm BW 1 Assy. 33464-3600GR - -

3 Martin® Compact Cleaner (Orange) for 800mm BW 1 Assy. 33464-3000 - -

4 Martin® Compact Cleaner (Orange) for 650mm BW 1 Assy. 33464-3400 - -

5 QC® #1 Extra Heavy Duty Cleaner 52" BW with Martin® Extra Heavy Duty Spring Tensioner 1 Assy. 35899-540048T - -

6 QC® #1 Extra Heavy Duty Cleaner 40" BW with Martin® Extra Heavy Duty Spring Tensioner 2 Assy. 35899-420036T - -

7 QC® #1 Heavy Duty Cleaner 40" BW with Martin® with MARTIN® TWIST™ Tensioner 1 Assy. 36898-420036T - -

8 QC® #1 Heavy Duty Cleaner 30" BW with Martin® with MARTIN® TWIST™ Tensioner 1 Assy. 36898-300024T - -

9 MARTIN® SC#16™ with T Bracket for 1300mm BW 1 Assy. SC#16/HAR/1350 - -

10 MARTIN® SC#16™ for 1000mm BW 3 Assy. SC#16/HAR/1050 - -

11 MARTIN® SC#16™ for 750mm BW 1 Assy. SC#16/HAR/750 - -

12 Martin® Torsion V-Plow for 1300mm BW 1 Assy. 28488-48R - -



15 Martin® Tracker™ - Performance Duty Upper Unit for 1300mm belt width 2 Assy. TKR-48US - -

16 Martin® Tracker™ - Performance Duty Lower Unit for 1300mm belt width 3 Assy. TKR-48LS - -





21 Martin® Trac-mount HD Impact Cradle for 1300mm BW 1 Assy. 37357-4845S - -

22 Martin® Trac-mount MD Impact Cradle for 1000mm BW 2 Assy. 30688-4245S - -

23 Martin® Trac-mount MD Impact Cradle for 750mm BW 1 Assy. 30688-3045S - -

24 Remaskirt with clamp 4 Lots n/a - -

25 Rubber lagging of Tail Pulley 400mm dia. X 850mm length 1 Lot n/a - -

26 Rubber lagging of Bend Pulley 280mm dia. X 850mm length 2 Lots n/a - -

27 Rubber lagging of Bend Pulley 400mm dia. X 850mm length 1 Lot n/a - -

28 Rubber lagging of Head Pulley 800mm dia. X 1450mm length 1 Lot n/a - -

29 Rubber lagging of Take-up Pulley 600mm dia. X 1450mm length 1 Lot n/a - -



32 Rubber lagging of Snub Pulley 300mm dia. X 1200mm length 1 Lot n/a - -

33 Rubber lagging of Tail Pulley 400mm dia. X 1200mm length 1 Lot n/a - -

34 Rubber lagging of Snub Pulley for Common Conv., BC10A and BC10B 3 Lots n/a - -

35 Rubber lagging of Take-up Pulley for BC10A 1 Lot n/a - -

36 Conveyor Belt for Common Conveyor (750mm) 1 Lot n/a - -

37 Carrying Roller Improvement (Mech'l works) 1 Lot n/a - -

1.1. Replacement and Installation of New Carrying Rollers.

1.2. Checking and squaring of roller frames.

Grand Total -

Note:

Item No. 21, 24, 34, 35, 36 and 37 for further inspection and evaluation.

lri iligan audit report for finish mill & crusher area (02-20-15).pdf

Documents

belt surface

inappropriate belt

joint portion of belt

belt cleaners primary

conveyor accessories

iligan plant inspection

material buildup solution

conveyor idpenetration