CHAPTER 1 INTRODUCTION

1.1 ORGANIZATION Fertilizers And Chemicals Travancore Limited is the largest public sector undertaking in Kerala. The Fertilizers And Chemicals Travancore Limited ,popularly known as FACT which setup the first large scale Nitrogenous factory in the country ,as early as 1944, on the back of Periyar at Udyogamandal, near the Cochin Port . From a single product fertilizer plant of the forties ,FACT has through the years grown into a large multi-product ,multi-divisional corporation today a legend of our times and triumph of the public sector .FACTS two fertilizer manufacturing divisions at Udyogamandal and Cochin together have so far produced and distributed millions of tones of fertilizer nutrients .which has helped farmers to produce over 50 millions tones of food grains .FACTS Marketing division has a well organized sales network, which ensures that even the farmer un the remotest village is fully benefited through its agronomy and rural developments services .The rich fund of expertise, experience and skill s gained over the years in manufacturing units of FACT were pooled together in the mind sixties to form two separate engineering divisions ,FACT Engineering & Design Organization(FEDO) & FACT Engineering Works (FEW). These two Divisions between them cover the entire spectrum of Consultancy and

Engineering Services and have contributed a great deal to attain self- reliance in fertilizer and chemical technology in the country .In 1990 ,FACT further diversified into the field of petrochemicals by setting up a Carprolactum unit .Today ,FACT integration . FACT COCHIN DIVISION is the second manufacturing Division of FACT The factory is situated at Ambalamedu adjacent to BPCL Kochi Refinery .The division was formed as a part of the planned efforts by Government to give the greatest scope to the use of indigenous technology in setting up large sized fertilizer plants. FEDO and P&D of PDIL were entrusted with responsibility of is on the threshold of further diversification and backward

installing these large plants with artificial reservoir over 200 acres to meet the water requirements of plants and townships. 1 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

The Phase 1 of the Division, with facilities to produce 1, 98,000 tonnes of Ammonia and 33,000 tonnes of Urea per annum went into commercial production in 1973.Licence for the Phase 2 conceived to manufacture complex fertilizer was issued in1972 .The Phase 2 plants were commissioned in the year 1976 .But due to financial crisis, Phase 1 plant is not produce presently. Only Phase 2 plants are to production now. Phase 2 consists of three plants namely ,Sulphuric acid Plants ,Phosphoric acid Plants and NP Plants having annul capacities of 3,33,000MT, 115200MT of P2O5 and 4,85,000 MT of complex fertilizer respectively. The Factory site is connected by road, rail and

waterways which facilitate the movement of raw materials and products. Consistent with commitment to environmental health ,all necessary safeguards have been built in to take of water and atmospheric pollution caused by effluent gases and liquids thrown out from the factory .FACT COCHIN DIVISION has a track record of earnestness in combating pollution .The effluent are treated with controlled lime addition, an amorphous recovery plant ,fumes scrubbers for emissions from Complex fertilizer Plant, DCDA Process with Candle Filters at the intermediate absorption tower of Sulphuric acid Plant and Alkaline scrubbing of emissions form Phosphoric acid Plant.

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1.2 NEED FOR THE PROJECT Operations and Plant Maintenance are crucial aspects and the overall profitability of any Company depends to a great extend on them. Maintenance plays a key role in keeping the plant available for effective operation through out the year .The maintenance practices followed by any Company can be improved by analyzing previous maintenance logs and equipment histories to find frequent troubles and finding solution to overcome those troubles by analyzing its root cause and adopting correct maintenance technique and by scheduling the maintenance program. It is said that An ounce of prevention and predictive maintenance is worth a pound of cure. Plant efficiency can be improved by analyzing method to decrease break down through adopting different techniques which does not increase the operational cost. A true maintenance optimization process continually monitors and optimizes the current maintenance, program to improve its overall efficiency and effectiveness. The effort to initiate the maintenance optimization process can be eliminated over time if additional effort is not taken to sustain the process.

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1.3 OBJECTIVE Maintenance Optimization is a process that attempts to balance the maintenance requirements (legislative, economic, technical, etc...) and the resources used to carry out the maintenance program (people, spares, consumables, equipment, facilities, etc). The goal of the maintenance optimization process is to select the appropriate maintenance technique for each piece of equipment within a system and identifying the periodicity that the maintenance technique should be conducted to achieve regulatory requirements , maintenance targets concerning safety, effectively

implemented it will : improve system availability reduce overall maintenance costs improve equipment reliability improve system safety The maintenance optimization process will effectively blend predictive, preventive, productive, and corrective maintenance strategies. This will allow the systems maintenance program to move from a reactive approach or a preventive approach to a planned approach .The planned approach conducts maintenance at the most optimum time, which is often before the equipment fails, whereas the reactive approach performs maintenance strictly on a scheduled basis. The objective of this project is the Optimization of Mechanical Maintenance of Phosphoric Acid Plant.

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CHAPTER 2 MAINTENANCE
Maintenance is a set of organized activities that are required to carry out in order to keep an item in its best operational condition with minimum cost acquired.

2.1 PREDICTIVE MAINTENANCE: It is a method of predicting the failure before it occurs, identifying the root causes for those failure symptoms and eliminating those causes before they results in extensive damage of equipment. This can be classified into two methods: Condition based predictive maintenance(CBM) Statistical based predictive maintenance.

There is a lot more useful information in the data collected than just the lubricant quality, trends, and tailing components. Aside from the reliability aspect that predictive maintenance can provide, there are significant cost savings potentials available through effective smart maintenance. Doing the right thing, at the right time, for the right reason.

Condition Based Maintenance (CBM): Most electric motors have small volume lubricant reservoirs and thus, oil analysis is generally done for equipment condition rather than lubricant quality. Oiled motors where originally set up with a one year frequency PM for oil changes. Even with good lubricant handling practices there were still significant swings in the ISO code cleanliness. The high spike was generally right after an oil change with the cleanest being right before an oil change. The dirt in circulation of a hydraulic system will cause damage. A motor may not have the same flow as a hydraulic, but the slinger rings do a great job of circulating wear debris within the bearing reservoir. This of course causes wear to the shaft journal and the slingering showing up as iron, chromium or brass in the oil analysis. Unfortunately most motors do not have circulation systems or filtration to remove wear debris once they are there, they must slowly be settled out to be stirred up again during an oil change. 5 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

Root Cause Analysis (RCA): Root cause analysis is an important part of a functional predictive maintenance program.Another ease for RCA revealing an oil related problem occurred in some of our motors with submerged coolers and hydraulic unit heat exchangers that were made of Copper. Another great example of a few minor changes to upgrade the equipment came when the effluent processing facility was modified to produce synthetic gypsum from our scrubber slurry. This change in operating process placed some of the equipment in different operating parameters which of course caused problems. The plant modifications were well worth it since it reduced our landfill use by up to 75%. One gear reducer was failing every 3 to 5 weeks from the ingress of fly ash which looked like lapping compound and was wearing the gears and bearings to failure. With some basic improvements such as an increase in lubricant viscosity, bearing isolators, kidney loop filtration, and breathers we have improved the time between failures to better than 3.

There was a crack developed in ball mill in ring gears. It was first identified through vibration data and monitored closely for almost a year until we were able to schedule the gear replacement. This allowed normal expediting of parts and workforce rather the added expense of doing it on an emergency basis. We are also able to identify ball mill gear, reducer gear, and bearing problems early enough to schedule and plan the replacement for a time of least economic impact. At times, the failure might progress faster than expected but at least we have everything ready, which removes the unknown factor from equation

2.2 PREVENTIVE MAINTENANCE: It is a set of activities that are performed on plant equipment, machinery and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degradation in their operating conditions. This method relies on the machines condition to accurately schedule the repairing interval e.g. cleaning, inspection, oiling and re-tightening etc. Objective of this type of maintenance is to retain the healthy condition of equipment and failure through the prevention of deteriorization by periodic inspection or equipment condition diagnosis. 6 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

CHAPTER 3 OPTIMIZATION
The design and operation of systems or processes to make them as good as possible in some defined sense. The approaches to optimizing systems are varied and depend on the type of system involved, but the goal of all optimization procedures is to obtain the best results possible (again, in some defined sense) subject to restrictions or constraints that are imposed. While a system may be optimized by treating the system itself, by adjusting various parameters of the process in an effort to obtain better results, it generally is more economical to develop a model of the process and to analyze performance changes that result from adjustments in the model. In many applications, the process to be optimized can be formulated as a mathematical model; with the advent of high-speed computers, very large and complex systems can be modeled, and optimization can yield substantially improved benefits. Optimization is applied in virtually all areas of human endeavor, including engineering system design, optical system design, economics, power systems, water and land use, transportation systems, scheduling systems, resource allocation, personnel planning, portfolio selection, mining operations, blending of raw materials, structural design, and control systems. Optimizers or decision makers use optimization in the design of systems and processes, in the production of products, and in the operation of systems.

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CHAPTER 4 PHOSPHORIC ACID PLANT

The phosphoric acid plant is designed to produce 360 TDP of P2O5 through the dihydrate route. The plant designed by FEDO in collaboration with Messers, Society of Prayon of Belgium employs the Prayon covetable process to give a product having strength of 30% P2O3. A separate concentration section is provided to concentrate this weak acid having strength of 45% P2O5. 4.1 PROCESS Rock phosphate of around 74 BPL is ground to the required size (90% through 100 Mesh Taylor Sieve) in a rock grinding section. This ground rock is fed at a regulated rate through a gravimetric (Libra) weigh feeder into a multi compartment Attack Tank where a large quantity of slurry is maintained in circulation. At another point in the attack tank 98% acid is fed along with weak recycle phosphoric acid. The rock phosphate react with Sulphuric acid and the following reactions results. Ca3(PO4)2 + 3H2SO4 2H3PO4 + 3CaSO4 Ca3(PO4)2 + 4H3PO4 3Ca(H2PO4)2 Ca(H2PO4)2 + 3H2SO4 3CaSO4 + 6H3PO4 A portion of slurry from the attack tank is continuously circulated through an evaporator cooler called the flash cooler to remove the excess water from the system as well as to prevent the attack tank slurry temperature from going up and causing semi hydrate formation. A portion of slurry over turn from the attack tank into a series of three digestive vessels (to give sufficient time for crystal formation) and is then pumped to a rotating tilting pan filter. In the filter known as prayon filter, the slurry which consists of phosphoric acid and gypsum (calcium sulphate dehydrate crystal) is filtered aided by vacuum. The filtrate is a product acid which goes to the 30% acid settler. The filter cake which is gypsum is deposited through a dry disposal system which has replaced the original system. In the filter after the recovery of 30% acid as filtrate the cake is washed counter currently first with water. The water yields 5% P2O5 acid and this is used again for 8 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

washing to yield12% acid and yet again to yield 18% acid which then goes to the attack tank along with Sulphuric acid as weak recyclic acid. The 30% P2O5 acid collected in the settler can be either stored as such in storage tank or can be concentrated further in a concentration section laid out in two streams. Forced circulation evaporators having Karate tube heat exchangers and operating under and a vacuum can concentrate all weak acid to 45% P2O5 or even 54% if a reduction in output is allowed. The fluorine content of the rock is liberated partly in the attack section during reaction with sulphuric acid. The major portion of fluorine going along with the products get liberated in the evaporator and is recovered by fluorine scrubber system as Fluosilic acid having 13% H2SiF6 the fluorine evolved in the attack tank is also collected in a scrubber and joins the Fluosilic acid from the concentration section.

Fig:1 Phosphoric Acid Plant

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CHAPTER 5 CORROSION OF METALS

The main mechanical problem in PAP is the cohesiveness of metals. The 20% of the total cost issued for materials, so it is very important to reduce corrosion by using corrosion preventive materials. In PAP we use HV9/904L and MSRL material. The cost of HV9 is comparatively higher than MSRL. So we use HV9 for machines/ equipments and MSRL for pipes. The failure rate of MSRL is found to be very high. The main reasons for failure are given below. 1. Bulging of lining 2. Failure of lining due to poor workmanship. 3. Damage to the lining caused during cleaning of pipes to remove deposits. In this project we have 50 nos of used tubes in primary reformer of ammonia plant(now ammonia plant is not working and it is scrap).The reformer tube is of material HK40 and HP50(casting).The material of composition of HK40 and HP50 are compared with HV9 material and found to have only minor changes in their chemical composition. If we use HK40 and HK50 in place of MSRL we can reduce the cost of MS and rubber lining and it is a good corrosion resistant material also.

TABLE 1 : COMPOSITIONS OF HK40, HP50 AND HV9 Alloy/elements HV9 HK40 HP50 C 0.02 0.35 0.5 Cr 19 25 26 Cu 1 Mn 2 0.4 0.73 Mo 4.5 Ni 24 20 32 P 0.04 0.03 0.04 S Si V 0.5

0.035 1 0.03 0.04 0.5 1.21

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TABLE 2 CORROSION RATE (MM/YEAR) PHOSPHORIC ACID Conc % weight 50 60 70 80 Boiling Boiling Boiling Boiling 0.03 0.08 0.15 0.40 0.01 0.14 0.35 0.61 0.18 0.28 0.13 0.31 CONDITION HP50 HK40 HV9

PHYSICAL PROPERTIES 0F HK 40 Density (lbs/in3)= 0.280 Melting Point(oF) =2540 @ 1760oF Thermal Conductivity =7.9 @ 212oF Thermal Expansion= 9.8 @ 70-1400oF

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CHAPTER 6 BUCKET ELEVATOR

A bucket elevator, also called a grain leg, is a mechanism for hauling flowable bulk materials (most often grain or fertilizer) vertically.

Fig: 2 Bucket Elevator It consists of: 1. Buckets to contain the material; 2. A belt to carry the buckets and transmit the pull; 3. Means to drive the belt; 4. Accessories for loading the buckets or picking up the material, for receiving the discharged material, for maintaining the belt tension and for enclosing and protecting the elevator. A bucket elevator can elevate a variety of bulk materials from light to heavy and from fine to large lumps. A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend entirely on the action of centrifugal force to get the material into the discharge chute and must be run at speeds relatively high. Inclined elevators with buckets spaced apart or set close together may have the discharge chute set partly under the head pulley. Since they don't depend entirely on the centrifugal force to put the material into the chute, the speed may be relatively lower. 12 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

Nearly all centrifugal discharge elevators have spaced buckets with rounded bottoms. They pick up their load from a boot, a pit, or a pile of material at the foot pulley. The buckets can be also triangular in cross section and set close to on the belt with little or no clearance between them. This is a continuous bucket elevator. Its main use is to carry difficult materials at slow speed. 6.1 PROBLEMS IN BUCKET ELEVATOR The problem it was facing was the frequent breakage of the drive chains. The reason was that, the non return valve of the elevator was broken, as soon as the machines were shut down the semi-loaded elevator returns due to the huge weight inside it and falls freely. This motion directly affects the chain linked to the gear box and serious cases of damages to the chain and the sprocket were recorded.

6.2 SUGGESTION: These set of damages can be overcome by two methods: A new back-stopper can be employed , which will, for sure prevent any backward motion of the bucket-elevator. Another method is to run the elevator for one round without loading, just before shutting the plant. By doing this the weight on either side of the elevator is balanced and there will not be any backward motion.

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CHAPTER 7 ATTACK TANK AGITATOR

Report On Attack Tank Agitators Drive Gear Box In Phosphoric Acid Plant The phosphoric acid plant was commissioned with Hansen transmission gear boxes for 11th 12th 13th 14 15 compartment agitators. Out of these 11 12 are identical. In the long run of the equipments several failures occurred. As part of indigenization of gear box, 3 gear boxes were produced from Greaves and in use now. The details of the gear boxes presently installed running are given below: 11th compartment Make Model RPM HP : : : : Hansen Patent 724 LITS 870/78.5 150 1000 AM 15 mss

Motor rpm : Pully dia.

: 355/400

Agitator speed : 78.5 12th compartment Make Model RPM HP : Hansen Patent : 724 LITS : 870/78.5 : 150

Motor rpm : 1000 Ah 315 mss Pully dia: : 355/400

Agitator speed : 78.5 13th compartment: Make Order no Type Ration : Greaves gears : 324569 : vb2 315sa : 12.6/1 14 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

14th compartment Name plate is not available Make : Hansen Patent 15th compartment: Make : Greaves gears

Order no : 75213 Type Ration : : vb2 315sa 12.6/1

16th compartment: Make : Greaves Type : vb2 250 sa

Ration : 17.1/1

Fig 3: Attack Tank Agitator

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7.1 DETAILS OF REAPIRS DONE IN ATTACK TANK AGITATORS (in the year 2011) TABLE 3: 12th Compartment: Date 21/1/11 TABLE 4: 14th Compartment: Date 26/2/11 10/10/11 TABLE 5: 15th Compartment: Date 26/2/11 7/6/11 10/10/11 COMPLAINT DEFECTS Agitator broken Agitator broken Agitator broken REPAIR DONE Agitator replaced Agitator replaced Agitator replaced COMPLAINTS Agitator broken Agitator broken REPAIR DONE Agitator replaced Agitator replaced COMPLAINTS Agitator broken REPAIR DONE Agitator replaced

Agitators in compartments 11,13,16,21 had no repairs done in this time period.

CONCLUSION There is all kind of spares of attack tank agitator gear boxes kept in the store. The gear boxes of 11 and 12 compartments are identical. By replacing other gear boxes with the gear boxes of compartment 11 and 12 it can be reduced the number of spares kept in the maintenance store. So the cost can be thus reduced.

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CHAPTER 8 PRAYON FILTER

Fig: 4 Prayon Filter

One of the key equipment in phosphoric acid plant is Prayon filter. Any failure in this will cause the extraction of acid into a halt. When analyzed it is found that the bearing of filter tray is frequently failing. The device for supporting the rotating shaft is called bearing. There are 20 x 1(outer roller), 18 x 1 (inner roller) and 14 x 1(supporting roller) which are used in this filter. The roller bearings are frequently failing because of the corrosive action of phosphoric acid and also the corrosion because of gypsum. From the inspections carried out it is found that the admission of acid and gypsum can be prevented if the bearings are properly lubricated with grease which acts as a seal. Any repair of the tray will consume at least 2 hours and require 6 labors .Hence by ensuring proper lubrication down time can be reduced as it is one of the major equipment there by increasing the operational efficiency.

8.1 IMPROVEMENTS A special compact vacuum box for separating gases and the various filtrates A fast-drain filtration cell which can increase filter capacity and filtration yield An automatic system to keep the pans horizontal A new tilting-track design for higher rotation speed and filtration capacity Support rollers designed for heavy loads A robust car frame with a replaceable wear plates TDI filter 17 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

Fig: 5 TDI filter

8.2 MAIN BENEFITS

Prayon filters are highly reliable due to their robust design. A number of filters sold in the 1960s are still in operation; On-stream factor of over 95%; Excellent ratio between capacity and extraction yield, due to batch filtration and a high level of authorized maximum vacuum; Extremely energy-efficient equipment; Negligible recycling of the solids recovered during cloth washing means that the cake discharged from Prayon filters contains a minimal quantity of free water;

High reliable experience with very large filters(e.g. 30-240 filter with a surface area of 275 m).

Main benefits of TDI filter Compactness Batch filtration Fewer mechanical parts Lower energy consumption Lower investment costs 18 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE

CHAPTER 9 CONVEYOR DESIGN MODIFICATION

9.1 DESCRIPTION Conveyors are rotating machines, which transmit raw materials, semi finished, finished material. Normally conveyors are used for short distance applications. Conveyors primarily perform the movement of uniform loads between fixed points. They occupy space continuously except when they are of portable type. They reduce handling. Different types of conveyors are belt, roller, screw, pipeline, monorail, trolley etc. Conveyors are useful when Loads are uniform Materials move continuously Routes do not vary Movement rate is relatively fixed

Conveyors have three parts rotor, idler and belt. The rotor connects with the motor by using coupling, chains. For longer belts a weight is added to the lower portion of belt to maintain tension in belt.

9.2 CONVEYORS USED IN PAP In PAP the materials are transmitted by using conveyors for solid/powder materials, fluid materials are passed by pipelines. Different conveyors used in PAP are described below. Belt conveyors for transmitting rock phosphate from barge to grinding mill. Bucket conveyors to transmit fine phosphate from grinding mill. Screw conveyor Gypsum belt conveyors transfer the byproduct gypsum into a temporary storage place.

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TABLE 6 : REPAIRS DONE IN CONVEYOR G3 (in 2011): Date 19/2/11 COMPLAINTS Sprocket damaged REPAIR DONE gear box with socket replaced ANALYSIS Oil seal leak

2/6/11 9/7/11

Belt worn Chain damaged

Belt replaced 1 Triplex chain replaced 1 Triplex chain replaced

Long run Lack of lubrication,

6/12/11

Chain damaged

gypsum deposits inside chain guard

6.3 PROBLEMS FOUND IN CONVEYORS The main aim is to optimize the mechanical maintenance and improve the operational efficiency of conveyors especially belt conveyors .Some repeated problems of belt conveyors (rock phosphate conveyor-R conveyor, gypsum conveyor G conveyor).By comparing the problems occurred in the R-conveyors as well as G conveyors ,it is found that the following failures occurs continuously in the G- conveyors. Belt problem Bearing damaged Connecting chain broken

6.4 ANALYSIS By analyzing the above 2 cases it is found that the continuous failure of G conveyor is due to two reasons 1. The traces of phosphoric acid contain in the byproduct gypsum. 2. Exposure of G-conveyor into atmosphere. These two reasons will lead to corrosion of materials. We can reduce this corrosion by reducing the exposure of G-conveyor to atmosphere and also by proper filtration of phosphoric acid.

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6.5 SUGGESTION We have to design proper roof covering for the G- conveyor to prevent the atmospheric exposure as in case of R-conveyor. The length of G-conveyor is around 120 meters and the material for covering is aluminum. There is another solution of reducing the load on the belt either by increasing the support by increasing the number of roller in effective contact. Secondly, the slope on the G3 conveyor can be decreased by increasing the height at the G2 side, but this suggestion is not practical anyhow.

Fig:6 Conveyor Belt

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ANSYS REPORT AFTER ANALYZING THE CURRENT DESIGN OF THE CONVEYOR BELT DESIGN

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FIGURE 7 Model (A4) > Static Structural (A5) > Remote Force

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FIGURE 8 Model (A4) > Static Structural (A5) > Remote Force > Figure

Solution (A6)
TABLE 7 Model (A4) > Static Structural (A5) > Solution Object Name Solution (A6) State Solved Adaptive Mesh Refinement Max Refinement Loops 1. Refinement Depth 2.

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TABLE 8 Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information Object Name Solution Information State Solved Solution Information Solution Output Solver Output Newton-Raphson Residuals 0 Update Interval 2.5 s Display Points All

TABLE 9 Model (A4) > Static Structural (A5) > Solution (A6) > Results Equivalent Stress Object Name Total Deformation State Solved Scope Scoping Method Geometry Selection Geometry All Bodies Shell Top/Bottom Definition Type Total Deformation Equivalent (von-Mises) Stress By Time Display Time Last Calculate Time History Yes Identifier Use Average Yes Results Minimum 0. mm 0. MPa Maximum 1.4995e-008 mm 9.1031e-007 MPa Minimum Occurs On convers1 Maximum Occurs On belt11 rollersupportbeam1 Information Time 1. s Load Step 1 Substep 1 Iteration Number 1

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FIGURE 9 Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation > Figure

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FIGURE 10 Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress > Figure

Material Data
Structural Steel
TABLE 10 Structural Steel > Constants Density 7.85e-009 tonne mm^-3 Coefficient of Thermal Expansion 1.2e-005 C^-1 Specific Heat 4.34e+008 mJ tonne^-1 C^-1 Thermal Conductivity 6.05e-002 W mm^-1 C^-1 Resistivity 1.7e-004 ohm mm

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TABLE 11 Structural Steel > Compressive Ultimate Strength Compressive Ultimate Strength MPa 0 TABLE 12 Structural Steel > Compressive Yield Strength Compressive Yield Strength MPa 250 TABLE 13 Structural Steel > Tensile Yield Strength Tensile Yield Strength MPa 250 TABLE 14 Structural Steel > Tensile Ultimate Strength Tensile Ultimate Strength MPa 460 TABLE 15 Structural Steel > Alternating Stress Alternating Stress MPa Cycles Mean Stress MPa 3999 10 0 2827 20 0 1896 50 0 1413 100 0 1069 200 0 441 2000 0 262 10000 0 214 20000 0 138 1.e+005 0 114 2.e+005 0 86.2 1.e+006 0 TABLE 16 Structural Steel > Strain-Life Parameters Strength Coefficient MPa 920 Strength Exponent -0.106 Ductility Coefficient 0.213 Ductility Exponent -0.47 Cyclic Strength Coefficient MPa 1000 Cyclic Strain Hardening Exponent 0.2

TABLE 17 Structural Steel > Relative Permeability Relative Permeability 10000 TABLE 18 Structural Steel > Isotropic Elasticity Young's Modulus MPa Poisson's Ratio Temperature C 2.e+005 0.3

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ANSYS REPORT AFTER ANALYZING THE MODIFIED CONVEYOR BELT DESIGN

Solution (A6)

TABLE 19 Model (A4) > Static Structural (A5) > Solution Object Name Solution (A6) State Solved Adaptive Mesh Refinement Max Refinement Loops 1. Refinement Depth 2.

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TABLE 20 Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information Object Name Solution Information State Solved Solution Information Solution Output Solver Output Newton-Raphson Residuals 0 Update Interval 2.5 s Display Points All

TABLE 21 Model (A4) > Static Structural (A5) > Solution (A6) > Results Equivalent Stress Total Deformation Object Name State Solved Scope Scoping Method Geometry Selection Geometry All Bodies Definition Type Equivalent (von-Mises) Stress Total Deformation By Time Display Time Last Calculate Time History Yes Use Average Yes Identifier Results Minimum 0. MPa 0. mm Maximum 1.6718e-005 MPa 6.2095e-008 mm Minimum Occurs On convers1 Maximum Occurs On Part17^totalconverafterfailedl Part24^totalconverafterfailedl Information Time 1. s Load Step 1 Substep 1 Iteration Number 1

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FIGURE 11 Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress > Figure

FIGURE 12 Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation > Figure

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Material Data
Structural Steel
TABLE 22 Structural Steel > Constants Density 7.85e-009 tonne mm^-3 Coefficient of Thermal Expansion 1.2e-005 C^-1 Specific Heat 4.34e+008 mJ tonne^-1 C^-1 Thermal Conductivity 6.05e-002 W mm^-1 C^-1 Resistivity 1.7e-004 ohm mm TABLE 23 Structural Steel > Compressive Ultimate Strength Compressive Ultimate Strength MPa 0

TABLE 24 Structural Steel > Compressive Yield Strength Compressive Yield Strength MPa 250 TABLE 25 Structural Steel > Tensile Yield Strength Tensile Yield Strength MPa 250 TABLE 26 Structural Steel > Tensile Ultimate Strength Tensile Ultimate Strength MPa 460 TABLE 27 Structural Steel > Alternating Stress Alternating Stress MPa Cycles Mean Stress MPa 3999 10 0 2827 20 0 1896 50 0 1413 100 0 1069 200 0 441 2000 0 262 10000 0 214 20000 0 138 1.e+005 0 114 2.e+005 0 86.2 1.e+006 0

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TABLE 28 Structural Steel > Strain-Life Parameters Strength Coefficient MPa 920 Strength Exponent -0.106 Ductility Coefficient 0.213 Ductility Exponent -0.47 Cyclic Strength Coefficient MPa 1000 Cyclic Strain Hardening Exponent 0.2

TABLE 29 Structural Steel > Relative Permeability Relative Permeability 10000

TABLE 30 Structural Steel > Isotropic Elasticity Temperature C Young's Modulus MPa Poisson's Ratio 2.e+005 0.3

CONCLUSION The stress analysis has been performed in ANSYS v12. Initially the existing design was evaluated and then the modified design that included the additional support roller was subjected to analysis. The results were obtained as expected i.e. the modified design showed decreased stress in the conveyor belt. Therefore, the modified design can be implemented and is sure to give reduced stress in the belt and thereby increasing the life of the belt

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CHAPTER 10 SULPHURIC ACID STORAGE IN PAP

Sulphuric acid manufactured at SAP is stored in tank numbers 1201-A to D (4 tanks) near the plant. It is then pumped to storage tank near the PAP and is then pumped to NPK and PAP according to their requirement. Currently acid is pumped through A 6 diameter pipe from 1201-A tank in SAP to H2SO4 day tank near PAP. The approximate length of that pipe is 250m. From the tank near PAP, acid is then pumped to PAP attack tank through 4 pipe of length 120m to NPK, two lines of 4 and 135m length is used to pump the acid in which one is kept as spare. Provisions are therefore direct supply of acid from main line to both PAP and NPK line without going to the tank. It is noticed that the shell thickness of the tank is below the safety limit. Replacement of tank will take long time causing decline in production capacity.

Proposal: The deteriorated H2SO4 tank can be eliminated by implementing the following suggestions: Provide direct connection from main tank to attack tank are shown in figure there by eliminating the pump and the line from current storage tank to attack tank(120m, 4 diameter). To fulfill the acid requirement of NPK plant, a line can be laid from tank 1201-D in SAP to NPK as shown in figure using the 4 pipe used to carry acid to PAP attack tank and also using the spare line currently provided. Pumps currently used at storage tank, PAP can be used for the proposed line. Benefits: By implementing the above suggestions we can ensure the efficient supply of acid to both PAP and NPK plant. It eliminates the maintenance of the existing tank for the construction of new line is available we can considerably decrease the laying cost. This is comparatively economical both financial wise and efficiency wise than constructing or fabricating new tank.

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CHAPTER 11 CONCLUSION
The study of various machinery present at the FACT-CD was performed. The report was prepared. The conveyor belt problem was analyzed in Ansys v12 and the modified design was accepted. The study was conducted in various other parts also. Remedies were proposed for them as well. Operational efficiency could be achieved if the availability and reliability of machinery is ensured.

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CHAPTER 12 SCOPE FOR FURTHER STUDY

The optimization of mechanical maintenance helps in increasing the operational efficiency of plant by decreasing the down time and ensuring availability of machinery throughout the production cycle. Hence it is very important to optimize the maintenance practices. We have made a detailed schedule for the optimization in phosphoric acid plant of FACT Cochin Division. Based on these data further study can be made as the objective of any organization efficiency at lower expenses.

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CHAPTER 13 LIMITATION OF THE STUDY

FERTILIZERS AND CHEMICALS TRAVENCORE LIMITED is a very old company. Its plant designs have been modified many times to cope with the increase in production requirements and hence the equipment available there has been replaced many times. So the proper record of machinery used at various positions is not available at the plant. To make permanent list of equipment details is a difficult task unless the entire system is computerized. The lack of proper data regarding many types of equipment was a limitation during this study.

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CHAPTER 14 REFERENCES
MAINTENANCE HISTORY RECORD OF EQUIPMENTS AT FACT-CD INVENTORY OF EQUIPMENTS AT FACT-CD KUBOTA METAL CORPORATION, ONTARIO ALLOY DATA SHEET 04/91 http://www.engineeringtoolbox.com/metal-corrosion-resistance-d_491.html http://www.prayon.com/en/professional/equipments/design-development.php www.prayon-profile.com

38 Optimization Of Mechanical Maintenance In Phosphoric Acid Plant SNGCE