THE ANALYSIS OF BELT SLIP

WEIGHFEEDER 534-WF2

PNJ-PT HOLCIM INDONESIA

CASE STUDY REPORT

BANDAR ZULFIAN
NIM : 5216220067
WISNU AGUNG SETIAJI
NIM : 5216220222

STATE POLYTECHNIC OF JAKARTA-EVE HOLCIM INDONESIA

MAJORING IN MECHANICAL ENGINEERING
CONCENTRATION OF ENGINEERING INDUSTRY
CILACAP 2018
 THE ANALYSIS OF BELT SLIP
WEIGHFEEDER 534-WF2

PNJ-PT HOLCIM INDONESIA

CASE STUDY REPORT

BANDAR ZULFIAN
NIM : 5216220067
WISNU AGUNG SETIAJI
NIM : 5216220222

STATE POLYTECHNIC OF JAKARTA-EVE HOLCIM INDONESIA

MAJORING IN MECHANICAL ENGINEERING
CONCENTRATION OF ENGINEERING INDUSTRY
CILACAP 2018

ii
 THE ANALYSIS OF BELT SLIP
WEIGHFEEDER 534-WF2

BANDAR ZULFIAN

NIM : 5216220067

WISNU AGUNG SETIAJI

NIM : 5216220222

Accepted and Approved

On 26 July 2018

Advisor I Advisor II

Arie Setiaji Ibrahim Fatahula, S.T., M.Kom

Assesor I

Drs. Supriyadi Nasution, S.T., M.Kom

iii
 PREFACE

Thanks to God for giving His bounty for preparing a case study report entitled
"Analysis of Belt Slip Weighfeeder 534-WF2". And thanks also to the parties who
have helped in working on this report. The author chose Weighfeeder 534-WF2 to
be used as a case study topic.

This report was made to complete a case study based on the curriculum of the
Enterprise-based Vocational Education (EVE) education of PT Holcim Indonesia
Tbk. And the State Polytechnic of Jakarta in the period of 4th semester.

This case study report contains information and causes of Belt Slip on
Weighfeeder 534-WF2, such as: engineering process, general design, engineering
data, operational parameters, performance, common problems, recommendations,
and economic aspects.

We expect criticism and suggestions from readers in order to improve this

report. We hope this report will be useful to readers. Thanks.

Cilacap, 22 March 2018

iv
 LIST OF CONTENTS

THE ANALYSIS OF BELT SLIP ........................................................................... i

THE ANALYSIS OF BELT SLIP .......................................................................... ii
THE ANALYSIS OF BELT SLIP ......................................................................... iii
PREFACE .............................................................................................................. iv
CHAPTER I INTRODUCTION ............................................................................. 1
1.1 Background .............................................................................................. 1
1.2 Problem Formation ................................................................................... 2
1.3 Boundary Problem .................................................................................... 2
1.4 Purpose ..................................................................................................... 2
1.4.1 General Purpose .................................................................................... 2
1.4.2 Special Purpose ..................................................................................... 2
CHAPTER II LITERATURE STUDY ................................................................... 3
2.1 Weighfeeder General Knowledge ............................................................ 3
2.1.1. Function ............................................................................................ 3
2.1.2. Working Principle ............................................................................. 3
2.1.3. Equipment Construction ................................................................... 4
2.1.4. Main Component............................................................................... 5
2.1.5. Parameter Operasi ........................................................................... 17
2.2 Spesification of Dolomite in Nusakambangan Quarry........................... 18
2.2.1 Main Utility......................................................................................... 18
2.2.2 Characteristic of Material ................................................................... 18
CHAPTER III ....................................................................................................... 19
METHODOLOGY ................................................................................................ 19
3.1 Flow Chart .................................................................................................. 19
3.2 Find Problem .............................................................................................. 20
3.3 Literatur Study ........................................................................................... 20
3.4 Analysis & Problem Solving...................................................................... 21
3.5 Report ......................................................................................................... 21
CHAPTER IV ....................................................................................................... 22

v
DISCUSSION ....................................................................................................... 22
4.1 Weighfeeder 534-WF2 ............................................................................... 22
4.2 Specification of Weighfeeder 534-WF2 ................................................... 22
4.3 Location of Weighfeeder 534 – WF2......................................................... 24
4.4 Performance Analysis of Weighfeeder 534-WF2 ( 2017 ) ........................ 25
4.5 Belt Slip...................................................................................................... 27
4.6 Belt Slip in Weighfeeder 534-WF2............................................................ 28
4.7 Root Cause Analysis of Belt Slip in Weighfeeder 534-WF2 ..................... 29
4.7.1 Belt Slack ........................................................................................ 29
4.7.2 Head and Tail Pulley not tight belt properly .................................. 31
4.8 Maintenance Cost Analysis Caused by Belt Slip ....................................... 34
4.9 Production Loss Analysis Caused by Belt Slip .......................................... 37
CHAPTER V......................................................................................................... 38
5.1 Conclusion ................................................................................................. 38
5.2 Solution ...................................................................................................... 38
BIBLIOGRAPHY ................................................................................................. 39

vi
 LIST OF FIGURES

Figure 2.1 Equipment Construction of Weighfeeder ............................................... 4

Figure 2.2 Bin in top of Weighfeeder ...................................................................... 5
Figure 2.3 Belt Scale ............................................................................................... 6
Figure 2.4 Speed Sensor .......................................................................................... 6
Figure 2.5 Shear Gate Form ................................................................................... 7
Figure 2.6 Skirtboards............................................................................................. 8
Figure 2.7 Pulleys.................................................................................................... 9
Figure 2.8 Idlers .................................................................................................... 10
Figure 2.9 Bearings ............................................................................................... 11
Figure 2.10 Motor ................................................................................................. 12
Figure 2.11 Gear Reducer ..................................................................................... 13
Figure 2.12 Belt Tensioner .................................................................................... 14
Figure 2.13 Belt Scraper ....................................................................................... 15
Figure 2.14 Strain Gauge ...................................................................................... 16
Figure 2.15 Wheatstone Bridge ............................................................................. 16
Figure 2.16 Load cellon Weighfeeder ................................................................... 17
Figure 3.1 Flow Chart Diagram of Methodology ................................................. 19
Figure 3.2 Data time, amount, dan causes stop in Finish Mill Area ..................... 20
Figure 4.1 Location of Weighfeeder...................................................................... 24
Figure 4.2 Data number of stop in Finish Mill Area ............................................. 25
Figure 4.3 Data stop duration Finish Mill area ..................................................... 26
Figure 4.4 Problem in Weighfeeder ...................................................................... 26
Figure 4.5 Belt Slip Animated .............................................................................. 27
Figure 4.6 Root Cause Analysis ............................................................................ 29
Figure 4.7 Belt Slack Animated ............................................................................ 29
Figure 4.8 Belt tension adjuster ............................................................................ 30
Figure 4.9 Belt tension .......................................................................................... 30
Figure 4.10 Bar damper chute ............................................................................... 31
Figure 4.11 Tail Pulley Weighfeeder .................................................................... 32
Figure 4.12 Rubber Lagging Head Pulley............................................................. 33
Figure 4.13 Material Sticky................................................................................... 33
Figure 4.14 Head pulley Weighfeeder ................................................................... 33
Figure 4.15 Number of repair diagram in 2017 .................................................... 34

vii
 LIST OF TABLES

Tabel 2.1 Specification of Weighfeeder ............................................................... 23

Tabel 4.1 Cost maintenance .................................................................................. 35
Tabel 4.2 Cost operational maintenance ............................................................... 36

viii
 1

CHAPTER I
INTRODUCTION

1.1 Background

PT. Holcim Indonesia Tbk Cilacap factory is highly dependent on production

capacity which is the main target in generating profit. In the cement production
process can not be separated also from the performance of a qualified production
equipment, not to mention the transport equipment in the Finish Mill area. In
Holcim Cilacap Plant there are several types of transport equipment, namely Belt
Conveyor, Chain Conveyor, Air Slide, Bucket Elevator, Screw Conveyor, Appron
Conveyor, Weighfeeder (Belt Scale) .From all of these equipments are the same
except for Weighfeeder (Belt Scale) which has special function and different
working principle.
Weighfeeder (Belt Scale) is a tool that serves to weigh material and transport
material in the cement industry. In PT Holcim Indonesia Tbk. Cilacap Factory,
Weighfeeder 534-WF2 functions to weigh and transport dolomite from Dolomite
Bin to Belt Conveyor 534-BC4 and then to Ball 564-BM2.
During 2017, the amount of stop duration due to the Unschedule Breakdown in the
Finish Mill area 2nd lane is dominated by mechanical trouble which reached 297
hours. Where Weighfeeder 534-WF2 ranks third with a duration of hours
Breakdown Unschedule of 46 hours.
From a brief review to the above problem, the Case Study is focused on
mechanical trouble analysis 534-WF2, where the main problem that is analyzed is
the cause of belt slip.
 2

1.2 Problem Formation

Based on this background, then the formulation of the problem in thisstudy are
as follows:
a. the root of the problem on the slip belt in Weighfeeder 534-WF2
b. Impact of belt slip on production process and other equipment.
c. Provides an appropriate solution to the root of the belt slip problem in 534-
WF2.
1.3 Boundary Problem

We need to classify the problem into several points in order to elaborate some

limits, so that it does not get out of the topic. Here are the issues related to the slip

belt problem in 534-WF2:

a. Weighfeeder 534-WF2 tool in mechanical and electrical terms.

b. Design Weighfeeder 534-WF2.
c. Maintenance Proccedure 534-WF2.
1.4 Purpose

1.4.1 General Purpose

As one of the requirements to complete the Diploma Program III

Department of Mechanical Engineering Polytechnic State Jakarta.

1.4.2 Special Purpose

a. Determining the root cause of slip belt on 534-WF2

b. Provide ideas for improvements to improve performance of 534-
WF2
 3

CHAPTER II
LITERATURE STUDY

2.1 Weighfeeder General Knowledge

2.1.1. Function

Weighfeeder (Belt Scale) is a tool that serves to weigh material and transport
material in the cement industry. In PT Holcim Indonesia Tbk. Cilacap Factory,
Weighfeeder 534-WF2 serves to weigh and transport dolomite from Dolomite Bin
to Belt Conveyor 534-BC4 and then to Ball 564-BM2.

2.1.2. Working Principle

The material is fed from the chute outlet bin dolomite to the Weighfeeder 534-
WF2 by opening Pin Gate 534-NG2. The material will flow to the belt weighfeeder
and will be weighed while passing through the belt using a load cell sensor. The
load cell will provide a signal of the voltage generated according to the weight that
will be forwarded to the CCR. This is called static weighing. The static balancing
aims to obtain an accurate weight when transported.
Unlike static weights, motion or dynamic weighing requires a second input,
which is a signal pulse proportional to the speed of the conveyor belt. Each pulse
speed sensor belt represents a fixed distance travel. Since the force measured by the
load cell is represented as the weight per unit length, it can be multiplied by the
distance of the belt journey (one pulse speed sensor) to give the product weight for
the belt segment.
Example: lbs / ft x ft = lbs
The sum of the samples provides a total throughput of product weight across
scales. With the right scale (calibration), the total weight takes the measurement
unit (pound, ton short, ton long, metric ton, etc.)
 4

2.1.3. Equipment Construction

Figure 2.1 Equipment Construction of Weighfeeder

 5

2.1.4. Main Component

In Holcim Cilacap Plant there are several types of transport equipment, namely
Belt Conveyor, Chain Conveyor, Air Slide, Bucket Elevator, Screw Conveyor,
Appron Conveyor, Weighfeeder (Belt Scale) .From all the equipment is the same
function except the Weighfeeder (Belt Scale) which has special functions and
different working principles. Weighfeeder (Belt Scale) is a tool that serves to weigh
material and transport material in the cement industry. In PT Holcim Indonesia Tbk.
The Cilacap Factory, Weighfeeder 534-WF2 serves to weigh and transport dolomite
from Dolomite Bin to Belt Conveyor 534-BC4 and then to 564-BM2 Ball Mill.

a. Silo, Bin and Hopper Applications

A rod or pin gate has a series of steel bars sliding inside a rectangular
opening. This valve provides full product flow when open, and is ideal
for product sizes of 0.5” (12mm) or greater. For applications with a large
variance between particle sizes with fine rods that interlock can be used
from both sides of the bin discharge for better flow control.

Figure 2.2 Bin in top of Weighfeeder

 6

b. Scale
The belt scale within the weighfeeder requires all the attention to
detail that a normal belt scale application requires, however the
weighfeeder is designed to be an optimum weighing device with the
scale integrated into it. Mounting load cells outside of the weighfeeder
frame allows for quick and easy cleaning as well as calibration. Vertical
adjustment of the scale allows for easy alignment with the approach and
retreat belt supports.

Figure 2.3 Belt Scale

c. Speed Sensor
The speed sensor is normally mounted to the driven pulley of the
weighfeeder. Return belt mounted versions can also be used, however
positive contact and installation space may be a concern. Motor-
mounted speed sensors are also an option, however belt-slip from the
drive pulley is not detected with a motor mounted version. An ideal
combination is a driven pulley primary speed sensor with a secondary
motor mounted sensor to detect belt slip as well as accurately monitor
the belt speed.

Figure 2.4 Speed Sensor

 7

d. Shear gate
The shear gate sets the material profile on the belt and bed depth.
There are two types of profile for a shear gate: flat and half moon style.
The flat type allows for more volumetric capacity on the conveyor belt,
but also provides more material contact on the skirtboards which can
lead to premature wear and also material bridging. The half moon style
shear gate profiles the material so that it has a minimal contact to the
skirtboards and also promotes a more consistent flow of material out of
the inlet as a flat profile can be unstable or shift as it is conveyed.

Figure 2.5 Shear Gate Form

e. Skirtboards
The material containment along the belt is critical to ensure accurate
weighing. The skirtboards should be flared out and up from the inlet so
that material plugging or jamming does not occur. In applications with
materials that can fluidize, skirtboard seals should be added so that
spills are avoided at the sides of the belt. The skirtboards should also be
designed for compatibility with the material. Caustic materials should
be met with stainless steel or coated skirtboards. In applications with
abrasive materials skirtboards constructed of AR400 or AR500 steel or
with wear plates should be used.
 8

Figure 2.6 Skirtboards

f. Belt
In general, weighfeeder belts should be the endless type for optimum
weighing accuracy. An endless belt has a more consistent cross section
over its entire length, where belts with a mechanical splice have a
singular heavy section which can impact accuracy. An endless style belt
requires a cantilevered weighfeeder frame for belt removal.
Cantilevered frames and endless belts also provide a faster changeover
than vulcanizing in place or mechanical splice belts. Belt PIW rating
must be determined by the application considerations such as material
bed depth, belt width, conveyor, and inlet length. The PIW rating must
be met or exceeded to ensure reliable conveying of the material. The
belt PIW rating should not exceed 400, as the belt becomes self-
supporting at that tension rating and will not provide proper deflection
for accurate weighing results. Weighfeeder belts are normally
supported on flat pans, bars, or idlers so that tension and temperature
influences are minimized. Heat dissipation through a belt to electronic
components is considered good but the temperature specifications of
the belt and of the weighfeeder should not be exceeded. Where possible,
actual temperature profiling can provide data for comparison with a
high degree of reliability.
 9

g. Pulleys
The pulleys of the weighfeeder should be crowned for positive belt
tracking. Drive pulleys must be lagged for consistent conveying without
slipping. Driven pulleys do not require lagging, however on short
conveyors (<6.5’ (2m) the driven pulley should also be lagged to avoid
changes in belt tension due to concentricity. Pulley lagging for wash
down applications is typically a food grade neoprene, mineral
processing uses a standard SBR lagging. Lagging style and thickness
can be per the end user specification; normally it is a minimum ¼”
(6mm). Pulleys can be welded to the shaft or use an XT hub for taper
locking to a keyed shaft.

Figure 2.7 Pulleys

h. Idlers
If the unit uses idlers for belt support, the scale idler and the idler
both before and after it must be scale quality. Idlers should meet the
CEMA standard for reliable conveying, and proper review of the belt
loading will determine what class of idler is needed. Lubricated and
sealed for life bearings help reduce maintenance time on the
weighfeeder and also provide excellent protection against
contamination and lubricant loss. A flat profile idler is recommended
for optimum belt tension and minimizing temperature effects on the
 10

belt. In some applications, the inlet idlers will require a higher CEMA
rating than the carrying idlers after the inlet. Special impact idlers can
also be applied under the inlet if long particle drops occur during empty
bin filling. An idler must always be located directly under the shear gate
and directly under the back of the inlet to provide adequate sealing with
the belt. Return belt idlers should be included on any unit that has a
pulley-to-pulley distance greater than 10ft (3m). The return idler
typically sits inside the belt and does not span the entire width. On
corrugated side wall belts, the return idler should allow for belt mis-
alignment and be no more than BW-10” (250mm) in width.

Figure 2.8 Idlers

 11

i. Bearings
The head and tail pulleys are mounted to the weighfeeder frame on
bearings. Bearings should be self-aligning to ensure bending stresses do
not prematurely fatigue the welds on the pulley face. Self-aligning
bearings also allow for easier mounting and alignment with all the
interconnections of the rotating parts. Flange or pillow block style are
normally used, however split housing style can also be applied that
allows for shaft removal while maintaining bearing position

Figure 2.9 Bearings

 12

j. Motor
The motor for the weighfeeder must meet or exceed the power
requirement for the application. Inverter duty motors are normally
required to achieve the weighfeeder turn down ratio or rate range.
Inverter duty motors feature a constant torque output. Constant torque
is a term used to define a load characteristic where the amount of torque
required to drive the machine is constant regardless of the speed at
which it is driven. For example, the torque requirement of most
conveyors is constant. The turn down ratio is determined by taking the
max flow rate and dividing it by the min flow rate. Weighfeeder
applications will typically have a 10:1 turn down ratio, and the unit must
provide accurate weighing results in this range. A standard AC motor
is only rated for a 6:1 turn down ratio. Special force air cooling with a
separate line feed or over sizing the motor can accomplish this however
some motors have standard inverter duty ratings up to 1000:1. With an
inverter duty motor and a VFD in the PID loop with the weighing
integrator, the belt speed can achieve the required turn down ratio.

Figure 2.10 Motor

 13

k. Gear Reducer
The motor for the weighfeeder is running at a very high speed, 1500-
1800 RPM, so a gear reducer converts that speed to a suitable belt travel
speed for accurate weighing and conveying. The gear reducer sizing is
dependent on many application details such as belt width, material
profile, conveyor length, material bulk density, and infeed length, as
well as motor power, shaft size, bearing size, and environmental
conditions. The torque required by the application must be met with a
minimum of a 1.2 safety factor. This allows for some jamming to occur
without damaging the gear reducer. A hollow bore shaft mount style is
the most popular option as it can be easily replaced and maintained
compared to a belt or chain drive style system. The helical bevel style
gear reducer provides optimum torque ratings as well as compact
mounting and versatile installation options. The input of the gear
reducer must match the flange type of the motor. The orientation of
mounting has an impact on the quantity of oil that is to be used. The
application will provide a precise reduction ratio required; the next
highest value provided by the gear reducer manufacturer is sufficient
for selection. Gear reducer construction is limited, however in wash
down applications they can be food grade epoxy coated. Food grade oil
can also be supplied when required.

Figure 2.11 Gear Reducer

 14

l. Belt Tensioner
The belt tension must remain constant during operation. For critical
or high accuracy applications, a gravity actuated belt tensioner allows
for changes in tension due to temperature influences or material flow
changes. The driven pulley bearings are normally mounted on some
kind of telescoper or threaded bearing slider to properly track and
tighten the belt.

Figure 2.12 Belt Tensioner

m. Belt Scraper
Keeping the belt clean during operation is critical for weighing
applications as material can build up and continuously be weighed
without discharging into the process, creating a performance offset. The
belt scraper cleans the material contact side of the belt at the discharge
end. The scraper blade should be positioned so that material that is
cleaned off the belt enters into the process. The scraper blade can
contact the belt from tension of a spring or counterweight. The blade
length needs to provide adequate cleaning, while also allowing for
minor belt tracking movements and not colliding with belt flanges.
 15

Figure 2.13 Belt Scraper

n. Load Cell
Load cell is an electrical device test device that can convert an
energy into another energy commonly used to convert a force into an
electrical signal. The change from one system to another is not
straightforward in two stages but must go through the mechanical
regulatory stages, the power and energy can feel the change of condition
from good to unfavorable. In strain gauge (load cell) or commonly
called strain gauge deformation. Strain gauge measures changes that
affect strains as electrical signals, because effective changes occur in
electric wire resistance loads. A load cell / slot typically consists of four
aspects of the strain gauge in the configuration system at Wheatstone
Bridge. Cell / load slot of a strain gauge or two strain gauges. Electrical
signal output is usually supplied and sequenced several millivolts and
requires amplification by the instrumentation amplifier before it can be
used. The output from monitoring of changing conditions can be
increased to calculate the force applied for the observation and
monitoring of the condition . The following is a picture of the strain
gauge and Wheatstone Bridge.
 16

Figure 2.14 Strain Gauge

Figure 2.15 Wheatstone Bridge

Strain gauge is the most important part of a load cell, with a function
to detect the magnitude of the distance dimension changes caused by
a force element. Strain gauge is commonly used in precision
measurement of force, weight, pressure, torque, displacement and
other mechanical quantities. Afterwards it is converted into voltage
energy into mechanical members. The gage strain results in a change
in the value of resistance proportional to the long-term changes or
changes through the length of the process.
 17

Figure 2.16 Load cell on Weighfeeder

2.1.5. Parameter Operasi

CCR Interface

 Feed Rate kg/s

 Q ( Tonnage ) t/h
 Dolomite ratio %
 Power Consumption kW

Calibration Interface

 Belt Load kg/m

 Belt Speed m/s
 Qr %
 18

2.2 Spesification of Dolomite in Nusakambangan Quarry

2.2.1 Main Utility

In the manufacture of portland cement, dolomite is one of the additive materials
with to reduce clinker factor. Dolomite is very important for cement making process
because in dolomite there is a chemical composition which becomes an important
criterion in the proportion of raw materials of cement production such as CaO, MgO
and other elements. In PT Holcim Indonesian Tbk Cilacap dolomite mining factory
is conducted in Nusakambangan Island.

2.2.2 Characteristic of Material

Is an anhydrous carbonate mineral formed from calcium magnesium carbonate,
ideally CaMg (CO3) 2. The term is also used for a sedimentary rock of carbonates
which is predominantly formed from dolomite minerals. This limestone rock
contains many micro nutrients: SiO2; Al2O3; Fe2O3, as well as macro nutrients
MgO and CaO.

Benefit of Dolomite

1. Buildings Materials
Dolomites of a soft or crushed size can be used as a base material for road
construction, concrete aggregates, and asphalt.

2. As cement making material

Dolomite can also be utilized as one of the basic ingredients of cement
making, namely cement clinker mortar, its manufacture is by adding
about 40% dolomite to the cement. This can help speed up the hydration
of cement.
 19

CHAPTER III
METHODOLOGY

3.1 Flow Chart

Below is a flow chart chart of the Case Study implementation method:

START

Find Problem

Literratur
& Field
Studies

Analysis &
Problem Solving
Decline

Report

Approved

FINISH

Figure 3.1 Flow Chart Diagram of Methodology

 20

Beginning

Started a case study with guidance from field employees and lecturers from PNJ.

3.2 Find Problem

The method of choosing a tool that will be analyzed for case study based on
the many problems contained in the tool. Here we choose Weighfeeder to be
our case study material, because there is one problem that often occur in the
tool, namely Belt Slip.

Figure 3.2 Data time, amount, dan causes stop in Finish Mill Area

3.3 Literatur Study

Learn the design and specifications of the Weighfeeder, and understand how
the tool works to analyze the problems that occur in the tool.
First: look for related data about the tools we will analyze by asking the field
employees, and also can search the source of the manual book contained in the
library.
 21

Second: process the data that has been obtained into a report and connect the
data with each other to determine what the root of the problem is likely to cause
the problem.
Third: to discuss with the supervisor and supervisor to make a good report and
in accordance with the issues that we will lift as the Case Study.

3.4 Analysis & Problem Solving

After completion of the literature study, an analysis of quality aspects, security

aspects, and analyzing the profitability will be obtained after our analysis is
applied.
The analysis is done by:
First: look at the actual conditions in the field like what, and what problems are
there in the area.
Second: look at stop data and production data to see why the problem occurred
and how to solve it in order to solve it.
Third: survey to related employees on the tool, when problems occur what
should be done in order to overcome temporarily, and ask when the problem
occurs what kind of tool conditions, so it can take a conclusion to add to the
root of the problem that may be the main cause
Fourth: after all is fulfilled, the final stage determines the root cause of the
problem that is causing the problem, and provides a solution to the problems
that occur so that the problem does not recur in the future and does not add
another problem.

3.5 Report

After the literature study and problem analysis as well as problem solving,
subsequent reports in the form of papers and presentations to display during
the trial, and before being shown will be tested or examined by the supervisor
whether feasible or not, if appropriate, will be approved and signed, if not
feasible it will be revised.
 22

CHAPTER IV
DISCUSSION

4.1 Weighfeeder 534-WF2

Weighfeeder (Belt Scale) is a tool that serves to weigh material and transport
material in the cement industry. In PT Holcim Indonesia Tbk. The Cilacap Factory,
Weighfeeder 534-WF2 serves to weigh and transport dolomite from Dolomite Bin
to Belt Conveyor 534-BC4 and then to 564-BM2 Ball Mill.
Material that is transported by weighfeeder is dolomite with 20% -35% of Ball
Mill's total capacity of 250 ton / hour. Dolomite is used to reduce clinker factor, ie
the amount of clinker used in the manufacture of cement. The use of dolomite also
aims to reduce the selling price of cement without reducing the quality of the cement
itself. The number of clinker used is as much as 65% -75% of the amount of Ball
Mill capacity. The remaining gypsum and fly ash are added to the cement mix of
5% -10%.

4.2 Specification of Weighfeeder 534-WF2

This is table that show the specification of Weighfeeder 534-WF2 in Finish

Mill Area at Holcim Plant.

Item Detail Unit Data

Type - DMO-36
Capacity( range ) t/h 30 MTPH
Accuracy % ± 1/2
General
Width of feeder mm 900
Shaft centers mm 3708
Speed range m/min .10 M/S

Material Description - Dolomite Add.

Conveyed Size mm ≤ 30
 23

Temperature ºC Ambient
Moisture Content % 10
Bulk Density t/m³ Bin
Type - N/A
Prefeeder
Installed power kW N/A
Type - N/A

Spillage Capacity t/h N/A

Conveyor Size Mm N/A
Installed power kW N/A
Type - DC
Motor Installed power kW 1.12
Speed rpm 1750

Tabel 2.1 Specification of Weighfeeder

 24

4.3 Location of Weighfeeder 534 – WF2

Figure 4.1 Location of Weighfeeder

 25

Weighfeeder (Belt Scale) is a tool that serves to weigh material and transport
material in the cement industry. In PT Holcim Indonesia Tbk. Cilacap Factory,
Weighfeeder 534-WF2 functions to weigh and transport dolomite from Dolomite
Bin to Belt Conveyor 534-BC4 and then to Ball 564-BM2.

4.4 Performance Analysis of Weighfeeder 534-WF2 ( 2017 )

Figure 4.2 Data number of stop in Finish Mill Area

During 2017, the amount of stop due to Breakdown Unschedule in Finish Mill
area line 2 is dominated 66 times. Where Weighfeeder 534-WF2 ranks third with a
number of stop Breakdown Unschedule is 7 times.
 26

Figure 4.3 Data stop duration Finish Mill area

During 2017, the amount of stop duration due to Breakdown Unschedule in

Finish Mill area line 2 is dominated by mechanical trouble which reached 297
hours. Where Weighfeeder 534-WF2 ranks third with a duration of hours
Breakdown Unschedule of 46 hours.

PROBLEM IN WEIGHFEEDER 534-WF2 (2017)

Belt Slip Material Plug

43%
57%

Figure 4.4 Problem in Weighfeeder

 27

During 2017, the most problem that happened in Weighfeeder 534-WF2

Finish Mill area line 2 is dominated by belt slip that have 57%. Meanwhile material
plug problem is 43%.

4.5 Belt Slip

Figure 4.5 Belt Slip Schema

Belt slip is when the friction grip becomes inadequate. When head pulley turn,
it doesn’t tight belt properly so belt not running and tail pulley not turn. This may
cause some forward motion of the driver without carrying a pulley driven with it.
This is called the slip of the belt and is generally expressed as a percentage.
Difference between slip and creep in drive belt Slipping Slip caused by wrong
tension on the belt so that the moving pulley moves and the movable pulley is not
moving Creep Belt is made of low modulus material. Thus there will be a significant
change in the length of the belt in moving from the tight side voltage to the sagging
side stress and hence creep occurs. This can also happen because the pulleys do not
parallel with each other. This is more prominent in flat belt propulsion. To avoid
creep, the pulley is crowned in the middle so there is no relative movement between
the pulley and the belt. Both slip and creep cause a relative movement between the
pulley and the belt. It also reduces power transmission. This should be reduced to a
minimum.
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4.6 Belt Slip in Weighfeeder 534-WF2

In this case study we chose the weighfeeder tool to be our analysis and research
material, and after observation in the field there are some problems that often occur
in the tool such as overload material, belt slip, blocking material, etc. For this case
we specifically analyze one problem that is not easy to detect either from CCR or
patrol and this problem is quite often so it can harm the factory because if dolomite
is not channeled then the use of clinker will be high and with the selling price set in
the market of course the factory will suffered a loss in production terms, also
incurred other costs for equipment repairs. In the case of Belt Slip itself, several
causes of the problem have been identified. From the cause it is hoped to find the
source of the most potential problem for Belt Slip and can find the right solution to
reduce or eliminate the problem. Cause Belt Slip among others as follows:

1. Worn Lagging head pulley

2. Belt Loose
3. Overload material in BC
4. Material too sticky
5. Error load cell ( dirty )
 29

4.7 Root Cause Analysis of Belt Slip in Weighfeeder 534-WF2

Fault Adjust Belt Caused of vibration

tension of machine
Belt Slack
Long Been Used

Worn lagging head

Belt Slip Head and Tail Pulley
not tight belt Surface of head and
properly tail pulley Cleaner not work
contaminated by optimally
material
Overload Material
Coating material Material too sticky
fall

Figure 4.6 Root Cause Analysis

Based on the RCA table above the belt slip occurs due to two factors: belt slack
and pulley do not bind belt optimally.

4.7.1 Belt Slack

Figure 4.7 Belt Slack Schema

 30

If the belt is slack then the belt does not bind perfectly to the pulley so that
when the pulley spins the belt does not come spinning, belt slack itself can be
caused by belt is worn, wear itself due to life time. A surprisingly small reduction
in belt tension yields a proportionally large reduction in slack-side tension. Slip
rates wildly increase as the slack-side tension approaches zero.

Belt Tension Adjuster

Figure 4.8 Belt tension adjuster

When the loose belt should be solved this problem by adjusting the firmness
of the belt itself so that when the arrangement is done incorrectly then the belt
will remain loose so that the belt slip will occur.

Figure 4.9 Belt tension

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Belt tension may be tested by pressing against the top of the belt midway
between the two pulleys. The proper deflection is determined by the distance
between the centers of the two shafts. To determine proper deflection simply
multiply the distance between the center points of the two shafts.

Bar damper on chut outlet

bin to 534-WF2 weighfeeder
serves as a retarder impact
material that falls from the
bin so that the belt is not
easily damaged. The
addition of an excessive
amount of bar dampers can
also cause coating and
Figure 4.10 Bar damper chute
eventually blocking
4.7.2 Head and Tail Pulley not tight belt properly

While for the pulley itself will not bind the belt properly because of several
factors such as the lack of type of pulley to the application in the field, for example
when the pulley is usually applied to the wet material then the pulley does not
bind well. Another thing can be caused because the surface of the pulley is worn
out so it can not run belt properly. The use of water in the dolomite bin may also
cause water-borne pulleys resulting in belt slippage due to reduced standard
friction.
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Tail Pulley does not wear rubber

lagging. But on the surface of the tail
pulley there is a groove.

Figure 4.11 Tail Pulley Weighfeeder

In Head Pulley there is a rubber

lagging that prevents the wear
pulley and increase the pull of the
pulley against the belt.

Figure 4.12 Rubber Lagging Head Pulley

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Figure 4.13 Material Sticky

Sticky dolomite material is transported through a weighfeeder. Due to the

sticky nature of the material sometimes this can cause blocking of the chute outlet
bin so that water is used to smooth the flow of material but this may cause the pulley
to be contaminated by the water resulting in reduced friction and resulting belt
slippage.

Friction on the pulley

and belt will be
reduced because it is
blocked by sticky
material so that the pull
is not maximal and will
result in belt slip

Figure 4.14 Head pulley Weighfeeder

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The Number of Repair in Weighfeeder 534 - WF2

8
7
6
5
4
3 7 The Number of Repair
2 4
1
1 1
0
Belt Roller Rubber Bar
Carier Lagging Damper

Figure 4.15 Number of repair diagram in 2017

Thats figure its describe about the number of repair in weighfeeder 534-
WF2. Based on the figure the most part that have been repaired is belt in
weighfeeder that have been repaired 7 times in 2017. The second is carrier roller as
much 4 times in 2017. For rubber lagging and bar damper just have to repaired just
1 times.

The Diagram show that Belt is the most part that damage in 2017 it can
means that belt slip is caused by worn belt. And in 2017 also do replace rubber
lagging once. It happens because the lifetime of rubber lagging is exhausted.

4.8 Maintenance Cost Analysis Caused by Belt Slip

Cost analysis aims to analyze the impact caused by belt slip that occur and
cause loss-cost costs for production, operations, and maintenance.
 35

Data Maintenance Cost di 534-WF2 tahun 2017/2018

Description Total Planned Costs Total Actual Costs

534-WF2 Repl Carrier Roller 2.767.470 2.794.194
534-WF2 Replace Blade Primary
Cleaner 4.317.486 4.317.486
534-WF2 Rep Belt 1.221.486 1.221.486
CC.534-WF2, Repair samb Belt nglupas 1.495.694 2.670.450
CC.534-WF2 Replace Roller carier 6.374.766 6.463.846
CC.534-WF2 Repl Belt ngelupas 23.501.438 25.308.112
CC.534-WF2 Install Rubber lagging 2.971.308 4.146.064
Bearing-Upgrade Shaft HeadPulley 534-
WF2 2.671.486 2.671.486
Rep Belt sobek sambungan 1.221.486 1.221.486
Upgrade Shaft Head Pulley 534-WF2 14.877.800 14.877.800
534-CH4 Repl Bar damper chute dol 7.721.486 5.816.436
534-WF2 Rep Belt sobek 500 mm 8.275.038 1.221.486
CC.534-WF2* Repl Carier roller
bearing 2.767.470 2.794.194
CC.534-WF2 Lagging Head Pully
lUpgrade 3.245.516 5.595.028
534-WF2 Repl Carier roller under chute 4.828.782 4.891.138
CC.534-WF2*Rep Belt WF Dolomit 1.495.694 2.670.450
TOTAL 89.754.406 88.681.142

Tabel 4.1 Cost maintenance

 36

Data Operational Cost di 534-WF2 tahun 2017/2018

Actual
Operational Cost Hour
work
534-WF2 Replace Blade Primary Cleaner 7,000 1.221.486
534-WF2 Repl Carrier Roller 7,000 1.221.486
534-WF2 Rep Belt 7,000 1.221.486
CC.534-WF2, Repair samb Belt nglupas 7,000 1.221.486
CC.534-WF2 Replace Roller carier 7,000 1.221.486
CC.534-WF2 Repl Belt ngelupas 7,000 1.221.486
Bearing-Upgrade Shaft HeadPulley 534-WF2 7,000 1.221.486
CC.534-WF2 Install Rubber lagging 7,000 1.221.486
534-WF2 , Tie in WF Dolomit jalur 2 14,000 2.442.972
534-WF2 , Tie in WF Dolomit jalur 2 14,000 2.442.972
Rep Belt sobek sambungan 7,000 1.221.486
534-CH4 Repl Bar damper chute dol 7,000 1.221.486
534-WF2 Rep Belt sobek 500 mm 7,000 1.221.486
CC.534-WF2* Repl Carier roller bearing 7,000 1.221.486
534-WF2 Repl Carier roller under chute 7,000 1.221.486
CC.534-WF2 Lagging Head Pully lUpgrade 7,000 1.221.486
CC.534-WF2*Rep Belt WF Dolomit 7,000 1.221.486
534-WF2 Check & Rep Joint belt 7,000 1.221.486
TOTAL 140,000 24.429.720

Tabel 4.2 Cost operational

The table above is a table of costs incurred for repairs on Weighfeeder 534-
WF2 equipment related to belt slip for the year 2017-2018 or a year. From the above
table it is known that the total cost planned to perform the activity is Rp
89.754.406,00. And the work that has been actualized until now requires a fee of
Rp 88.681.142,00 and maintenance operational costs incurred by Rp
24,429,720.00. So total cost maintenance that incured is :

Rp 88.681.142,00 + Rp 24,429,720.00 = Rp. 113.110.862,00

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4.9 Production Loss Analysis Caused by Belt Slip

The loss of its own production due to stop equipment weighfeeder 534-WF2.

Tonnage : 210 ton/h

Duration Stop : 37 hours

Cement Cost : Rp 85.959,00 /ton

Loss = Tonnage x Duration Stop x Cement Cost = Rp 667.901.430,00

So the production loss in Cement when Weighfeeder 534-WF2 stop is Rp

667.901.430,00.

The Effect of Weighfeeder Stop to Quality Cement that make loss production:

Initial Cement Composition :

Dolomit 27%

Gypsum & Fly Ash Bottom Ash 6%

Clinker 67%

Loss that caused by weighfeeder stop during 0-2 hours that will increase the quality
of cement quality by increasing clinker factor.

Cement composition when weighfeeder stop:

Gypsum & Fly Ash Bottom Ash 6%

Clinker 94%
 38

CHAPTER V
CONCLUSION

5.1 Conclusion

In 2017 the Weighfeeder 534-WF2 equipment has a stop with a duration of

46 hours which is the third largest in the finish mill area where the cause is a
belt slip.
In 2017 maintenace cost at Weighfeeder 534-WF2 is Rp. 113.110.862,00.
And the production loss is Rp. 170.829.280,00.
Belt slip problems usually occur due to several factors such as lagging head
pulley wear, belt loose, too much material on BC, material too wet, load cell
error (dirty). And at Weighfeeder 534-WF2 belt slip occurs due to worn lagging
pulley factor, worn belt and wet material.

5.2 Solution

1. Replace belt and rubber lagging pulley that has worn out.

2. Regularly ordering belt tension so that belt slip does not occur.

3. Cleaning the material that stick on the pulley because it can reduce friction
between the belt and the pulley so it is not binding.

4. Upgrade rubber lagging into ceramic lagging.

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BIBLIOGRAPHY

[1] Technical Data of 534-WF2, Manual Book Weighfeeder Schenck

[2] Manual Book 101 Weighfeeder Schenck

[3] https://w3.siemens.com/mcms/sensorsystems/SiteCollectionDocuments/wt
/application_guides/Weighfeeder_Application_Guidelines.pdf

[4] ABB. (2018, 2015). Technical Information System. Diambil kembali dari
Knowledge Manager: http://hc-cc-tis-srv/km/