unit #2 amendment

UNIT # 2 AMENDMENT

Prepared by / Mohamed Khamis

Aim of the project

Complete overhauling for the system by replacing the old machines by new ones.

To increase the overall efficiency of the system , increase its durability , decrease break down rate and increase productivity and production rate .

old system arrangement and its situation

Feeder Bucket Elevator .1 Crusher Bucket

Elevator .2 Screen Outlet Hoppers

Machine Picture of the machine Condition

Old feeder

the feeder body and its vibrating cart were completely depreciated

Old Screen The screen needs complete overhauling for its body and its decks


Old Buckets

The two buckets body and its components such as upper and lower drums and its gear boxes were very depreciated.

Old Filter The filter efficiency was very low , due to complex suction tree ( bad engineering design and selection ).

New system arrangement

Feeder Bucket Elevator Screen Outlet

Hoppers


New feeder

Completely new feeder with new vibrating cart and new grizzly screen .

New Bucket Elevator

New bucket elevator with new drive unit and larger capacity .


New ScreenCompletely new screen with different drive mechanism and with larger capacity ..

New Outlet hoppers

Completely new hopper with larger capacity and new chaises .

RGS maintenance team scope

1. Manufacturing new hoppers Manufacturing 3 new hoppers with the following dimensions - Length = 2m - width = 1.5 m - height = 1.5 m - thickness = 10mm- Each hopper capacity = 4 ton.- Manufacturing a new chaises for all hoppers .

Task Specification Material & labor cost

Combi offer

Manufatering 3 new hoppers with chaises

• length = 2m•Width = 1.5m •Height = 1.5 m•Chaises ( H20 beam , length= 3.75m

40,000 EGP 72,000 EGP

We already saved 32,000 EGP

2. Electrical preparation

Completely new power panel and control panel with its accessories such as contactors , circuit breakers ,,,,,,,,ETC.

Automatic operation by applying timing sequence . Completely new cables tray with new cables and new distribution .

Control panel Power panel

Task Specification Materials , labor cost

External offer

Power panel Dim 1x2x0.5 m 8,000 EGP 13,000 EGP

Control panel Dim 1x2x0.5 m 14,000 EGP 20,000 EGP

Cable trays & cables & lighting

160 m cable trays With cables 8 spots

4,000 EGP 10,000 EGP


3. Filter Adjustment

Relocate the filter and the fan to simplify the suction tree . Technical adjustment to increase filter efficiency by changing inlet and outlet pipes

location and adjust its elevation . Only 3 suction points ( on bucket , screen and hoppers will increase the filter

efficiency.

Task Specification Material &labor cost

External offer

Relocate filter Adjust suction tree

•Adjust filter input &output and fan elevation •Install new suction points

12,000 EGP 25,000 EGP


4. Walkers , Handrails , Stairs and Scales chaises

Manufacturing a new walkers for technicians to make their movement more easier , handrails and stairs were attached to this walkers .

Manufacturing a new chaises for scales with a simple design and high quality

Task Specification Material &labor cost

External offer

• manufacturing new walkers with handrails and stairs

•Manufacturing new scales chaises

•20 square meter walkers , 5 stairs and handrails .

• H10 beam chaises with its frame and hocks

25,000 EGP 43,000 EGP


Task Saved Amount

1 New Hoppers 32,000 EGP

2 Electrical preparation 17,000 EGP

3 Filter Adjustment 13,000 EGP

4 Walkers , chaises' 18,000 EGP

Total Saving 80,000 EGP

Total Saving

Advantages of the new Amendment To simplify the system and production line by

decreasing no. of machines without affecting on its productivity .

And to decrease break down ratio . And to make the movement of handling equipments

more easier The old situation let the crusher take the first shock

and this condition lead to hard impact on its drums . On the old situation we have to change its drums

every 2 months , and we have to change 4 or 6 bearings every month , and this is a huge extra cost .

The current situation will increase the crusher durability as we installed it after the screen .

unit #2 amendment

Documents