Failure Analysis of Belt Conveyor system in a Thermal Power ... - ijater

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199319941995199619971998199920002001200220032004International Journal of Advanced Technology & Engineering Research (IJATER)Figure 2 scheme of drive unit in belt conveyor systemIt is easy to notice the significant decreasing number offailure for 2004-2006 one of possible reason is that coalhandling system using condition monitoring techniques.In this section will be consider the types of fault that35Figure 4 Percentage of failure for gearboxes used in coalhandling system30252015105totalnumberoffailuregearedwheelbearing0Figure 3 Number of failure of drive unit gearbox used inbelt conveyor systemAnalysis for drive units used in coal handling systemdone by [6]show that over 50% problems are related toinput stage that is a bevel stage.PulleysFigure 5 Example of damaged geared wheelThe pulley consists of two bearing, shaft, shell andcoating (special material in order to improve belt-pulleycontact), figFigure 6- pulleyISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 196
199319941995199619971998199920002001200220032004MainDepartmentAs it is shown on fig. (The number of failures dependingon pulley type) especially drives are very sensitiveelements.International Journal of Advanced Technology & Engineering Research (IJATER)Figure 7 Number of failure for different types of pulleysused in coal handling machinesAs Matuszewski [5] shown number of pulley failures mayreach over 60 per year that is 12% of used pulleys, fig.one may notice two sources of primary problems, namely:bearing, shell and coating.70605040302010035302520151050KWK1500sKWK800MRs 560SchRs900droppingotherdrivetotalnumberoffailurebearingFig. 9 Examples of pulley faultsMotor-Coupling-Gearbox-Pulley in CoalHandling SystemBased on data obtained from maintenance department(data from period January- November 2008) in one coalhandling system a simple analysis have been performed inorder to get the convince that many breakdown situationscould be omitted if CM is used. In fig. we show that forso called department /flat BCS (MBCS) number ofbreakdowns is much higher than that for smaller, so calleddepartment/flat BCS (DBCS). The reason of this is thatMBCS is heavier loaded than DBCS (SEE FIG.)6050403020100Number of failure vs type ofbelt conveyorNumber offailure vs typeof beltconveyorIn fig.8 one may see examples of damaged pulley coatingand bearingFigure-10 Number of failure related to MBCS and DBCSIn fig.9 the number of failure related to elements of driveunit is presented. As one may see the number of failure ismore or less similar for each element, however thenumber of failures of gearboxes is in the highest value.ISSN NO: 2250-3536 VOLUME 2, ISSUE 3, MAY 2012 197
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Failure Analysis of Belt Conveyor system in a Thermal Power ... - ijater

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