Study on Utilization of Wagon loading system at OCL INDIA LIMITED

Studied & submitted by UDAYKUMAR SASTURE Date of Visit: 23rd to25th Jan-2013

TECHNICAL SERVICES NEW DELHI

EXECUTIVE SUMMARY The study on wagon loading system has been carried out in order to see the feasibility in increasing of no. of cement rakes from the present level 60 nos per month. During the study the following bottlenecks force to increase the number of shunting: 1. Subhash chowk and Railway gate, people and vehicle traffic obstructing the shunting of rake. 2. The single track line at railway gate restricted the entry of rakes (Clinker. Gysum,slag, cement, coal and furnace oil wagon) one at a time 3. The curvature of track line is more than 12 degree as against the std. 6 to 7 degree hence the no. of shunting will be more. Based on the time study it is found and possible to load the rakes up to 75 to 80 (potential 85 nos.) nos every month as against the present level 60nos with the following recommendation: Rake arrangement : Presently there is a gap time in receipt of rakes for loading and it works out to 260 hrs to 359 hrs in a month. It is recommended to arrange the rakes at an interval of every 6 to 7hrs in liaison with railway authority so as to ensure the availability of rakes for loading. Packer feed rate : It is observed that the present packer feed rate works out to 157TPH as against the designed capacity 240 TPH. This requires discussion with Packer supplier M/s ENEXCO and study to improve the packer output rate further. Wagon Tippler line -11 : There is a space for extension of track by another 100 to 150 meters which facilitates to accommodate 10 or12 no. of wagons more in addition to the present 24nos ( Total-34 to36), thereby the shunting will reduce to 2 times per rake. This help in availability of loco for cement rake loading.

 Seek line in exchange yard: The extension of the existing seek line track facilitates to convert this track to use for stable rake formation in case the power of railway authority delays in taking the entire rake formed earlier in turn affect the other rake formation as the no. of line available is two. Fly over at railway gate: The flyover at railway gate help in shunting of the wagons at a faster rate as this is the junction point, without hindering public moment. As a result of above the no. of rake loading shall increase to 80nos from present level of 60 Avg./month, thereby the Sales volume and value increases to 54000 tons and 1.62 crore (approx.) respectively on monthly basis.

Study on Utilization of Wagon loading system at OCL INDIA LIMITED

1.0 OBJECTIVE:
To study the utilization of packing machines and its associated activities right from the receipt of Railway wagon, wagon placement and loading in order to suggest improvement actions for further increase in the no. of Cement Rake loading

2.0 Methodology:
Time study To arrive at the cycle time of the wagon loader. Basic data of last six month. Identification of bottleneck

3.0 OBSERVATIONs & RECOMMENDATION:

The finished Product (cement) of different grades is being dispatched by Rail and Road Based on the six month data analysis it is works out that about 70% of cement being dispatched through Rail and rest by road. The rake of cement and other raw materials( Slag, Gypsum, coal)to be loaded/unloaded are bringing to the exchange yard from the main station ( Rajgangpur) located at distance of 2.0 km away. The intimation of receipt of railway wagon is being received 2 hrs. Well in advance. The cement Rakes comprises of the following types of cement wagon BCN, BCNA & BCNAH : Each rake consists of 42 nos, of wagon of mixed combination of above types. The no. of cement bags to be loaded in wagons varies from 1238 to 1278.

EXCHANGE YARD: The cement wagons to be loaded of 42nos is being brought to exchange yard or directly to the packer loading platform from railway station depending on the loading platform empty condition by our power loco only.

There are four lines in exchange yard being used as junction: To form the stable cement rake after being loaded, to handover the railway authority. To bring the Raw materials wagons to be unloaded from railway station.

The time taken to bring the wagons from railway main station to the exchange Yard is as follows: Min. Move with the loco to railway station in case of cement wagon Attached to the rake and coupling Awaiting for Vacuum Pressure build up to 6kg and Release Start move to exchange yard Total (Min.) : 07.00 : 02.50 : 15.00 : 17.00 : 41.50

The cement rake of 42 wagons is divided in to three parts at exchange yard as: Wagons 12 nos Wagons 12nos and Wagons 18nos

Bottlenecks in exchange yard: 1. Subash chowk which is heavy public moment road, the no. of wagons will accommodating on the approved line of railway authority is limited to 36 nos as against the 42nos cement wagons/ 59 nos of raw material wagons. 2. The line-1 and line 2 are critical line cannot be used for keeping the wagons for longer time. These lines are main shunting lines of wagons to be loaded / unloaded, are taken inside and outside plant. 3. There is only one rail line available to take rail wagons inside & outside the plant from the exchange yard through rail gate. - Cement for loading and, - Slag, Gypsum & Coal for unloading inside the plant There is also a public cross road between exchange yard and main rail entry gate of the plant. The entire cement rake is divided in to three parts and taken inside the plant in the shortest time (2 to 3 minutes) for the convenience of the public movement to avoid the agitation at Railway gate as well as Subhash chowk.

OPERATION OF RAKES INSIDE THE PLANT: The cement wagons to be loaded are taken inside plant (packing plant) at the four loading platform as follows: Track Line -4: The no. of cement wagons to be loaded is allocated 12 or 14 nos as against Max 20nos. The wagon positioned in the form 3-3-3-3 and time taken to position the Same is 15 to 17 minutes. Track Line -5 : The no, of cement wagons to be loaded is allocated 12 or 14nos as against Max 20nos. The wagon positioned in the form 3-3-3-3 and time taken to position the Same is 15 to 17 minutes. The line 4 and 5 is used for loading of cement wagon by the packers -1 and 2. Track Line -1 : The no. of cement wagons to be loaded is allocated 8 or 9 nos as against the 19 nos. Max. The wagon positioned in the form 2-2-2-3 and time taken to position the same is 15 to 17 minutes. Track Line -1A : The no, of cement wagons to be loaded is allocated 8 or 9 nos as against 19 nos. max. The wagon positioned in the form 2-2-2-3 and time taken to position the same is 15 to 17 minutes The line 1and 1A is being used for cement wagon loading using the packers -4 and 5. Sl.No Packers 01 Packing Machine-1, 16 spouts, and discharges on two side. Make Enexco, Design Capa-240TPH,5rpm 02 Packing Machine-2, 16 spouts, discharge on two side. Make Enexco ,Design capa-240TPH,5rpm 03 Packing Machine-3, 16 spouts, discharge on two side. Make Enexco,240tph Design,5rpm 04 Packing Machine-3, 16 spouts, discharge on two side. Make Enexco,240TPH ,5rpm No. of loaders Platform Total 4nos - 2 nos for each belt Track Line -4 discharge of packers &5

Total 4nos - 2 nos for each belt Track Line -4 discharge of packers &5

Total 4nos - 2 nos for each belt Track Line -1 discharge of packers & 1A

Total 4nos - 2 nos for each belt Track Line -1 discharge of packers & 1A

GAP TIME BETWEEN THE RAKES: Presently the cement rakes being received one after another and thereby it is observed that a gap time between the two rakes. The gap time works out to 260 to 359 hrs every month out of total available 720 hrs to 744 hrs. in a month. During this time the packer machine are mostly ideal utilizing for loading of trucks. The manpower engaged for loading of cement is on rake basis. It is recommended to plan the arrangement of the rakes on continues basis in consultation with the railway authority to reduce the gap time ( an Avg. 4 hrs to 5 hrs.). The time between receipts of one rake to another should be of 6 hrs. This will help to increase no. of cement rakes loading by another 15 to 20 nos more. Thereby the no. of rakes shall increase from Present level 60 nos to 75 - 80 on every month. There will be increase in dispatch quantity further by 54000 tons-Max by following the same pattern of loading Presently the no. of rakes presently handling/month on an avg. 95 to 101 as follows : Cement SlagCoal GypsumClinker 62 Rakes 11 rakes 13 rakes 04 rakes 11 rakes

PACKER FEED RATE: Based on the time study the loading of cement wagon using the loader has been carried out at the feed rate of 157 TPH as against the rated capacity of 240 TPH. This is due to because of the following: Problem in the nozzle. Early filling of bag. No falling of the bag. Higher Cement blain Further the productivity level can be improved by closely attending the nozzle related problem. Further this helps in reduction of loading time of cement wagon.

TWO RAKE LOADING AT A TIME: The loading of two rakes, one each at loading platform is possible but the cycle time increases to 480 minutes as the number of loading point at a time will be reduced to 4times from earlier 8 times. The total cycle time required for handing over to railway authority will be 10hrs with including the shunting time as against the permissible time 9 hrs. .This shall force us in to the demurrages threshold. This could be tried after improving the feed rate of packer more than 175 to 180 TPH. TRACH LINE 2 an 10: These line tracks are buried with the slag about 35% of its total length. It suggested to clear off the track line from slag so as to utilize these entire length of track lines for keeping of the empty wagons. SEEK LINE IN EXCHANGE YARD: In exchange yard the seek line length may be extended to use for stable rake formation, as this would help in handling no. of rakes in case when the power engine of railway authority delays to take the stable rake from Exchange yard. RAW MATERIAL UNLOADING LINE-11: The wagon tippler line 11 to be extended further by 100 to 150 meter towards boundary wall in order to accommodate more no. of empty wagons of coal/wagon/slag would facilitates in handling of raw material n type wagons. CLINKER LOADING LINE LINE-9: The clinker wagon loading system requires loco permanently which is also restricts the nonavailability of loco for cement wagon SHUNTING. The existing side arm charger is not in operation. The track length of clinker wagon line 9 is limited to 13 to 14nos which prolonging the loading time and multiple handling of the N-type -wagons. The following bottlenecks are in the inside the railway gate: 1. The upward gradient of the railway track limit the pulling of the loaded wagons up to 18 nos. 2. The track line curves are 15 degree which is more than the standard 6 to 8 degree, this further increases the handling of wagons in shorter length. 3. If clinker wagons to be loaded the wagons from raw material track line-11 to Line-9 is to be carried out at railway gate junction only

Wagon loading Cycle time: Based on the time study the cycle time of the wagon loader has been works out as follows: Placement and preparatory work: Placement of wagon on the Line 4 min Placement of wagon on the line 5 Preparatory work of wagon loader Actual 15 .0 min 14.24 min 03.45 min

Cycle time: Wagon loader. Loader 1st cycle 2ND Cycle 3rd cycle 14.04 Min 13.56 min 07.06 Min 06.50 min. 05.37 Min 05.46 min. Total A 26.47 Min 26.52 min Changeover of loader to second door is being done without the stoppage of packer operation Loader 1st cycle 10.10 Min 08.00 Min nd 2 Cycle 06.10 Min 06.52 Min rd 3 cycle 05.50 min 06.00 Min Total B 22.10 Min 20.52 Min Avg cycle time per Wagon 48.57 Min 47.44 Min 280 Min.

Total time taken for loading of the entire rake :

Product change over Stoppage hrs Rake shunting Move to Exchange yard Form a stable rake line Total rake cycle time work out to:
*

05 Min 130 Min* 20 Min 24Min 10 Min 501 minutes

0.20 W/l 3 Telescopic problem 0.30 RP-1 NZ-12 Ventilation fault 0.30 RP-1,NZ-7 Pressure pipe problem 0.20 W/L 8 Belt problems. 0.20 W/L 5 bag diverter 0.20 W/l 9+10 discharge belt jammed 0.70 W/L 13 and 14 electrical prob

WAGON LOADING SYSTEM AT OCL INDIA LTD.

SL.NO. Observation Recommendations Tar gate date Respons Remarks ibility S/s

01

Based on the time study, Packer feed rate works out to157 TPH as against the Design capacity 240 TPH. Avg. It should be 190 TPH. Wagon loader 9 to 16 needs attention to smoothen the operation

02

Rake Arrangement: Presently it is found that there is a gap time in arrival of rake to rake works out to 8hrs to 10 hrs i.e varies from 260hrs to 360 hrs in month

03

SEEK LINE EXTENTION IN EXCHANGE YARD: This line is used for keeping the wagon to be repaired. Track line -11: Raw material unloading has limitation to accommodate 24 wagons after unloading by wagon tippler

Make Functioning of 16 spouts effectively. Bag falling after attaining the required weight of 50kg No bag falling. The RPM of the packer is found 2 rpm as against the design 5 rpm The rake to be arranged in consultation with Railway authority at an interval of every 6 to 7th Hr one each. This helps in loading of rakes by 15 to 20 more i.e 54000 tons per month by following FIFO basis. There will be increase in the sale quantity by 54000 ton per month. The extension of seek line help to utilize in stable rake formation in case power of railway authority delays in taking the stable rake from the exchange yard There is a space available to extend by 100 to 150 meters will help to keep 10 to 14 wagons more continuously to reduce the shunting frequency.

04

WAGON LOADING SYSTEM AT OCL INDIA LTD.

SL.NO. Observation Recommendations 05 Clinker loading wagon : It is found that the loco is engaged exclusively till the rake is loaded. Shunting is required for every 24 nos of wagons. It means three time shunting. The extention of rake length is possible but we have to procure land . Track lines -2 and 10: These lines of some length are buried with the slag, the same could be cleared off to keep empty wagons in emergency case Two Rake loading: Possible but it will increase the loading cycle time to double due to reduction in no. of loading point to 4 as against earlier 8. No. of wagon can be placed on 4 & 5 to the extent of 20Max on each line and on line 1 &1a 19 wagons each side Railway gate : There is a Single track line to take all type of wagon inside the plant. The public and vehicle moment affected largely to the shunting wagons. Sometime entire rake is divided in to three parts Tar gate date Responsibility Remarks S/s

WINCH Machine working to be made to release the loco for other wagon shunting

06

07

No of gangs will increase from present 2 nos to 3 or 4 Two rake loading could be tried after improvement in the packer feed rate to at least 190 TPH It is proposed to have a flyover at railway gate facilitates in smooth operation of the wagon shunting without the interruption of the public moment,

08