Wagon Loader System

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Study on

Utilization of Wagon loading system

at

OCL INDIA LIMITED

Studied & submitted by

UDAYKUMAR SASTURE

Date of Visit: 23rdto25th Jan-2013

TECHNICAL SERVICES

NEW DELHI


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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 obstructingthe 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 to7 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 monthas 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 withPacker 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.


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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 presentlevel of 60 Avg./month, thereby the Sales volume and value increases to 54000

tons and 1.62 crore (approx.) respectively on monthly basis.


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Study on Utilization of Wagon loading system

at OCL INDIA LIMITED

1.0OBJECTIVE: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

2.0Methodology:Time study

To arrive at the cycle time of the wagon loader. Basic data of last six month. Identification of bottleneck

3.0OBSERVATIONs & 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.


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There are four lines in exchange yard being used as junction:

To form the stable cement rake after being loaded, to handover the railwayauthority.

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 : 07.00 Attached to the rake and coupling : 02.50 Awaiting for Vacuum Pressure build up to 6kg and Release : 15.00 Start move to exchange yard : 17.00

Total (Min.) : 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 wagonswill 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 thewagons 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 plantThere 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.


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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 No. of loaders Platform

01 Packing Machine-1, 16

spouts, and discharges on

two side. Make Enexco,

DesignCapa-240TPH,5rpm

Total 4nos - 2 nos for each belt

discharge of packers

Track Line -4

& 5


spouts, discharge on two

side. Make Enexco ,Design

capa-240TPH,5rpm



Track Line -4

& 5



side. Make Enexco,240tph

Design,5rpm



Track Line -1

& 1A



side. Make Enexco,240TPH

,5rpm



Track Line -1

& 1A


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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 62 Rakes Slag- 11 rakes Coal - 13 rakes Gypsum- 04 rakes Clinker 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.


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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 LINELINE-9:

The clinker wagon loading system requires loco permanently which is also restricts the non-

availability 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 to18 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-9is to be carried out at railway gate junction only


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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: Actual

Placement of wagon on the Line 4 15 .0 minmin

Placement of wagon on the line 5 14.24 minPreparatory work of wagon loader 03.45 min

Cycle time: Wagon loader.

Loader 1stcycle 14.04 Min 13.56 min 2NDCycle 07.06 Min 06.50 min. 3rdcycle 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 1stcycle 10.10 Min 08.00 Min 2ndCycle 06.10 Min 06.52 Min 3rdcycle 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

Total time taken for loading of the entire rake : 280 Min.

Product change over 05 Min

Stoppage hrs 130 Min*

Rake shunting 20 Min

Move to Exchange yard 24Min

Form a stable rake line 10 Min

Total rake cycle time work out to: 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


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WAGON LOADING SYSTEM AT OCL INDIA LTD.

SL.NO. Observation Recommendations Tar

gate

date

Respons

ibility

S/s

Remarks

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

Make Functioning of16 spouts

effectively.

Bag falling afterattaining the

required weight of

50kg

No bag falling. The RPM of the

packer is found 2

rpm as against the

design 5 rpm

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

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.

03 SEEK LINE EXTENTION

IN EXCHANGE YARD:

This line is used for

keeping the wagon to

be repaired.

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

04 Track line -11:

Raw materialunloading has

limitation to

accommodate 24

wagons after

unloading by wagon

tippler

There is a space available toextend by 100 to 150

meters will help to keep 10

to 14 wagons more

continuously to reduce the

shunting frequency.


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WAGON LOADING SYSTEM AT OCL INDIA LTD.

SL.NO. Observation

Recommendations

Tar

gate

date

Responsibility

S/s

Remarks

05 Clinker loading wagon :

It is found that the loco

is engaged exclusivelytill

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 .

WINCH Machine

working to be

made to release

the loco for other

wagon shunting

06 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

07 Two Rake loading:

Possible but it will

increase the loadingcycle 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

No of gangs will

increase frompresent 2 nos to 3

or 4

Two rake loading

could be tried after

improvement in

the packer feed

rate to at least 190

TPH

08 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

It is proposed tohave a flyover at

railway gate

facilitates in

smooth operation

of the wagon

shunting without

the interruption of

the public moment,


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Documents

Wagon Loader System