Bina tubes breakdown summary steel plant pipe tubes

steel plant

1. Project Pinnacle Bina tubes Breakdown Summary 14-07-2023

2. Bina tubes Total Reported Breakdown Summary: (Time period from 26 th April’ 23 till 5 th July’ 23) Sr No Summary Time Unit 1 Total time 1680 hrs 2 Available time 1600 hrs 3 Total Downtime (Breakdown) 133 (7.9%) hrs 4 Total number of Breakdowns 104 hrs 5 MTBF 15 hrs 6 MTTR 1.3 hrs Data Source: Mill Breakdown Report – Bina tubes

3. Only 5 areas contributing to 80% of total breakdowns Data Source: Mill Breakdown Report – Bina tubes

4. Only 5 areas contributing to 80% of total breakdowns Sr No Machine Assembly Time in hrs In % MTTR (in hrs) MTBF (in hrs) 1 Cutter 41 31% 1.4 39 2 Sizing section Power Roll Stand no 12 26 20% 1.4 62 3 Forming section Power Roll Stand no 6 17 13% 2.8 96 4 HF Welder 11 8% 1.0 147 5 Forming section Power Roll Stand no 5 9 7% 1.5 178   Total 104 78%     Data Source: Mill Breakdown Report – Bina tubes

5. 1. Top breakdowns at Cutter Area Sr No List of breakdowns at Cutter Area Time for each breakdown 1 FLYINGAW MOTOR ROTOR SHAFT BROKEN 1200 2 flyingsaw machine not working properly 155 3 flyingsaw machine housing BRG. Broken 135 4 coc cutter arm welding broken 125 5 Flyingsaw Motor Burnt. 110 6 coc block brg. Broken and pin damage 95 7 FLYINGSAW CUTTER CYL. NOT WORKING 90 8 coc head cyl. Open 55 9 flyingsaw m/c belt burnt 55 10 flyingsaw m/c valve burnt and stopper crack 50 11 FLYINGSAW CUTTER LONG CYL. NOT WORKING PROPERLY 45 12 Flyingsaw belt broken. 40 13 flyingsaw coil burnt 40 14 flyingsaw cutter belt change 35 15 flyingsaw coil burnt 30 16 flyingaw machine belt burnt 30 Data Source: Mill Breakdown Report – Bina tubes

6. 2. Top breakdowns at Sizing section Power roll Stand no 12 Sr No List of breakdowns at Sizing section Power roll Stand no 12 Time for each breakdown 1 12No. Stand Gear box shaft broken&BRG . 430 2 12No. Stand gear box chain sproket key shear. 215 3 12No. Gear box key shear 205 4 12 No. stand bottom block sleeve broken an d 14no. Stand bottom block bearing and sleeve broken. 170 5 12 no stand top gear box side cross bolt broken 70 6 14 no stand mill side top coupling broken and gear box side bolt broken 70 7 12 No. top cross bolt broken 55 8 12 No. stand cross bolt broken. 40 9 12th no. stand top mill side cross bolt broken 40 10 14No. & 12No. Stand cross bolt broken 30 11 14 no. top cross bolt broken 30 Data Source: Mill Breakdown Report – Bina tubes

7. 3. Top breakdowns at Finpass section Power roll Stand no 6 Sr No List of breakdowns at Finpass section Power roll Stand no 6 Time for each breakdown 1 6 No. stand gear box shaft broken and 7 No. stand pinion broken. 550 2 6 no. stand gear box top coupling side shaft broken 225 3 6 no.stand bottom block brg. Burnt. 110 4 6 no stand bottom cross bolt broken mill side 70 5 6 no. stand top gear box side cross bolt broken 30 Data Source: Mill Breakdown Report – Bina tubes

8. 4. Top breakdowns at HF welder area Sr No List of breakdowns at HF welder Time for each breakdown 1 HF Welder heat trip 150 2 water temp. high in hf welder 110 3 HF Welder contact trip 90 4 hf welder contact moving cyl. Not working. 65 5 HF welder contact spark. 60 6 hf welder contact spark 60 7 hf welder trip because welder parameter is not perfect. 40 8 HF welder contact spark. 30 Data Source: Mill Breakdown Report – Bina tubes

9. 5. Top breakdowns at Finpass section Power roll Stand no 5 Sr No List of breakdowns at Fin pass section Power roll Stand no 5 Time for each breakdown 1 5 no stand mill side cross coupling broken and pipe line broken 250 2 5No. Stand Top & Bottom cross pad broken. 125 3 5 no stand bottom cross coupling key shear 55 4 flyingsaw valve damage and 5 no. & 16no. Stand bolt broken 45 5 5 No. stand top block BRG. Broken 40 Data Source: Mill Breakdown Report – Bina tubes

10. Power Rolls - frequent breakage of cross bolts     Fin pass Section - Power Roll Sizing Section - Power Roll Stand no:   5 6 7 12 14 16 Total breakdowns   2 2 2 11 7 6 Top Gear Box side   1   2 2 1 Mill side       1     Bottom Gear Box side             Mill side   1         Description missing   2   2 8 5 5 Data Source: Mill Breakdown Report – Bina tubes

11. Mill schematic diagram

12. Pre Forming Rolls – Stand no 1, 2, 3 & 4 from right to left (Left side view) 4 1 2 3

13. Pre Forming Rolls – Stand no 1, 2, 3 & 4 from left to right (Right side view) 4 1 2 3

14. Vertical Forming Rolls stand no 1, 2 & 3 from right to left (Left side view) 1 2 3

15. Finpass Forming Rolls stand no 5, 6 & 7 from right to left (Left side view) 7 5 6

16. Vertical Forming Rolls stand no 1, 2 & 3 and Finpass Forming Rolls stand no 5, 6 & 7 from Left to Right (Right side view) 5 7 6

17. Fin pass roll stand no 6 & 5 shaft condition Cross bolt Cross bolt

18. HF Welding (Left side view)

19. Sizing Rolls stand no 11 to 16 from Right to Left (Left side view)

20. Sizing Roll stands (Front side view) Gear Box Side Mill Side Cross bolt Cross bolt Cross bolt Cross bolt

21. Turk Head 1 & 2 – from right to left (Left side view)

22. Cutter Section (Back side view)

23. Cutter Section (Front side view)

24. Thankyou