Innovation Storyboard

[EMIRATES ALUMINIUMCOMPANY LTD ] [Torque measuring device ]

[SID 055] [Reduction R1]

1. About the Organization

• Emal is one of the world’s largest green field smelter

• Emal aims at high quality delivery of its products to customers, safety, every thing can be improved

• Aluminium ingots, sow, slabs

• Taweelah

2. The Idea

TORQUE MEASURING DEVICE

• The production of aluminium is by the process of electrolysis

• The anode is clamped to the bus bar by the anode clamps .

POT CELL

VIEW OF THE SUPERSTRUCTURE WITH ANODES

Anode clamp

The Problem

ANODE CLAMPS DAMAGES WHILE ANODE SETTING BY ABRE/PTM

NO INSTRUMENT TO COMPARE THE VALUES AND SETTING ON

ABRE

DAMAGES TO THE ANODE STEM AND THE BUS BAR

• Damaged anode clamp shaft

Damaged anode clamps view

Damaged clamps (July- Dec-2010)=321

Damaged clamps (Jan- Apr 2011) =180

Damaged anode clamp shaft

The Proposal / Solution

TORQUE MEASURING DEVICE FOR ABRE & PTM CALIBRATION

INTRODUCTION OF A TORQUE TRANSDCER ON A

FABRICATED JIG TO:

PERIODICALLY COMPARE AND SET THE TORQUE OUT PUT

OF THE PNEUMATIC / HYDRAULIC WRENCHES

Implementation

The transducer was assembled and mounted on the jig

fabricated ,custom made for this purpose .

The jig is placed in position with the anode clamping and

the clamp calibrated to the set torque of 340 N m

The readings recorded for each of the 36 anode clamp on

the ABRE

This value is compared with the torque in the PTM

available in the touch screen while changing the anode.

The nearest value is around + / - 2 %

IMPLEMENTATION

ANODE CLAMP DUMMY BOLT

WELDED ON A SOCKET

TORQUE TRANSDUCER

FABRICATED DEVISE

MOUNTING JIG

RUBBER CUSHIONING

TORQUE METERING DEVISE FOR ABRE & PTM WRENCH CALIBRATION

IMPLEMENTATION:

FORKLIFT FORK TORQUE METERING DEVISE

ACTUAL CALIBRATION DONE IN ABRE-2

3. People Involvement

• Suggestors: Leyson, Ullas Gereliv

Implementation

The transducer was assembled and mounted on the jig

fabricated ,custom made for this purpose .

The jig is placed in position with the anode clamping and

the clamp calibrated to the set torque of 340 N m

The readings recorded for each of the 36 anode clamp on

the ABRE

This value is compared with the torque in the PTM

available in the touch screen while changing the anode.

The nearest value is around + / - 2 %

BENEFITS

By applying a set torque of 340 N M and calibrating the

ABRE to the set torque (pneumatic) and comparing it

with PTM applied torque (while anode changing ) the

result of :

1) Drastic reduction of breakages of the anode clamps is

established which was due to over / under torquing is

achieved

2) Substantial amount of saving is achieved

7. Way Forward

• All the team members were awarded .

• Selected as the best suggestion for Emal

• Applied in the calibration of further anode clamps .

• Motivated in providing many more innovative suggestions

Q & A

Thank You