Maintenance Activities in Best Way Cement Industry Chakwal.

PRESENTED BY

SUBHAN ULLAH

CLASS NO: 67

AZIZ UR REHMAN

CLASS NO: 66

IntroductionCement Production ProcessPreventive Maintenance

Daily Maintenance Weekly MaintenanceFortnightly MaintenanceMonthly Maintenance

Corrective MaintenanceShutdown MaintenanceEquipment recordsInventory control

OVERVIEW

Bestway Cement Limited is part of the Bestway Group of the United Kingdom, founded by Sir Mohammed Anwar Pervez nearly thirty three years ago.

Initially in 1994 a cement plant was installed at hattar haripur having a production capacity of about 1.6 million tons per year.

In 2004, another plant was installed at Chakwal.Currently there are two production lines at Chakwal having a combined

production capacity of 4 million tons per year.With 6 million tons of annual production Bestway is the 2nd largest

cement producer in the country.Best way enjoys about 20% of the local market share.It mainly exports its product to Afghanistan, Bangladesh and Sri Lanka.It is the first cement industry of the country that has installed a WHRPP

INTROCTION

Crushing, blending and fine milling of limestone (calcium carbonate) and other materials containing silica, alumina and iron oxides

This fine powder is then heated to temperatures as high as 1,450°C in a kiln where the compounds react chemically to form clinker

Cooling the clinker in grate coolerOther additives such as fly ash and gypsum added to clinker and

converted to fine powder in a large ball mill, known as cement mill

CEMENT PRODUCTION PROCESS

clinker

STEPS

PM may be described as the care and servicing by individuals involved with maintenance to keep equipment/facilities in satisfactory operational state

In BW the preventive maintenance is carried out on daily, weekly, fortnightly and monthly basis

The condition of the equipment is judged by the noise, temperature, vibration level at different intervals during the shift

Daily PM operations includes : CleaningListening to abnormal voice and noting the vibration, speed(rpm),

current and temperature etcChecking all the instrumentsShift report

Preventive Maintenance

PM Schedules

Daily Maintenance

Weekly Maintenance

Fortnightly Maintenance

Monthly Maintenance

Preventive Maintenance contd…

To repair an equipment/item to its operational state.It is unplanned maintenance and performed when an item

is out of orderThe industry has its own workshop equipped with lathe

machines, drilling machines, milling machines and other equipment to carryout the corrective maintenance

In CM the equipment is to be stopped and for such maintenance a WORK PERMIT is required

Corrective Maintenance(repair)

Maintenance activities performed when the plant shutdown

In every process industry there the production goes on 24 hrs a day and you can’t stop the plant for performing minor maintenance

Shut down maintenance is planned on the basis of historical data ( shift reports and equipment records)

Generally the plant is shutdown after every 4 months for 3 to 4 days, depending upon the maintenance required

It includes both the PM and CMAnnual over haul

Shutdown Maitenance

Every section has an Equipment register.Containing;

Maintenance historyOperating manuals and Drawings

Each part has a unique identification code.Provides guidance for future.INVENTORY

Inventory plays a vital in maintenanceInventory is maintained on the basis of historical dataEach year in preparing the budgets every department

provides a list of spare parts and other equipment needed for the maintenance work

Equipment Records and Inventory