Internship Report

Cherat Cement Company Limited

Submitted to: Head of The Department (Mechanical)

Submitted by: Waleed khan

Under Graduate Student of Cecos University of IT and Emerging Sciences

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Cherat Cement Company Limited is a Ghulam Faruque Group (GFG) Company. Its main business
activity is manufacturing, marketing and sale of Ordinary Portland Cement with the brand name
of ‘Cherat’. The Company is amongst the pioneers of cement industry in Pakistan and is the
number 1 cement in its region. Therefore, there are no compromises on Quality Management.
The plant is located at Village Lakrai, District Nowshera, Khyber Pakhtunkhwa (KPK) Province .

Cement Manufacturing Process:

The process of cement manufacturing starts with blasting the mountains to get the required
raw material or mix limestone. This material is brought from mountains to the cement industry
through the help of trucks and then drop it into hopper of crusher to crash the material. Here
we also brought clay and literate for crushing this material is brought from outside areas. After
getting crushed, the material is then brought to the stacker area by the conveyor belt. Now the
piles of these materials are made by the stacker. The material then loaded on to another
conveyor belt by the reclaimer. The material is then taken by the conveyor belt to the hoppers.
Underneath the hoppers, there are weigh feeders which send the required proportions of each
of the four types of materials to the raw press area. The material is then fed into the V
separator where the fine material is been sucked up by the dynamic separator and the coarse
material is been rejected then it goes to a feeding bin through a bucket elevator. The feeding
bin then feed the material to the roller press where the material is been pressed. This material
again goes to V separator through bucket elevators. Again, the acceptance and rejection cycle
take place. After the material is accepted by the dynamic separator, it is then taken to the multi

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cyclones. This material is then carried to the CF Silo. From the CF Silo the material then comes
down to a feeding bin through bucket elevator. The material is then sent to the first stage of
the pre heater after passing through a feed fister which regulates the feed of the material. In
pre heater the material comes from top to bottom and the hot gases go from bottom to top.
These hot gases come from the PC of the pre heater. The material is heated so that the material
may undergo the process of calcinations. The material is heated up to 850 degrees Celsius. It is
then brought to kiln where further heating up to 1450 degree Celsius takes place. This material
goes through the clinker cooler where it is cooled down by aeration. After the cooling of clinker,
the material undergoes crushing in the clinker crusher. Then this clinker is carried to the clinker
silo by the pin conveyor. From this clinker silo, the clinker is then shifted to the clinker hopper.
Gypsum and PI are also brought to their respective hoppers by bucket elevator. Gypsum is
crushed in the gypsum crusher before coming to the hopper, whereas the limestone is also
crashed in crusher before coming to the hopper. Underneath the hoppers, there are weigh
feeders which send the required proportions of each of the three materials to a bucket elevator
which drops it into a feeding bin. This feeding bin drops material into a roller press where the
material is pressed. After getting pressed, this material goes to the V separator through bucket
elevator. The fine material is accepted by the dynamic separator, whereas the material rejected
then goes to the cement mill through an air slide. After the material is milled, the material is
put back into the dynamic separator by a series of air slides and bucket elevator. From the
dynamic separator the fine material is been sucked by the bag filter. After the process of
purging, the material is dropped into an air slide. This air slide leads to a bucket elevator which
drops the material into the cement silo. The cement comes to the packing plant through the air
slides. It is loaded in the feeding bin first by a bucket elevator. It is then dropped to the packer.
Before coming to the packer, the cement passes through a vibrating screen which removes any
unwanted material from the cement like metal rods, coarse material etc. It also passes a rotary
valve which is there to control the flow of cement. The cement is then packed into bags and
sent for loading.

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Week No: 1

Crusher
Crusher:
Crusher is a kind of machinery that is widely used in the cement production industry. It is
mainly used in the material preparation process to crush the raw materials into proper size
particles.

This is the first area where the raw material for the manufacture of cement comes.

Hammer Crusher:
The hammer crusher machine completes the crushing
material operation by the impact energy. During the
operation of hammer crusher machine, the motor drives the
rotor to rotate at a high speed, and the material enters the
crusher cavity evenly. The high-speed rotary hammer
impacts, shears and tear the material, all the materials are
broken.

We have hammer crusher in line 2 and 3. It has a 560-kW

motor for each of its two rotors. On each rotor, there are five
shafts and on each shaft there are seven hammers. Each
hammer weighs 160 kg. The hopper of the crusher has a
maximum capacity of 200 tons. Crushing of the material is
done by the rotating hammers on the shafts.

Impact Crusher:
In line 1, the crusher is an impact crusher. The impact crusher consists of a rotor that rotates
and throws the material on the impact plates by which the material is crushed. There are two
kinds of impact plates. They are namely the primary impact plate and the secondary impact
plate. Primary plate is closer to the inlet point and is placed above the secondary plate, so,
crushing is done first by the primary plate.

Apron:
Apron is a mode of transportation for the raw material from the
hopper of the crusher to the crusher itself. This apron chain has 55
kW motor that runs at 1482 rpm. It also has a gear box which acts as
a reducer. The apron conveyor can operate from 80 to 800 t/h.

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Bag Filter:
It is a filter that is used for the dust control in various
areas of the factory. One of its functions is also to avoid
any wastage of material. It is also important for the
environment. It helps the environment to be pollution
free. This equipment is present in every area of the
factory where there is dust.

A bag filter consists of a fan that sucks the air and dust
from the material. The dust particles get stuck to bags in
the bag filter, whereas, the cleaned air goes out to the
environment. In the bags, the dust particles combine to
form larger particles. Then in order to put these particles back into the cycle, there are three
different kinds of mechanisms:

 Mechanical Shakes: In this method, the top side of bags is connected to a beam which is
connected to a motor that vibrates the beams in order to shake the material off the
bags.
 Reverse Air Pressure: In this method, fresh air is both ejected as well as injected. The
injected air helps clean the off the bags.
 Jet Impulse

The mechanism used here is Jet Impulse. A jet of air in reverse direction is passed through these
bags in reverse direction after every 10 to 15 seconds. This process is also known as purging.

Stacker:
The raw material comes from the crusher to the stacker via
the belt conveyer. The stacker is a machine that makes piles of
the material in the stacker area before it is sent to the raw
press area. Stacker has a limit switch. The stacker will stop
itself when a particular height of the pile is achieved.

Reclaimer:
It is a large machine that loads the material onto the belt conveyor. From there, the material
goes to the hoppers in the raw press area.

There are two kinds of reclaimers in line 2. One of them is called a mount reclaimer and the
other is called side reclaimer. The difference between the two is this that, mount reclaimer has
teeth on both sides, whereas side reclaimer has teeth on only one side.

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The reclaimer has three different motors. One
of the motor is for the buckets of the reclaimer.
This motor has a power of 75 kW and it runs at
1490 rpm. There is a gear box as well which
acts as a reducer. The buckets of the reclaimer
help in pushing the material onto the belt
conveyor. One of the motors is for the linear
movement of the reclaimer and the last motor
is for the movement of the teeth. The teeth of
the reclaimer help in making the material fall
from the pile so that the buckets can push it.
The second and third motors have a clutch
between them.

In line 2, the stacker and reclaimer assembly is

linear, whereas, in line 3, it is circular. In circular
assembly, the stacker and reclaimer work
together at the same time. They move around
in circles stacking and discharging at the same
time. This circular assembly takes lesser space
than the linear assembly.

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Week No: 2

Raw Press
The raw material reaches the raw press area from the stacker area through belt conveyor.

Hoppers:
In the raw press area, there are 4 hoppers. Each hopper is specified for one type of material.
Following are the 4 different types of materials in these hoppers:

1. Mixed Limestone
2. Laterite
3. Clay/Slate
4. Pure Limestone

The hopper that contains mixed limestone has a greater capacity than others. It can hold a
maximum of 790 tons. The capacity of clay hopper is 200 tons and that of laterite and pure
limestone is 230 tons.

Each of these hoppers has a bag filter at the top of them except for the hopper that contains
pure limestone. This bag filter is there to reduce the amount of dust in the hoppers and also to
avoid any sort of material wastage.

There are specific percentages of all these materials. These specific percentages are sent
forward with the help of weigh feeder. Each hopper has a weigh feed under it which controls
the feed rate of material from the hopper.

Weigh feeder:
It is a material feed controlling device. It is placed mostly under the hoppers in this plant. It
controls the amount of each material dropping from the hopper. The feed of material is
changed by changing the speed of the belt on the weigh feeder.

V Separator:
V Separator is a type of separator that separates coarse and fine
particles. It does not have any moving part. That is why, it is also
called static separator. A V separator does not have any running
cost. Along with separating fine and coarse material, a V
separator also performs the function of removing the moisture
from the material because hot gases from the conditioning
tower are passed through the v separator.

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A V separator consists of a casing and dispersion plates. Dispersion plates are there for the
protection of the casing as the material coming from the hopper will fall directly on these
dispersion plates, hence avoiding any damage to the casing.

The suction of the fine material from the v separator is done by the fan of dynamic separator.
The fine material is sucked up to the dynamic separator and the coarse material is rejected to
the bucket elevator which then goes to the bin and roller press.

Dynamic Separator:
Dynamic separator also performs the same function of separating the fine and coarse materials
but with a different mechanism.

A dynamic separator consists of static guide vanes,

dynamic vanes and a fan for suction. The fan is there
for the suction of material. When the material enters
the dynamic separator, the dynamic vanes provide the
rotation to the material. So, now the material is under
equal centripetal and centrifugal force. The fine
particles having a lesser mass will be sucked up by the
fan, whereas, the coarse particles having a greater
mass will keep circling until they go through the gap
between the vanes. Then, they will collide with the
static guide vanes and fall down towards the static separator.

Multi Cyclones:
After the dynamic separator, the
material comes towards the cyclones.
In these cyclones the separation of the
fine material and air takes place. The
material coming from the dynamic
separator enters the cyclones in such a
way that it adopts the path of a
cyclone. This is because of the
centrifugal force of the particles. The air on the other hand stays in the middle and is been
extracted out by the fan through the dip pipe present in the center of the cyclone. There are
four cyclones where the material is been stored before it is taken to the CF Silo.

Roller Press:
Roller press consists of two rollers. One of them is stationary and the other is moveable. There
is a 25 to 30 mm gap between the two. It is for the material to go through the rollers. When a

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large rock having a size greater than 25 mm
passes through the rollers, it causes the
moveable roller to move back. It is pushed
forward by the hydraulic jags. Two hydraulic
jags are there on the drive and two on the
non drive side. Hydraulic jags maintain a
pressure of 80 to 120 bars.

For each roller, there is a drive of 1600 kW

that runs at 992 rpm. These drives have a
planetary gear box as reducer. The drive and
the gear box are connected by a universal coupling. The reducers of these drives have a ration
of 48.7:1.

The gear box has a lubrication unit as well. The lubrication is done by 320 oil. For the cooling of
this oil, the lubrication unit also has a water supply.

Conditioning Tower:
Conditioning tower is also called GCT (Gas Conditioning
Tower). The function of this tower is to cool down the
hot gases coming from the pre heater. This
conditioning tower also has connections with other
equipments through a duct. It is connected to the V
Separator to which it supplies the hot gases as per the
requirement. In V Separator, the hot gases are required
to remove any sort of moisture from the material. The
conditioning tower also provides hot gases to the coal
mill for the grinding of coal.

The cooling process inside the conditioning tower takes

place by water sprays. These sprays are sprayed at the hot gases after a specific interval. After
cooling down, these gases can be released into the atmosphere.

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Week No: 3

Kiln and Coal Mill

The material from the multi cyclones comes to the CF Silo via the air slides and bucket elevator.

CF Silo:
CF Silo stands for Controlled Flow Silo. It is a storage
equipment to store the powdered material from the
raw press. CF Silo has 7 extraction points. 6 of these
points work in pairs. Only one pair works at a time.
The last extraction point in middle works at all time.
Each point has a pressure relief cone which has
blowers on all its side. They help release the material.
CF Silo also has a bag filter at the top of it for dust
management.

Coal mill:
Coal is used as the main fuel in kiln and pre heater. Coal comes from the coal reclaimer area
towards the coal mill. Here the coal is
collected in a feeding bin. From that feeding
bin it is fed to the coal mill for milling
purpose.

Coal is mill is a vertical type mill. It has a

grinding plate and 3 vertical rollers. For
each roller there are 2 hydraulic jags which
lift the rollers up. During the process, the
pressure of the jags is released and the
rollers come down on the material for
grinding. The grinding plate is connected to
a motor, whereas the rollers are free. The
rollers move due to the contact with coal or
the grinding plate. When the material is
grinded into powder, it is been sucked up by the bag filters. In the bag filters, purging takes
place to knock the material off the bags and into the storage bins. There are two storage bins.
One of them is for the main burner of kiln and the other is for the calciner. The material is sent
to the burners after passing through a feed fister. The requirement of PC is greater than the
main burner. The feed fister of PC send 20 to 25 tons per day and the feed fister of kiln main
burner send 10 to 15 tons per day towards their respective burners.

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Apart from this, there is a duct coming towards the coal mill from the conditioning tower. This
is for the heating up of the coal so that the grinding is easier.

Feed Fester:
It is also a material feed controlling device. It is used in the coal
mill and also in the pre heater. Feed Fester has two bucket
plates. One of the plates rotates. This plate has a hole in it. So,
the only way for the material to come out is this hole. The
material is extracted out of feed Fister either through suction or
through gravity.

There are two ceiling plates as well. Higher ceiling plate is

between the two bucket plates. And the lower ceiling plate is
below the lower bucket plate.

The feed of material is changed by changing the rotational speed.

Preheater:
There are two processes of cement
manufacture. One of them is dry process
and the other is wet process. Pre heater
is used in the dry process. Pre heater is
the core element of the dry process. It
preheat the material before it goes into
the kiln, hence, reduces the size of kiln.
Heating in pre heater takes place in the
calciner. It is called calciner because the
process of calcination takes place in
here. Calcination is the process of
thermal decomposition of limestone.
The calcinations of limestone begin at a temperature of 800 to 850 degree Celsius.

The chemical reaction is given below:

CaCO3  CaO + CO2

The pre heater in this factory is single string 5 stage in line calciner pre heater in the pre heater,
the material is dropped from the top and the hot gases come from the bottom as the calciner is
at the bottom. On each stage of the pre heater, there are cyclones. In these cyclones, the
material enters in such a way that it adopts the path of a cyclone. In the center of each cyclone,
there is a dip pipe. It is for transport of hot gases.

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Kiln:
It is a core equipment of clinker production. Inside
the kiln, the calcination process is completed and
clinker is made.

Kiln in line 2 has a diameter of 4.4 m and a length

of 52 m. A maximum of 3500 tons/day of clinker
can be taken out of the kiln.

Kiln has two drives. One of them is the main drive

and one is an auxiliary drive. Each drive has a
reducer. The drive rotates the pinion which in
turn rotates the girth gear on which the kiln is
mounted. There is a jaw coupling that connects
the two reducers on drives. Whenever we want to
use the main drive, we will decouple the coupling. The main drive has a power of 450 kW and it
operates at 989 rpm. The speed of kiln on the main drive is 4 to 4.5 rpm. Then whenever we
want the kiln speed to be slower, we will run it on the auxiliary drive. It runs the kiln at less than
1 rpm. On the auxiliary drive, the speed of kiln gets this slow because the transmission passes
through 2 reducers.

Apart from this kiln also has roller supports. These roller supports have general bearings on
both sides. In these general bearings oil is been used. Kiln also has a thrust roller. This thrust
roller has an axial thrust device as well. This assembly compensates for the axial force that the
kiln applies because of its 3 to 4 percent degree. This axial thrust device uses hydraulic oil 46 to
apply pressure through a hydraulic jag to put the kiln back on its position. This push back occurs
every 8 to 14 hours or depending upon the load in kiln.

Clinker Cooler and Crusher:

After coming out of Kiln, the clinker is red hot at a
temperature of almost 1400 degree Celsius. It has
to be cooled down. This is done by the clinker
cooler.

The cooler in line 2 is a Sino walk cooler. This cooler

has 7 chambers. Each of these chambers is for the
aeration purpose. Each of them has a fan connected
in them. The pumps of the fans have a power of
160 kW and they run at 1485 rpm. Chamber 3 and 6 have connection of 9 rows of 2-way
hydraulic jacks. They are for the movement of the cross bars which in turn moves the material

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forward. The sequence of movement is such that the forward movement of all the bars is the
same and the reverse movement is in groups of three.
First the row 1,4 and 7 move back and so on. The
hydraulic jags maintain a pressure of 140 to 180 bars
normally. There are three axial pumps for these
hydraulic jacks. In these hydraulic jacks hydraulic oil 46
is used.

After the cooler, the clinker falls into a crusher. This

crusher has 4 rotors. Each rotor has a motor of power
11 kW running at 1460 rpm. In crusher, the motor and
the gear box are connected by a flange coupling.

Electrostatic Precipitator:
It is a device used for dust control in such places where the
temperature is very high as the bag filters cannot operate
at very high temperatures.

EP works on the working principle of the attraction of a

charged particle by the oppositely charged plate. Then
after the particles are stuck to the plate, they are removed
and put back into the process by hammering.

WHR:
WHR stands for Waste Heat Recovery. There are two WHR
units. One is connected with the kiln main burner and the other is connected to the PC. These
WHR units are actually steam boilers that use the excess heat of the burners to form steam that
is used to run the turbines to produce electricity.

Excess Heat:
The whole kiln area works on the heat produced in the burners. The temperature in the PC is
about 850 to 900 degree Celsius and in the main burner the temperature is up to 1450 degree
Celsius. If the heat in the main burner exceeds this optimum value, then the heat is transferred
to PC via the Treachery Air Duct.

The excess heat is also used in WHR to produce steam which is in turn used to produce
electricity.

If still excess heat is left, then the hot gases are sent to the conditioning tower from where they
are sent to the V separator and the coal mill as per the requirement. The remaining hot gases
are cooled down by the periodic water sprays in the conditioning tower.

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Week No: 4

Cement Mill
Clinker Silo:
The material after going through the clinker crusher
comes to the clinker silo via the pin conveyor. Here the
clinker is stored. There are three groups of shoots in
the clinker silo. At a time, material is extracted of only
one of them. Below each group there is a separate belt
conveyor. These belt conveyors unite into one after
some distance. That belt conveyor then goes towards
the clinker hopper.

Hoppers:
There are three hoppers in this area.

Clinker Hopper:
It is the largest hopper out of the three. Its maximum capacity is 660 tons. Material comes to
this hopper from the clinker silo.

Gypsum Hopper:
Gypsum hopper has a capacity of 180 tons. Gypsum, before coming to the hopper undergoes
the crushing process in the gypsum crusher. The gypsum crusher has a single rotor that runs on
a drive that has a power of 250 kW and a speed of 990 rpm. The material after going through
the crushing process comes to the hopper by the bucket elevator.

PI Hopper:
PI stands for Performance Improver. Its hopper has a maximum capacity of 190 tons. The
material comes to the hopper via the same bucket elevator which carries gypsum to its hopper
as well.

Then a calculated amount of each material is sent forward. This is done by weigh feeders. More
than 90 percent, clinker is sent forward. 5 percent gypsum and 4 percent PI is added.

Cement Mill:
There are two different kinds of cement mills in this cement industry:

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Ball Mill:
In line 1 and 2, there is a ball
mill. In a ball mill, the grinding
of material occurs by both
pressing (friction) and impact.
In a ball mill, there are balls
which are called media. When
the material is dropped to a
ball mill, first of all the grinding
is done by pressing. This
happens when the material
comes between these media.
The second type of crushing
occurs when the mill rotates.
The media rotate with it up to
a certain height. Then the media falls down and the material is grinded further due to the
impact of these media with the material.

The ball mill has 2 chambers in it. The chambers are distinguished by the size of media in them.
Apart from this, the ball mill has two drives. One of them is a main drive and the other is
auxiliary drive. The main drive has a power of 3550 kW and runs at 1480 rpm. The main drive is
connected to the main reducer through a gear coupling. The reduction ratio of the main
reducer is 1:46.97. So, on the main drive the mill operates at 15.6 rpm. Mill also has a auxiliary
drive that has a power of 45 kW and runs at 744 rpm. The auxiliary drive and auxiliary reducer
are connected by a pin bush coupling.

Ball mill has four general bearings as well, two on each side. The working of these bearings
depends upon the pressure developed by the pumps. For each side there are 2 high pressure
pumps and a low pressure pump. The high pressure pump is used at the start to lift the ball mill.
It does this by maintaining a pressure of 70 to 100 bars. After the ball mill is lifted 0.2 mm, the
low pressure pump starts working. Its job
is to maintain this level of oil.

Vertical Mill
In line 3, the cement mill is a vertical mill.
Its working is the same as the coal mill.
But it is bigger than the coal mill. It has 6
vertical rollers in it and a single grinding
table.

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Week No: 5

Packing Plant
The cement comes to the packing plant via the air slides. This cement is thrown into the bucket
elevator. This cement is then thrown into a feeding bin.

Vibrating screen:
Before going to the packer, cement goes
through a vibrating screen. This vibrating
screen removes any sort of unwanted solid
material from the cement such as any sort
of metal scrap which was accidentally
dropped in the cement.

Packer:
Packer is the device that packs
the cement into bags. The bag
is held by the bag holder and
the bag is placed in the bag
chair. When the bag is filled as
per the programmed value of
weight, the bag is then closed
and sent forward. In the packer
the material comes out of
nozzles. There is continuous
flow of air through them to
avoid any choking of nozzles.

fter the cement is packed in the bags, the bags go through a series of belts.

Cleaning Belt:
In this belt the bags of cement are been cleaned of any sort of dust or cement on them.

Weighing Belt:
In this belt the bags are been weighed. They should be 50 kg each.\

Rejection Belt:
The bags that do not weigh 50 kg are been rejected by the rejection belt.

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Long Belt:
After passing the rejection belt, the bags are carried by the long belt. On this belt, there are two
diversions. These diversions are used depending upon where the truck is standing for loading.

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Week No: 6

Workshop
Lathe Machine:
A lathe machine is a machine that removes undesirable material from a rotating work piece in
the form of chips in order to achieve the desired shape. It is one of the oldest production
machines known to man. This machine is also called the mother of all machines.

Some of the main parts of the lathe machine are given below:

 Bed: It is the base of the whole machine on which the other parts are mounted.
 Headstock: The main function of this part is to transmit power to other parts.
 Chuck: It is the part where the work piece is held. It may have 3 or 4 jaws. The 3-jaw
chuck is used for regular shaped work piece and the 4 jaw for the irregular shaped work
piece. 3-jaw chuck is called a universal chuck and 4-jaw chuck is called an independent
chuck.
 Tailstock: This part can be moved back and forth. It is used mainly for drilling, boring or
to hold large work piece tightly alongside the jaws.
 Tool Post: This is the part used to hold the tool.
 Cutting Tool: Different types of tools are used for different operations. The tool used for
most of these operations has a carbide tip as its cutting edge.

Some important operations that are done on the lathe are given below:

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  Turning: In this
operation the
diameter of the
work piece is
reduced. The tool
used for this is the
turning tool. It is the
most used
operation. In order to
get a better
finishing on the
work piece, cutting oil
is used. It gives a
well-polished
finishing. For
finishing on silver
kerosene oil is used and for copper and steel oil is used.
 Tapered turning: In this operation the diameter of the work piece is reduced as well but
in a slope. For this the tool post is set up on a degree.
 Facing: In this operation the face of the work piece is polished by removing a very thin
layer of material from it.
 Threading: For the required thread on the work piece, setting is done on the head stock
and then the feed is started. By doing so, we get the required thread on the work piece.
 Parting: In this operation a deep groove is made on the material to remove a specific
part.
 Chamfering: In this operation, the ends of the work piece are beveled in order to avoid
cuts due to sharp edges.
 Knurling: In this operation the surface is made rough by imparting a regular pattern onto
it. This is done for a better grip. For this process knurling tool is used.
 Drilling: In this operation, holes are made in the work piece. For this a drill is used. This
drill is fitted in the tail stock.
 Boring: Boring is also called internal turning. This operation helps increase the diameter
of an already existing hole.

Some of the materials that are used as work piece are:

 MS (Mild Steel)
 SS (Standard Steel/ Stainless Steel)
 Teflon

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  Brass
 Cast Iron etc.

Shaper:
Shaper is a machine used for
producing horizontal, vertical or
flat surfaces. The shaper holds a
single point cutting tool in a ram
and holds the work piece on the
table of the machine. The tool
then reciprocates back and forth in
order to remove the unwanted
material from the work piece.

Shaper is used in the work shop for

the production different types of
parts. It can be used to make nuts.
It can also be used to make
grooves that are required in
different parts.

Power Hacksaw:
It is a machine used to cut
huge shafts into sizes that
are required. First of all,
the shaft is fitted on to the
machine. Then, the blade of
the machine starts to
move back and forth to
produce the cut required.
There is a supply of water
given to the place where
the cut is been made for cooling
purpose.

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Drill Machine:
A drill machine is used to form holes in a work
piece. Let’s say we have a flange as our work
piece and we want to make 4 holes in it that
have equal angular distance between them. For
that first we will have to make markings of the
holes. That is done by a divider. After that we
will place our work piece on the drill machine. If
the holes to be made are small, then we can
simply use the drill of the required diameter.
But, if the holes are large, then we should first
make a small hole and then enlarge that hole by
using the drill of required diameter. If this is not
done, then there is possibility that hole will be
not be accurately drilled on the marking.

Measurement Instruments:
Vernier Caliper:
It is an instrument used for linear measurement. It is the most
used instrument for measurements in the workshop. It can
measure linear lengths, internal and external diameters, and even
depths. The least count of this instrument is 1 point (0.1 mm).

Micrometer:
It is a gauge used to measure small distances or thickness of a
body. This instrument is used when a greater accuracy is required
as it is more accurate than the vernier caliper. The least count of micrometer is 1 hundred (0.01
mm).

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Mercer Gauge:
It is an instrument used for finding the internal diameter of bores. It is
used in areas where vernier caliper cannot be used. It is a very
precise instrument having an accuracy of 0.01 mm.

Internal Caliper:
This is a tool used to find internal diameters. It does not have a
calibration on it. So, after fitting it in a bore, we have to use a vernier
caliper to get the reading of the diameter.

Bevel Protractor:
It is an instrument that we use to measure the angle between the surfaces of an object. The
bevel protractor is opened and the surfaces are set up in it and then the screw is tightened
again. There is a calibration of degrees on this instrument which gives us the angle between the
surfaces.

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Depth Gauge:
This instrument is just like a vernier caliper in terms of design and reading method. But it is only
specified for measuring depths.

Thread Gauge:
It is an instrument used to measure the pitch of threads on a work piece. It has calibrations of
both threads/mm and threads/inch.

Fabrication Workshop:
Welding:
Welding is a fabrication process whereby two or more
parts are fused together by means of heat, pressure or
both.

In the workshop, the machine used for welding is a 3-

phase welding machine. It is a 500A machine. A 3-phase
welding machine has 3 sources of AC power supply.

For welding purpose, different kinds of materials are

used. Some of those materials are listed below:

 Cast Iron: Cast Iron is a brittle material. It is used

for high temperature application.
 MS (Mild Steel): Mild steel is the most used welding rod in the workshop. It is a ductile
material having a high tensile strength, hence making it a good welding material. A
single weld of MS 7018 can bear a mass of 1 ton.
 Nicro HLS: This material is used for applications like gear welding and kiln tire welding.

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Gouging Machine:
It is a machine used to cut off metal from a material using
Carbon electrode electric arc welding. Compressed air is
used to thoroughly remove the metal from the surface.
The machine that this process uses is a 1000A machine.

Fire Cutter:
It is cutting equipment used to cut materials with fire in
the workshop as well as in other areas of the factory. It
uses two gases. These gases are stored in two different
cylinders. One of these gases is Oxygen and the other is
DA. This equipment is also used to pre-heat
some jobs before welding. For some steel
alloys’ jobs or jobs having a thickness of
more than 1 inch, preheating of the job is
important. This is done so that the welded
material is able to bond with the material
of the job. This is done using the fire cutter.

Chain Lock:
This is an equipment which is used to lift very heavy stuff with comparably very less effort. This
equipment consists of pulley arrangements. One of the pulleys is used for the input that is the
pulling by the rigger and the other is for the output that is the lifting of the object. The speed
with which the object is lifted is much slower than the speed with which the other pulley is
pulled. But this slow speed is compensated by the fact that the force required to pull the input
pulley is much less than the actual weight of the object.

Grinding Machine:
It is a machine that is used to give a finishing to the
welding been done of the job.

Different kind of metal sheets used in workshop:

 MS (1 mm – 60 mm)
 Hard X (6 mm – 50 mm)
 Watted (This is actually MS coated with Hard X)
 SS
 GI Sheet

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Transportation of material:
For the transportation of material, various types of equipments are used. These equipments are
discussed below:

Bucket Elevators:
Bucket elevator is the equipment that is used to convey the material vertically up or down.
Depending on the type of material been conveyed, different types of bucket elevators are used.
The two different types of bucket elevators are used:

Chain Bucket Elevator:

Chain bucket elevator is used when coarse material is
to be moved. In chain bucket elevator, the buckets are
connected by a chain on both the sides. A chain
bucket elevator can also carry material at a higher
temperature. Chain bucket elevator can only carry the
material 60 to 70 m. This is because of the tensile
strength of the material with which the chain is made.
The material can only bear a weight equivalent to this
much height, otherwise, there is a huge risk of an
accident. This kind of bucket elevator is used in the
raw press area and also in the cement mill area where the material is coarse.

Belt Bucket Elevator:

Belt Bucket Elevator is used when the fine and a low
temperature material is to be moved. In this type the
buckets are attached together by a belt. Coarse material
cannot be moved in belt bucket elevator as it may cause
damage to the belt on which all the buckets are attached.
High temperature may also cause damage to the belt. One
of the advantages of this type of bucket elevator is its
increased range in terms of height. It can carry the
material to higher height than the chain bucket elevator.
This is used in the pre heater to take the material from the
feed fister to the first stage cyclone which is at the top of the pre heater. It is also used to take
the cement to the cement silo.

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Belt Conveyor:
Belt Conveyor is also used to carry material from
one place to another. It is also used for inter area
transportation of material. It is mostly used for the
movement of coarse material as it is open from the
top so it cannot carry powdered material. It is
present in almost all the areas of the factory. It
consists of belt which moves on rollers to transport
the material.

Pin Conveyor:
Pin conveyor transports material by means of pins that are mounted on roller chains. Pin
conveyor is used in carrying the clinker from the clinker crusher to clinker silo.

Air Slide:
An air slide is used to carry material that is in powdered
form from one place to the other. In an air slide the
material is fluidized by low pressure air. Then due to the
slight angle of the air slide, the material comes forward
under the action of gravity. Air slide is used in many parts if
the factory, for example, it is used to transfer the cement
from the cement mill area to the bucket elevator of
cement silo.

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Couplings:
A coupling is a machine component that is used to connect two shafts together.

Various types of couplings are been used in the whole plant. The selection of coupling is been
done on the basis of the needs. Some of these couplings are discussed below:

Fluid Coupling:
It is the type of coupling in which the transmission of torque is
done by a fluid. This coupling consists of a casing, an impeller
and a turbine. The impeller is connected to the drive side and
the turbine to the driven side. When the impeller rotates, it
pushes the fluid forward towards the turbine. Pressure is
developed slowly and when sufficient pressure is developed,
the turbine will start to rotate. In the plant, fluid coupling is
used to connect the motor and the reducer in many places such
as the bucket elevators or the dynamic separator. Some
advantages of fluid coupling are as follows:

 It allows transmission without any mechanical contact, so it can absorb any sort of
mechanical shocks.
 It allows the motor to start at zero load, hence, reducing any chance of damage to the
motor.
 It can easily be decoupled by draining the oil out of it.
 It has a temperature switch which melts at the extreme temperature. This causes the oil
to drain out, hence, decoupling the shafts.

Universal Coupling:
It is the type of coupling that allows relative rotation in
two axes. In the plant, this type of coupling can be seen
connecting the drive and reducer of the roller press. Some
of the advantages of this coupling are:

 It transmits torque between such shafts that have

angular misalignment.
 It also transmits torque between such shafts whose angular misalignment is
continuously changing.
 It can absorb shocks very effectively due to its flexibility.

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Gear Coupling:
Gear coupling is a coupling that is used to couple two shafts that
are not collinear. In this type of coupling both input and output
shafts have a gear at their ends. These are connected by a sleeve
with internal gears. In the plant, gear coupling is used to connect
the main drive and main reducer of the ball mill. Some
advantages of this type of coupling are:

 It can transmit huge torques.

 It can deal with slight linear misalignments.

Pin Bush Coupling:

It is the type of coupling in which there are two flanges mounted
on both the input and the output shaft. They are connected by
pins over which rubber bushes are used. In the plant, this type of
coupling is used to connect the auxiliary drive and auxiliary
reducer of the ball mill. Some of the advantages of this coupling
include:

 It is having a simple design.

 It can be assembled and dismantled easily.
 It can transmit high torques.
 It can work with slight shocks and vibrations.

Jaw Coupling:
It is the type of coupling in which there are two jaws
mounted on both the drive and the driven shaft.
These jaws are connected by a rubber spider in order
to avoid any sort of metal contact that may cause
wear. In the plant jaw coupling is used to connect the
fluid coupling to the reducer of the motor of bucket
elevator. It is also used to connect the main and
auxiliary reducer of kiln. Some advantages are given
below:

 This coupling can bear slight misalignments.

 It also has the ability to damp the shocks and vibrations, hence, protecting the other
components.

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Bearings:
Bearing is a machine element that constrains undesired motion and allows desired motion.

Various types of bearings are used in the plant. Some of them are discussed below:

Ball Bearings:
It is the type of bearing in which there is a ring of metal balls. It is
designed such that machine parts roll over each other rather than
sliding. This type of bearing is used in places where the rotational
speed is high.

Roller Bearings:
In this type of bearing, there is a ring of cylindrical rollers. This type of bearing is used in places
where the load is high.

Spherical Roller Bearings:

In this type of bearing, there are two rows of cylindrical rollers. They are
placed at such a degree that the whole shape seems like part of a sphere.
This type of bearing can bear angular misalignments. That is why it is also
called self aligning bearing. This type of bearing can bear more load than
ball bearing and can be operated at a higher speed than roller bearing.

Tapered Bore Bearings:

This is the type of bearing, in which the bore of the bearing is tapered.
This type of bearing can be mounted on a tapered shaft directly. In the
case when we need to mount this bearing on a cylindrical shaft, we use
an adapter sleeve or a with drawl sleeve.

Journal Bearings:
This is the type of bearing which does not use any balls or rollers. Instead
it uses oil as a media for rolling. This type of bearing is used with the roller
supports of the kiln and also in the ball mill.

The End

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