Maintenance Management Case study

Helwan Plant

Focus Group:
1- Eng.Mohamed Fathy .
2- Eng. Mohamed Atef.
3- Eng. Mahmoud Tammam .
4- Eng.islam Roushdy.

Supervisor
Dr. Attia Gomaa
Contents

Introduction For Raw Mills

Flow chart of Raw Mills system

Equipements List & Tag no.

Equipment specifications

Case study for Raw Mills system

Introduction:-

 A raw mill is the equipment used to grind raw materials into "raw mix"
during the manufacture of cement. Raw mix is then fed to a cement
kiln, which transforms it into clinker, which is then ground to make
cement in the cement mill.

 Helwan plant raw Mill system is a close type circuit

Raw Mills line 2 system and flow chart:-
Equipment tag no.

M/C no. up stream feeding Tag no.

2007366 LIMESTONE APRON FEEDER........RAW MILL 3 R3A01
2007367 LIMESTONE B/C TO COLLECT B/C..RAW MILL 3 R3A03
2007368 CLAY APRON FEEDER.............RAW MILL 3 R3A01
2007369 CLAY B/C TO COLLECTING B/C....RAW MILL 3 R3C09
2007370 IRON ORE WEIGHT BELT FEEDER...RAW MILL 3 R3D01
2007371 IRON ORE B/C TO COLLECT B/C...RAW MILL 3 MISSING
2007372 IRON ORE WEIGHT BELT FEEDER (STDBY) RM 3 MISSING
2007373 COLLECTING BELT CONVEYOR 4/3..RAW MILL 3 R3A04
2007374 COLLECTING BELT CONVEYOR 5/3..RAW MILL 3 R3A05
2007375 ROTARY FEEDER BEFORE CRUSHER..RAW MILL 3 R3A06
2007376 HAZEMAG HAMMER CRUSHER........RAW MILL 3 R3A07
2010806 R3A07M1-HAZEMAG CRUSHER (SC-315 kW) RM 3 R3A07M1
2010807 R3A07M2-HAZEMAG CRUSHER (SC-315 kW) RM 3 R3A07M2
2007377 ROTARY FEEDER AFTER CRUSHER...RAW MILL 3 R3A08
2007378 COARSE MATERIAL BELT CONVEYOR RAW MILL 3 R3A10
2007379 ROTARY FEEDER COARSE MATERIAL RAW MILL 3 R3A11
Equipment tag no.
M/C no. Raw mill 3 crushing Tag no.
2007380 ID FAN KILN 2.................RAW MILL 3 J3J01
2007381 J3J01M1-ID FAN (SC-2800 kW)...RAW MILL 3 J3J01M1
2007387 R3M03M1-MAIN MOTOR (SR-1880 kW).....RM 3 R3M03M1
2007388 MAIN GEARBOX..................RAW MILL 3 R3M02
2007389 GIRTH GEAR AND PINION.........RAW MILL 3 MISSING
2007390 SHELL / HEAD AND SUPPORTS.....RAW MILL 3 MISSING
2007391 LINING AND DIAPHRAGM..........RAW MILL 3 MISSING
2007392 GRINDING MEDIA................RAW MILL 3 MISSING
2007393 GROUP CONTROL SEPARATOR.......RAW MILL 3 R3S01M
2007395 AIR SEPARATOR (SEPAX).........RAW MILL 3 R3S01
2007396 MULTI-CYCLONES................RAW MILL 3 R3S03-04
2007401 R3S07M1-MILL CIRCUL FAN (DC-1750kW) RM 3 R3S07M1
2007400 MILL FAN......................RAW MILL 3 R3S07
2007382 COOLING TOWER.................RAW MILL 3 J3K11
Equipment tag no.
M/C no. up stream feeding Tag no.
2007520 S/C UNDER CYCLONES RAW MILL 3...HOMO L 2 R3U03
2011623 DRAG CHAIN #1 BAG FILTER RM 3...HOMO L 2 J3P12
2011624 DRAG CHAIN #2 BAG FILTER RM 3...HOMO L 2 J3P14
2011627 ROTARY VALVE UNDER DRAG CHAIN #1 BF RM 3 J3P13
2011631 ROTARY VALVE UNDER DRAG CHAIN #2 BF RM 3 J3P15
2007521 SAMPLING SYSTEM RAW MILL 3......HOMO L 2 R3U05
2007522 AIRSLIDE TO AIRLIFT RAW MILL 3..HOMO L 2 R3U17
2007523 AIRLIFT RAW MILL 3..............HOMO L 2 R3U06
2007524 AIRLIFT BLOWER #1 RAW MILL 3....HOMO L 2 R3U07
2010871 R3U07M1-BLOWER #1 AIRLIFT RM 3(SR-220kW) R3U07M1
2007525 AIRLIFT BLOWER #2 RAW MILL 3....HOMO L 2 R3U08
2010872 R3U08M1-BLOWER #2 AIRLIFT RM 3(SR-220kW) R3U08M1
2007526 AIRLIFT BLOWER (STDBY) RM 3-4...HOMO L 2 R3U09
2010873 R3U09M1-BLOW ST AIRLIFT RM 3-4(SR-220kW) R3U09M1
Equipment Specifications
Drive
No. Machine / Equipment OEM Year Type capacity Purpose Drive KW
Type
1300/250
1 Hazemag Crusher Novo rotor Hazemag 2001 260 T/h Crusher lim&clay 315 kw
0
&EPR
Grinding raw
2 Tirax Mill ( Tube Mill ) F.L.S 1982 46X6.75 260 T/hr 1880KW Motor
material

SD70 HA8 -

BBC
500 V
raw meal
3 Collecting belt conveyor F.L.S 1982 800mm 240 T/h 35 kw
transportation
width
raw meal
4 Collecting belt conveyor F.L.S 1982 1000mm 240 T/h 7.5 kw
transportation
width
5 Clay belt conveyor T.O. 2001 800 mm 120t/hr Clay transportion 30 kw
Equipment Specifications

No. Machine / Equipment Make Year Type Purpose Drive KW

Separation fine
1 Air Separator (sepax) F.L.S 2001 475M.134 128 KW
material
from coorase 126 r.p.m
Mill Fan
2 F.L.S 2001 HPW Mill Fan 1750 kw

400/435 Gear box 1750 kw

n1 = 990 r.p.m
X100
n2 = 623 r.p.m

3 I.D Fan F.L.S 2001 HAF ID Fan 1835 KW

965 r.p.m
315/335
f 3350

4 E.P Fan F.L.S 2001 MT315SS E.P 762 KW

698 r.p.m
f 3150
Equipment specifications

Raw Mills
Inside diameter of the mill (Other dimension) 4.42 m dia., (L=6.6 m)

Starting motor power 1880 kw

Lime stone ≈ 75---80 %
Clay ≈ 20---25 %
Feeding material Corrective ≈ 1---2 %
Dolomite ≈ 5 %
RPM 14.4
Temp. 320 --- 350 ˚c (drying chamber)
The finesse degree 16 to 20 % (on 90 micron)
Capacity of the mill 220 t/hr
The degree of the ball charge 22.60%
Suction of the mill fan= 360000 m³/hr
Other Suction of the E.P. Fan= 513000 m³/hr
Suction of the I.D. Fan= 527000 m³/hr
Raw Mills area Case study

Raw mills system ( work in series).

Working conditions : 24 hrs/day.
Raw Mill Capacity : 220 Ton/hr.
Maintenance : internal Manpower + contractor

PM level Weekly Monthly Quarterly Annually

•Cleaning •Cleaning •Cleaning •Cleaning
•Check operation •Check operation •Check operation •Check operation
•Check noise •Check noise •Check noise •Check noise
•Check vibration •Check vibration •Check vibration •Check vibration
Check •check belt conv vulcanizing •check belt conv vulcanizing •check belt conv vulcanizing
•Check crusher wear rate •Check crusher wear rate
•Check plates wear rate
•Change worn-out mill plates •Change worn-out mill plates •complete crusher grates •Complete grates crusher

•change worn out crusher grates •Change worn-out mill plates •Change hammers of crusher

•Chang bearing for air slide •Change Rotor of crusher

Change /replace •Change damaged seals •Change Rotor of sepax
•Change worn-out plates

•Change bearing for air slides

•Change damaged seals

•Change damaged Filter bags

Maintenance type •Stopped •Stopped •Stopped •Stopped

Maintenance information
In PM stopped ( 1 raw mill running & 1 standby)
Working conditions : 24 hrs.'/day
Raw Mill Capacity : 220 Ton/hr
Maintenance : internal Manpower + contractor
Annually Stoppage: 15 days (24Hrs).
Normal PM Shift :(8Hrs).
Every Raw Mill stopped once /week
PM level Weekly Monthly Quarterly Annually
•Cleaning •Cleaning •Cleaning •Cleaning
•Check operation •Check operation •Check operation •Check operation
•Check noise •Check noise •Check noise •Check noise
•Check vibration •Check vibration •Check vibration •Check vibration
Check
•check belt conv vulcanizing •check belt conv vulcanizing •check belt conv vulcanizing
•Check crusher wear rate •Check crusher wear rate

•Check plates wear rate

•Change worn-out mill plates •Change worn-out mill plates •complete crusher grates •Complete grates crusher

•change worn out crusher grates •Change worn-out mill plates •Change hammers of crusher

•Chang bearing for air slide •Change Rotor of crusher

Change /replace •Change damaged seals •Change Rotor of sepax
•Change worn-out plates

•Change bearing for air slides

•Change damaged seals

•Change damaged Filter bags

Maintenance type •Stopped •Stopped •Stopped •Stopped

 Annual Maintenance schedule ( Maintenance Matrix )

1 2 3 4 5 6 7 8 9 10 11 12

M M M M M M M M M M M M

Q Q Q Q
A

Note:

• The Raw Mills system consists for two main Equipment ( Raw Mill & 3&4 ).
and they stopped alternately for example in week 1 raw Mill 3 stopped and raw Mill 4 will
be on operation .
• We don’t have any semiannually activities .
• We will work based on 52 week in the calendar .
• All the activities during stopped phase (weekly – Monthly – quarterly – annually ).
 Annual Maintenance schedule ( Maintenance Matrix )

R.M# 3

1 2 3 4 5 6 7 8 9 10 11 12 13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
X W X M X W X M X W X Q X W X M X W X M X W X Q X W X M X W X M X W X Q X W X M X W X M X W X A X W X W

M M M M M M M M M M M M

Q Q Q Q

R.M# 4 1 2 3 4 5 6 7 8 9 10 11 12 13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

W X W X M X W X M X W X Q X W X M X W X M X W X X W X M X W X M X W X Q X W X M X W X M X W X A X W X
S
M M M M M M M M M M M M

Q Q Q Q

2W Not stopped R.M# 3 R.M# 4

W weekly W 14 W 14
M Monthly Colors M 9 M 8
Q Quarterly Q 3 Q 3
A Annually
Legend
A 1 A 1
X 26 X 26
 Equipment Months
1 2 3 4 5 6 7 8 9 10 11 12 13

No. of weekly PM Raw Mill # 3 1 1 1 1 1 1 1 1 1 1 1 1 2

No. of weekly PM Raw Mill # 4 2 1 1 1 1 1 1 1 1 1 1 1 1

Cost of of weekly PM 3*5 2*5 2*5 2*5 2*5 2*5 2*5 2*5 2*5 2*5 2*5 2*5 3*5

Total Cost of of weekly PM 140,000 EGP

No. of Monthy PM Raw Mill # 3 1 1 Q 1 1 Q 1 1 Q 1 1 A 1

No. of Monthy PM Raw Mill # 4 __ 1 1 Q 1 1 Q 1 1 Q 1 1 A

Cost of of Monthly PM 1*30 2*30 1*30 1*30 2*30 1*30 1*30 2*30 1*30 1*30 2*30 1*30 1*30

Total Cost of of Monthly PM 480,000 EGP

No. of Quarter PM Raw Mill # 3 Q Q Q

No. of Quarter PM Raw Mill # 4 Q Q Q

Cost of of Quarter PM 1*150 1*150 1*150 1*150 1*150 1*150

Total cost of of Quarterly PM 900,000 EGP

The cost of annual PM 600,000 EGP
Total Mianitnence cost X1000
EGP
140,000+480,000+900,000+600,000= 2,120,000 EGP
W: (5,000) M(30,000) Q(150,000) A( 300,000) EGP
Note: cost is assuming global including ( Material , Manpower, Rentals & etc. ) .
Case Study:- Maintenance Control
PM level Weekly Monthly Quarterly Annually
•Cleaning •Cleaning •Cleaning •Cleaning
•Check operation •Check operation •Check operation •Check operation
•Check noise •Check noise •Check noise •Check noise
•Check vibration •Check vibration •Check vibration •Check vibration
Check
•check belt conv vulcanizing •check belt conv vulcanizing •check belt conv vulcanizing
•Check crusher wear rate •Check crusher wear rate
•Check plates wear rate

•Change worn-out mill plates •Change worn-out mill plates •complete crusher grates •Complete grates crusher

•change worn out crusher grates •Change worn-out mill plates •Change hammers of crusher

•Chang bearing for air slide •Change Rotor of crusher

Change /replace •Change damaged seals •Change Rotor of sepax
•Change worn-out plates

•Change bearing for air slides

•Change damaged seals

•Change damaged Filter bags

Maintenance type •Stopped •Stopped •Stopped •Stopped

Annual P.M Performance

Planned PM stoppages 28 17 6 2

Number of Actual PM work order 20 14 6 2

Total PM down Times (hrs.) 160 112 48 720

Annual C.M Performance

C.M Stoppage Causes fan tripped Mill internal Hazemag crusher Filter problems

No. of C.M 5 3 8 3

Total C.M down Time (hrs.) 10 24 64 12

 Equipment Maintenance Control
Annual P.M Performance
Planned PM stoppages 28 17 6 2
No. of Actual PM work order 20 14 6 2
Total PM down Times (hrs.) 160 112 48 720
Annual C.M Performance
C.M Stoppage Causes fan tripped Mill internal Hazemag crusher Filter problems

No. of C.M down Time 5 3 8 3

Total C.M down Time (hrs.) 10 24 64 12

• Standard working hours / line = 8760 hrs X 2running / 2 Total = 8760 hrs
MTBF :-
MTBF(for the line) = Total operating Time / No. (CMS + PMs).
For sub Equipment stoppage
MTBM MTBF
item
(Mean Time between maintenance ) (Mean Time between Failure )
Fans Tripped = (8760 / (5 CM+ 2 PM) = 1251 Hrs./failure. (8760 / (5 CM )=1752 Hrs./failure.
Mills Internal = (8760 / (3 CM+ 42 PM) = 195 Hrs. /failure. (8760 / (3 CM) = 2920 Hrs. /failure.
Hazemag Crushers = (8760 /(8 CM+22 PM) = 292Hrs. / failure. (8760 /(8 CM) = 1095Hrs. / failure.
Filters Problems = ( 8760/ ( 3 CM+ 2 PM) = 1752Hrs. /failure . ( 8760/ ( 3 CM) = 2920Hrs. /failure .
 Case Study:- Maintenance Control

CM/PM Ratio Number:-

Hazemag Filter
Item Target Fan tripped Mill internal
crusher problems
CM/PM 20% 5/2=250% 3/42= 8% 8/22= 37% 3/2=150%
Recommendations RCFA Update PM RCFA
Case Study:- Maintenance Control

PM Efficiency : PM % on Time
Maintenance type •Stopped •Stopped •Stopped •Stopped

Annual P.M Performance

Planned PM stoppages 28 17 6 2
Number of Actual PM work order 20 14 6 2
Total PM down Times (hrs.) 160 112 48 720

Annual C.M Performance

C.M Stoppage Causes fan tripped Mill internal Hazemag crusher Filter problems

No. of C.M down Time 5 3 8 3

Total C.M down Time (hrs.) 10 24 64 12

Item Total PM SD Maintenance Target

PM Efficiency 42/52= 80.7% 2/2= 100% 100%
Backlog % 19.30% 0%
Recommendations updating PM
Case Study:- Operating analysis

Reliability , Availability & Utilization

Standard Time (TT) = 8,760 X 2 = 17,520 hrs.

Target Time (PT) 17520 -1,040= 16,480 hrs. P.M

1,040 hrs.
Available Time (AT) 16,480-110= 16,370 hrs. C.M
110 hrs.

Operating Time (OP)=16,370-550=15,820 hrs

S/B
550 hrs D = 1,150 hrs

Reliability = AT/PT = 16,370 /16,480 = 99.33%

Availability= AT/TT = 16,370 /17,520 = 93.43%

Assumption :-
Waiting Time /year = 550 Hrs. for Raw Mills (3,4).

Utilization =OP/AT = 15,820/16,370= 96.64%

Facility Management
Performance,Quality&OEE .
based on production capacity

Actual Production for both mills = 400 T/Hrs.

Target Production For Both Mills = 440 T/Hrs.

Performance = 400/440 = 90.9%

Reject Quantity = 5 T/Hrs

Quality = 400-5/400= 98.75%

Quality Yield = 395/440 = 89 %

OEE = 93.43%*96.64%*90.9%*89.77% = 73.62%

System Management .KPI’s Report

KPIs Actual Target

Availability 93.43% 99%

Reliability 99.33% 99.80%

Utilization 96.64% 97.50%

Performance 90.90% 95%

Quality 98.75% 99%

OEE 73.62% 90%

120.00%

100.00%

80.00%

60.00% Acutal
Target
40.00%

20.00%

0.00%
Availability Reliability Utilization Performance Quality OEE
Case Study:- Supporting documents

Inspection , Notification, Work order & Feed back

 •Notification type (N5 ,N1) Notification type (N1 ,N2)
•Notification priority C,D,E,F
Notification priority A&B

• Planner

NO Yes

Created and the

Status :CRTD-TBPR • MCC planner in co-ordination with execution

Standing order
(Minor & Non
critical Jobs Only)

Yes
not
available
available
Do the planning & preparation
•Maintenan Manpower +resources+spares
CRTD-IPRE • All departments
ce /MCC
manager
do the job

NO Costs • MCC Planner

Accepted Yes Validate all the works of the week in
Then
Release the weekly meeting and releaseWO's
the WO cost check and approved
for PR

WO prepared and
ready for
execution
Close Notification status REL-WFPA
Assign to project CRTD-RTLA
or close

• Planner
Execute the job • Execution

Follow PR,PO till

spares in Job finished
Warehouse
Close
Notification

Update Actual hrs. Execution feedback

Spares arrive update spare parts + Planner +
in Warehouse Attach any necessary docs warehouse
REL- RTCL

• MCC Planner
Close WO- TECO
Close Notification

Equipment History
Inspection , Notification, Work order & Feed back:-
Inspection , Notification, Work order & Feed back:-