Vikram Cement: Reliability Based Maintenance

1
VIKRAM CEMENT
RELIABILITY BASED MAINTENANCE
EXPERIENCE & BENEFITS
2
RELIABILITY BASED MAINTENANCE
RELIABILITY BASED MAINTENANCE IS A TECHNIQUE

THAT
UTILIZES
DETERMINE
THE
ZERO
BASE
OPTIMUM
APPROACH
TO
MAINTENANCE
REQUIREMENT OF EQUIPMENTS IN THEIR OPERATING

ENVIRONMENT.
3
NEED OF RELIABILITY BASED MAINTENANCE
TO OPTIMISE MAINTENANCE ACTIVITIES BY :A)
REDUCTION IN REPAIR TIME
B)
REDUCTION IN MAINTENANCE FREQUENCY
C)
REDUCTION IN EXCESSIVE MAINTENANCE
TO ELIMINATE ROOT CAUSE OF BREAKDOWN
RBM ORGANIZATION
PLANNED MAINTENANCE
SUB-COMMITTEE CHAIRMAN
RBM CO-ORDINATOR
RBM
CORE
GROUP
MEMBER MEMBER MEMBER MEMBER MEMBER MEMBER

(MECH.) (ELECT.) (INSTT.)
(MID.)
(PROD.)
(MID.)
REM
TEAMS
MEMBER
(MECH.)
MEMBER
(ELECT.)
MEMBER
(INSTT..)
CORE GROUP MEMBERS = 12

TOTAL MEMBERS = 65
MEMBER
(PROD.)
RBM
CONSULTANT
NO. OF REM TEAMS = 13

(FOR EVERY SECTIONS)
RBM FLOW DIAGRAM
PREPARATION OF RELIABILITY BLOCK DIAGRAM

CHOOSE CRITICAL MACHINE & TARGETS
INSERT/ADD ALL FAILURE MODES TO MACHINES & PROCESS
PHASE - I
ROOT CAUSE & WARNING

DEFINE TASKS CLEARLY TO ADDRESS ROOT CAUSE,
FREQUENCY AND TRAINING NEEDS
FOCUSSED IMPROVEMENT
LUBRICATION
BRGFAILURE STUDY
HEAT EXCHANGER STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES
ASSESS EFFECTIVENESS (COST)

PROCUREMENT PROCEDURE
FAILURE
ANALYSIS
PHASE-II -
CONTINUE
6
RELIABILITY BLOCK DIAGRAM
OF COOLER SECTION (VC-1)
GRATE
1
ESP
GRATE
2
CLINKER
CRUSHER
ESP
RAL-1
COOLER
FAN 1
COOLER
FAN 2A
COOLER
FAN 3
COOLER
FAN 4
COOLER
FAN 5
LUB
PUMP
CD FAN-1
DPC-2
Standby
CD FAN-2
DPC-1
ESP
RAL-2
COOLER
FAN 2B
COOLER DISCHARGE GATE
COOLER DISCHARGE GATE
ESP
RAL-3
ESP
SC-1
ESP
SC-2
ESP
SC-3
ESP
SC-4
ESP
SC-5
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
8
EQUIPMENT CRITICALITY RATING CHART
LP
BAND
1
2
3
4
5
6
7
8
9
DOWN
TIME
0 - 10 min
10 - 30 min
30 - 60 min
1 - 2 hrs
2 - 4 hrs
4 - 8 hrs
8 - 16 hrs
10 - 32 hrs
> 32 hrs
RC & SEC. DAMAGE SAFETY &ENVIRONMENT

BAND
1
2
3
4
5
6
7
8
9
COST
0 - 15,000
15,000 - 25,000
25,000 - 1.0 L
1.0 - 2.0 L
2.0 - 5.0 L
5.0 - 10 L
10 - 20 L
20 - 50 L
> 50 L
BAND
1
2
3
4
5
6
7
8
9
LP = LOST PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE
CR = FR/10 ( LP+RC+SD+S+E)
FR = FAILURE RATE ( NO OF FAILURES / YEAR)
RISK
Minimal
Significant
Serious
Potentially fatal
Disaster
CALCULATION OF CRITICALITY
UNIT :VC
SECTION: KILN (COOLER
EQPCODE
EQUIPMENT NAME
LP
RC
SD
FR
FR/YEAR CR
1CLCL01 - DR001 GRATE DRIVE 2
1CLCL01 - DR002 GRATE DRIVE 1
1CLCR01 - CR001 CLINKER CRUSHER
3.9
2.7
2.4
1CRFN02 - FN001 COOLER FAN -2A
1.8
1CLFN03 - FN001 COOLER FAN -3
1.5
1.2
1CLFN06 - FN001 BEARING COOLING FAN
1.0
1.0
1.0
1CLCL01 - AC112 DISCHARGE GATE 1
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
DISCHARGE GATE 9
1.0
LUB PUMP 1
0.6
0.5
0.5
1CLFN02 - FN002 COOLER FAN -2B

LUB PUMP 2
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
CALCULATION OF CRITICALITY
UNIT : VC
10
SECTION : KILN (COOLER)
EQPCODE
EQUIPMENT NAME
LP
RC
SD
FR
FR/YEAR CR
1CLDP01 - CV001DPC 1
45
81.0
1CLDP02 - CV001DPC 2
40
68.0
1CLFN07 - LR001 C.D FAN -1
3.0
1CLFN08 - LR001 C.D FAN -2
1.5
DISCHARGEGATE 11
1.0
DISCHARGEGATE 12
1.0
DISCHARGEGATE 13
1.0
DISCHARGEGATE 14
1.0
1CLES01 - AL001 E.S.P RAL-1
0.5
0.5
0.5
1CLSC01 - SC001 E.S.P S/C 1
0.5
0.5
0.5
0.5
0.5
LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

FR = FAILURE RATE ; CR = CRITICALITY RATIO ; S = SAFETY ; E = ENVIRONMENT
11
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
EQP CODE : 1CLDP01 & 1CLDP02

EQP NAME : DPC I & II (KILN)
SUB SPARE MODE OF WARNING
ROOT
TASK
DEPT. PERIOD TIME
NAME
(FREQ) REQ .
FAILURE
EFFECT
CAUSE
DPC Roller
Brg cage
Motion
Roller brg grease Overhauling of
M
24 W 30 min
failure
detector
contaminated
rollers .
operated
due to dust
Double flap valve at
M
Once
discharge gate to be
installed
Links
Links
Abnormal
Due to aging of Checking of roller & M
1 W 1 hrs
cracked
sound
links .
chain
Chain to be replaced
M
Once 10days
REVIEW OF EQPT. MAINTENANCE
Buckets Uclits
Welding
cracked
Rail
Worn out
Guide
rail
Support
bracket
weld cracked
.
Overload of
drive
Poor welding
MAINT.
TYPE
PM
DOM
CBM
PM
Bucket taken out &

its U clit welded
Misalignment of Rail alignment to be

rails .
rectified
Higher size rail to be
installed
52 W
Once
52 W
4 hrs
1W
1/2 hrs CBM
Welding inspection
to be done.
Check the motion
sensing flag &
actuation .
12
3W
PM
DOM
CBM
EQP CODE : 1CLDP01 & 1CLDP02 REVIEW OF EQPT. MAINTENANCE

EQP NAME : DPC I & II (KILN)
SUB SPARE MODE OF WARNING
ROOT
TASK
DEPT. PERIOD TIME
NAME
(FREQ) REQ .
FAILURE
EFFECT
CAUSE
Gear Oil seal
Wornout
Leakage
Misalignment Output coupling
M
24 Hrs Once
Box
alignment to be
improved
Dust
Two way flap valve
M
Once
Contamination to be installed in CSP
discharge
MD
Lever Hinge failure Drive tripped Hinge locking pin locking pin to be
I
1 W 15 Min
worn out .
checked .
Probe
Broken
Transistor short To replace sensor
I
52 W 30 min
sensor short
Motor Motor Motor
Fuse blown , Underrated main Replace with 70
E
Once
winding burnt thermal
power cable
mm2 cable.
overload relay (35mm2)
operated
Insulation heated Termination
E
24 W 15 min
up
Checking .
Check motor body
E
4 W 1/2 hrs
temp(<85 deg. c)
Check vibration .
MID
4 W 15 min
13
MAINT.
TYPE
PM
DOM
PM
OFM
DOM
PM
CBM
CBM
14
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
15
SEAL FAILURE STUDY OF DPC GEAR BOX

MINOR LEAKAGE FROM OIL SEAL
CHECK FOR
COUPLING
AND GEAR TRAIN
MISALIGNMENT
OUTPUT
COUPLING
MISALIGNMENT
CORRECTED
FOUNDATION
STRUCTURE OF
GEAR BOX
STRENGTHENED
TO AVOID
JERK ON
GEAR BOX
SCRATCHES ON
SHAFT SURFACE
CHECK
ABRASIVE
CONTAMINATES
IN LUBRICANT
(OIL
CENTRIFUSED)
MEASURE
SHAFT
DIMENSION
>40 RC
(FOUND 52 RC)
INADEQUATE
INTERFERENCE
FIT BETWEEN
SHAFT & SEAL
CHECK SHAFT
DIMENSION
(FOUND O.K.)
HEAT EXCHANGER - A CASE STUDY
16
EQUIPMENT:CEMENT MILL MAIN DRIVE GEAR BOX HEAT EXCHANGER - 2 NOS.

EXISTING SURFACE AREA = 2.2 + 2.2 = 4.4 M2
OBSERVATION:OIL TEMPERATURE REDUCTION = 2 DEG. C
AT INLET WATER TEMPERATURE = 34 DEG. C
AMBIENT TEMPERATURE = 28 DEG.C
IMPROVEMENT PLAN:MOTOR KW = 2250 KW
MAXIMUM POWER DRAWN = 1900 KW
HELICAL GEAR BOX EFFICIENCY = 90% (ESTIMATED)
HEAT DESSIPATION IN GEAR BOX = 1900 X 10% = 190 KW
AT INLET WATER TEMPERATURE = 38 DEC. C (IN SUMMER SEASON)
REQUIRED HEAT EXCHANGER SURFACE AREA = 22 M2 (FROM GRAPH)
17
RESULTS:- NEW PLATE TYPE HEAT EXCHANGER WITH SURFACE AREA (20 M2)
INSTALLED
- IMPROVEMENT IN OIL TEMPERATURE REDUCTION
IN NEW HEAT EXCHANGER = 8 DEG.C
- WATER TEMPERATURE RISE = 10 - 12 DEC.C
- SIGNIFICANT REDUCTION IN GEAR BOX OIL TEMPERATURE =
57 (BEFORE) - 43 (AFTER) = 14 DEG. C
- OIL SEAL LIFE AT INPUT AND OUTPUT END INCREASED BY 2.5 YEARS
SELECTION OF LUBRICANTS - A CASE STUDY

EQUIPMENT:CEMENT MILL MAIN DRIVE GEAR BOX
PINION DIA = 240mm
OIL VISCOSITY USED = 460 CSK
INPUT SPEED = 990 RPM
CALCULATION OF INPUT PIONION PERIPHERIAL SPEED:VS = PIE x D x N
60
= 3.14 x 240 x 990 = 12.5 M/Sec.
60 x 1000
FOR 10 TO 12 M/Sec. INPUT SPEED VISCOSITY SHOULD BE = 320 CSK
ACTION:OIL VISCOSITY CHANGED FROM 460 CSK TO 320 CSK
OIL TEMPERATURE AND SEAL LIFE IMPROVED
18
19
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
20
IMPLEMENT & MONITOR

DEVELOP CHECKLIST FOR EACH DISCIPLINE (CONVERSION OF REM
SHEETS)
DEVELOP CBM CHECKLIST
COMPUTERIZATION OF CHECKLISTS AND SCHEDULING OF RBM MASTER
EXECUTION OF CHECKLIST (TRIAL RUN)
REVIEW AND MODIFY THE CHECKLISTS
21
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
SPARE PART ENGINEERING

FOR RELIABILITY ENHANCEMENT
22
COMPONENT
LESS THAN
STANDARD LIFE
WEAR
5, 7, 8
3
RANDOM
6, 1, 2, 9
LIFE
FULL LIFE
SELECT HIGH
COST AREA FOR
IMPROVEMENT
TOO EARLY
9, 8,3
1.
2.
3.
4.
5.
6.
7.
8.
9.
OPERATION IMPROVEMENT
MAINTENANCE IMPROVEMENT
INSPECTION IMPROVEMENT
STORAGE / TRANSPORT
ENVIRONMENT IMPROVMENT
VENDOR IMPROVEMENT
LUBE / OTHER CONDTION
IMPROVEMENT
MATERIAL
DESIGN REVISION
SPARE LIFE ENHANCEMENT - A CASE STUDY
23
NAME OF THE SPARE - BUCKET ELEVATOR BOTTOM BOOT BEARINGS

OBSERVATIONS:PREVIOUS LIFE : 3 - 4 MONTHS (TOO EARLY FAILURE)
MODE OF FAILURE : BEARING CAGE WEAR DUE TO POOR LUBRICATION
CONDITION
TYPE OF BEARING : ANTIFRICTION BEARING
ENVIRONMENT
: DUST PRONE AREA
FREQUENCY OF LUBRICATION : DAILY
ACTION PERFORMED:MATERIAL CHANGE : NI HARD JOURNAL BEARING INSTALLED
ENVIRONMENT IMPROVEMENT : DUST SPILLAGE CONTROLLED
IN OPERATION
IMPROVEMENT IN FREQUENCY: FORTNIGHTLY
OF LUBRICATION
LIFE : RUNNING SINCE 1.5 YEARS
RBM FLOW DIAGRAM
24

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
25
STANDARD CHECKING PROCEDURE
OF L.T. MOTOR
CHECK INSULATION VALUE WITH 500 VOLT MEGGAR AND RECORDS

VALUE. IF VALUE LESS THAN 1 MEGAOHM, IMPROVE THE VALUE.
CHECK INDUCTANCE AND RESISTANCE WITH MOTOR CHECKER AND

RECORD THE VALUE. DIFFERENCE OF R,Y,B SHOULD NOT BE >5%
CHECK MOTOR TERMINATION
CHECK GLAND FOR TIGHTNESS

CHECK FOR PROPER DOUBLE EARTHING
CHECK FOR ANY HEATING OF LUGS
CHECK TERMINAL BOX SEALING
26
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
CHRONIC FAILURES OF BAG HOUSE FAN

MODE OF FAILURE: INNER RACE CRACKED
BEARING HOUSING BORE DAMAGED
BEARING CLEARANCE GOT HIGH
BEARING SEATS GOT WORNOUT
FAN SHAFT BROKEN
COUPLING KEYWAY DAMAGE
WARNING EFFECT: HIGH VIBRATION
KNOCKING SOUND
HIGH BEARING TEMPERATURE
27
CHRONIC FAILURES OF BAG HOUSE FAN

ROOT CAUSE ANALYSIS: BEARING PEDESTAL FOUNDATION IS WEAK
PEDESTAL LEVELLING IS NOT PROPER SINCE ERECTION
HIGH JERK AT SHAFT BEARING SEAT DURING CHANGEOVER
FROM SPRS TO LRS AND VICE VERSA
TOLERANCE OF BEARING HOUSING BORE DIMENSION IS
NOT PROPER
ACTION PERFORMED: BEARING PEDESTAL FOUNDATION IS REGROUTED AND
PEDESTAL LEVELLING IS DONE
DRAWING DEVELOPED FOR BEARING HOUSING WITH
REQUIRED TOLERANCE
SHAFT TOLERANCE AT BEARING SEAT IS CHANGED
TRACKING SYSTEM FOR REGULATING FAN SPEED IS INSTALLED
28
29
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
30
BENEFITS OF RELIABILITY BASED MAINTENANCE
NO.OF PLANTS UNDER RBM
- 3
% OF EQUIPMENTS COVERED UNDER RBM - 62

(MOST CRITICAL + CRITICAL)
RESULTS OF RBM
EQUIPMNT UNDER CBM
PREVIOUS
`
208
AFTER
322
% PM ACTIVITIES
100
58 Reduction by 42%
DESIGN OUT MAINT. CASES
28
% INCREASE IN CBM ACTIVITIES
82:18
58:42 Increase by 24%
31
VIKRAM CEMENT
12000
B/D HOURS
10000
REDUCTION OF BREAKDOWN HOURS

RBM
IMPLEMENTATION
9819.3
8000
BETTER
6000
6189
5052.8
4000
2000
4014.9
2488.8
2174.4
1554.7
999.9
1375.86
1362.47
1106.46
0
91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 '01-02
YEAR
32
VIKRAM CEMENT
3000
REDUCTION OF BREAKDOWN FREQUENCY

RBM
IMPLEMENTATION
2688
B/D FREQUENCY
2500
2372
2171
2000
1500
1981
BETTER
1450
1263
1000
803
646
500
739
529
391
0
91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 '01-02
YEAR
33
VIKRAM CEMENT
IMPROVEMENT IN MTTR
RBM
IMPLEMENTATION
3.65
HOURS
2.85
2.55
2.13
2.13
1.97
2.02
1.93
2.09
BETTER
1.84
1.49
1
0
91-92 92-93
93-94
94-95
95-96 96-97
YEAR
97-98
98-99
99-00
00-01 '01-02
34
VIKRAM CEMENT
IMPROVEMENT IN MTBF
130
120.8
120
110
90
HOURS
112.6
DUE TO AFFECT OF
PETCOKE ON
SPARE LIFE
100
87.02
79.8
80
70
BETTER
69.32
RBM
IMPLEMENTATION
60
50
40
30
20
28.02
27.65
35.83
39.24
43.19
20.86
10
0
91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 '01-02
YEAR
35
VIKRAM CEMENT
IMPROVEMENT IN MAINTENANCE COST
160
157.48
148.71
COST PER TON
140
128.22
120
100
BETTER
106.4
98.27
84.11
80
61.24
65.27
60
RBM
IMPLEMENTATION
40
20
0
94-95
95-96
96-97
97-98
YEAR
98-99
99-00
00-01
'01-02
36
RBM FLOW DIAGRAM

PHASE - I

LUBRICATION
BRGFAILURE STUDY

SEAL FAILURE STUDY
(FORMATION OF
- REM SHEETS
- CHECKLIST
- RELIABILITY
CALCULATION)
IMPLEMENT & MONITOR
SPARE ENGINEERING
ADD NEW M/CS
TRAINING AS PER REM

REVIEW
RESULTS
CHRONIC CASES

FAILURE
ANALYSIS
PHASE-II -
CONTINUE
37
ASSESSMENT OF CRITICALITY OF EQUIPMENT
IDENTIFY FAILURE MODES OF FAILED SPARE
DEVISE KEY RELIABILITY ASSESSMENT CRITERIA

- APPLICATION OF (PRESSURE/TEMPERATURE/IMPACT/WEAR)
DEVISE KEY RELIABILITY ACCEPTANCE CRITERIA

- PHYSICAL, METALLURGICAL, CHEMICAL, VISUAL, DIMENSIONAL
DEVISE APPROPRIATE QUALITY SAMPLING PLAN FOR

ACCEPTANCE QUALITY LEVEL
STANDARDIZE PURCHASE PROCEDURE
38
A WAY FORWARD
MAJOR CHALLENGES
CASTING LIFE GET REDUCED DUE TO PETCOKE AFFECT
INCREASED SULPHUR
INCREASED TEMPERATURE
INCREASED MATERIAL HANDLING LOAD AT BELT CONVEYOR

SYSTEM
OUTPUT INCREASED FROM 1800 TPH TO 2800 TPH
INCREASED CLINKER TEMPERATURE
CYCLONE JAMMING AND LESS REFRACTORY AND CASTABLE

LIFE IN PREHEATER
RBM TASK FORCE IS FORMED TO OVERCOME THESE PROBLEMS.

Vikram Cement: Reliability Based Maintenance

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Vikram Cement: Reliability Based Maintenance

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1

RELIABILITY BASED MAINTENANCE IS A TECHNIQUE

REQUIREMENT OF EQUIPMENTS IN THEIR OPERATING

TO OPTIMISE MAINTENANCE ACTIVITIES BY :A)

REDUCTION IN REPAIR TIME

REDUCTION IN MAINTENANCE FREQUENCY

REDUCTION IN EXCESSIVE MAINTENANCE

TO ELIMINATE ROOT CAUSE OF BREAKDOWN

MEMBER MEMBER MEMBER MEMBER MEMBER MEMBER

CORE GROUP MEMBERS = 12

NO. OF REM TEAMS = 13

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

ROOT CAUSE & WARNING

HEAT EXCHANGER STUDY

IMPLEMENT & MONITOR

TRAINING AS PER REM

ASSESS EFFECTIVENESS (COST)

COOLER DISCHARGE GATE

COOLER DISCHARGE GATE

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM

ROOT CAUSE & WARNING

HEAT EXCHANGER STUDY

IMPLEMENT & MONITOR

TRAINING AS PER REM

ASSESS EFFECTIVENESS (COST)

RC & SEC. DAMAGE SAFETY &ENVIRONMENT

LP = LOST PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

SECTION: KILN (COOLER

1CLCL01 - DR001 GRATE DRIVE 2

1CLCL01 - DR002 GRATE DRIVE 1

1CLCR01 - CR001 CLINKER CRUSHER

1CRFN02 - FN001 COOLER FAN -2A

1CLFN03 - FN001 COOLER FAN -3

1CLFN01 - FN001 COOLER FAN -1

1CLFN06 - FN001 BEARING COOLING FAN

1CLFN04 - FN001 COOLER FAN -4

1CLFN05 - FN001 COOLER FAN -5

1CLCL01 - AC112 DISCHARGE GATE 1

1CLCL01 - AC113 DISCHARGE GATE 2

1CLCL01 - AC114 DISCHARGE GATE 3

1CLCL01 - AC115 DISCHARGE GATE 4

1CLCL01 - AC116 DISCHARGE GATE 5

1CLCL01 - AC117 DISCHARGE GATE 6

1CLCL01 - AC118 DISCHARGE GATE 7

1CLCL01 - AC119 DISCHARGE GATE 8

1CLFN02 - FN002 COOLER FAN -2B

LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

SECTION : KILN (COOLER)

1CLFN07 - LR001 C.D FAN -1

1CLFN08 - LR001 C.D FAN -2

1CLES01 - AL001 E.S.P RAL-1

1CLES01 - AL002 E.S.P RAL-2

1CLES01 - AL003 E.S.P RAL-3

1CLSC01 - SC001 E.S.P S/C 1

1CLSC02 - SC001 E.S.P S/C 2

1CLSC03 - SC001 E.S.P S/C 3

1CLSC04 - SC001 E.S.P S/C 4

1CLSC05 - SC001 E.S.P S/C 5

LEGEND: LP = LOSS PRODUCTION ; RC = REPAIR COST ; SD = SECONDARY DAMAGE

RBM FLOW DIAGRAM

PREPARATION OF RELIABILITY BLOCK DIAGRAM