Team Members:

• Agha Ejaz Hussain

• Javed Islam

• Saqib Ali

• Safdar Shah

• Faizan Qadir

• Faisal Attique

• Muhammad Nazir

• Muhammad Aslam

Submitted To:

Intezar Ahmad

DGM Mechanical

Pakcem Ltd

• Normal operating pressure= (80~130)Bars, Upper limit 260bars and Lower limit 25bars, During Mill start up pressure dropped to 20 bars, Due to this issue we have replaced 5Nos. of high pressure pumps and 8Nos. Of repair kits during one-Year.

• During inspection white metal pitting found on Slide Ring

• Red lead (Sundoor)

• Slide shoe bearings

• Felt seal for round Rings

• Rubber Gasket

• Samad Bond

• Silicone Tube

• Mustard Oil

• Hydraulic Jacks

• Wooden Blocks

• Emery Paper

• Fitter Tool Kit

• Scrapers

• Dial Gauge

• Manpower:

Site Engineer: 01

Area Planner: 01

Area Inspector: 01

Site Supervisor: 01

Fitter: 04

Welder: 01

Rigger: 04

• Dismantling of side covers• Dismantling of Lubrication Pipes• Dismantling of Water Pipes• Dismantling of Top Covers• Lifting of Mill up to 5mm• Dismantling of Movable slide shoe bearing• Dismantling of Fixed slide shoe bearing • Scrapping of bearings• Polishing of Live Ring• Cleaning of Bearings Housing/Sump• Slide Shoe Water Jackets cleaning• Installation of Fixed slide shoe bearing• Installation of Movable Slide Shoe bearing• Down the Mill back to its position/Removal of Hydraulic jacks &

supports• Installation of Lubrication and Water Pipes• Installation and Sealing of side & Top covers• Lubrication Oil Refilling• Test Run

• Dismantling of Side Covers & Top Covers

• Scaffolding

•Installation of Support Frame & Hydraulic Jacks•Lifting of Mill up to 5mm

• Installation of fixture & Dismantling of moveable slide shoe bearing Assembly

• Installation of Fixture & Dismantling of Fixed Slide Shoe bearing Assembly

• Scrapping activity

• Installation of Movable slide shoe bearing

• Installation of Fixed slide shoe bearing

• Installation of Lubrication and Water pipes

• Installation and Sealing of Side and Top covers

• Lubrication Oil Re-filling

• Test Run of Pumps and Lines

• Test Run

• Hydraulic Jacks taken from bestway Chakwal have no lock system, and there was a probability of seal leakage & also not reliable for safe mill lifting.

• Mill tripped on high pressure after running up to two hours, on inspection it was observed that thermal expansion occurred in white metal and high pressure oil pocket vanished.

• After failure of local babbitted slide shoe we have no spare shoes in warehouse & other BCL works.

• At BCL Hattar there were locally babbited Slide shoes available but there radius did not match with our slide shoes specifications.

• Supplier was called at site for inspection of slide shoes & during meeting with PakCemManagement they predicted that either problem of composition or quality of work.

• To ensure the predicted problem material composition of locally babbitted and FLS original slide shoes samples were tested from different Material Composition testing laboratories.

Sample/Element Sn% Sb% Pb% Cu%

Composition as per PakcemDrawing

80 10 4 6

Sample tested from QadbrosEngg Lab.

FLS Sample 85.5 10 3 1.5

Qadbros sample side 1

83.3 8.2 4.6 3.4

Qadbros Sample side 2

93 2.5 2.2 1.3

Sample tested from HMC Lab.

FLS Sample 80.88 12.78 1.35 3.48

Qadbros Sample 87.7 6.4 1.7 2.9

Sample tested from SupraaSteel Lab.

FLS Sample 79.32 11.21 3.58 5.24

Qadbros Sample 80.03 6.98 9.97 3.02

• After failure of slide shoe bearing it was decided to install one old slide shoe bearing and one discarded shoe by FLS expert during Mill erection.

• Dismantling of side covers.

• Dismantling of Lubrication pipes.

• Dismantling of water pipes.

• Dismantling of top covers.

• Lifting of Mill up to 5mm.

• Dismantling of movable slide shoe bearing.

• Dismantling of fixed slide shoe bearing.

• Scrapping of bearings.

• Slide shoe water jackets cleaning.

• Installation of movable slide shoe bearing.

• Installation of Fixed slide shoe bearing

• Down the Mill back to its position/Removal of Hydraulic jacks & supports

• Installation of Lubrication and Water Pipes

• Installation and Sealing of side & Top covers

• Lubrication Oil Refilling

• Test Run

Thank You