Dated: 27-08-2014

To :- General Manager ( Works ) Lucky Cement Ltd.

From :- MK Pahsa
Subject :- Comprehensive Inspection Report of the Plant
Dear Sir ,
Comprehensive Inspection Report is being sent to you for your information and necessary action.
Following are my observations:-
1. High vibration and knocking sound generated from girth gear and pinion. Gears teeth are
worn out of mill no 1. Due to lake of lubrication greasing spray pump was damage need one
sets of spray pump and with spares
2. High vibration and knocking from mill main drive gear due to uneven worn out teeth.
Reduction gear is worn out causing increase in the vibration. There is no spare gear box of
mill # 1 need urgent with one gear box spare for both cement mill
3. Pinion coupling is flexible type instead of gear coupling which is one of the basic reasons of
high vibration. Need to be change of type, because flexible type of coupling cannot bear the
Axial thrust and high torque
4. Shortage of insufficient and skilled manpower is one of the major reasons that cause the
hurdles in smooth and continuous operation of the plant.
5. Safety and protection of equipment need to be install to protect the equipments and
controlled the damages to stable the production problem here if same thing happened then
difficult to manufacture in local market and also fabrication of mechanical components so
we have to arrange and install the mechanical work shop like 8 rft Lath machine, 12 Rft lath
machine,Redial Universal drill machine, shaper machine, hecsaw machine, grinding machine
and cutting machine e.t.c.
6. Chemical Lab there is quality issue and equipments handling we need competent Lab In
charge plus production to controlled the Lab and quality procedure and train the people
7. Mechanical work shop it is also very important for plant because we are facing difficulties
due to non-availability of our own workshop, to save time as well as expenditures.
RECOMMENDED ACTIONS :
The following remedial action may be taken accordingly to control the vibration of the equipment
and to lead smooth operation and to minimize the problems.
1. Replacement of girth gear and its pinion.
2. Replacement of gear box of both Cement Mills .
3. Replacement of flexible coupling with gear coupling.
4. Replacement of shell liners and diaphragm liners e.t.c.
5. Induction of skilled and hardworking staff in the department that includes :-
Mechanical Engineer
Electrical Engineer
Workshop staff
Laboratory plus Production In-charge.




Please find below the pictures of each and individual equipment discussed in the observation.
Picture #1: Girth gear and pinion
Picture #2: Main drive gear
Picture #3: Reduction gear
Picture #4: Pinion Coupling

Note:-
Main technical problem, I am facing is that, there are no any catalogs/drawings of all the
equipments, and no any specifications available. In addition to this, there is no name plate
available at the equipments. And also there is no ISO documentation and scheduling of
maintenance and lubrication so we have to prepare PM procedures I need main power as above
mentioned


Best Regards
Mustafa Kamal Pasha