Mechanical/Electrical plant audit
A Customer Services consultant will provide an overall evaluation of the present mechanical and/or electrical condition of the complete or agreed upon part of the cement production line. Plant maintenance and spare parts handling systems may also be included in the audit.
The result of the examination will be presented in the form of a written report outlining possible and advantageous improvements in the plant’s equipment and layout. Recommendations for additional, thorough specialist analysis of specific areas may also be given.
Attention will be focused on possibilities of increasing or improving:
- Production economy
- Plant reliability
- Equipment availability
- Issues regarding modifications and bottlenecks will also be dealt with.
Kiln
- Mechanical kiln inspection
- Machining of kiln tyres & supporting rollers
Regular, mechanical inspection of the kiln can maximise the availability of the installation. Customer Services offers a wide selection of mechanical inspection programs, ranging from a total kiln inspection – which includes hot alignment checks of the kiln axis by laser beam technology, determination of the kiln shell ovality and axial balance of the kiln – to a brief follow-up inspection to verify the mechanical condition of the kiln. The results of all the inspections, which to the extent possible are carried out during normal operation by Customer Services consultants, are carefully evaluated and presented in a report with recommendations for adjustment and repair.
For additional information, please see Brochures.
Gear inspection A typical gear inspection carried out by a Customer Services consultant comprises: measurement of the vibrations of large gear units, assessment of tooth impressions and a visual inspection of the condition of the gear. The vibrations are recorded, charted and analysed in our laboratories. The final report includes vibration spectrograms, an evaluation of gear condition, and our recommendations for adjustment and repair.
For additional information, please see Brochures.
Ball mill inspection
A ball mill inspection includes a thorough visual inspection for wear and lubrication performance in the main bearings. Areas particularly exposed to high stresses (e.g., mill heads and trunnions) are checked for surface cracks by magnetic particle testing, and the mill shell and mill liners are examined for abnormal wear. Auxiliary equipment is also examined for possible functional deficiencies. The final report contains the results of the inspection and recommendations.
Vertical roller mill inspection A vertical mill inspection consists of an evaluation of the ATOX mill during operation and standstill. By evaluating the wear and mechanical condition of the main mill components (including the gearbox), this inspection contributes to ensuring optimal, uninterrupted operation of the mill. The final report includes proposals for activities to be added to the general mill maintenance program and proposals for immediate action.
Grate Cooler Inspection
The Grate Cooler Inspection is carried out in cold condition during a shut down of the kiln installation by an FLS cooler specialist. Depending of the design of the cooler, the inspection includes an examination of wear parts and mechanical key components, seals, cooling air and air blaster system, bearings and lubrication system, interlocks, hydraulic equipment and pump station, clinker breaker and other auxiliary equipment. The data collected during the inspection will be carefully evaluated, and the result will be compiled in a written report with recommendations for adjustments and replacement of parts. On request, the Customer Services specialist can supervise adjustments and/or replacement of warn-out parts in continuation of the inspection.
Inspection of Miscellaneous Auxiliary Equipment
Customer Services consulltants can also be contracted to evaluate various auxiliary equipment such as compressors, crushers, electrostatic precipitators, Fluxo pumps, packers, etc. and will be based on the requirements in each individual case. Inspection of the Electrostatic Precipitator includes an evaluation of the general condition of the machinery and the alignment of discharge electrodes and collecting plates as well as a thorough examination of rapping gear and other internal parts. The precipitator housing is also checked for signs of corrosion. The rectifiers and other electrical equipment will also be investigated for possible faults. A report of the results of the inspection and recommendations will be submitted. Dust emission measurements can also be performed upon special request.
Ultrasonic crack detection
Ultrasonic crack detection of welds, shafts, etc., tests key machinery parts that are particularly exposed to high stresses, such as: supporting roller shafts, live-rings and mill trunnions. These tests can help prevent potentially costly maintenance repair work. The Customer Services consultants carrying out the ultrasonic testing can also be contracted as supervisors in connection with major welding repair jobs and magnetic particle testing of planetary cooler supports.
Inspection of miscellaneous auxiliary equipment
Customer Services consultants can also be contracted to evaluate miscellaneous auxiliary equipment such as compressors, bag filters, crushers, FLUXO pumps, packers, etc., based on the requirements in each case.
General troubleshooting
Customer Services consultants assist in troubleshooting to solve mechanical problems at a cement plant. Contracting a Customer Services consultant for troubleshooting can usually be done at short notice for urgent assignments.
Erection services
Customer Services field engineers can be contracted to supervise the erection of new installations, machinery or new parts in connection with renovation at a plant. This may also include assistance in establishing an erection program and general preparations.
Material handling equipment inspection
Mechanical inspection
- Inspection of all intermediate bearings
- Inspection of all screw conveyors regarding wear, etc
- Inspection of inlet device
- Inspection of grease system
- Inspection of cable reel
- Visual control of steel structure
- Visual inspection of dust collector
- General control of all functions
- Laser alignment of vertical screw conveyor
- Alignment check of horizontal and gantry screw (with theodolite)
Electrical inspection
- Switch gear/ Electrical house (crane)
- Testing procedure of the main-distribution board
- Inspection of breakers, contactors, connections
- Inspection of power cables and control cables
- Cables reels
- Dust collector & lubrication
- Main switch gear supply
- Interlock between the conveyer section/ship