Cement Plant Services V 3
Cement Plant Services V 3
Cement Plant Services V 3
VRM/BM (cement)
Preheater
Crusher
Quarry
Cooler
Filter
Kiln
Gas analyser
Gear
Gear
Gear
3
Predictable performance
The reliable choice in cement plant maintenance
FLSmidths service agreement includes The scope of our services covers all major Reduce energy consumption and
everything from on-site plant inspections cement plant equipment, including impact on the environment
and remote support to technical non-FLSmidth equipment. Gain access to experienced, qualified
assistance and training. This provides service engineers
plant managers everything they need to We listen to the real issues you face and Upskill in-house plant staff
optimise plant performance while adopt a flexible approach to match your Gain insight into your plants actual
reducing energy consumption and the specific demands. performance
cost of maintenance. Get a reduced price for scheduled
Why enter into a service inspections
The value of our service agreement lies in agreement? Achieve possible warranty extension on
the strength of our on-site service With an FLSmidth service agreement, spare parts
engineers. With unrivalled cement plant you can:
knowhow, they can provide industry- Minimise unplanned stoppages Set your mind at ease with an FLSmidth
leading technical support for any task Optimise plant availability to meet service agreement that improves the
across the full flowsheet of cement plant production goals predictability of your cement plant
operations. Maximise economic benefits and operations.
increase business certainty
Packing plant
AUTOMATION
Plant objectives
PROCESS Cross-evaluation Fuel savings
Bottleneck analysis TPO improvements
Hidden root causes Reduced spare part use
INSPECTION REPORT Improved availability
4
Crusher Services
Optimal storage control and material homogenisation
boost plant performance
Repair and
refurbishment
services
Hard facing
FLSmidth offers hard facing of:
Rotor discs
Hammers
Field balancing
Vibration analysis and balancing of
crusher components resulting in:
Reduced energy consumption
Improved equipment lifetime
Minimised wear and tear
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
6
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
8
Vertical roller mills are viewed as the FLSmidths vertical mill services ensure
most energy-efficient mill for grinding that your mill operates at maximum
raw material, coal or cement. Vertical efficiency.
mills have become an important link
in the production line in plants all over You can optimise performance and
the world. identify issues that can cause costly
failures or breakdowns with our
Failure to closely monitor the mill periodic mill inspections and expert
condition and perform the necessary technical support.
maintenance will lead to decreased mill
performance and potential shutdowns. We provide customised inspections
and ongoing technical support based
Identify and eliminate root on our industry-leading expertise as a
causes to avoid: vertical mill OEM supplier. Inspections
Excessive downtime are carried out by an experienced
Hydraulic system failure vertical mill specialist during shutdown.
Contaminated lubrication oil
Oil leakage from rollers FLSmidth recommends carrying out a
Repeated failures mill inspection every year.
Vibrations
*For ATOX mill inspections **For OK mill inspections ***For FRM mill inspections
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
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SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
12
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
14
Kiln Services
Eliminate root causes with advanced maintenance techniques
Load on bearing
Bending stress in tyre
Engineering Contact pressure between supporting roller and tyre
study* Bending stress in kiln shell
Tangential bending stress in kiln shell
Kiln stiffness
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
See pages 34-35 for combined hands-on kiln maintenance training by our kiln specialists.
16
Tangential suspension
T he tyres tangential suspension limits
dynamic kiln shell ovality to very low values,
typically wrel 0.15%, while allowing the
kiln shell to expand in the radial direction.
The tangential tyre suspension is therefore
likely to increase lining life significantly com-
Wrel P 0.30% Wrel P 0.15%
pared with a similar kiln with migrating tyres.
Frequent inspections are recommended to
get a clear picture of the tangential suspen-
sion system.
Drive system
The frequency drive settings are checked
and adjusted to reduce the risk of
vibration and facet (wash board) creation
on kiln tyres and supporting rollers.
Wear
If wear is not uniformly compensated for
by the tensioning rod spring function,
increased ovality and overloading of
brackets and retainer irons may occur.
Cooler Services
Two-stage inspection for optimal cooler availability
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
20
*Optional
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
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Repair and
refurbishment
services
Kiln inlet analyser upgrade
FLSmidth can refurbish and upgrade
existing kiln inlet analyser systems of
any brand with our market-leading
Kiln Loq probe system.
SUPPORT MODULES
Remote troubleshooting: Access to remote gas analyser troubleshooting within working hours
Technical consultancy: Access to gas analyser technical advisory group
On-site troubleshooting: Prioritised on-site assistance in emergency situations
See pages 32-33 for more details on the individual support modules.
24
Repair and
refurbishment
services
On-site supervision
To ensure correct installation and
reliability of equipment and parts, we
offer supervision of:
Installation/upgrade of mechanical
parts
Upgrade of electrical system and
power supply
Upgrade of automation and control
system
On-site auditing
To ensure correct packing plant
operations, we offer additional services
such as:
Monitoring the plants status and
compiling a check-up report
Preparing complete lists of
recommended spare parts
Providing technical advice, fine-
tuning and general training for plant
personnel
25
Packing and Dispatching Service Agreement Modules
SUPPORT MODULES
See pages 36-37 for more details on the individual support modules.
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SUPPORT MODULES
Remote troubleshooting: 24/7 remote automation troubleshooting ensures the fast help
Remote engineering: Remote engineering to accommodate for process changes
Managed antivirus: Managed antivirus solution to protect automation systems
Software updates: Software updates with new features and improved stability
On-site troubleshooting: Prioritised on-site assistance in emergency situations
Condition monitoring: Proactive maintenance recommendation based on monitoring
Performance monitoring and optimisation: Optimisation suggestions based on monitoring
See pages 32-33 for more details on the individual support modules.
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Repair and
refurbishment
services
Upgrades
Upgrading electrical and
instrumentation equipment can reduce
energy consumption as well as provide
production personnel with additional
information to optimise production.
Examples of upgrades:
Installation of VFDs for variable fan
and pump control
Change of hard-wired
instrumentation to serial I/O
Installation of intelligent relays
Part replacement
Supervision, installation and
engineering of:
Power distribution panels
Transformers
Instrumentation
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Electrical and Instrumentation Service Agreement Modules
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
30
Process Audits
Identify and realise improvement potentials across your plant
SUPPORT MODULES
See pages 32-33 for more details on the individual support modules.
32
Support Modules
A service agreement with FLSmidth provides you much more than favourable
pricing for scheduled inspections. You can gain access to reliable, industry-leading
technical support covering the full range of cement plant operations.
Plant condition overview Get performance data of key components, so you can
All service contracts include a comprehensive maintenance effectively plan maintenance and spare part requirements
overview, which summarises the recommendations of all the Reduce production downtime
different specialists who have inspected the plant. In particular,
we look out for specific issues that can have wider implications
This service uses FLSmidth LiveConnect, providing you a
on plant performance. For example, performance inefficiencies
secure, fast and reliable remote link direct to FLSmidths
in the raw mill could originate from issues with the crusher, and
specialists.
the report will outline recommendations for resolving these
issues.
Performance monitoring and optimisation
FLSmidth specialists monitor equipment performance on a
Condition monitoring
regular basis, determining the best course of action with site
By constantly monitoring equipment conditions, such as
engineers and optimising accordingly.
temperatures and vibrations in key spots, we can assist you
Improve the performance of your equipment
in proactively identifying destructive conditions before any
equipment stoppage is caused. Monitoring and analysis is ptimise plant production over the long term as the flow
O
carried out by a team of highly experienced FLSmidth specialists, sheet changes
who give you feedback on your equipments condition.
TH TECHNOLOGY CENTER
Training
Plant performance relies heavily on the skills and competencies of the people who
operate and maintain it on a daily basis. By increasing their skills, you raise the
bar on plant performance.
TRAINING BY
Production training
We also offer a range of courses within the field of cement
production which can be conducted on site:
Grinding technology
Coal handling and safety
Kiln process and operation
The training will cover major theoretical issues, and when
applicable operational issues will be trained by use of a
simulator. All this combined with visits to your site. The aim is
that the participants are able to make operational decisions
35
Kiln system maintenance training on site technical skills and developed capacity within the kiln system
The objective of this training is to give participants knowledge maintenance resulting in increased lifetime and availability
and understanding of specific maintenance areas of modern of the kiln installation as well as well described, realistic
kilns. By developing the skills to perform diagnostic site maintenance action plans.
measurements and strengthening competencies through
evaluation of the results, technical conclusions and future action
plans, the seminar will meet the objective. The training will
include a spectra of site skills through group works, technical
measurings and individual evaluation and conclusions based on
such investigations.
After completing the training, the participants will be able to
Know and account for kiln root causes, symptoms and
their maintenance theory
Execute important kiln diagnostic measurements
Evaluate, analyze and draw technical conclusions based on
the obtained results
Elaborate and describe relevant action plans for the kiln
maintenance
This will result in benefits such as improved knowledge, new
FLSMIDTH INSTITUTE
on the given topic. The knowledge gained for each training is and machinery in use, pinpoint the areas of development
measured by tests. and structure each program with topics relevant to your
organisation.
We develop customised training programs to help increase
Customised training
awareness and understanding of:
FLSmidth offers customised training designed from the ground Mechanical and electrical maintenance practices
up to meet the needs of your cement plant in all its uniqueness. Proper operating procedures
This is the best way of ensuring that you get maximum value Maintenance and operational safety
out of your investment in training. Training need analysis by testing of personnel.
Our customised training programs are flexible solutions
designed to address the specific challenges facing the staff
at your plant. We take into account the actual processes
C 07-16 000-61-ENG V3
Copyright 2016 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties
(express or implied), and information and data contained in this brochure are for general reference only and may change at any time.
Inspection variation may occur depending on equipment model. Wear parts are not included in an inspection.
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Co. Fisher is a registered trademark of Fisher Controls International LLC. Rosemount is a registered trademark of Rosemount Inc. Durag
is a registered trademark of Durag Holding AG. NEO is a trademark of Norsk Elektro Optikk AS. www.flsmidth.com