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    Overhaul of Raw Material Mill Gearbox Saves More Than 300,000 Euros

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    jesus rodriguez
    The cement manufacturer Asia Cement Public Company Limited was looking for a more cost and time efficient solution for overhauling the large 82-ton raw material mill gearbox. Schaeffler proposed using an induction heating system with medium-frequency technology to mount and dismount the gearbox components. This reduced the overhaul time from 30 days to 15 days, cutting costs by more than 300,000 euros and increasing safety by eliminating open flames. The customer was satisfied with the improved efficiency and will use the induction heating system for future overhauls.

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    Overhaul of Raw Material Mill Gearbox Saves More Than 300,000 Euros

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    jesus rodriguez
    34 views5 pages
    The cement manufacturer Asia Cement Public Company Limited was looking for a more cost and time efficient solution for overhauling the large 82-ton raw material mill gearbox. Schaeffler proposed using an induction heating system with medium-frequency technology to mount and dismount the gearbox components. This reduced the overhaul time from 30 days to 15 days, cutting costs by more than 300,000 euros and increasing safety by eliminating open flames. The customer was satisfied with the improved efficiency and will use the induction heating system for future overhauls.

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    MFT_Medium_Frequency_Technology_1656593789

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    The cement manufacturer Asia Cement Public Company Limited was looking for a more cost and time efficient solution for overhauling the large 82-ton raw material mill gearbox. Schaeffler proposed using an induction heating system with medium-frequency technology to mount and dismount the gearbox components. This reduced the overhaul time from 30 days to 15 days, cutting costs by more than 300,000 euros and increasing safety by eliminating open flames. The customer was satisfied with the improved efficiency and will use the induction heating system for future overhauls.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    34 views5 pages

    Overhaul of Raw Material Mill Gearbox Saves More Than 300,000 Euros

    Uploaded by

    jesus rodriguez
    The cement manufacturer Asia Cement Public Company Limited was looking for a more cost and time efficient solution for overhauling the large 82-ton raw material mill gearbox. Schaeffler proposed using an induction heating system with medium-frequency technology to mount and dismount the gearbox components. This reduced the overhaul time from 30 days to 15 days, cutting costs by more than 300,000 euros and increasing safety by eliminating open flames. The customer was satisfied with the improved efficiency and will use the induction heating system for future overhauls.

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    Customer

    Success
    We pioneer motion
    Stories

    Overhaul of raw material mill gearbox


    saves more than 300,000 euros

    Every year, Asia Cement Public Company Limited produces several million tons
    of different types of cement in Thailand. For the planned overhaul of the 82-ton
    raw material mill gearbox, the company was looking for a cost- and time-efficient
    solution for mounting and dismounting.
    The cement manufacturer decided to go with the induction system with Medium- Customer
    Frequency-Technology (MFT).
    Asia Cement Public
    Company Limited
    Sector
    Customer benefits
    Cement
    • Quick and easy installation of the large components
    Application
    • Significantly reduced downtime and production loss
    Raw material mill gearbox
    • Reduced labor cost for fitters and gearbox specialist
    Solution
    • Increased occupational safety – no work with open flame
    or heated oil bath Mounting and Dismounting

    medias.schaeffler.de/en/success-stories
    What drives our customer ...

    Rough environmental conditions

    Challenge

    Traditionally, the customer spends approximately Mounted FAG Bearings


    30 days to overhaul their gearbox. This large raw 22348-BEA-XL-MB1
    mill gearbox contains 6 shafts with 5 gear sets of 22352-BEA-XL-MB1
    various sizes. Each shaft comprises 2-3 large size 24152-BE-XL
    bearings. Moreover, a large coupling is part of the 23264-BEA-XL-MB1
    mounting/dismounting process. The complexity 23064-BEA-XL-MB1-C3
    and size cause difficulties in the overhauling 24180-BE-XL
    process that consume a significant amount of 24092-BEA-XL-MB1
    time. The Schaeffler mounting experts had the 230/710-B-MB
    challenge to reduce the time of the overhauling
    process and improve the efficiency of the
    maintenance team.

    Technical information - Raw mill gearbox

    Power 4200 kW

    Weight 82 tons

    Gearbox reduction ration 66.62


    What Schaeffler has to offer ...

    Solution

    The Schaeffler mounting experts analyzed the For highest efficiency the Schaeffler Medium-
    challenges of the overhaul process especially Frequency-Technology heating device with the
    considering the mounting and dismounting of the flexible inductors was chosen to reduce the costs
    large size components which need to be heated of the overhaul process to a minimum. All bearings
    during the mounting and dismounting process. and other gearbox components were dismounted
    and mounted accurately, rapidly and safely ready
    to be inspected by a gearbox specialist.

    What’s special

    This was the first time at Asia Cement Public consumption by 50%. Consequently, the downtime
    Company Ltd. to mount and dismount gearbox of the equipment could be reduced significantly and
    components including the large sized bearings work safety could be increased as no open flames
    using the Medium-Frequency-Technology heating or oil baths were used.
    device. The flexible inductors could be used for
    several sizes of bearings and other gearbox The customer expressed his satisfaction and will also
    components. make use of the mounting service and the Schaeffler
    MFT tool rental for his next overhaul. This service
    The goal for Schaeffler to improve the efficiency solution can be used across all fields of sectors with
    of the overhaul was achieved by reducing the time similarly large bearings.

    Bearing dismounting by heating leftover bearing inner ring on the shaft Gearbox assembly
    What Schaeffler has to offer ...

    Induction units with medium frequency technology


    New orientation
    Unlike induction heating devices, induction units with At the time, the solution was realized with the HEAT-
    medium-frequency technology are not only suitable for GENERATOR40-2 medium-frequency heating device.
    thermal mounting but also for removal. They can also Today, Schaeffler would use the environmentally friendly
    be used to heat up very large and heavy components. and reliable induction unit with medium-frequency
    heating device MF-GENERATOR3.0-44KW of the new
    Each unit comprises a generator and inductor that is generation. It also comes with 10% more power.
    positioned on the workpiece. A rigid or flexible inductor
    is used, depending on requirements.

    Depending on the application, flexible inductors can be


    fitted in the bore or on the outside diameter of the work-
    piece. They are suitable for heating of bearing inner rings
    or for large components.

    Rigid inductors are particularly well suited to volume


    production. Flexibility is less of a priority here than
    short setup times and a high level of process reliability.

    Technical information

    MFT MF-GENERATOR3.0-44KW

    Power 44 kW

    Outlet frequency 10 to 25 kHz

    Frequency 50 to 60 Hz
    First heating outer ring by
    fixing inductor at the outer
    Dimensions (LxWxH) 600 x 650 x 580 mm ring. Then heating inner ring by
    fixing inductor at the inner ring.
    Weight 78 kg
    What our customer saves...

    Gearbox overhaul – costs and time

    50 %
    Gas flame Medium frequency
    Method heating heating

    Working time 30 days 15 days

    Manpower (Including 30 days x € 1.500 15 days x € 1.500


    gearbox’s specialist) € 45.000 € 22.500 less working time
    Resource cost / 6 days x € 1.250
    MFT rent cost € 190 € 7.500
    30 days x € 20.000 15 days x € 20.000

    LESS
    Downtime cost
    € 600.000 € 300.000

    Total cost € 645.190 € 330.000

    Savings € 315.190
    ENERGY

    Customer
    Asia Cement Public Company Limited was
    established on August 23, 1989.
    With a current installed production capacity of
    5 million tons of cement per year, Asia Cement
    Public Company Limited is now one of the major
    cement producers in Thailand. The company
    produces various types of cement.

    The Induction units with medium-frequency


    technology (MFT) is part of the Schaeffler
    Lifetime Solutions portfolio, which offers
    a comprehensive range of products, services
    and solutions for industrial maintenance. It is
    designed to support maintenance engineers
    over the entire lifetime of a machine.

    Expert Services and Trainings


    www.schaeffler.de/lifetime-solutions

    Success Story 0135, 2020/02, version 2022/06, contact: [email protected] / phone +49 2407914966

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