CEMENT INDUSTRY

The typical processes in a cement plant are :

  • Extractors are used for Quarrying.
  • Crushers are used for crushing huge rocks into coarse raw material.
  • Blenders and Mixers are used to mix the ingredients in correct proportion.
  • Grinders mix the ingredients well to be heated in the rotary kiln.
  • The heating and cooling is carried in rotary kiln.
  • Finally, the cement is packed and dispatched using conveyor belts or transportation vehicles.
Cement Manufacturing Process>

Equipment are monitored because

01. Equipments are over-maintained for higher productivity.

02. Equipment operates in harsh environment.

03. Bearings are replaced frequently to ensure equipment is in operations.

04. Expensive repair and replacement costs.

05. Ensure workforce safety and avoid accidents.

Typical Issues in Cement Plant

  • Loosening of nuts, bolts, springs, plates, spring rods, flywheel, bearings, shaft, coupling housing, hammer rotor
  • Motor failure, Conveyor belt, Breakage, bearing failure, stretching rod breakage, breakage of separator blade
  • Fan bearing breakage, fan unbalance
  • Gear knocking, gear tooth wear, gear deformation, gear spitting and spalling
Typical issues with a Cement Plant
  • Disc liner shift
  • Rolling mill cracks, tubing failure, pump failure, spoke breakage
  • Grate plate breakage
  • Axle spindle breakage, crusher bearings failure, slip tape breakage

How can Predictive Maintenance help Cement Plant?

  • Vibration reading of equipment can be collected.
  • On the basis of real-time triaxial vibrations, a trend can be obtained.
  • An insight can be generated which can be considered during weekly or scheduled maintenance work. Further analysis of the insights can speedup decision-making.
  • If any abnormality is detected, it can be sent to Maintenance team in the form of SMS and emails.
  • A timely remedial measure can be implemented to prevent breakdown, avoid production loss and ensure safety at work.
  • Predictive Maintenance can be accordingly scheduled. Corrective measures like Centrifuging, oil top up, oil replacement, bearing/gearbox inspection can be carried.
Predictive Maintenance Analysis in Cement Plant

Predictive Maintenance for Cement plant equipment that’s used for grinding crushing, material transport systems, ball and roller mills, and material separators include:

  • Air Compressors
  • Belt drives or conveyors
  • Fans
  • Blowers
  • Kiln Rollers
  • Motor Bearings
  • Vertical and Horizontal Mills
  • Hammer Mills

Monitoring vibration energy, acoustics, and temperature helps to understand health condition of equipment.

Predictive Maintenance Process

Case Studies

Cement/Fan
Cement/Fan

Smart vibration monitoring installed on a critical raw mill fan helped in preventing 50 hours and 44 Thousand USD

Cement/Fan
Cement/Fan

IDE installed on a critical kiln fan prevented downtime of 144 hours and saved 6.4 Million USD.

Cement/Gearbox
Cement/Gearbox

vEdge on a raw mill gearbox helped in preventing unplanned downtime of 50 hours and saved 223 Thousand USD

Cement/Gearbox
Cement/Gearbox

IDE vEdge on a raw mill gearbox in a plant of India’s largest cement producer saved 8 hours & 396 Thousand USD

Cement/Fan
Cement/Fan

Edge computing device on a cooler fan in cement mill saved downtime of 8 hours & 258 Thousand USD

Cement/Bearing
Cement/Bearing

The smart sensor, IDE vEdge monitored critical pinion bearing in cement mill prevented downtime of 16 hours

Testimonials

We have been using the real-time Diagnostic services rendered by Infinite Uptime and obtaining the customized reports along with the spectrum analysis. The System effectively triggers the alarms of impending failure, thus facilitating Predictive Maintenance in the Plant. We are now subscribing to these services in our other plants too.

Mr. E. N Patro, Maintenance Executive - Honda Motorcycle & Scooter India Pvt. Ltd., Karnataka

Infinite Uptime's Vibration Monitoring Solution for Predictive Maintenance has measured high on our expectations of quality, flexibility and in-depth knowledge and has continuously raised the bar. I must say the Diagnostic Services offered at a reasonable cost has increased the reliability of the equipment and reduced the investment in spares-inventory.

Mr. Keshav Prasanna, Senior Vice President - Reliance Industries Limited

We maintained our equipment well but still faced production losses and high downtime. Thank you Infinite Uptime for the real-time Vibration monitoring and Diagnostic services provided to monitor our gearboxes, motors, bearings and pumps. Our Maintenance Team is empowered and can now submit the history of equipment to auditors.

Mr. Sajo Paul, Plant Manager & Development Officer - TVS Motors

As promised by Infinite Uptime, the diagnostic services offered provided valuable data to find the root cause of abnormal behaviour of the helical gearbox. With the insights into the operating equipment, maintenance to prevent the breakdown turned the vibration levels to normal.

Mr. Shahikant Bhujbal, Sr. Manager - Integrated Electrical - Tata Steel Tarapur

We are monitoring our state-of-art machines using Infinite Uptime’s Diagnostic Services. The insights into critical equipment provided in real-time facilitate our maintenance to predictive. The plug and play Vibration monitoring System helps to avoid unexpected downtime and saves cost. The triggering of alarms with notifications on our mobiles has added an instantaneous rectification process increasing machine availability

Imran Hidayath, CEO - Hidayath Group of Industries, UAE

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The India Cements Ltd
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