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 tested IDE vEdge from last one month and got the detailed reports along with FFT spectrum, this system seems to be effectively triggering the alarms of impending failure as promised by Infinite Uptime. It is very useful and now we are planning to fix this in our multi-spindle Gang head gearbox.

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

Infinite Uptime has measured high on our expectations of quality, flexibility, and in-depth industry knowledge and has continuously raised the bar. I must say vEdge is an outstanding product, I'll recommend vEdge as an optimum cost solution.

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

We worked carefully with all our equipment that helped us for our living. We maintained them as and when required but still faced production losses and high downtime. Thank you Infinite Uptime for installing the IDE, to monitor gearboxes, motors, bearings and other critical mechanical rotating parts at real-time. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

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

Thanks to Infinite Uptime for providing insights into our critical equipment. The plug and play real time monitoring IOT 4.0 solution, avoided unexpected breakdowns and detected large savings capabilities. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Mr. Bhide/Mokashi, Maintenance Manager - Bharat Forge

As promised by Infinite Uptime, the IDE sensor provided valuable data to find the root cause of abnormal vibration of the helical gearbox. With scheduled maintenance, vibration levels are normal now. We found the IDE sensor useful to avoid the breakdown.

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

Thank You very much to everyone for installing the IU devices, integrating them with PLC in optimal time. We are now able to have an insight into tool life monitoring and can schedule predictive maintenance for the machines.
We look forward to continue work with you. We appreciate your dedicated time and efforts invested to achieve our goals.

Mr. Rahul Nalawade, Maintenance & Automation Head - Hirschvogel Components India Ltd.

We are monitoring our state of art machines with Infinite Uptime’s vEdge. It is providing insights into our critical equipment thereby transforming our maintenance to predictive. The plug and play real-time industrial 4.0 vEdge help 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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