Predictive Maintenance Checklist for Cement Industry

India is the second largest producer of cement in the world. India’s cement industry plays an important part in the economy, providing employment to more than a million people, directly or indirectly and accounted for more than 8 percent of the global installed capacity. India’s overall cement production capacity was nearly 545 Million Tonnes (MT) in Last financial year.

Cement Manufacturing Process cement manufacturing process

For cement production 

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

The production is based on performance of these equipment. So it is important to monitor motors, conveyors, fans, blowers, gearbox used with these equipment.

The downtime associated with these equipment are the costliest to the company. 

Challenges in Cement Industry

In the cement industry, operating costs saving is directly linked to keeping equipment running for longer duration and more efficiently, reducing risk of unexpected shutdowns, and optimizing preventive maintenance operations. In particular, the kiln shell has to be under close surveillance.

Smart sensors can provide live temperature data on the kiln shell as it rotates. They allow control room operators to put the kiln shell under 24/7 high surveillance and alarm is generated when threshold levels on critical parameters such as hot spot detection, coating loss are reached or tyres slip out of range.

Solution

Vibration monitoring is the best advanced predictive maintenance tool for optimizing plant performance. 

Spectrum analysis is used to measure the various frequencies in vibration data. To determine the machine condition, the vibration severity is compared with the standard severity table. Fast Fourier Transform (FFT) spectrum analysis is used widely to develop a unique predictive analytics technique for monitoring the condition of the equipment.

The end-users get relevant information on a dashboard. They get alerts on email/SMS for any violation of the configured alarm limits. They can view reports, FFT spectrum of fault frequencies, and analyses of these FFTs to predict faults in advance.

When data is required to verify compliance, it is readily and instantly available when needed, minimizing production delays, and ensuring work can carry on as expected.

Monitoring equipment is necessary because

    • Expensive repair and replacement costs.
    • Bearings are replaced frequently to ensure equipment is in operations.
    • Equipment are over-maintained for higher productivity.

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
    • Axle spindle breakage, crusher bearings failure, slip tape breakage
    • Disc liner shift
      • Rolling mill cracks, tubing failure, pump failure, spoke breakage
    • Grate plate breakage

Predictive Maintenance helps 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 speed up decision-making.
    • If any abnormality is detected, it can be sent to the 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 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 and blowers
Kiln rollers Motor bearings Vertical and horizontal mills 

Infinite Uptime’s Industrial Data Enabler (IDE), a Made In India, patented edge-computing Vibration monitoring system for predictive analytics and maintenance remotely gathers tri-axial vibrations, noise, and temperature of any mechanical rotating equipment in real-time. It empowers the Maintenance team to monitor the machine uptime, reduce unplanned downtime, and combat impending equipment damage in advance. Moreover, the end-to-end solution with visual indicators ensures maximum machine-availability, decreased inventory of spares and maintenance costs, and complies with the guidelines on safety and physical distancing directed by the Government.  Not only does it help reduce maintenance fixed costs at a time where a reduction in costs and manpower is a dire need, but it also enhances social distancing by allowing remote monitoring of a plant without physical intervention.

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