Cement Plant Services

2

IndexCrusher Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Stacker and Reclaimer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Vertical Roller Mill Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9Ball Mill Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11Gear Unit Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13Kiln Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15ROTAX-2® Kiln Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17Cooler Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19Air Pollution Control Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21Gas Analysis Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23Packing and Dispatching Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25Automation Equipment Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27Electrical and Instrumentation Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29Process Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31Support Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35

As a reliable, longstanding and flexible service partner to cement plant owners and operators around the world, FLSmidth delivers market-leading knowhow and technical assistance covering the full flowsheet of cement plant operations.

One source – many capabilities- Spare parts

- Maintenance services

- Operating services

- Training and seminars

- Upgrade projects

- Management services

- Outsourcing services

INSPECTION REPORT

Cru

sher

Qu

arr

y

VR

M/B

M (

raw

/co

al)

Kil

n

VR

M/B

M (

cem

en

t)

Pack

ing

pla

nt

Filt

er

Gear

Gear

Gas

an

aly

ser

Gear

Co

ole

r

Pre

heate

r

• Cross-evaluation• Bottleneck analysis• Hidden root causes

AUTOMATION

PROCESSPlant objectives• Fuel savings• TPO improvements• Reduced spare part use• Improved availability

3

Predictable performanceThe reliable choice in cement plant maintenance

FLSmidth’s service agreement includes everything from on-site plant inspections and remote support to technical assistance and training . This provides plant managers everything they need to optimise plant performance while reducing energy consumption and the cost of maintenance .

The value of our service agreement lies in the strength of our on-site service engineers . With unrivalled cement plant knowhow, they can provide industry-leading technical support for any task across the full flowsheet of cement plant operations .

The scope of our services covers all major cement plant equipment, including non-FLSmidth equipment .

We listen to the real issues you face and adopt a flexible approach to match your specific demands .

Why enter into a service agreement?With an FLSmidth service agreement, you can:• Minimise unplanned stoppages• Optimise plant availability to meet

production goals • Maximise economic benefits and

increase business certainty

• Reduce energy consumption and impact on the environment

• Gain access to experienced, qualified service engineers

• Upskill in-house plant staff• Gain insight into your plant’s actual

performance• Get a reduced price for scheduled

inspections• Achieve possible warranty extension on

spare parts

Set your mind at ease with an FLSmidth service agreement that improves the predictability of your cement plant operations .

INSPECTION REPORT

Cru

sher

Qu

arr

y

VR

M/B

M (

raw

/co

al)

Kil

n

VR

M/B

M (

cem

en

t)

Pack

ing

pla

nt

Filt

er

Gear

Gear

Gas

an

aly

ser

Gear

Co

ole

r

Pre

heate

r

• Cross-evaluation• Bottleneck analysis• Hidden root causes

AUTOMATION

PROCESSPlant objectives• Fuel savings• TPO improvements• Reduced spare part use• Improved availability

4

Crusher Services Optimal storage control and material homogenisation boost plant performance

Hammer crushers and impact crushersare the most efficient primarycrushers for raw materials in the cement industry . The crusher installation has therefore become an important part of the cement production line .

Failure to closely monitor the condition of the crusher and take action when issues arise decrease performance and can lead to costly repairs and potential stoppages . Regular crusher inspections and ongoing technical support can prevent failures or breakdowns before they occur .

FLSmidth’s crusher services ensure that your equipment keeps operating at maximum efficiency .

Identify and eliminate root causes to avoid:• Excessive downtime• Capacity decrease• Change in output size• Chain wear• Repeatedly failures

• Vibrations

FLSmidth recommends carrying out crusher inspections every one to three years .

Service benefits- Higher availability

- Preventive action planning

- Spare part planning advice

- Short pay-back time due to fewer unforeseen stoppages

- Potential for capacity increase

- Knowledge sharing with maintenance staff during inspection

Repair and refurbishment services

Hard facingFLSmidth offers hard facing of:• Rotor discs • Hammers

Field balancingVibration analysis and balancing of crusher com ponents resulting in:• Reduced energy consumption• Improved equipment lifetime• Minimised wear and tear

Supervision of crusher repairIn order to ensure correct tolerances and installation of crusher parts, FLSmidth offers supervision of:• Apron feeder alignment• Retrofit upgrades • Parts replacement

5

Cru

sher Service A

greem

ent M

od

ules

INSPECTION CONTENT RECOMMENDATIONS

External inspection

• Visual inspection of feed material and spillage from casing• CCR trend curve analysis • Casing inspection incl . analysis of potential dents• Casing assembly and wear plate bolts• Main shaft sealing check

Conclusions We present our findings to you in a follow-up meeting so you can take immediate action where required . ReportYou receive a comprehensive report clearly describing:• Findings• Measurements• Conclusions• Recommended actions• Improvement potential

The recommendations serve as a basis for planning your next maintenance stoppage and maintaining high equipment availability .

Moreover, the findings serve as input for cross-evaluation of the equipment on the plant .

Internal inspection

• Flaps (feeding connection)• Visual inspection of wear plates (chipping, cracks)• Inlet roller inspection • Rotor disc and hammer inspection (wear, chipping, cracks)• Stay bolts and hammer bolt inspection• Functionality and position of anvil - wear plate inspection• Spot check of rotor disc and hammers using penetrant fluid• Inspection for wear, dents and cracks in outlet grate bars• Outlet grate positioning and hammer wear

Hydraulic and bearing inspection

• Inspection of hydraulics, cylinders and oil analysis• Cylinder and hoses functionality pressure and leakage• Extraction tool inspection • Bearing external / internal (cleaning) inspection

Drive and electrical

inspection

• Visual inspection of gearbox and bearings• Oil sample check from gear box• Check of coupling and membrane plates pins• Check of all connections / functionality against CCR data• Motion and temperature sensors

Apron feeder

• Visual inspection of skirt plates, frame and lamellas• Frame alignment check (frame railways parallel)• Horizontal alignment of drive and tension shaft• Inspection of chain and chain sprockets (wear, screw)• Bearing inspection / check of base plates • Support roller wear, rail and lubrication system inspection• Take-up system inspection • Pressure check, cylinder hose functionality• Load curves for VFD drives

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote crusher troubleshooting• Technical consultancy: Access to crusher technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring

See pages 32-33 for more details on the individual support modules .

6

Stacker and Reclaimer ServicesOptimise storage conditions and improve cement production quality




- Short pay-back time due to fewer unforeseen stopp ages



Poor storage control and material homogenization affects production quality throughout the entire cement production process .

You can optimise storage conditions and identify issues that can cause failure or breakdown with periodic storage equipment inspections and expert technical support .

FLSmidth offers a wide range of services including comprehensive performance evaluations of all your stacker and reclaimer equipment .

Identify and eliminate root causes to avoid:• Excessive downtime• Repeated failures• Operational and process problems

We evaluate the plant’s overall storage performance and, if necessary, recommend potential design and capacity upgrades . The inspection also includes a mechanical appraisal of the stacker and reclaimer equipment . FLSmidth recommends a stacker and reclaimer inspection every one to three years .

Stacker and

Reclaim

er Service Ag

reemen

t Mo

du

les

Chain system refurbishments and upgradesWe offer engineering, installation and supervision of chain system upgrades .

Capacity upgradesA wide range of FLSmidth’s stacker and reclaimers are modular-built equipment which allow for capacity upgrades without major mechanical changes .

We offer complete upgrade solutions from engineering to complete delivery including installation and commissioning .

Rake car rail upgradesFor circular and longitudinal bridge scraper applications, we offer rail upgrades from welded square bar rails to standard easily replaceable crane rails .

Parts replacementWe offer supervision, installation and engineering of:• Chain systems • Slew bearings for circular stores• Boogie systems


7

Stacker and

Reclaim

er Service Ag

reemen

t Mo

du

les


Storage

• General operation evaluation • Production and operational data logging • Raw material evaluation• Pile size evaluation and optimisation

Conclusions We present our findings to you in a follow-up meeting so you can take immediate action where required . ReportYou receive a comprehensive report clearly describing:• Findings• Measurements• Conclusions• Recommended actions• Improvement potential



Stacker

• Travel arrangement inspection and alignment check• Rail inspection and alignment check• Adjustment of pulleys/idlers/belt cleaners • Wear and spillage check in conveyor transition points• Hydraulic system test and operational data logging• Visual inspection of major steel parts • Slewing arrangement condition check • Instrumentation check and calibration• Control system adjustment and alarm list investigation

Reclaimer

• Travel arrangement inspection and alignment check• Rail inspection and alignment check• Traverse travel drive check and adjustments• Harrow condition check and minor adjustments• Steel structure, teeth and plough system check• Scraper blade system check incl . blades/buckets, chain,

sprockets, chain guide system and tension system • Chain drive check and operational data logging• Hydraulic function test and operational data logging• Visual inspection of major steel parts • Critical mechanical check e .g . slew and scraper arm bearings• Lubrication system inspection incl . operational setting adjustment• Hoisting arrangement inspection and functional test• Instrumentation check and calibration• Control system adjustment and alarm list investigation

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote stacker and reclaimer troubleshooting• Technical consultancy: Access to stacker and reclaimer technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring


Vertical roller mills are viewed as the most energy-efficient mill for grinding raw material, coal or cement . Vertical mills have become an important link in the production line in plants all over the world .

Failure to closely monitor the mill condition and perform the necessary maintenance will lead to decreased mill performance and potential shutdowns .

Identify and eliminate root causes to avoid:• Excessive downtime• Hydraulic system failure• Contaminated lubrication oil• Oil leakage from rollers• Repeated failures• Vibrations

FLSmidth’s vertical mill services ensure that your mill operates at maximum efficiency .

You can optimise performance and identify issues that can cause costly failures or breakdowns with our periodic mill inspections and expert technical support .

We provide customised inspections and ongoing technical support based on our industry-leading expertise as a vertical mill OEM supplier . Inspections are carried out by an experienced vertical mill specialist during shutdown .

FLSmidth recommends carrying out a mill inspection every year .

8

Vertical Roller Mill ServicesImprove energy efficiency and mill performance


- Longer vertical mill life





- Complete mill department analysis

Vertical R

oller M

ill Service Ag

reemen

t Mo

du

les

Supervision of VRM repairIn order to ensure correct tolerances and installation of mill parts, we offer supervision of:• Alignment of rollers on grinding

table to optimise the grinding process

• Replacement of bearings in hubs• Complete grinding roller overhaul• Segment replacement on grinding

rollers and table• Separator overhauls• Upgrade of electrical system and

power supply• Upgrade of mill automation and

control systems

Hard facingFLSmidth offers hard facing of:• Roller table segments• Grinding roller segments

Repair of hydraulic componentsTo get the best possible performance of your hydraulic components, our certified engineers can overhaul your hydraulic pumps and cylinders .

GearboxTo ensure optimal gearbox availability, we offer a complete range of services for gearboxes by certified engineers .


9

Vertical R

oller M

ill Service Ag

reemen

t Mo

du

les


Hydraulic system

• Hydraulic operation data logging and pump analysis• Nitrogen system condition check• Oil reservoir leakage, filter and cooling system• Tensioning cylinder condition• Hydraulic max pressure and oil cleanness test• Setting and adjustment of plant valve• Control system adjustment and alarm list investigation

ConclusionsWe present our findings to you in a follow-up meeting so you can take immediate action where required . ReportYou receive a comprehensive report clearly describing:• Findings• Measurements• Conclusions• Recommended actions• Improvement potential



Lubrication system

• Lubrication operation data logging, setpoints and data • Bearing condition analysis through oil filters and oil

sample analysis• Start/stop limits for feed pumps• Oil cooling system condition• Control system adjustment and alarm list investigation

Visual inspection

• Sealing air fan system condition*• Mill housing, liners, feedtube, scrapers and dam ring• Material and oil leakage inspection• Mill foundation and housing condition• Water injection system• HiCr/Hardfaced/Sintercast• Reject system• Grinding aid for OK mill**• Material outlet and inlet bellows

Roller assembly and tensioning

system

• Front/rear oil seal and seal air ring condition*• Joint head, torque rod and pull rod condition*• Rollers centering on table*, fixation segments/clamps• Grinding segment profile analysis• Swing out roller system condition**/***• Thrust bearing at fulcrum shaft**• Adjustment of mechanical roller stopper**• Bearing condition; bearing clearance• Min . gap between rollers/table segments**• AVD system condition***

Separator

• Housing and attachment to mill • Grease lubrication unit functionality• Rotor seal wear and seal gaps• Wear on guide vanes and rotor• CCR operation data analysis

*For ATOX® mill inspections **For OK™ mill inspections ***For FRM™ mill inspections

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote vertical roller mill troubleshooting• Technical consultancy: Access to vertical roller mill technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring• Performance monitoring and optimisation: Suggestions based on monitoring


10

Ball Mill ServicesMaintain optimal conditions and efficient mill operations

Service benefits- Root cause analysis

- Performed by highly experienced specialists

- Optimal mill availability

- Uninterrupted production

- More predictable maintenance costs

- Knowledge sharing with maintenance staff

- Recommendations for process improvements

- Complete mill department analysis

Regular inspections and technical support from FLSmidth are your best guarantee for maintaining optimal conditions and efficient mill operations .

In order to target and eliminate the root cause of any problem, it is necessary to collect and evaluate data and measurements during mill standstill as well as operation . This provides the most reliable picture of the mill condition .

Identify and eliminate root causes to avoid:• Excessive wear on bearings and

journals/slide shoes• Hydraulic system issues• Decreased production capacity• Contamination of

lubri cation oil

FLSmidth provides maintenance services for all ball mills, regardless of brand . We have seen that many of the conditions leading to excessive wear can be eliminated by performing regular inspections . Using measuring equipment such as vibration analysers, FLSmidth can detect potential threats before they become a problem .

FLSmidth recommends carrying out mill inspections every year .

Supervision of ball mill repairIn order to ensure correct tolerances and installation of mill parts, we offer supervision of:• Replacement or reversal of girth gear

and pinion, drive included • Replacement of mill sections or head

walls• Change of inlet and outlet cones• Change of diaphragms and liners

On-site repairBy employing our on-site mobile machining tools we carry out:• Crack welding of any kind• Machining of slide rings, flanges and

trunnions

Alignment and measuringWe apply advanced measuring techniques for a wide range of measurements on all rotary equipment:• Alignment of drive system• Vertical and horizontal axis• Shell test• Temperature profile• Girth gear and pinion run-out/

wobble• Measurement and alignment of

drive systems


11

Ball M

ill Service Ag

reemen

t Mo

du

les


Mill visual inspection

• Ball mill foundation and drive foundation condition• Mill shell, trunnion and door conditions• Ball mill inlet and outlet conditions• Bearing seals condition




Mill bearing lubrication system

• Oil level• Oil temperature, flow and pressure• Pump, filter and cooler function• Operation analysis

Gear box and lubrication system

• Oil level• Oil temperature, flow and pressure• Pump, filter and cooler function• Visual check of gearbox

Vibration analysis

• Vibration measurement of motor, gear box and pinion drive • Vibration measurement of separator drive• Trending of vibration level • Vibration analysis, recommendation and conclusion

Separator

• Housing and wear condition• Grease lubrication unit functionality• Bearing condition; upper, middle and lower• Wear on guide vanes and rotor

Mill bearings condition checks

• Mill bearing clearances• Mill bearing condition check • Mill bearing axial clearance check• Trunnion surface condition check• Mill lift measure by high pump pressure

Girth gear

• Girth gear radial and axial reading• Girth gear root gap and backlash readings• Girth gear and pinion tooth evaluation• Girth gear and pinion alignment evaluation• Grease spray and grease consumption evaluation

Mill internal inspection

• Liner wear measurement • Diaphragm inspection• Ball charge analysis• Filling % evaluation

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote ball mill troubleshooting• Technical consultancy: Access to ball mill technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring• Performance monitoring and optimisation: Suggestions based on monitoring


12

Gear Unit ServicesOptimise mill availability with a well-functioning gear unit

Service benefits- Condition-based preventive

maintenance

- Root cause analysis

- Performed during both normal operation and standstill

- Performed by highly experienced specialists

- Optimal mill availability


- More predictable maintenance costs

- Knowledge sharing with maintenance staff

A gear unit should drive the mill with the right speed and power – efficiently and with minimum downtime . Conse-quently, the mill’s availability is totally dependent on the gear unit’s condition and performance .

FLSmidth’s gear inspection services determine the status and condition of the individual components in the gear unit .

The gear internals are machined and ground to very narrow profile and helix tolerances in order to ensure the required tooth contact in the gear-

ing, and it is important that this is maintained together with the correct alignment and lubrication .

Identify and eliminate root causes to avoid: • Pitting and fracture• Adhesion and scuffing• All kind of wear• Bearing damages

FLSmidth recommends carrying gear inspections every year or every 1,000, 6,000, and 12,000 running hours .

Gear Service A

greem

ent M

od

ules

Overhaul and repairFLSmidth MAAG® Gear performs all calculations and gear designs . With our close coordination between engineering and services, our super-vision during replacement is good business for you .

Examples of overhaul and repair jobs:• Complete parts dismantling• Parts condition evaluation• Parts repair or replacement• Rotating parts• Bearings• Designed components• Commodity components• Assembly and function test

Installation and commissioningBeing the OEM installation and commission supervision by FLSmidth is the obvious choice for:• New gear installation• Installation of gear replacement• Start up of installations


13

Gear Service A

greem

ent M

od

ules


Mechanical condition

• Tooth surface condition• Tooth contact conditions• Alignment check• Run-out check• Rotary back lash• Bearing seals condition• Coupling conditions• Sealing condition• Foundation condition• Membrane characteristic




Vibration measurement

• Broad band evaluation• Narrow band measurement• Vibration analysis and conclusion• Vibration monitor configuration

Lubrication

• Oil level check• Oil temperature, flow and pressure check• Pump, filter and cooler function test• Oil analysis evaluation• Oil analysis performance

Interlock

• Check of interlocking• Check of safety system• Check of overload• Recommendation of update of safety devices

NDT test of critical parts

• Supervision of magneto flux (surface cracks)• Supervision of ultrasonic test (sub-surface cracks)

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote gear troubleshooting• Technical consultancy: Access to gear technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring


14

Kiln Services Eliminate root causes with advanced maintenance techniques

A kiln’s operations are essential to the efficiency of the entire cement plant . FLSmidth’s kiln services ensure that your kiln operates at maximum efficiency .

Failures are usually caused by four root causes:• Kiln axis misalignment• Kiln shell ovality/shell flex• Kiln crank• Kiln axial misbalance

Identify and eliminate root causes to avoid: • Hot bearings• Kiln cracks• Wear on rollers and tyres• Wear between kiln shell and tyres• Lining failure

With periodic kiln alignments, you can identify such problems before a possible failure or breakdown .

Our alignment methods are based on advanced measuring techniques and customised hardware and software solutions .

The alignment is carried out by an experienced kiln specialist during normal operation of the kiln so that cement production can continue .

FLSmidth recommends a comprehensive hot kiln alignment every third year .


- Longer kiln life

- Alignment carried out during normal kiln operation



- Knowledge sharing with maintenance staff during alignment

- Complete kiln department analysis

Grinding of rollers and tyresResurfacing worn faces of support rollers and tyres during normal kiln operation . This eliminates vibrations, reduces power consumption, optimises alignment problems and maximises bearing life . The service will correct:• Concave/convex wear• Rolled over edges• Facets• Taper wear• Irregular face profiles

Roller alignmentAlignment of rollers in order to correct and minimise axial thrust (skew) of support rollers, which optimises the axial float of the kiln . This service will:• Reduce bearing temperatures• Reduce wear on tyre and roller

contact surfaces• Reduce wear on thrust roller

components

Field balancingVibration analysis and balancing of kiln drive components to:• Reduce energy consumption• Improve equipment lifetime• Minimise wear and tear

Non-Destructive Testing (NDT)NDT of kiln support rollers, tyres and girth gear to:• Identify cracks before they become

critical

Part replacementSupervision, installation and engineering of:• Heavy/light kiln sections • Girth gear and pinion• Inlet and outlet sections• Supporting roller and bearings


15

Kiln

Service Ag

reemen

t Mo

du

les


Kiln axis*• Vertical kiln axis• Horizontal kiln axis




Ovality/Shell flex*• Tyre migration• Kiln shell ovality

Kiln crank*

• Thermal crank• Mechanical crank• Tyre throw• Polar diagram• Kiln shell centre runout• Kiln shell deformation

Axial balance

• Evaluation of thrust• Hydraulic thrust device• Skewing and inclination of supporting rollers• Supporting rollers and tyres profiles

Kiln drive

• Axial girth gear runout• Radial girth gear runout• Root clearance• Pinion temperature profile

Supporting measurements and visual inspection

• Bearing position and temperature• Base plate leveling• Base plate tilting• Tyre and supporting roller diameter• Visual condition check of kiln components• Tyre position on supporting rollers

Engineering study*

• Load on bearing• Bending stress in tyre• Contact pressure between supporting roller and tyre• Bending stress in kiln shell• Tangential bending stress in kiln shell• Kiln stiffness

*Not included in inspections of ROTAX-2® kilns

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote kiln troubleshooting• Technical consultancy: Access to kiln technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring

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

ROTAX-2® Kiln Services Adjust frequency drives and reduce risk of vibration and facet creation

Tangential suspension The tyre’s 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-pared with a similar kiln with migrating tyres .

Frequent inspections are recommended to get a clear picture of the tangential suspen-sion system .

If wear is not uniformly compensated for by the tensioning rod spring function, increased ovality and overloading of brackets and retainer irons may occur .

In order to monitor the wear, the free, overhanging length of the tension rod should be measured during planned kiln shutdowns .

Wear

1. Bracket2. Retainer iron3. Axial guide4. Cover plate5. Tension screw6. Slide shoe7. Wedge8. Tension rod

1

5

43

27

6

8

Migrating tyre system ROTAX- 2® Kiln: Tangentially suspended system

Wrel P ≈ 0.30% Wrel P ≈ 0.15%

Drive systemThe frequency drive settings are checked and adjusted to reduce the risk of vibration and facet (wash board) creation on kiln tyres and supporting rollers .

17

RO

TAX

-2® K

iln In

spectio

n Pro

gram

me

ROTAX-2® KILN INSPECTION DURING OPERATION SCHEDULE

Meeting and preparations for kiln inspection Day 1

Positions of tyres on supporting rollers Day 1

Positions of bearings for supporting rollers Day 1

Side guides: clearances and width Day 1

Measuring of axial thrust/Temperature of supporting roller bearings Day 1

Theodolite measurement/Position of thrust roller Day 1

Visual inspection Day 1, 2 and 3

Calculations Day 1, 2 and 3

Measuring of tyre diameters Day 2

Measuring of supporting roller diameters Day 2

Tyre temperatures Day 2

Supporting roller temperatures Day 2

Kiln shell temperatures, inlet and outlet side Day 2

Throw of kiln shell Day 2

Check of drive controller setting (Applies for ABB only . Requires a short kiln stop) Day 2

Tangential suspension system - visual inspection Day 2

Evaluation of contact between tyre and supporting rollers Day 3

Tensioning rods - Free overhanging lengths - Visual inspection Day 3

Measuring of supporting roller surface profiles Day 3

Polar diagrams Day 3

Drive station vibration measurements Day 3

Control of frequency drive parameters Day 3

Check for tyre throw Day 3

Levelling of baseplate heights Day 3

Cleaning and packing of equipment Day 4

Follow-up meeting Day 4

ROTAX-2® KILN INSPECTION DURING STOPPAGE SCHEDULE

Meeting and preparations for kiln inspection Day 1

Tensioning rods - Measurement of free overhanging lengths Day 1 and 2

Measurement of spring tension length Day 1 and 2

Measurement of position of wedges Day 1 and 2

Side guides: Measurement of clearances, width and wear Day 1 and 2

Visual inspection Day 1 and 2

Cleaning and packing of equipment Day 1 and 2

Check of contact between wedges, slide shoes and brackets Day 2

Check of drive controller setting (Applies for ABB only) Day 2

Tangential suspension system - visual inspection Day 2

Calculations Day 2

Follow-up meeting Day 3

18

Cooler Services Two-stage inspection for optimal cooler availability

Service benefits- Optimised hydraulic system

performance

- Electronic data logging and evaluation of both operation and standstill conditions

- Optimal cooler availability


- Predictable maintenance costs

- Professional evaluation for your maintenance team

- Complete cooler department analysis


Cooler alignmentTo achieve the best possible cooler performance, we offer supervision, installation and alignment of:• Linear bearings • Drives and cylinders• Frames • Mechanical parts• Fixed inlet

UpgradeIn order to increase output and ef-ficiency, we offer various upgrades:• Installation of fixed ABC™ inlet to

eliminate snowman formation• Fixed inlet upgrade (CIS to ABC)• SF™ to Cross-Bar® cooler upgrade for

improved transport efficiency

• Extension of existing cooler for tpd increase

• Upgrade of cooler control system• Overhaul and upgrade of crusher/

hydraulic roller breaker

Overhaul of hydraulicsTo get the best possible performanceof your hydraulic components, we offer:• Overhaul of your hydraulic pumps

and cylinders by specialists• Site flushing of hydraulic systems

to ensure maximum lifetime of the system

Start-upAfter a complete cooler overhaul, we can stay on-site and assist in adjusting of operational parameters during start-up to ensure optimal heat operation of the cooler .

Many issues leading to excessive wear of cooler parts can be eliminated with regular preventive inspections .

An inspection by FLSmidth provides a complete evaluation of your cooler . Since a problem detected in one area can have its root cause in another, each individual element is given an in-depth analysis .

Identify and eliminate root causes to avoid: • Clinker fall through• “Red rivers”• Excessive wear on grate line and

under grate compartment• Hydraulic system issues• Reduced heat recuperation

FLSmidth uses the latest fault-finding technologies, such as electronic data-loggers and thermal cameras . This provides the best means for targeting and eliminating root causes in order to maintain production levels, reduce downtime and minimise production costs .

Inspections are carried out in two stages . The first is before shut down to evaluate operating parameters, and the second after kiln stop to assess the cooler’s parts .

FLSmidth recommends annual cooler inspections .

19

Co

oler Service A

greem

ent M

od

ules


During production

• Hydraulic oil sample analysis and on-site particle counting• Data logging of pressures and behaviour of hydraulics• Operation parameters collection and optimising• Under grate compartment air flow analysis• Visual inspection of grate compartment• Root cause analysis of control panel alarm history

ConclusionsWe present our findings to you in a follow-up meeting so you can take immediate action where required . ReportYou receive a comprehensive report clearly describing:• Findings• Measurements• Conclusions• Recommended actions• Improvement potential• Recommended spare part list



Hydraulic system

• Adjustment / control of parameters for hydraulic unit• Offset adjustment of hydraulic pumps• Control and adjustment of nitrogen bladders• On-site particle counting of system oil• Inspection of piping and valves connections• Functioning test and alignment of hydraulic cylinders• Supervision of overhaul of hydraulic components

Inlet

• Control and adjustment of temperature transmitters• Control and adjustment of airblaster system• Functionality check of mechanical flow regulators• Check of drive plates and sealings• Functionality and cleanness of air distribution plates

Grate line

• Control of retainer brackets• Wear analysis of moveable/stationary Cross-Bars• Wear and clearance check of U- and C-profile• Air distribution plates and grate protection plates

Under grate compartment

• Hydraulic cylinders, brackets and cleave pins control• Alignment check and adjustment of moveable frame• Functionality check of mechanical flow regulators• Wear analysis of linear bearings• Check of intermodular straps and sealings• Adjustment of length transducers/drive profiles• Control and adjustment of temperature transmitters• Functionality check of lubrication system

Cruscher/HRB• Control and adjustment of alignment• Visual inspection and clearence check of key components• Visual inspection and alignment check of grizzly bar

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote cooler troubleshooting• Technical consultancy: Access to cooler technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring• Performance monitoring and optimisation: Suggestions based on monitoring


20

Air Pollution Control Services Reduce emissions and increase efficiency and profitability





- Potential for capacity in-crease and operational cost reduction


Maintaining air pollution control equipment is critical for your production, profitability and the environment .

In addition to your daily maintenance, we offer a complete preventive maintenance strategy, periodic inspections and technical support .

FLSmidth´s services ensure that your filters keep operating at maximum efficiency, minimising the risk of failures or breakdowns .

Identify and eliminateroot causes to avoid: • Excessive downtime• Unwanted emissions• Repeated failures• Process problems• Energy waste

Failure to closely monitor conditions and perform necessary maintenance will lead to decreased performance, shutdowns and hazardous emissions . Our services are tailored to your needs and local environmental requirements . FLSmidth recommends inspections of air pollution control equipment every one to three years .

Air Po

llutio

n C

on

trol Service A

greem

ent M

od

ules

UpgradeWe design upgrade solutions to meet more strict environmental regulations based on your current equipment and requirements .

Bag and cage replacement• Optimised material selection• Proprietary bags and cage

manufacturing

Perfect collecting and discharge system alignment• Maximum dust removal

Extensive process investigation• Get the best advice on how to

control your process

Optimised gas distribution• Computerized Fluid Dynamics

analysis (CFD) by our specialists

Supervision and installation• Global and local experts network• Erection services for repair and

upgrade jobs

Spare partsPurchasing original spare parts has multiple benefits:• Ensure proper fit and minimum

installation time• Lowest Total Cost of Ownership• Lifetime availability or replacement

alternative


21

Air Po

llutio

n C

on

trol Service A

greem

ent M

od

ules


Bag filter

• Bag and cage condition• Bag and cage fit• Test of diaphragm valves and connectors• Compressed air supply functionality• Inlet and outlet damper inspection and functionality• Thorough analysis of filter bag material and lifetime evaluation*




Electrostatic precipitator

• Gas distribution screen inspection• Collecting and discharge system inspection• Inlet and outlet chamber inspection• Insulator and compartments inspection• High-voltage supply evaluation• No-load and CVC curve sampling/analysis*

Gas conditioning tower

• Inlet cone and gas distribution screen inspection• Lance, valve and annular instruments test• Nozzle spraying pattern test• Water filter cartridge check • Pump pressure supply and functionality check• Probe inspection and calibration• Compressed air functionality check• Dust moisture sampling*

General

• Access doors- and covers inspection• Dust transport and bottom hopper inspection• Gear motor and drive station inspection• Heating elements testing• Instrument calibration• Control system fine tuning during operation

*Optional

SUPPORT MODULES

• Remote troubleshooting: Access to 24/7 remote air pollution control troubleshooting• Technical consultancy: Access to air pollution control technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages• Condition monitoring: Proactive maintenance recommendation based on monitoring


22

Gas Analysis Services Reduce unforeseen stoppages with safe, stable gas analysis systems


- Longer life time

- Hotline



- Knowledge sharing with maintenance staff during service visit


Kiln inlet analyser upgradeFLSmidth can refurbish and upgrade existing kiln inlet analyser systems of any brand with our market-leading Kiln Loq probe system .

Analysers, gas conditioning, cleaning and cooling systems are evaluated and refurbished or upgraded, resulting in:• Reduced maintenance time • A run factor greater than 95%• Powerful probe cleaning• Reduced fuel costs • Fewer production stoppages

The ability to monitor emissions does not just impact plant production; it also enables the plant to comply with emission regulatives, which offers financial benefits to the organisation .

FLSmidth repairs and supports the following analyser brands: • ABB®

• Siemens®

• Emerson®/Fisher®

• Emerson®/Rosemount®

• Durag®

• NEO™

Regular maintenance helps you reduce system downtime and optimise system and plant performance .

Analysers can be repaired in our own specialised workshop, which carries a full range of spares for major brands . The turn-around time for an analyser is guaranteed to be less than 12 days after it has been received .

FLSmidth recommends yearly maintenance inspections in order to keep the gas analysis system in good working condition, providing you with a safe and stable gas analysis system .

23

Gas A

nalysis Service A

greem

ent M

od

ules


Probe system

• Filter and O-rings• Set points• Cooling system • Probe cleaning system




Gas conditioning system

• Sample lines• Filters• Cooler functionality• Solenoid valves• Pumps• Test gas and connections• Parameter setup at HMI• Cabinet cleaning

Analysers• Zero and span check• Linearity check• Complete analyser check incl . sample cell

Leak test • Leak test of complete system from probe tip to analyser

Dust monitors

• Sender / receiver unit• Cleaning of glasses• Purge air unit• Zero and span check• Linearity check• Cleaning of dust monitor

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


24

Packing and Dispatching ServicesHigh-quality spare parts and expert engineering knowhow

It is essential that packing and dispatching machinery is kept in good condition to maintain production flow with maximum efficiency and minimum downtime .

Identify and eliminate root causes to avoid: • Bag bursting due to overfilling• Double revolution filling• Loss of bags during loading• Product spillage during filling• PLC, HMI and electrical failures• Mechanical and pneumatic failures

FLSmidth Ventomatic® provides genuine, high-quality spare parts to help optimise performance . In addition to parts, we provide engineering and testing services to help your equipment achieve maximum performance and durability .

FLSmidth recommends annual inspections of packing and dispatching equipment .


- Longer life time

- Spare part planning adviceand inventory control

- Knowledge sharing with maintenance staff during service visit


On-site supervisionTo 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 auditingTo ensure correct packing plant operations, we offer additional services such as:• Monitoring the plant’s 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

Disp

atchin

g Service A

greem

ent M

od

ules


Rotary packer

• Calibration of weighing units• Test and control of pneumatic system• Mechanical functionality test• Control and adjustment of electrical systems• Wear check of critical parts• Instrumentation check-up• General fine-tuning of the equipment




Automatic bag applicator

• Set-up of the equipment• Test and control of mechanical parts• Electronic cam functionality test• Test and adjustment of local PLC and HMI• Synchro testing/tuning

Palletizer

• I/O full testing• Test and control of electro-mechanical part• Encoders functionality test• Test and adjustment of local PLC and HMI• Fine-tuning during operation• Advanced troubleshooting

Automatic truck loaders and bag

handling

• Calibration of truck loading system• Test and control of hydraulics• Mechanical functionality test• Test and adjustment of parameters in control device• Fine-tuning• Operation overview

SUPPORT MODULES

• On-site troubleshooting: Prioritised on-site assistance in emergency situations


Equipment lifecycle extensionUpgrade services to keep automation assets up to date and in a maintainable condition . Examples include:• Control system upgrade• PLC system upgrade• HMI panel replacement• New scanner head for infrared kiln

scanner

System recoverySupport in getting failed systems into operation again .

Risk assessment 360-degree survey followed by detailed recommendations to prevent costly downtime .

Software assurance programEnsures automation systems are updated with the newest software and PC-hardware based on a fixed yearly fee .

EngineeringSystem modifications and extensions to accommodate for new equipment .

Automation surveyOverall in-depth survey to evaluate the state of the equipment’s condition, maintenance and lifetime .

26

Automation Equipment Services Updating and maintaining automation equipment to maximise return on assets

Service benefits- Improved system

performance

- Higher run factor

- Extended system lifetime

- Optimised systems ready for extensions

- First priority status

- Fixed yearly fee

To ensure fast support from FLSmidth, a team of experienced automation experts is available 24/7 to troubleshoot problems remotely .

FLSmidth provides: • Fast and skilled support• Advanced maintenance• Advice on operation, maintenance

and upgrades• Maximised return on assets

Preventive inspection and maintenance is carried out following a detailed analysis of the system to ensure high availability .

Best performanceThe best performance of automation systems is guaranteed by continually upgrading to the latest technologies and using best practices .

Depending on customer preferences, an inspection can be arranged to focus on providing recommendations .

Au

tom

ation

Service Ag

reemen

t Mo

du

les


27

Au

tom

ation

Service Ag

reemen

t Mo

du

les


Process controlsystem

• Alarm optimisation• System check• Software updates• Network optimisation




High level processcontrol

• Performance assessment• Modifications to accommodate for process and equipment changes• Verification of control strategy• Tuning

Automatic mixcontrol

• Analysis of data• Assessment of the control strategy• Evaluation of problems and opportunities• Optimisation of control

Sampling andsample

transport

• Visual inspection of equipment• Check for material build-up, wear and damages• Change of wear parts• Functionality check• Cleaning

Automated samplepreparation and

analysis

• Check of pneumatic connections• Cleaning of machinery• Change of wear parts• Functionality check

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


28

Electrical and Instrumentation Services Efficient, easy plant control and a clear maintenance plan

An incorrect setting in the power distribution systems or a pressure transmitter can not only cause production stoppage, but, at worst, fatal accidents or severe equipment damage .

Identify and eliminateroot causes to avoid: • Signal disturbance due to EMC• Lack of emergency power when

required• Power loss due to false conditions• Electrical shock due to installation

errors• Excessive power con sumption

Regular monitoring prevents such occurrences and ensures the correct functionality and optimal performance of the systems .

FLSmidth has a large pool of experienced electrical engineers who can effectively and accurately analyse the plant’s electrical systems and instrumentation . This makes it easier for production personnel to manage and control the plant and it helps identify potential sources of energy loss . An FLSmidth inspection concludes with a report describing recommendations and an implementation plan for further improvements . It also includes minor corrections and adjustments .

FLSmidth recommends that electrical and instrumentation systems are inspected thoroughly every one to three years .

Service benefits- Reduce number of

unforeseen stoppages

- Optimised energy consumption

- Improved information available for production personnel

Repair and refurbishment services UpgradesUpgrading 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 replacementSupervision, installation and engineering of:• Power distribution panels• Transformers• Instrumentation

29

Electrical and

Instru

men

tation

Service Ag

reemen

t Mo

du

les


Medium voltage systems

• Thermographic analysis of MV switchgears (On)• Verification of relay and protective settings (Off)• Evaluation of operation climate, cleanness and safety (On)• Test of mechanical functionality of MV switchgears (Off)• Earthing and cable connection check (Off)• Insulation test / polarisation test of power cables (Off)




Low voltage systems

• Thermographic analysis of LV switchgear (On)• Verification of relay and protective settings (Off)• Evaluation of operation climate, cleanness and safety (On)• Test of mechanical functionality of LV switchgear (Off)• Earthing and cable connection check (Off)• Visual condition check and polarisation test of distribution

transformers HV Side (Off)

Variable frequency drives

• Thermographic analysis of VFD panels (On)• Verification of relay and protective settings (On/Off)• Evaluation of operation climate, cleanness and safety (On)• Earthing and cable connection check (Off)• Evaluation of EMC measures (Off)

Emergency supply• Check of battery and battery charger systems (Off)• Functionality and setting check of UPS supply (Off)• Functionality test of emergency generators (Off)

Instrumentation

• Temperature transmitter test and adjustment (By-pass)• Pressure transmitter test and adjustment (By-pass)• Switch test and adjustment (By-pass)• Motion detector test and adjustment (By-pass)

SUPPORT MODULES

• Remote troubleshooting: Access to remote electrical troubleshooting within working hours• Technical consultancy: Access to electrical technical advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Local-language assistance: Available in selected languages


30

Process Audits Identify and realise improvement potentials across your plant

Service benefits- Preventive action planning

- Sustainable production increases

- Optimised energy consumption

- Improved precision and product quality

FLSmidth offers comprehensive performance evaluations of all plant departments from the quarry to the packing plant, including evaluation of:• Process and production methods• Quality and pollution control

procedures• Visual inspection of equipment

FLSmidth´s process audit will: • Identify bottlenecks• Identify improvement potential

within production, reliability and availability

• Provide a customised action plan

By analysing plant performance data, equipment downtime and chemistry, the areas presenting the most significant improvement potentials are identified .

Specialised audits can then be proposed to inspect and evaluate relevant areas .

The audit report consists of technical recommendations and an action plan for how to best realise the improvement potentials . When possible, we estimate the gains to be seen from executing the individual steps of the action plan .

The central aim of a process audit is to give good, clear and implementable recommendations .

We measure our success in the actual improvement achieved by you .

Process A

ud

its Service Ag

reemen

t Mo

du

les

Optimisation of grinding plantTo make good, practical recommendations, a complete overview is needed . This is achieved based on an external and internal inspection of the mill, relevant measurements, and an evaluation of the operation .

Mills can be optimised according to various results:• Production (t/h, residue/Blaine)• Wear (reducing or changing wear

patterns)• Energy consumption (kWh/t)

Clinker quality auditBased on the results of a clinker microscopi and burnability test, an experienced burner master will fine-tune the burner set-up and optimise kiln operation .

By training the daily operators, the following benefits may be achieved:• Improved 28 day strengths of

cement and/or increased additive to cement ratio

• Increased lifetime of kiln lining• Decreased fuel consumption• Decreased energy consumption in

cement mills due to easier grindable clinker


31

Process A

ud

its Service Ag

reemen

t Mo

du

les

PROCESS AUDIT MODULES RECOMMENDATIONS

Quarry• Optimised utilisation• Stabilising chemical and physical variations• Controlling critical elements; i .e . moisture and sulphur content




Material handling

• Achieve required homogenisation• Evaluation of storage logistic and capacities• Optimised schedule at required output rate• Transport equipment• Material blockages; i .e . sticky materials, lump formations etc .

Grinding process

• Product quality• Wear analysis• Energy consumption• Vertical mill set-up, i .e . dam ring etc .• Ball mill set-up; i .e . ball charge etc .• Separator set-up and efficiency

Pyro process

• Kiln condition; i .e . stability• Fuel and energy consumption• Burner set-up• Cooler set-up and efficiency• Pyro line process

Quality control

• Raw mix optimisation• Clinker quality; i .e . burnability, grindability etc .• Sampling methods• Lab equipment evaluation and calibration

Upgrade and conversion

• Capacity upgrade study• Fuel conversions• Waste Heat Recovery

SUPPORT MODULES

• Technical consultancy: Access to process advisory group• On-site troubleshooting: Prioritised on-site assistance in emergency situations• Performance monitoring and optimisation: Suggestions based on monitoring


32

Support ModulesA 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 overviewAll service contracts include a comprehensive maintenance overview, which summarises the recommendations of all the different specialists who have inspected the plant . In particular, we look out for specific issues that can have wider implications on plant performance . For example, performance inefficiencies in the raw mill could originate from issues with the crusher, and the report will outline recommendations for resolving these issues .

Condition monitoringBy constantly monitoring equipment conditions, such as temperatures and vibrations in key spots, we can assist you in proactively identifying destructive conditions before any equipment stoppage is caused . Monitoring and analysis is carried out by a team of highly experienced FLSmidth specialists, who give you feedback on your equipment’s condition .

• Get performance data of key components, so you can effectively plan maintenance and spare part requirements

• Reduce production downtime

This service uses FLSmidth LiveConnect™, providing you a secure, fast and reliable remote link direct to FLSmidth’s specialists .

Performance monitoring and optimisationFLSmidth specialists monitor equipment performance on a regular basis, determining the best course of action with site engineers and optimising accordingly .• Improve the performance of your equipment

• Optimise plant production over the long term as the flow sheet changes

Remote engineering With this service, you can carry out remote system changes and extensions as well as add new equipment to your software control systems . You decide what service you need; together we agree a mutually beneficial time schedule – at a lower fee than the standard list price .• Make tailored adjustments to your systems

• Gain access to FLSmidth’s specialist knowhow

The service uses FLSmidth LiveConnect™, providing you a secure, fast and reliable remote link direct to FLSmidth’s specialists .

Software license upgrade subscriptionThis subscription service provides you upgrades for your ECS, Process Control software and QCX (Quality Control software) allowing your systems to be continuously maintained and upgraded .• Get the latest features of the software when they become

available

• Improve stability and availability of your software systems

• Gain fast access to troubleshooting by FLSmidth’s service team

• Extend the lifetime of your systems

SUPPORT FROM FLSMIDTH TECHNOLOGY CENTER

33

This service uses FLSmidth LiveConnect™, providing you a secure, fast and reliable remote link direct to FLSmidth’s specialists .

Remote troubleshootingRemote troubleshooting provides additional competent resources to your service and maintenance team in case of emergencies . Our remote service is manned by a team of highly experienced specialists giving you fast response and first priority when you need to solve problems and reduce equipment downtime . The service is available 24/7 or within normal working hours depending on the equipment type .• Boost the capabilities of your troubleshooting team with

specialist knowledge within specific equipment areas

• Minimise the need for in-house specialists

• Reduce equipment downtime

On-site troubleshootingWhen the unexpected happens and production stops, you need to get people with the right competencies on-site as fast as possible to get your plant up and running . FLSmidth’s on-site troubleshooting service ensures you the fastest possible access to qualified specialists . Since terms and conditions are agreed in advance, you get booking priority over non-agreement customers .• Get specialist competencies on-site – fast

• Minimise production downtime in the event of breakdown

Technical consultancyThis provides you face-to-face dialogue with our specialist design engineers through phone and video conference . You set the agenda, and FLSmidth provides qualified specialists to assist you with your specific issue .• Get specialist advice on your specific issues

• Investigate special issues

• Co-develop high-end solutions

Local-language assistanceFLSmidth offers local-language assistance for troubleshooting in selected languages . This allows you to address issues with a specialist who speaks your own language .• Improve communication to ensure a fast solution to your

problem

SUPPORT FROM FLSMIDTH TECHNOLOGY CENTER

34

TrainingPlant 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.

Online trainingIn our effort to bring you easy access to learning, FLSmidth has produced a series of online courses that we have made available via FLSmidth’s website . This means that in addition to inviting you to learn on site or in our class rooms, we are now bringing learning to you, inviting you to learn where you are, on your terms, on your schedule . This is an important step in our ever ongoing effort to get closer to you and service you on your terms . We have taken our training online giving you easy and immediate access to our specialised technical training on cement equipment and cement production – all you need is a PC and an internet connection .Adapting our training to your needs means that you can study at home, at work, or on the road, and at any time of the day – you are unbound by time and place . It means that you can eliminate the travel time you would normally spend getting to a training venue . And it means you can cut time you would normally spend away from your work station to do training to a

fraction of your workday . Additionally our 24/7/365 availability means that you can get your new employee started on their necessary training immediately and without delay . And finally it is worth mentioning, that online training is self-paced . This does not mean slow-paced, in fact e-learning sessions are often up to 75 % shorter than a class room session, but without losing effectivity . Self-paced does however mean that you can watch the training in a pace that suits you and re-watch sequences or entire training session several times . Available e-learning courses for cement includes:• Introduction to cement• Introduction to conveyors• Basic cement chemistry• Ball mill - Basic learner course• Overview of the FK pump• Grinding technology

Production trainingWe 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

TRAINING BY FLSMIDTH INSTITUTE

35

Kiln system maintenance training on siteThe objective of this training is to give participants knowledge and understanding of specific maintenance areas of modern kilns . By developing the skills to perform diagnostic site 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 measuring’s 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

technical skills and developed capacity within the kiln system maintenance resulting in increased lifetime and availability of the kiln installation as well as well described, realistic maintenance action plans .

on the given topic . The knowledge gained for each training is measured by tests .

Customised training

FLSmidth offers customised training designed from the ground up to meet the needs of your cement plant in all its uniqueness . This is the best way of ensuring that you get maximum value out of your investment in training . 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

and machinery in use, pinpoint the areas of development and structure each program with topics relevant to your organisation .We develop customised training programs to help increase awareness and understanding of:• Mechanical and electrical maintenance practices• Proper operating procedures• Maintenance and operational safety• Training need analysis by testing of personnel .

TRAINING BY FLSMIDTH INSTITUTE

Cement Plant ServicesE-mail: internationalservice@flsmidth .com

www.flsmidth.com C 0

7-16

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.

ABB® is a registered trademark of ABB Asea Brown Boveri Ltd. Siemens® is a registered trademark of Siemens AG. Emerson® is a registered trademark of Emerson Electric 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.

Cement Plant Services

Documents

Transcript of Cement Plant Services