Cement Plant Services

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Predictable performance

The reliable choice in cement plant maintenance

Index

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

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

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

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VRM/BM (raw/coal)

Ki

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VRM/BM (cement)

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Gas analyser

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• Cross-evaluation

• Bottleneck analysis

• Hidden root causes

AUTOMATION

PROCESS

Plant objectives

• Fuel savings

• TPO improvements • Reduced spare part use • Improved availability

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Crusher Services

Optimal storage control and material homogenisation

boost plant performance

Hammer crushers and impact crushers are the most efficient primary crushers 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 facing

FLSmidth offers hard facing of: • Rotor discs

• Hammers Field balancing

Vibration analysis and balancing of crusher com ponents resulting in: • Reduced energy consumption • Improved equipment lifetime • Minimised wear and tear Supervision of crusher repair In order to ensure correct tolerances and installation of crusher parts, FLSmidth offers supervision of: • Apron feeder alignment • Retrofit upgrades • Parts replacement

Crusher Service Agr

eement Modules

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.

Report

You 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 30-31 for more details on the individual support modules.

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Stacker and Reclaimer Services

Optimise storage conditions and improve cement production quality

Service benefits

- Higher availability

- Preventive action planning

- Spare part planning advice

- Short pay-back time due

to fewer unforeseen

stopp ages

- Potential for capacity

increase

- Knowledge sharing with

maintenance staff during

inspection

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.

• 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 Reclaimer Service Agr

eement Modules

Chain system refurbishments and upgrades

We offer engineering, installation and supervision of chain system upgrades. Capacity upgrades

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

Parts replacement

We offer supervision, installation and engineering of:

• Chain systems

• Slew bearings for circular stores • Boogie systems

Repair and refurbishment services

Storage

• General operation evaluation

• Production and operational data logging • Raw material evaluation

• Pile size evaluation and optimisation

Conclusions

Report

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

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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.

Vertical Roller Mill Services

Improve energy efficiency and mill performance

Service benefits

- Higher availability

- Longer vertical mill life

- Spare part planning advice

- Short pay-back time due

to fewer unforeseen

stopp ages

- Potential for capacity

increase

- Knowledge sharing with

maintenance staff during

inspection

- Complete mill department

analysis

V

ertical Roller Mill Service Agr

eement Modules

Supervision of VRM repair In 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 facing

FLSmidth offers hard facing of: • Roller table segments • Grinding roller segments

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

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

Repair and refurbishment services

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

Conclusions

Report

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

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

• Drive and bearing (upper, middle and lower) condition • 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 See pages 30-31 for more details on the individual support modules.

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Ball Mill Services

Maintain 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.

• 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.

Ball Mill Service Agr

eement Modules

Supervision of ball mill repair In 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 repair

By employing our on-site mobile machining tools we carry out: • Crack welding of any kind

• Machining of slide rings, flanges and trunnions

Alignment and measuring We 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

Repair and refurbishment services

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

Conclusions

Report

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

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Gear Unit Services

Optimise 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

- Uninterrupted production

- 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.

Maintenance includes machining and grinding the gear parts to a very nar-row profile and helix tolerance, which ensures the required tooth contact.

It is important this is maintained to-gether 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 Agr

eement Modules

Overhaul and repair

FLSmidth 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 commissioning Being the OEM installation and commission supervision by FLSmidth is the obvious choice for:

• New gear installation

• Installation of gear replacement • Start up of installations

Repair and refurbishment services

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

Conclusions

Report

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

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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.

Service benefits

-

Higher availability

-

Longer kiln life

-

Alignment carried out

during normal kiln

operation

-

Spare part planning advice

-

Short pay-back time due

to fewer unforeseen

stopp ages

-

Knowledge sharing with

maintenance staff during

alignment

-

Complete kiln department

analysis

Grinding of rollers and tyres Resurfacing 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 alignment

Alignment 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 balancing

Vibration 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 replacement Supervision, installation and engineering of:

• Heavy/light kiln sections • Girth gear and pinion • Inlet and outlet sections • Supporting roller and bearings

Kiln Service Agr

eement Modules

Repair and refurbishment services

Kiln axis* • Vertical kiln axis • Horizontal kiln axis

Conclusions

Report

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

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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

- Uninterrupted production

- Predictable maintenance

costs

- Professional evaluation for

your maintenance team

- Complete cooler

department analysis

Repair and

refurbishment

services

Cooler alignment

To achieve the best possible cooler performance, we offer supervision, installation and alignment of: • Linear bearings

• Drives and cylinders • Frames

• Mechanical parts • Fixed inlet Upgrade

In 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 hydraulics To get the best possible performance of 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-up

After 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.

• 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.

Cooler Service Agr

eement Modules

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

Conclusions

Report

• Recommended actions • Improvement potential • Recommended spare part list 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. 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

(10)

Air Pollution Control Services

Reduce emissions and increase efficiency and profitability

Service benefits

- Higher availability

- Preventive action planning

- Spare part planning advice

- Short pay-back time due

to fewer unforeseen

stopp ages

- Potential for capacity

in-crease

- Knowledge sharing with

maintenance staff during

inspection

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

In addition to your daily maintenance, we offer a complete preventative 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 eliminate root 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 Pollution Contr

ol Service Agr

eement Modules

Upgrade

We 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 parts

Purchasing original spare parts has multiple benefits:

• Ensure proper fit and minimum installation time

• Lowest Total Cost of Ownership • Lifetime availability or replacement

alternative

Repair and refurbishment services

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*

Conclusions

Report

Moreover, the findings serve as input for cross-evaluation of the equipment on the plant. 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 andannular instruments test • Nozzle spraying pattern test

• Water filter cartridge check

• Pump pressure supply and functionality check • dP 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

(11)

Gas Analysis Services

Reduce unforeseen stoppages with safe, stable gas analysis systems

Service benefits

- Higher availability

- Longer life time

- Hotline

- Spare part planning advice

- Short pay-back time due

to fewer unforeseen

stopp ages

- Knowledge sharing with

maintenance staff during

service visit

Repair and

refurbishment

services

Kiln inlet analyser upgrade FLSmidth 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.

Gas Analysis Service Agr

eement Modules

Probe system

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

Conclusions

Report

Moreover, the findings serve as input for cross-evaluation of the equipment on the plant. 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 See pages 30-31 for more details on the individual support modules.

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Packing and Dispatching Services

High-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.

Service benefits

- Higher availability

- Longer life time

- Spare part planning

adviceand inventory control

- Knowledge sharing with

maintenance staff during

service visit

Repair and

refurbishment

services

On-site supervision

To 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 auditing

To 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

Packing and Dispaching Service Agr

eement Modules

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

Conclusions

Report

Moreover, the findings serve as input for cross-evaluation of the equipment on the plant. 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 See pages 30-31 for more details on the individual support modules.

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Equipment lifecycle extension Upgrade 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 recovery

Support in getting failed systems into operation again.

Risk assessment

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

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

Engineering

System modifications and extensions to accommodate for new equipment. Automation survey

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

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 performance

The 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.

Automation Service Agr

eement Modules

Repair and refurbishment services

Process control system • Alarm optimisation • System check • Software updates • Network optimisation Conclusions

Report

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

control

• Performance assessment

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

• Tuning Automatic mix

control

• Analysis of data

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

Sampling and sample transport

• Visual inspection of equipment

• Check for material build-up, wear and damages • Change of wear parts

• Functionality check • Cleaning

Automated sample preparation 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 See pages 30-31 for more details on the individual support modules.

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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 eliminate root 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

Upgrades

Upgrading 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 replacement

Supervision, installation and engineering of:

• Power distribution panels • Transformers

• Instrumentation

Electrical and Instrumentation Service Agr

eement Modules

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)

Conclusions

Report

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

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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.

Pr

ocess Audits Service Agr

eement Modules

Optimisation of grinding plant To 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 audit Based 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

Repair and refurbishment services

PROCESS AUDIT MODULES RECOMMENDATIONS

Quarry

• Optimised utilisation

• Stabilising chemical and physical variations

• Controlling critical elements; i.e. moisture and sulphur content

Conclusions

Report

Moreover, the findings serve as input for cross-evaluation of the equipment on the plant. 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 See pages 30-31 for more details on the individual support modules.

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Support Modules

A 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 overview

All 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.

Training

Plant performance relies heavily on the skills and competencies of the people who operate it on a daily basis. By increasing their skills, you raise the bar on plant performance. FLSmidth specialists can provide the necessary training to the plant maintenance team through sharing their knowledge and demonstrating how to get the most out of the equipment.

Condition monitoring

By 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 optimisation FLSmidth 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

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

Remote troubleshooting

Remote 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 troubleshooting

When 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

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 subscription

This 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

Technical consultancy

This 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 assistance

FLSmidth 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

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Cement Plant Services Cement Plant Services

E-mail: [email protected]

www.flsmidth.com

C 12-14 000-61-ENG V2