Cement Plant Services

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 Index

many capabilities Crusher Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Stacker and Reclaimer Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
- Spare parts Vertical Roller Mill Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Ball Mill Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
- Maintenance services
Gear Unit Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
- Operating services Kiln Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
- Training and seminars ROTAX-2 Kiln Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
- Upgrade projects Cooler Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
Air Pollution Control Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
- Management services
Gas Analysis Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23
- Outsourcing services Packing and Dispatching Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Automation Equipment Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27
Electrical and Instrumentation Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29
Process Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Support Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35
VRM/BM (raw/coal)

VRM/BM (cement)
Preheater
Crusher
Quarry

Cooler
Filter

Kiln
Gas analyser

Gear
Gear

Gear

Predictable performance
The reliable choice in cement plant maintenance
FLSmidths 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.
Packing plant
AUTOMATION
PROCESS
INSPECTION REPORT
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
Cross-evaluation
Bottleneck analysis
Hidden root causes
3
Reduce energy consumption and
impact on the environment
Gain access to experienced, qualified
service engineers
Upskill in-house plant staff
Gain insight into your plants 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.
Plant objectives
Fuel savings
TPO improvements
Reduced spare part use
Improved availability
4
Crusher Services
Optimal storage control and material homogenisation
boost plant performance
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
Hammer crushers and impact crushers
are the most efficient primary
FLSmidths crusher services ensure that
your equipment keeps operating at
crushers for raw materials in the maximum efficiency.
cement industry. The crusher
installation has therefore become Identify and eliminate root
an important part of the cement causes to avoid:
production line. Excessive downtime
Capacity decrease
Failure to closely monitor the condition Change in output size
of the crusher and take action when Chain wear
issues arise decrease performance and Repeatedly failures
can lead to costly repairs and potential Vibrations
stoppages. Regular crusher inspections
and ongoing technical support can FLSmidth recommends carrying out
prevent failures or breakdowns before crusher inspections every one to
they occur. three years.
Repair and
refurbishment
services
Hard facing
FLSmidth offers hard facing of:
Rotor discs
Hammers
Field balancing
Vibration analysis and balancing of
crusher components 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
 5
Crusher Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Visual inspection of feed material and spillage from casing Conclusions

CCR trend curve analysis We present our findings to you
External
Casing inspection incl. analysis of potential dents in a follow-up meeting so you
inspection
Casing assembly and wear plate bolts can take immediate action where
Main shaft sealing check required.

Flaps (feeding connection)

Report
Visual inspection of wear plates (chipping, cracks)
You receive a comprehensive
Inlet roller inspection
report clearly describing:
Rotor disc and hammer inspection (wear, chipping, cracks)
Internal Findings
Stay bolts and hammer bolt inspection
inspection Measurements
Functionality and position of anvil - wear plate inspection
Conclusions
Spot check of rotor disc and hammers using penetrant fluid
Recommended actions
Inspection for wear, dents and cracks in outlet grate bars
Improvement potential
Outlet grate positioning and hammer wear

Inspection of hydraulics, cylinders and oil analysis The recommendations serve as

Hydraulic
Cylinder and hoses functionality pressure and leakage a basis for planning your next
and bearing
Extraction tool inspection maintenance stoppage and
inspection
Bearing external / internal (cleaning) inspection maintaining high equipment
Visual inspection of gearbox and bearings availability.
Drive and Oil sample check from gear box
Moreover, the findings serve as
electrical Check of coupling and membrane plates pins
input for cross-evaluation of the
inspection Check of all connections / functionality against CCR data
equipment on the plant.
Motion and temperature sensors

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)
Apron feeder 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 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
stoppages
- 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.
Repair and refurbishment services
Chain system refurbishments
and upgrades
We offer engineering, installation and
supervision of chain system upgrades.
Capacity upgrades
A wide range of FLSmidths 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.
Identify and eliminate root
causes to avoid:
Excessive downtime
Repeated failures
Operational and process problems
We evaluate the plants 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.
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
 7
Stacker and Reclaimer Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

General operation evaluation Conclusions

Production and operational data logging We present our findings to you
Storage
Raw material evaluation in a follow-up meeting so you
Pile size evaluation and optimisation can take immediate action where
required.
Travel arrangement inspection and alignment check
Rail inspection and alignment check
Report
Adjustment of pulleys/idlers/belt cleaners
You receive a comprehensive
Wear and spillage check in conveyor transition points
report clearly describing:
Stacker Hydraulic system test and operational data logging
Findings
Visual inspection of major steel parts
Measurements
Slewing arrangement condition check
Conclusions
Instrumentation check and calibration
Recommended actions
Control system adjustment and alarm list investigation
Improvement potential
Travel arrangement inspection and alignment check
Rail inspection and alignment check The recommendations serve as
Traverse travel drive check and adjustments a basis for planning your next
Harrow condition check and minor adjustments maintenance stoppage and
Steel structure, teeth and plough system check maintaining high equipment
Scraper blade system check incl. blades/buckets, chain, availability.
sprockets, chain guide system and tension system
Reclaimer Chain drive check and operational data logging Moreover, the findings serve as
Hydraulic function test and operational data logging input for cross-evaluation of the
Visual inspection of major steel parts equipment on the plant.
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

See pages 32-33 for more details on the individual support modules.
8
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
stoppages
- Potential for capacity
increase
- Knowledge sharing with
maintenance staff during
inspection
- Complete mill department
analysis
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
Repair and refurbishment services
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
FLSmidths 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.
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.
 9
Vertical Roller Mill Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Hydraulic operation data logging and pump analysis Conclusions

Nitrogen system condition check We present our findings to you
Oil reservoir leakage, filter and cooling system in a follow-up meeting so you
Hydraulic system Tensioning cylinder condition can take immediate action where
Hydraulic max pressure and oil cleanness test required.
Setting and adjustment of plant valve
Control system adjustment and alarm list investigation Report
You receive a comprehensive
Lubrication operation data logging, setpoints and data
report clearly describing:
Bearing condition analysis through oil filters and oil
Findings
sample analysis
Lubrication system Measurements
Start/stop limits for feed pumps
Conclusions
Oil cooling system condition
Recommended actions
Control system adjustment and alarm list investigation
Improvement potential
Sealing air fan system condition*
Mill housing, liners, feedtube, scrapers and dam ring The recommendations serve as
Material and oil leakage inspection a basis for planning your next
Mill foundation and housing condition maintenance stoppage and
Visual inspection Water injection system maintaining high equipment
HiCr/Hardfaced/Sintercast availability.
Reject system
Grinding aid for OK mill** Moreover, the findings serve as
Material outlet and inlet bellows input for cross-evaluation of the
Front/rear oil seal and seal air ring condition* equipment on the plant.
Joint head, torque rod and pull rod condition*
Rollers centering on table*, fixation segments/clamps
Grinding segment profile analysis
Roller assembly
Swing out roller system condition**/***
and tensioning
Thrust bearing at fulcrum shaft**
system
Adjustment of mechanical roller stopper**
Bearing condition; bearing clearance
Min. gap between rollers/table segments**
AVD system condition***

Housing and attachment to mill

Grease lubrication unit functionality
Separator 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

See pages 32-33 for more details on the individual support modules.
10
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.
equipment such as vibration analysers,
Repair and refurbishment services
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
Identify and eliminate root
causes to avoid:
Excessive wear on bearings and
journals/slide shoes
Hydraulic system issues
Decreased production capacity
Contamination of
lubrication 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
FLSmidth can detect potential threats
before they become a problem.
FLSmidth recommends carrying out
mill inspections every year.
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
 11
Ball Mill Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Ball mill foundation and drive foundation condition Conclusions

Mill visual Mill shell, trunnion and door conditions We present our findings to you
inspection Ball mill inlet and outlet conditions in a follow-up meeting so you
Bearing seals condition can take immediate action where
required.
Oil level
Mill bearing Oil temperature, flow and pressure
Report
lubrication system Pump, filter and cooler function
You receive a comprehensive
Operation analysis
report clearly describing:
Oil level Findings
Gear box and Oil temperature, flow and pressure Measurements
lubrication system Pump, filter and cooler function Conclusions
Visual check of gearbox Recommended actions
Vibration measurement of motor, gear box and pinion drive Improvement potential
Vibration measurement of separator drive
Vibration analysis The recommendations serve as
Trending of vibration level
Vibration analysis, recommendation and conclusion a basis for planning your next
maintenance stoppage and
Housing and wear condition maintaining high equipment
Grease lubrication unit functionality availability.
Separator
Bearing condition; upper, middle and lower
Wear on guide vanes and rotor Moreover, the findings serve as
Mill bearing clearances input for cross-evaluation of the
Mill bearing condition check equipment on the plant.
Mill bearings
Mill bearing axial clearance check
condition checks
Trunnion surface condition check
Mill lift measure by high pump pressure

Girth gear radial and axial reading

Girth gear root gap and backlash readings
Girth gear Girth gear and pinion tooth evaluation
Girth gear and pinion alignment evaluation
Grease spray and grease consumption evaluation

Liner wear measurement

Mill internal Diaphragm inspection
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

See pages 32-33 for more details on the individual support modules.
12

Gear Unit Services

Optimise mill availability with a well-functioning gear unit

Service benefits A gear unit should drive the mill with

- 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
the right speed and power efficiently
and with minimum downtime. Conse-
quently, the mills availability is totally
dependent on the gear units condition
and performance.
FLSmidths 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.

Repair and refurbishment services

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.
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

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
 13
Gear Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Tooth surface condition Conclusions

Tooth contact conditions We present our findings to you
Alignment check in a follow-up meeting so you
Run-out check can take immediate action where
Mechanical Rotary back lash required.
condition Bearing seals condition
Coupling conditions Report
Sealing condition You receive a comprehensive
Foundation condition report clearly describing:
Membrane characteristic Findings
Measurements
Broad band evaluation
Conclusions
Vibration Narrow band measurement
Recommended actions
measurement Vibration analysis and conclusion
Improvement potential
Vibration monitor configuration

Oil level check The recommendations serve as

Oil temperature, flow and pressure check a basis for planning your next
Lubrication Pump, filter and cooler function test maintenance stoppage and
Oil analysis evaluation maintaining high equipment
Oil analysis performance availability.
Check of interlocking
Moreover, the findings serve as
Check of safety system
Interlock input for cross-evaluation of the
Check of overload
equipment on the plant.
Recommendation of update of safety devices

NDT test of Supervision of magneto flux (surface cracks)

critical parts 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

See pages 32-33 for more details on the individual support modules.
14

Kiln Services
Eliminate root causes with advanced maintenance techniques

Service benefits A kilns operations are essential to

the efficiency of the entire cement
With periodic kiln alignments, you
can identify such problems before a
- 
Higher availability plant. FLSmidths kiln services ensure possible failure or breakdown.
that your kiln operates at maximum
- 
Longer kiln life
efficiency. Our alignment methods are based on
- 
Alignment carried out advanced measuring techniques and
during normal kiln Failures are usually caused by four root customised hardware and software
operation causes: solutions.
Kiln axis misalignment
- 
Spare part planning advice
Kiln shell ovality/shell flex The alignment is carried out by an
- 
Short pay-back time due Kiln crank experienced kiln specialist during
to fewer unforeseen Kiln axial misbalance normal operation of the kiln so that
stoppages cement production can continue.
Identify and eliminate
- 
Knowledge sharing with
root causes to avoid: FLSmidth recommends a
maintenance staff during Hot bearings comprehensive hot kiln alignment
alignment Kiln cracks every third year.
- 
Complete kiln department Wear on rollers and tyres
analysis Wear between kiln shell and tyres
Lining failure

Repair and refurbishment services

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
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

Roller alignment Part replacement

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
Supervision, installation and
engineering of:
Heavy/light kiln sections
Girth gear and pinion
Inlet and outlet sections
Supporting roller and bearings
 15
Kiln Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Vertical kiln axis Conclusions

Kiln axis*
Horizontal kiln axis We present our findings to you
in a follow-up meeting so you
Tyre migration
Ovality/Shell flex* can take immediate action where
Kiln shell ovality
required.
Thermal crank
Mechanical crank Report
Tyre throw You receive a comprehensive
Kiln crank*
Polar diagram report clearly describing:
Kiln shell centre runout Findings
Kiln shell deformation Measurements
Evaluation of thrust Conclusions
Hydraulic thrust device Recommended actions
Axial balance Improvement potential
Skewing and inclination of supporting rollers
Supporting rollers and tyres profiles
The recommendations serve as
Axial girth gear runout a basis for planning your next
Radial girth gear runout maintenance stoppage and
Kiln drive
Root clearance maintaining high equipment
Pinion temperature profile availability.
Bearing position and temperature
Base plate leveling Moreover, the findings serve as
Supporting input for cross-evaluation of the
Base plate tilting
measurements and equipment on the plant.
Tyre and supporting roller diameter
visual inspection
Visual condition check of kiln components
Tyre position on supporting rollers

Load on bearing
Bending stress in tyre
Engineering Contact pressure between supporting roller and tyre
study* 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
T he tyres 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-
Wrel P 0.30% Wrel P 0.15%
pared with a similar kiln with migrating tyres.
Frequent inspections are recommended to
get a clear picture of the tangential suspen-
sion system.

Migrating tyre system ROTAX- 2 Kiln: Tangentially suspended system

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

Wear
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
4 should be measured during planned kiln
3 6 shutdowns.
1
7
5 2 1. Bracket
2. Retainer iron
3. Axial guide
4. Cover plate
8
5. Tension screw
6. Slide shoe
7. Wedge
8. Tension rod
 17
ROTAX-2 Kiln Inspection Programme

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
- Uninterrupted production
- Predictable maintenance
costs
- Professional evaluation for
your maintenance team
- Complete cooler
department analysis
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
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
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
coolers parts.
FLSmidth recommends annual cooler
inspections.
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.
 19
Cooler Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Hydraulic oil sample analysis and on-site particle counting Conclusions

Data logging of pressures and behaviour of hydraulics We present our findings to you
Operation parameters collection and optimising in a follow-up meeting so you
During production
Under grate compartment air flow analysis can take immediate action where
Visual inspection of grate compartment required.
Root cause analysis of control panel alarm history
Report
Adjustment / control of parameters for hydraulic unit
You receive a comprehensive
Offset adjustment of hydraulic pumps
report clearly describing:
Control and adjustment of nitrogen bladders
Findings
Hydraulic system On-site particle counting of system oil
Measurements
Inspection of piping and valves connections
Conclusions
Functioning test and alignment of hydraulic cylinders
Recommended actions
Supervision of overhaul of hydraulic components
Improvement potential
Control and adjustment of temperature transmitters Recommended spare part list
Control and adjustment of airblaster system
Inlet Functionality check of mechanical flow regulators The recommendations serve as
Check of drive plates and sealings a basis for planning your next
Functionality and cleanness of air distribution plates maintenance stoppage and
Control of retainer brackets maintaining high equipment
Wear analysis of moveable/stationary Cross-Bars availability.
Grate line
Wear and clearance check of U- and C-profile
Air distribution plates and grate protection plates Moreover, the findings serve as
input for cross-evaluation of the
Hydraulic cylinders, brackets and cleave pins control equipment on the plant.
Alignment check and adjustment of moveable frame
Functionality check of mechanical flow regulators
Under grate Wear analysis of linear bearings
compartment Check of intermodular straps and sealings
Adjustment of length transducers/drive profiles
Control and adjustment of temperature transmitters
Functionality check of lubrication system

Control and adjustment of alignment

Cruscher/HRB 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

See pages 32-33 for more details on the individual support modules.
20
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
stoppages
- Potential for capacity in-
crease and operational cost
reduction
- 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 preventive
maintenance strategy, periodic
inspections and technical support.
FLSmidths services ensure that your
filters keep operating at maximum
efficiency, minimising the risk of
failures or breakdowns.
Repair and refurbishment services
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
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.
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
 21
Air Pollution Control Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Bag and cage condition Conclusions

Bag and cage fit We present our findings to you
Test of diaphragm valves and connectors in a follow-up meeting so you
Bag filter
Compressed air supply functionality can take immediate action where
Inlet and outlet damper inspection and functionality required.
Thorough analysis of filter bag material and lifetime evaluation*
Report
Gas distribution screen inspection
You receive a comprehensive
Collecting and discharge system inspection
report clearly describing:
Electrostatic Inlet and outlet chamber inspection
Findings
precipitator Insulator and compartments inspection
Measurements
High-voltage supply evaluation
Conclusions
No-load and CVC curve sampling/analysis*
Recommended actions
Inlet cone and gas distribution screen inspection Improvement potential
Lance, valve and annular instruments test
Nozzle spraying pattern test The recommendations serve as
Gas conditioning Water filter cartridge check a basis for planning your next
tower Pump pressure supply and functionality check maintenance stoppage and
Probe inspection and calibration maintaining high equipment
Compressed air functionality check availability.
Dust moisture sampling*
Moreover, the findings serve as
Access doors- and covers inspection
input for cross-evaluation of the
Dust transport and bottom hopper inspection
equipment on the plant.
Gear motor and drive station inspection
General
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

See pages 32-33 for more details on the individual support modules.
22
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
stoppages
- Knowledge sharing with
maintenance staff during
service visit
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.
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
 23
Gas Analysis Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Filter and O-rings Conclusions

Set points We present our findings to you
Probe system
Cooling system in a follow-up meeting so you
Probe cleaning system can take immediate action where
required.
Sample lines
Filters
Report
Cooler functionality
You receive a comprehensive
Gas conditioning Solenoid valves
report clearly describing:
system Pumps
Findings
Test gas and connections
Measurements
Parameter setup at HMI
Conclusions
Cabinet cleaning
Recommended actions
Zero and span check Improvement potential
Analysers Linearity check
Complete analyser check incl. sample cell The recommendations serve as
Leak test Leak test of complete system from probe tip to analyser a basis for planning your next
maintenance stoppage and
maintaining high equipment
Sender / receiver unit
availability.
Cleaning of glasses
Purge air unit
Dust monitors Moreover, the findings serve as
Zero and span check
input for cross-evaluation of the
Linearity check
equipment on the plant.
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 32-33 for more details on the individual support modules.
24
Packing and Dispatching Services
High-quality spare parts and expert engineering knowhow
Service benefits
- Higher availability
- Longer life time
- Spare part planning
adviceand inventory control
- 
Knowledge sharing with
maintenance staff during
service visit
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.
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 plants 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 Dispatching Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Calibration of weighing units Conclusions

Test and control of pneumatic system We present our findings to you
Mechanical functionality test in a follow-up meeting so you
Rotary packer Control and adjustment of electrical systems can take immediate action where
Wear check of critical parts required.
Instrumentation check-up
General fine-tuning of the equipment Report
You receive a comprehensive
Set-up of the equipment
report clearly describing:
Test and control of mechanical parts
Automatic bag Findings
Electronic cam functionality test
applicator Measurements
Test and adjustment of local PLC and HMI
Conclusions
Synchro testing/tuning
Recommended actions
I/O full testing Improvement potential
Test and control of electro-mechanical part
Encoders functionality test The recommendations serve as
Palletizer
Test and adjustment of local PLC and HMI a basis for planning your next
Fine-tuning during operation maintenance stoppage and
Advanced troubleshooting maintaining high equipment
Calibration of truck loading system availability.
Test and control of hydraulics
Automatic truck Moreover, the findings serve as
Mechanical functionality test
loaders and bag input for cross-evaluation of the
Test and adjustment of parameters in control device
handling equipment on the plant.
Fine-tuning
Operation overview

SUPPORT MODULES

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

See pages 36-37 for more details on the individual support modules.
26
Automation Equipment Services
Updating and maintaining automation equipment to maximise
return on assets
Service benefits
- Improved system
performance problems remotely.
- 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
FLSmidth provides:
Fast and skilled support
Advanced maintenance
Advice on operation, maintenance
and upgrades
Maximised return on assets
Repair and refurbishment services
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.
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.
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 equipments condition,
maintenance and lifetime.
 27
Automation Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Alarm optimisation Conclusions

Process control System check We present our findings to you
system Software updates in a follow-up meeting so you
Network optimisation can take immediate action where
required.
Performance assessment
High level process Modifications to accommodate for process and equipment changes
Report
control Verification of control strategy
You receive a comprehensive
Tuning
report clearly describing:
Analysis of data Findings
Automatic mix Assessment of the control strategy Measurements
control Evaluation of problems and opportunities Conclusions
Optimisation of control Recommended actions
Visual inspection of equipment Improvement potential
Sampling and Check for material build-up, wear and damages
sample Change of wear parts The recommendations serve as
transport Functionality check a basis for planning your next
Cleaning maintenance stoppage and
maintaining high equipment
availability.
Check of pneumatic connections
Automated sample
Cleaning of machinery Moreover, the findings serve as
preparation and
Change of wear parts input for cross-evaluation of the
analysis
Functionality check equipment on the plant.

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 32-33 for more details on the individual support modules.
28
Electrical and Instrumentation Services
Efficient, easy plant control and a clear maintenance plan
Service benefits An incorrect setting in the power
distribution systems or a pressure
- 
Reduce number of transmitter can not only cause
unforeseen stoppages production stoppage, but, at worst,
fatal accidents or severe equipment
- Optimised energy damage.
consumption
- 
Improved information Identify and eliminate
available for production root causes to avoid:
personnel 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 consumption
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 plants 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.
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
 29
Electrical and Instrumentation Service Agreement Modules

INSPECTION CONTENT RECOMMENDATIONS

Thermographic analysis of MV switchgears (On) Conclusions

Verification of relay and protective settings (Off) We present our findings to you
Medium voltage Evaluation of operation climate, cleanness and safety (On) in a follow-up meeting so you
systems Test of mechanical functionality of MV switchgears (Off) can take immediate action where
Earthing and cable connection check (Off) required.
Insulation test / polarisation test of power cables (Off)
Report
Thermographic analysis of LV switchgear (On)
You receive a comprehensive
Verification of relay and protective settings (Off)
report clearly describing:
Evaluation of operation climate, cleanness and safety (On)
Low voltage Findings
Test of mechanical functionality of LV switchgear (Off)
systems Measurements
Earthing and cable connection check (Off)
Conclusions
Visual condition check and polarisation test of distribution
Recommended actions
transformers HV Side (Off)
Improvement potential
Thermographic analysis of VFD panels (On)
Verification of relay and protective settings (On/Off) The recommendations serve as
Variable frequency
Evaluation of operation climate, cleanness and safety (On) a basis for planning your next
drives
Earthing and cable connection check (Off) maintenance stoppage and
Evaluation of EMC measures (Off) maintaining high equipment
Check of battery and battery charger systems (Off) availability.
Emergency supply Functionality and setting check of UPS supply (Off)
Functionality test of emergency generators (Off) Moreover, the findings serve as
input for cross-evaluation of the
Temperature transmitter test and adjustment (By-pass) equipment on the plant.
Pressure transmitter test and adjustment (By-pass)
Instrumentation
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

See pages 32-33 for more details on the individual support modules.
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
FLSmidths 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.
Repair and refurbishment services
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)
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.
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
 31
Process Audits Service Agreement Modules

PROCESS AUDIT MODULES RECOMMENDATIONS

Optimised utilisation Conclusions

Quarry Stabilising chemical and physical variations We present our findings to you
Controlling critical elements; i.e. moisture and sulphur content in a follow-up meeting so you
can take immediate action where
Achieve required homogenisation
required.
Evaluation of storage logistic and capacities
Material handling Optimised schedule at required output rate
Report
Transport equipment
You receive a comprehensive
Material blockages; i.e. sticky materials, lump formations etc.
report clearly describing:
Product quality Findings
Wear analysis Measurements
Energy consumption Conclusions
Grinding process
Vertical mill set-up, i.e. dam ring etc. Recommended actions
Ball mill set-up; i.e. ball charge etc. Improvement potential
Separator set-up and efficiency

Kiln condition; i.e. stability The recommendations serve as

Fuel and energy consumption a basis for planning your next
Pyro process Burner set-up maintenance stoppage and
Cooler set-up and efficiency maintaining high equipment
Pyro line process availability.

Raw mix optimisation Moreover, the findings serve as

Clinker quality; i.e. burnability, grindability etc. input for cross-evaluation of the
Quality control
Sampling methods equipment on the plant.
Lab equipment evaluation and calibration

Capacity upgrade study

Upgrade and
Fuel conversions
conversion
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 32-33 for more details on the individual support modules.
32

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 Get performance data of key components, so you can
All service contracts include a comprehensive maintenance effectively plan maintenance and spare part requirements
overview, which summarises the recommendations of all the Reduce production downtime
different specialists who have inspected the plant. In particular,
we look out for specific issues that can have wider implications
This service uses FLSmidth LiveConnect, providing you a
on plant performance. For example, performance inefficiencies
secure, fast and reliable remote link direct to FLSmidths
in the raw mill could originate from issues with the crusher, and
specialists.
the report will outline recommendations for resolving these
issues.
Performance monitoring and optimisation
FLSmidth specialists monitor equipment performance on a
Condition monitoring
regular basis, determining the best course of action with site
By constantly monitoring equipment conditions, such as
engineers and optimising accordingly.
temperatures and vibrations in key spots, we can assist you
Improve the performance of your equipment
in proactively identifying destructive conditions before any
equipment stoppage is caused. Monitoring and analysis is  ptimise plant production over the long term as the flow
O
carried out by a team of highly experienced FLSmidth specialists, sheet changes
who give you feedback on your equipments condition.

SUPPORT FROM FLSMIDT

Remote engineering Software license upgrade subscription

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 FLSmidths specialist knowhow
The service uses FLSmidth LiveConnect , providing you a secure,
fast and reliable remote link direct to FLSmidths specialists.
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 FLSmidths service
team
Extend the lifetime of your systems

This service uses FLSmidth LiveConnect, providing you a
secure, fast and reliable remote link direct to FLSmidths
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
TH TECHNOLOGY CENTER
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
33
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. FLSmidths 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
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
34

Training
Plant 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 training fraction of your workday. Additionally our 24/7/365 availability

In our effort to bring you easy access to learning, FLSmidth
has produced a series of online courses that we have made
available via FLSmidths 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
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

TRAINING BY

Production training
We 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
 35

Kiln system maintenance training on site technical skills and developed capacity within the kiln system
The objective of this training is to give participants knowledge maintenance resulting in increased lifetime and availability
and understanding of specific maintenance areas of modern of the kiln installation as well as well described, realistic
kilns. By developing the skills to perform diagnostic site maintenance action plans.
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
measurings 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

FLSMIDTH INSTITUTE

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.
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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.

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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. www.flsmidth.com

Cement Plant Services

E-mail: internationalservice@flsmidth.com