CONDITION BASED MONITORING - Knowledge Platformknowledgeplatform.in/wp-content/uploads/2016/07/Vasavadatta-Cement-CM.pdfTrusted Technology – Solid Strength VIBRATION MONITORING Vibration

Trusted Technology – Solid Strength

Kesoram Industries Ltd [Cement Division]

UNIT: VASAVADATTA CEMENT, SEDAM

CONDITION BASED MONITORING

Trusted Technology - Solid Strength





Instillation of Roto Scale for Fly Ash feeding

Fly Ash Feeding Roto

Scale Started on 25th Dec

2015 at Unit-4 Cement

Mill

Fly Ash Feeding Roto

Scale Started in Unit-3

In Jan 2016.

Fly Ash Feeding Roto Scale

Platform and Separate Surge

Bin Ready at Unit-1 & 2

Cement Mill Started on 22nd

Jan 2016

Hot Disc


Various Types of Waste used in Hot Disc


Type Of AFR Source

Shredded Tyre Chips Imported

Tyre & Tyre Waste Imported

Goa MSW Goa

Plastic Waste From Sunrays Compost Bangalore

FRP Waste From Suzlon Mangalore

Polyfiber Gujarat

Plastic Waste From Moogambigai Mangalore

Agriculture Waste Local

Coconut Coir Waste Mangalore

Shredded Toot Stalks Mangalore

Shredded Cotton Stalks

In-house generated Dumper Tyre Waste In House Garage

Plastic Waste From Paper Mill Dandali

MSW from HIL Bangalore

Total Alternate Fuel Co-processed in Vasavadatta Cement Sedam All

Figures in (MT)



Idle running hours optimization and Savings S.No

Area LAC UNITS /

ANNUM Saving

(Lac Rs)

For The Year 2011-12

1 Lime Stone Loading Belts Unit -1 to 4 Coal Mill 1 to 4 and Packing Plant 1to 4.

290.70 130.85

For The Year 2012-13

1 Unit -4 RABH fan running Optimized With DP 2.87

12.93

2 Raw Coal Transportation in Power Plant 5.55

25.00

3 Idle Running of Air Dryers in Cement Plant. 2.64

11.88

4 Idle Running of Air Dryers in CPP. 2.64 11.88

5 Receiver Mounted Compressor Optimization 0.79 3.46

Total 305.19 65.15


Savings S.No

Area LAC UNITS /

ANNUM Saving

(Lac Rs)

1 Lime Stone Loading Belts Unit -1 & 2 4.15 18.76

2 Lime Stone Loading Belts Unit -3 2.00 9.01

3 Lime Stone Loading Belts Unit -4 5.23 23.56

4 Operation of Coal mill -1 0.51 2.30




8 Packing Plants 1 to 4 13.3 59.85

Total Saving 29.07 130.85


CONDITION BASED MONITORING

1.Vibration monitoring.

2.Oil and grease analysis.

3.Thermography.

4.Thickness measurement.

5.Ultrasound technique


VIBRATION MONITORING

Vibration monitoring of Critical equipments of all four cement plants and Five power

plants. So, there are total of 591 equipments/month in route and there are nearly 50

numbers of equipment we monitor off route.

Vibration reading of all the equipments is collected and on the basis of vibration trend

and its signature a report is generated and will be sent to the concerned department if

found abnormal. In addition to the preventive maintenance systems these reports are

considered during weekly or annual maintenance work.

A feedback report is been taken from all the sections which contains the information like

what action the maintenance people have taken to arrest the problem. The same

information can be used for further analysis.


VIBRATION REPORT FORMAT


FREQ. ESS NO. DESCRIPTION

MONTHLY

EMM091 VIBRATION MONITORING MONTHLY ESS

EMM092 THERMOGRAPHY MONTHLY ESS

EMM167 POLYCOM BEARINGS GREASE SAMPLE COLLECTION MONTHLY ESS

QUARTERLY EMQ0117 OIL SAMPLE COLLECTION QUARTERLY ESS

EMQ131 POLYCOM GREASE SAMPLE COLLECTION END COVER OPENING QUARTERLY ESS

YEARLY

EMY141 THICKNESS MEASUREMENT YEARLY ESS

EMY142 KILN SHELL THICKNESS YEARLY ESS

EMY153 ULTRASONIC TESTING

CBM SCHEDULES


CBM INSTRUMENTS


CBM INSTRUMENTS CONDITION MONITORING INSTRUMENTS DETAILS

Sl.No. Instruments Name / Model Make

1 CSI 2130 Machinery health analysis Emerson Process Management

2 Thermography Instrument Ti-32 Fluke

3 Ultrasound flaw detector "Einstein - II TFT" with color display.

Modsonic

4 Ultrasound Leak detection instrument, (CTRL UL - 101)

Perma Weld Pvt, Ltd.

5 Ultrasonic Thickness Guage (Edison - 1) Modsonic

6 Nova Strobe DBX Monarch Mechanalysis

7 Digital Tachometer Model-2241 Kusam-Meco

Thermography :

Thermal images for Preheater

cyclones, feed pipes, gas ducts, cooler

hoods at frequency of 4 months.

Reports sent to the concerned

department for corrective action.

Corrective actions like immediate

installation of boxes and repair with

castable and brick lining during

shutdown.

Unit – 3 PC Duct at Hot Disc side

Electrical Cable Cellar


CONDITION BASED MAITENANCE

Oil Analysis : - Oil and Grease samples (115

Nos.) at a frequency of Quarterly, sent for

analysis to M/s Predict Hyderabad.

Corrective actions like Centrifuging, oil top up,

oil replacement, bearing/gearbox inspection are

carried out.



Grease Analysis: - Grease samples (24 Nos.) at a frequency of 45 days

once at Raw mill-3 & 4 and Quarterly once at Cement mill-1,2,3&4 Polycom

bearings grease sent for analysis to M/s Predict technologies Hyderabad.

As per grease analysis report Raw mill-3 Polycom fixed DE bearing given

as Critical condition, So that we have inspected and found that bearing was

in damaged condition.





Thickness Measurement: Thickness of Kiln shells, chimneys, ducting,

etc in annual




Dynamic Balancing:-

Advantages:

• Avoided unwanted Mill stoppages due to fan vibration tripping.

• Transfer of high vibrations to the floors ( fan located at 2nd floor)

• Bearing life enhancement due to fan running in minimum vibrations.

• Oil leakages from the bearing housings.

•DYNAMIC BALANCING JOBS.xlsx

CASE PLANT SECTION EQUIPMENT

BEFORE BALANCING VIBRATION

IN mm/s

AFTER BALANCING

VIBRATION IN mm/s

BALANCING WEIGHT IN

gms

Case – 1 VC CEMENT MILL-3

HR SEPARATOR FAN 8 2.9 1600

Case – 2 KC CEMENT MILL-1 & 2

LNV HT FAN 12.8 2.2 430

Case – 3 KC CEMENT MILL-3

O-SEPA HT FAN 10.1 5 1500

Case - 4 VC CEMENT MILL-2

HR SEPARATOR FAN 5.5 1.9 760

DYNAMIC BALANCING JOBS.xlsx








Head Sprocket

Dri

ve

Sid

e

No

n D

rive

Sid

e

1840 mm

840 mm

Defect

Ultra sound Testing: - Testing of the all cooler fans shafts, B/E

head drum shafts, DPC head sprocket shafts, Kiln tyres, supporting

rollers, Thruster shafts with external party in the annual shutdowns


Documents

CONDITION BASED MONITORING - Knowledge Platformknowledgeplatform.in/wp-content/uploads/2016/07/Vasavadatta-Cement-CM.pdfTrusted Technology – Solid Strength VIBRATION MONITORING Vibration