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
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.
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 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.
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
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.
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 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.
Identify and eliminate root
causes to avoid:
• Excessive downtime
• Repeated failures
• Operational and process problems
We evaluate the plant’s overall storage
performance and, if necessary,
recommend potential design and
capacity upgrades. The inspection also
includes a mechanical appraisal of the
stacker and reclaimer equipment.
FLSmidth recommends a stacker and
reclaimer inspection every one to
three years.
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
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.
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.
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
equipment such as vibration analysers,
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 mill’s availability is totally
dependent on the gear unit’s condition
and performance.
FLSmidth’s gear inspection services
determine the status and condition of
the individual components in the gear
unit.
The gear internals are machined and
ground to very narrow profile and
helix tolerances in order to ensure the
required tooth contact in the gear-
ing, and it is important that this is
maintained together with the correct
alignment and lubrication.
Identify and eliminate
root causes to avoid:
• Pitting and fracture
• Adhesion and scuffing
• All kind of wear
• Bearing damages
FLSmidth recommends carrying gear
inspections every year or every 1,000,
6,000, and 12,000 running hours.

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 kiln’s operations are essential to

the efficiency of the entire cement
With periodic kiln alignments, you
can identify such problems before a
- 
Higher availability plant. FLSmidth’s 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 tyre’s tangential suspension limits
dynamic kiln shell ovality to very low values,
typically wrel ≤ 0.15%, while allowing the
kiln shell to expand in the radial direction.
The tangential tyre suspension is therefore
likely to increase lining life significantly com-
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
cooler’s 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.
FLSmidth´s 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 plant’s status and
compiling a check-up report
• Preparing complete lists of
recommended spare parts
• Providing technical advice, fine-
tuning and general training for plant
personnel
 25
Packing and 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
- 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
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 equipment’s 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 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.
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

FLSmidth offers comprehensive Specialised audits can then be

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
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.

FLSmidth´s process audit will: When possible, we estimate the

• 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.
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.

Service benefits Repair and ­refurbishment services

- Preventive action planning
- Sustainable production
increases
- Optimised energy
­consumption
- Improved precision and
product quality
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
 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 FLSmidth’s
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 equipment’s 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 FLSmidth’s specialist knowhow
The service uses FLSmidth LiveConnect , providing you a secure,
™
fast and reliable remote link direct to FLSmidth’s 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 FLSmidth’s service
team
• Extend the lifetime of your systems

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
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. 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
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 FLSmidth’s website. This means that in addition to
inviting you to learn on site or in our class rooms, we are now
bringing learning to you, inviting you to learn where you are,
on your terms, on your schedule. This is an important step in
our ever ongoing effort to get closer to you and service you on
your terms. We have taken our training online giving you easy
and immediate access to our specialised technical training on
cement equipment and cement production – all you need is a
PC and an internet connection.
Adapting our training to your needs means that you can study
at home, at work, or on the road, and at any time of the day
– you are unbound by time and place. It means that you can
eliminate the travel time you would normally spend getting to
a training venue. And it means you can cut time you would
normally spend away from your work station to do training to a
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
measuring’s and individual evaluation and conclusions based on
such investigations.
After completing the training, the participants will be able to
• Know and account for kiln root causes, symptoms and
their maintenance theory
• Execute important kiln diagnostic measurements
• Evaluate, analyze and draw technical conclusions based on
the obtained results
• Elaborate and describe relevant action plans for the kiln
maintenance
This will result in benefits such as improved knowledge, new

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.
 C 07-16 000-61-ENG V3

Copyright © 2016 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties
(express or implied), and information and data contained in this brochure are for general reference only and may change at any time.
Inspection variation may occur depending on equipment model. Wear parts are not included in an inspection.

ABB® is a registered trademark of ABB Asea Brown Boveri Ltd. Siemens® is a registered trademark of Siemens AG. Emerson® is a registered trademark of Emerson Electric
Co. Fisher® is a registered trademark of Fisher Controls International LLC. Rosemount® is a registered trademark of Rosemount Inc. Durag®
is a registered trademark of Durag Holding AG. NEO™ is a trademark of Norsk Elektro Optikk AS. www.flsmidth.com

Cement Plant Services

E-mail: internationalservice@flsmidth.com