Cement Industry

•The Industry ConCem

•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder

Condition Monitoring Solutions

•OMNITREND®
•Reference List

for the Cement Industry

Cement Industry
The Industry

•The Industry • Few 'global players'

•Our position at PT There has been a process of consolidation going on
•What PT offers worldwide in the cement industry for the last few years.
•Diagnostic Center That means we can find an increasing concentration
•Real case study
within a few big international groups, and at the same
•How cement is
time the natural selection of less productive
made
manufacturers accelerates in the market place.
•Quarry
•Crusher
•Conveyor • Many critical machines
•Mixing Bed The implementation of a CM system is worthwhile to
•Roller Mill avoid any downtimes causing high production losses.
•Ball Mill
•Exhaust fans
•Pre-heater
• High cost pressure
•Kiln That means for every manufacturer: the availability of
•Cooler the machinery has to improve and the productivity has
•Roller Press to increase even further.
•Product Finder
•OMNITREND®
• Potential savings
•Reference List
The use of CM systems increases the productivity by 2-
5%
Cement Industry
Our Position at PRÜFTECHNIK Condition Monitoring

•The Industry
•Our position at PT
PRÜFTECHNIK Condition Monitoring:
•What PT offers
•Diagnostic Center • has experience in the cement manufacturing.
•Real case study
• has good knowledge of the market situation based on
•How cement is
own researches and experiences of the sales
made
departments.
•Quarry
•Crusher • has gained good application knowledge as well –
•Conveyor based on several projects in the cement industry.
•Mixing Bed
• offers all the necessary condition monitoring devices:
•Roller Mill
VIBCODE®, VIBROTIP, VIBSCANNER®, VIBREX®,
•Ball Mill
VIBRONET® Signalmaster, VIBROWEB®,
•Exhaust fans
VIBROWEB® XP and VIBNODE®,
•Pre-heater
•Kiln • furthermore: OPTALIGN® PLUS, ROTALIGN® PRO,
•Cooler PULLALIGN®, etc.
•Roller Press
• provides a software that handles all data: from online
•Product Finder
and offline vibration measurements, alignment
•OMNITREND®
measurements, in addition also thermography pictures,
•Reference List
oil analysis data, etc…
Cement Industry
What does PRÜFTECHNIK Condition Monitoring offer?
Measurement instrumentation
•The Industry • Offline devices for vibration data collection : VIBROTIP®,
•Our position at PT VIBSCANNER® and VIBXPERT®.
•What PT offers
• Online protection systems: VIBREX®, VIBROTECTOR®
•Diagnostic Center
•Real case study • Online monitoring systems: VIBNODE®, VIBROWEB® XP,
•How cement is
VIBROWEB® and VIBRONET® Signalmaster
made
•Quarry OMNITREND PC software
•Crusher
•Conveyor
• Storage, evaluation and reporting platform
•Mixing Bed • One database and user interface for all the field systems
•Roller Mill
• Additional condition information like oil analysis data, alignment data,
•Ball Mill thermography pictures etc. are stored in the same database
•Exhaust fans
• extended reporting capabilities (starts with OMNITREND® WebReport)
•Pre-heater
•Kiln • interface to Maintenance Management systems using Web Services
•Cooler • ideal tool for big co-operations as data can be exchanged and reporting
•Roller Press can be done over the Internet using Web Services. This will help a great
•Product Finder deal for group wide reliability engineering
•OMNITREND®
• fully compatible to WIN 98, 2000, NT, XP – and open for the future
•Reference List

Diagnostic Services
• Services provided by the experts of PRÜFTECHNIK’s Diagnostic Center
Cement Industry
PRÜFTECHNIK Diagnostic Center

•The Industry • Customer can benefit from PRÜFTECHNIK Condition

•Our position at PT Monitoring’s Diagnostic Center – professional tele-support
•What PT offers for predictive and diagnostic maintenance from experienced
•Diagnostic Center engineers on international level!
•Real case study
•How cement is • Mobile Measurement and Diagnostic Service
made – Acceptance measurements, balancing and alignment, mobile vibration diagnostic
•Quarry measurements, special mobile measurements such as noise and stress analysis,
•Crusher inspection service including video endoscopy and thermography
•Conveyor • On site Engineering and Training
•Mixing Bed – Introduction of CM programs including reference measurements, consultancy
•Roller Mill and accompaniment in the introduction of a CM program, specific training in our
•Ball Mill PRÜFTECHNIK facilities for machine operators and service companies
•Exhaust fans • Temporarily and Telediagnostic Services
•Pre-heater – Temporary online monitoring of machines and plants, remote monitoring of
•Kiln machines and plants, determination of load distribution and automatic overload
•Cooler monitoring, periodical vibration diagnostic service including supply of result
•Roller Press
documentation (pdf) or via Internet with interactive result presentation
(OMNITREND® WebReport).
•Product Finder
•OMNITREND® • Consulting and Engineering
•Reference List – Compilation of CM concepts for machine operator and manufacturer, failure and
damage analysis, compilation of expert’s reports by independent technical
experts, operation load survey and simulation for optimization of existing power
train systems, FMEA for mechanical drives (Root cause analysis)
Cement Industry
Real case – cement plant saved 370,000 EUR

•The Industry • Based on a frequency analysis a • Possible consequences without

•Our position at PT fault on the outer race of a CbM monitoring:
•What PT offers separator fan bearing was • Substantial damage to the blower.
•Diagnostic Center diagnosed. Possible damage to the motor.
•Real case study
• Due to the monitoring the repair • The spare parts required can be
•How cement is
could be delayed until the next supplied ex stock. Thus the
made
regular production downtime, production loss had not been too
•Quarry
which was scheduled within two high.
•Crusher
weeks.
•Conveyor
•Mixing Bed
•Roller Mill
Costs of repair: Estimated costs:
•Ball Mill • Material 800. EUR • Material 14,800 EUR
•Exhaust fans • Personnel 1,000. EUR • Personnel 6,000 EUR
•Pre-heater • Production loss 0. EUR • Production loss 96,000 EUR
•Kiln
•Cooler
•Roller Press Total 1,800 EUR Total 116,800 EUR
•Product Finder
•OMNITREND® (Estimated: 15 hours, production loss = output of mill * profit

•Reference List
clinker production * clinker coefficient (CbM basics))

Amount saved: 115,000 EUR

Cement Industry
Real case – cement plant saved 370,000 EUR

•The Industry
•Our position at PT
• Based on a frequency analysis a fault on the outer race of a separator fan
•What PT offers
bearing was diagnosed.
•Diagnostic Center • The damage frequency of the outer race and the corresponding harmonic
•Real case study are shown in the graphic below.
•How cement is
made Envelope spectrum velocity
•Quarry
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Real case – cement plant saved 370,000 EUR

•The Industry • Based on offline measurements • Possible consequences without

•Our position at PT at the drive of the kiln #2 clinker CbM monitoring
•What PT offers cooler a bearing fault was • Substantial damage at the drive.
•Diagnostic Center diagnosed at an early stage and The damage cannot be repaired.
•Real case study could be repaired before The spare part is unavailable.
•How cement is substantial damage occurred. Production loss is very high.
made
•Quarry
•Crusher Costs of repair: Estimated costs:
•Conveyor • Material 150 EUR • Material 26,700 EUR
•Mixing Bed
• Personnel 1,850 EUR • Personnel 13,300 EUR
•Roller Mill
•Ball Mill
• Production loss 10,000. EUR • Production loss 227,000 EUR
•Exhaust fans
•Pre-heater Total 12,000 EUR Total 267,000 EUR
•Kiln
•Cooler (Estimated: 8 hours, production loss = output of kiln * profit (Estimated: 8 work days, production loss = output of kiln *
•Roller Press clinker production (CbM basics)) profit clinker production (CbM basics))

•Product Finder
•OMNITREND®
•Reference List Amount saved: 255,000 EUR
Cement Industry
Real case – cement plant saved 370,000 EUR

•The Industry • The graphic clearly indicates first evidences of roller bearing damages with
•Our position at PT consequential increase of peak and carpet values.
•What PT offers • The electrical problem detected was removed by installation of isolated
•Diagnostic Center bearings.
•Real case study
•How cement is Shock Pulse

made
•Quarry
•Crusher
•Conveyor
•Mixing Bed First evidence

•Roller Mill
•Ball Mill
Bearing fault
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
How Cement is made

•The Industry
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
• Cement is a building material made by grinding calcined limestone
•Exhaust fans and clay to a fine powder. It acts as the binding agent when mixed
•Pre-heater with sand, gravel or crushed stone and water to make concrete.
•Kiln • The following slides explain in detail the different steps in
•Cooler
production and the various kind of machines used in the process.
•Roller Press
•Product Finder • In addition, the measurement points defined on each machine are
•OMNITREND® highlighted, as well as the typical defects and damages and the
•Reference List measurement tasks performed.
Cement Industry
Raw materials extraction

•The Industry
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry 1. Quarry: Typically limestone, marl and • 2. Crusher: The quarried material is
•Crusher clays as well as other materials then reduced in size by compression
•Conveyor containing the required proportions of and/or impact in various mechanical
•Mixing Bed calcium, silicon, aluminum and iron crushers. Crushed rock is reduced in
•Roller Mill oxides are extracted using drilling and size from 120 cm to between 1.2 and 8
•Ball Mill
blasting techniques. cm. Drying of raw material may also be
necessary for efficient crushing and
•Exhaust fans
pre-blending.
•Pre-heater
•Kiln
• Classification: A - very critical
•Cooler
•Roller Press
• Critical machines/ parts:
•Product Finder
– Rollers / Roller bearings
•OMNITREND®
•Reference List – Coupling
– Gearbox
– Foundation
 Measurement locations & parameters
Cement Industry
Crusher – measurement locations & parameters

•The Industry Typical defects

•Our position at PT • Bearing damage
•
•What PT offers
Coupling defects (wear, misalignment,..)
•
•Diagnostic Center
Gear mesh
• Foundation damage due to high vibration load
•Real case study (max. 50mm/s)
•How cement is
made Recommended monitoring solution
•Quarry • VIBROTIP / VIBSCANNER
•Crusher (shock pulse meas. under no-load conditions)
•Conveyor • VIBREX
(vibration meas. under load condition
•Mixing Bed
•Roller Mill
Measurement locations
•Ball Mill 1, 2 = Motor, bearing condition + vibration RMS
•Exhaust fans 3, 4 = Motor, vibration RMS
•Pre-heater 5 = Gearbox, input, bearing condition (no-load
•Kiln condition)
•Cooler 6 = Rollers, vibration RMS
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Transportation of materials & blending

•The Industry
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry 3. Conveyor: raw material is then 4. Mixing bed: the crushed limestone and
•Crusher transported from the quarry using clay is homogenized by stacking and
•Conveyor conveyors, rail wagons or other reclaiming in a long layered stockpile.
•Mixing Bed suitable logistics solutions specific to This material is then ready for milling
•Roller Mill the cement plant. and drying in the kiln.
•Ball Mill
•Exhaust fans • Classification: B - critical
•Pre-heater
•Kiln • Critical machines/ parts:
•Cooler – Rollers / Roller bearings
•Roller Press – Conveyor belt
•Product Finder – Gearbox
•OMNITREND®
– Drive motor
•Reference List

 Measurement locations & parameters

Cement Industry
Conveyor – measurement locations & parameters
Typical defects Measurement locations
•The Industry • Bearing damage 1, 2 = Motor, bearing condition +
•Our position at PT • Coupling defects (wear, misalignment,..) vibration RMS
•What PT offers •
3, 4 = Motor, vibration RMS
Gear mesh 5, 6, 7 = Gearbox, bearing condition,
•Diagnostic Center • Foundation damage due to high vibration load (max. vibration RMS
•Real case study
50mm/s) 8, 9 = Drive roller, bearing condition,
•How cement is
vibration RMS (in load
Recommended monitoring solution direction)
•
made 10, 11 = Deflection roller, bearing
VIBROTIP / VIBSCANNER
•Quarry (shock pulse meas. under no-load conditions) condition, vibration RMS (in
•Crusher •
load direction)
VIBREX
•Conveyor (vibration meas. under load condition
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Blending

•The Industry
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry
•Crusher
•Conveyor
•Mixing Bed 5a. Roller mill - the raw materials are 5b. Ball mill - the raw materials are milled
•Roller Mill milled and dried in a roller mill and/or and dried in a ball mill. The course
•Ball Mill ball mill. Heavy rollers are held over a material is milled in the rotating
•Exhaust fans rotating table and the course material cylindrical mill body through balls made
•Pre-heater is milled until it is fine enough to be of steel until it is fine enough to be
•Kiln
carried by air to a homogenizing silo. carried by air to a homogenizing silo.
•Cooler
•Roller Press • Classification: A - very critical • Classification: A - very critical
•Product Finder
•OMNITREND® • Critical machines/ parts: • Critical machines/ parts:
•Reference List – Drive motor – Drive motor / Roller Bearings
– Gearbox / Bevel gear 1. stage – Gearbox
– Gearbox / Planetary stage
 Measurement locations & parameters  Measurement locations & parameters
Cement Industry
Roller Mill – measurement locations & parameters

•The Industry
Typical defects
•Our position at PT
• Drive motor: unbalance, misalignment, wear
•What PT offers electrical problems, bearing condition
•Diagnostic Center
•Real case study • Gear box: gear mesh of pinion and planetary stage;
•How cement is
bearing condition at drive shaft; oil supply

Recommended monitoring solution

made
•Quarry
• VIBROWEB
•Crusher
Measurement locations
•Conveyor
1, 2 = Motor, bearing condition +
•Mixing Bed vibration RMS
•Roller Mill 3, 4 = Motor, vibration RMS
•Ball Mill
5, 6 = Gearbox, input
7, 8 = Gearbox, bevel gear
•Exhaust fans 9, 10 = Gearbox, planetary stage
•Pre-heater
•Kiln Additionally: Motor current
•Cooler Parameters for gearbox:
•Roller Press - Spectra, envelope spectra and
•Product Finder vibration acceleration
•OMNITREND®
- Perform band analysis
Grinding table: Temperature of
•Reference List friction bearing

Oil supply:
- Temperature
- Pressure
Cement Industry
Ball Mill – measurement locations & parameters

•The Industry
•Our position at PT Typical defects Measurement locations
• 1, 2 = Motor, bearing condition +
•What PT offers
Bearing damage
• vibration RMS
•Diagnostic Center
Gear mesh
3, 4 = Motor, vibration RMS
•Real case study 5, 6 = Gearbox, planetary stage,
Recommended monitoring solution
•How cement is
vibration RMS, spectra,
• Small mills ( < 2 MW) - VIBSCANNER envelope spectra
made • Large mills ( > 2 MW) - VIBRONET Signalmaster with 7, 8 = Mill, journal bearing,
•Quarry field multiplexer spectra + envelope spectra
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Exhaust Fans

•The Industry
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater 6. Exhaust fans - The exhaust gas from many kilns is used for drying
•Kiln raw materials, thus improving the energy efficiency of the plant.
•Cooler
•Roller Press • Classification: A - very critical
•Product Finder
•OMNITREND®
• Critical machines/ parts:
•Reference List
– Motor
– Fan / Roller Bearings, blades

 Measurement locations & parameters

Cement Industry
Exhaust Fans – measurement locations & parameters

•The Industry
•Our position at PT Typical defects Measurement locations
• 1, 2 = Motor, bearing condition +
•What PT offers
Bearing damage
• vibration RMS
•Diagnostic Center
Unbalance
3, 4= Motor, vibration RMS
•Real case study 5, 6 = Fan, bearing condition, vibration
Recommended monitoring solution
•How cement is
RMS
• VIBSCANNER with VIBCODE and VIBREX for meas.
made location: Fan, Bearing, Ds
•Quarry • VIBRONET Signalmaster with field multiplexer
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Clinkerization

•The Industry 7. Pre-heater - cyclone pre-heaters enable the

•Our position at PT
raw material of cement production to be
preheated before entry into the kiln. This
•What PT offers increases the energy efficiency of the kiln as
•Diagnostic Center
the material is 20-40% calcined at the point
of entry into the kiln.
•Real case study
•How cement is
made
•Quarry
•Crusher
•Conveyor 8. Kiln - the kiln is designed to maximize the
•Mixing Bed efficiency of heat transfer from fuel burning to
•Roller Mill
the raw material. In the pre-heater tower the
raw materials are heated rapidly to a
•Ball Mill temperature of about 1000°C, where the
9. Cooler - the molten cement clinker is then
•Exhaust fans
limestone forms burnt lime. In the rotating kiln,
the temperature reaches up to 2000°C. At this cooled as rapidly as possible. The
•Pre-heater high temperature, minerals fuse together to ambient air used to cool the clinker is
•Kiln form predominantly calcium silicate crystals – then fed into the kiln as combustion air -
cement clinker.
•Cooler ensuring high utilization of the heat
•Roller Press • Classification: A - very critical produced.
•Product Finder • Classification: A - very critical
•OMNITREND® • Critical machines/ parts:
–
•Reference List • Critical machines/ parts:
Drive / Motor
– Spur gear
– Pinion / gear rim – Cooler fan / blades
– Drive motor / Roller Bearings

 Measurement locations & parameters  Measurement locations & parameters

Cement Industry
Kiln – measurement locations & parameters
Typical defects Measurement locations
•The Industry • Drive motor: unbalance, misalignment, wear, electrical 1, 2 = Motor, bearing condition + vibration RMS
•Our position at PT problems, bearing condition 3, 4= Motor, vibration RMS
•What PT offers
5, 6 = Gearbox, input, vibration RMS
• 7, 8 = Gearbox, output, bearing condition
•Diagnostic Center
Gear box: unbalance, misalignment, wear, gear mesh of
1st. - 3rd. stage (wear, breakage, tooth damage), 9, 10, 11 = Intermediate shaft, bearing
•Real case study bearing condition of drive shaft, intermediate shaft, condition + vibration RMS
•How cement is output shaft 12, 13 = Kiln, vibration RMS

made
•
Additionally: visual inspection of lubrication /
•Quarry
Pinion drive: mesh (wear, breakage, tooth damage), soiling of pinion and gear rim.
bearing condition of pinion shaft
•Crusher
•Conveyor Recommended monitoring solution
•Mixing Bed • VIBSCANNER
•Roller Mill • Large kiln drive (> 1MW): VIBRONET
•Ball Mill Signalmaster with field multiplexer
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Cooler – measurement locations & parameters

•The Industry
•Our position at PT Typical defects Measurement locations
• 1, 2 = Motor, bearing condition +
•What PT offers
Bearing damage
• vibration RMS
•Diagnostic Center
Unbalance
3, 4= Motor, vibration RMS
•Real case study 5, 6 = Fan, bearing condition, vibration
Recommended monitoring solution
•How cement is
RMS
• VIBSCANNER with VIBCODE and VIBREX for meas.
made location: Fan, Bearing, Ds
•Quarry • VIBRONET Signalmaster with field multiplexer
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Grinding & distribution

•The Industry
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill 11. Cement mill (roller press): finish milling
10. Clinker silo - clinker may be either
•Ball Mill stored on site in preparation for grinding
is the grinding together of cement
•Exhaust fans
clinker, with around 5% of natural or
to form cement, or transported to other
synthetic gypsum. Other cementitious
•Pre-heater sites.
materials such as slag, fly-ash or other
•Kiln pozzolans may also be incorporated into
•Cooler the final cement powder.
•Roller Press
•Product Finder • Classification: A - very critical
•OMNITREND®
•Reference List
• Critical machines/ parts:
– Motor
– Gear box
 Measurement locations & parameters  Measurement locations & parameters
Cement Industry
Cement Mill (roller press) – measurement locations & parameters
Typical defects Measurement locations
•The Industry • Unbalance 1, 2 = Motor, bearing condition + vibration RMS
•Our position at PT • Misalignment 3, 4 = Gearbox, vibration acceleration, spectra,
•What PT offers •
envelope spectra
Wear 5, 6 = Rollers, bearing condition
•Diagnostic Center • Electrical problems
•Real case study • Bearing damage
•How cement is • Gear mesh
made
Recommended monitoring solution
•Quarry
• VIBRONET Signalmaster with field multiplexer
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder
•OMNITREND®
•Reference List
Cement Industry
Grinding & distribution

•The Industry
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill 12. Cement silos / Logistics - final cement
may be transported pre-bagged or as a
•Ball Mill bulk powder. The method of transport
•Exhaust fans selected varies according to location -
•Pre-heater and may include transport via truck, rail
or ship.
•Kiln
•Cooler • Classification:
– Separator: A - very critical
•Roller Press – Separator fan: A (limited number);
•Product Finder B (great many)

•OMNITREND® • Critical machines/ parts:

•Reference List – Separator / Roller Bearings, Gearbox
– Separator fan / Roller Bearings, Blades

 Measurement locations & parameters

Cement Industry
Cement Mill (roller press) – measurement locations & parameters

•The Industry
Typical defects
•Our position at PT
• Bearing damage
•What PT offers • Gear mesh
•Diagnostic Center • Unbalance
•Real case study
•How cement is Recommended monitoring solution
made • VIBSCANNER with VIBCODE and VIBREX
•Quarry • VIBRONET Signalmaster with field multiplexer
•Crusher
•Conveyor
•Mixing Bed
•Roller Mill
Measurement locations
•Ball Mill
1, 2 = motor, separator bearing condition + vibration
•Exhaust fans RMS
•Pre-heater 3 = motor, separator, vibration RMS
•Kiln
4 = gearbox, input, bearing condition
5, 6 = rotor bearing, bearing condition, envelope
•Cooler spectra
•Roller Press 7, 8 = motor (fan), bearing condition + vibration RMS
•Product Finder 9, 10 = fan, bearing condition, temperature
•OMNITREND®
•Reference List
Cement Industry
Product Finder

•The Industry • The ideal solution for the cement industry is a mix of online and offline
•Our position at PT instruments. Below you will find some examples of typical machines and the
•What PT offers units that can be used for each of the machines.
•Diagnostic Center • PRÜFTECHNIK Condition Monitoring will help you to choose the right tool for
•Real case study
the right application – from simple overall value data collection with portable
•How cement is
devices to sophisticated online systems with diagnostic capabilities and
made
automatic alarming via email / SMS notification.
•Quarry
•Crusher
•Conveyor

VIBSCANNER® +

VIBROTECTOR®

VIBROWEB® XP
•Mixing Bed

Signalmaster
VIBROWEB®

VIBRONET®
VIBNODE®
VIBCODE
•Roller Mill

VIBREX®
•Ball Mill
•Exhaust fans
Crusher   
•Pre-heater
Conveyor belt  
•Kiln
Raw mill  
•Cooler
Ball mill     
•Roller Press
Fans     
•Product Finder
•OMNITREND® Kiln drive  

•Reference List 
Roller press

Separator     
Cement Industry
OMNITREND® - a complete platform for all condition data

•The Industry • The powerful and user-friendly software platform allows you not
•Our position at PT only to store measured machine data, but also to store all relevant
•What PT offers
machine data – weather it is pictures from a thermography camera,
•Diagnostic Center
•Real case study
or oil analysis images, alignment data and other relevant
•How cement is information as comments on visual inspections or even complete
made manuals of the machine (pdf) – maintain your data organized and
•Quarry up-to-date.
•Crusher
•Conveyor Alignment Balancing Repair Replacement
•Mixing Bed
•Roller Mill
ROTALIGN® Pro
•Ball Mill
Alignment file
•Exhaust fans PDF
Oil analysis OMNITREND® smartALIGN®
•Pre-heater
jpg
•Kiln smartSCANNER®
Thermography
•Cooler
•Roller Press
Measurement data
•Product Finder
•OMNITREND® offline data online data
•Reference List Visual VIBSCANNER® VIBXPERT® VIBRONET® VIBNODE®
inspection
VIBROTIP® Signalmaster VIBROWEB® / XP
Cement Industry
Reference List

•The Industry • Holcim, Switzerland - Untervaz plant

(no. 2 worldwide):
•Our position at PT 3 mills, 2 kilns, output 715 kt/a
 1x VIBRONET Signalmaster, 80 sensors
•What PT offers VIBROTIP & VIBSCANNER
•Diagnostic Center
• Lafarge, Italy - Pescara plant
•Real case study (no. 1 worldwide):
•How cement is 2 mills, 1 kiln, output 400 kt/a
made  2x VIBRONET Signalmaster, 120 sensors
•Quarry (80 vibration, 40 temperature)
•Crusher
VIBROTIP & VIBSCANNER

•Conveyor • CEMEX, USA - Charlevoix, MI plant*

•Mixing Bed
(no. 2 in the U.S.A):
3 mills, 1 kiln, output 1300 kt/a
•Roller Mill
 2x VIBRONET Signalmaster, 150 sensors
•Ball Mill *Sold to Votorantim in 2004
•Exhaust fans
•Pre-heater • HeidelbergCement, Germany
•Kiln  VIBROTIP & VIBSCANNER
•Cooler
• Alsen AG, Germany (= Holcim Group)
•Roller Press  VIBROTIP & VIBSCANNER
•Product Finder
•OMNITREND® • PT Indocement, Indonesia
(= Heidelberg Cement Group)
•Reference List  VIBROTIP
Cement Industry

•The Industry
Thank you for your attention!
•Our position at PT
•What PT offers
•Diagnostic Center
•Real case study
•How cement is
made
•Quarry
•Crusher PRÜFTECHNIK Condition Monitoring GmbH
•Conveyor
Oskar-Messter-Strasse 19-21
•Mixing Bed
•Roller Mill 85737 Ismaning / Germany
•Ball Mill
•Exhaust fans
•Pre-heater
•Kiln
•Cooler
•Roller Press
•Product Finder For more information visit our website at www.pruftechnik.com
•OMNITREND®
•Reference List