Report

Author: Baltasar Fajardo Serrano

Date: (due date Mai 15, 2009)
Title: Implement PMRs on “A” fans
Company: Holcim Spain
Plant: Gádor
Copies to external: Hans Bärtschi, Ignacio Diaz, Beat Lüthi
Tanja Meier,
Copies to internal: Sergio Martinez Hernandez, Enrique Coto Gonzalez,
Alino Bértolo

Executive Summary

Situation and project objectives:

In 1977 started the activity at Gádor plant, which is located in the southeast of Spain
province of Almería. The yearly clinker production capacity has raised from 625.000 Ton. to
740.000 Ton. due to a kiln modification in 2001. The current yearly cement production capacity is
1.0 mill Ton. to made fifth different types. In 1990 started the consumption of AFRs in order to
reduce the consumption of conventional fuel obtaining a TSR higher than 20%.

The next table shows the overall data of the plant:

EQUIPMENT TYPE SUPPLIER SIZE CAPACITY

Crashers Impact Hazemag 700 Tn/h

Stackers Reclaimer KHO 300/90 PHB 50.000 Tn
Ball mill Polysius Ø 4.4 m ; L 13,34 m
Raw mill 200 Tn/h
Center discharge
Homogenization Claudius Ø 10.0 m; L 16,0 m
Raw Meal Silo (2) 2 x 2.500 Tn/h
storage Peters Ø 10.0 m ; L 28,0 m
Dry process Ø 4.4 m ; L 70.0 m
Kiln Polysius 2.400 Tn/d
3 supports
Cooler 2 grate sections Fuller
Ball mill Ø 4.4 m ; L 14.14m
Cement mill Polysius 110 to 140 Tn/h
2 chambers
Ø 14.0 m ; L 32.0m 3 x 5.000 Tn
Cement Silo storage
Ø 15.0 m ; L 39.0 m 2 x 7.500 Tn
Packing Ventomatic 180 Tn/h

1
 As can see in Pareto analysis, in previous years, Gádor plant has suffered some problems
in “A” Fans in 2007-2008:
 A big explosion was happened on the VFD and the transformer also was damaged
on the raw meal filter fan. A SOLVE session was done to find the root cause of the
problem but due to lack of recorded data from the equipment it was not possible to
find a clear explanation for the problem, even to the manufacturer of the equipment
could not find a explanation.
 One year later more or less, a new fire on the VFD of Dopol exhaust gases fan
happened and the equipment had to be repared.

The Solve action plan was implemented before the second problem but it is obvious that is
not enough, is necessary to implement PMR and condition monitoring matrix on A Fans according
to HGRS standards, and gaps obtained from the comparison with our current maintenance
program are going to be eliminated.

The next table shows data about the importance of the problem

DATE EQUIPMENT PROBLEM CAUSE SOLUTION IMPACT

Jun 2007 GA.421-VE1 VFD and TRAFO New VFD and Downtime:42 Hs
Trafo burnout Trafo Cost mat: 150 m€

Sept 2007 GA.421-VE1 Trafo burnout The trafo from Buy a new trafo Downtime:45 Hs
the store room Cost mat: 50 m€
was too old
Oct 2008 GA.441-VE1 VFD: DC link DUST Refurbish the Downtime: 72 Hs
capacitors VFD with spare Cost: 70 m€
burnout parts

The objects of the project are rise the MTBF on A Fans and reduce the unplanned work.

2
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frecuencia frecuencia
Description of project content:
In order to achieve the objectives, the project has been split into different phases:
 Identify main electric components of fans where it is necessary to apply
maintenance. (i. e. transformer, VFD, electric motor, …).
 Define the proper maintenance according to HGRS standards (PMRs, CM) for
each equipment.
 Compare with the current maintenance program to identify:
o Good practices already implemented in the plant.
o Gaps and bad practices compared to the standards.
 Create an action plan to:
o Get the necessary tooling and or instruments to do the maintenance.
o Do the training.
o Update the current preventive maintenance program at SAP.
 Evaluate the results.

Conclusions / recommandations and/or messages:

The lesson learned that we’ve got with this project is to implement preventive
maintenance routines quickly and efficiently is necessary to take into account the
following aspects:
 The development of ITOPs is essential to ensure the quality of inspections,
specifying all necessary elements that there be no mistake. It also becomes a
reference document for training workers in the inspection, therefore have great
value adding photos, diagrams, etc.. on them.
 The result of an inspection should be reflected quantitatively in a report, since it
is essentially a further analysis of the results not only on an individual basis,
because sometimes you need to have the whole number of inspections to make
decisions.
 Having monitored the results of inspections graphically over time is very easy to
observe changes in equipment and anticipate potential problems.

While performing this job, we appreciate the useful techniques that are preventive
maintenance, not only for better knowledge of our equipments but we have helped to
avoid potential failures of equipment as in the case of the exhaust gases fan motor, by
EMD we detected a potential failure on the rotor, the next step is monitoring the motor
by VA to control the evolution of the rotor until next kiln shutdown, where after doing a
revision we will make a decision.

A good recommendation is to expand these PMR to similar equipment that we have in

plant.

The obtained feedback from operators, subcontractors, courses, books, .. will be very
useful for the continuous improvement of ITOPs, Checklist, trend graphs, ... since the
development of preventive maintenance is closely related to the evolution of its tools.

4
Table of content
1. INTRODUCTION 6
2. DESCRIPTION OF THE PROJECT APPROACH / METHODOLOGY 6
3. IDENTIFY MAIN COMPONENTS ON “A” FANS 7
4. DEFINE THE PROPER MAINTENANCE ACCORDING TO HGRS STANDARDS 7
4.1 TRANSFORMER 8
4.2 VARIABLE FREQUENCY DRIVE 8
4.3 ELECTRICAL MOTOR 9
4.4 FAN 9
5. REVISION OF THE CURRENT MAINTENANCE PROGRAM 10
5.1 TRANSFORMER 10
5.1.1 Visual Inspection 10
5.1.2 Revision of PMRs 11
5.2 VARIABLE FREQUENCY DRIVE 12
5.2.1 Visual Inspection 12
5.2.2 Revision of PMRs 13
5.3 MOTOR 13
5.3.1 Revision of PMRs 13
5.4 FAN 14
5.4.1 Revision of PMRs 14
6. ACTION PLAN 15
7. RESULTS OF THE ACTION PLAN 17
7.1 FULLFILMENT OF THE ACTION PLAN 17
7.2 IMPLEMENTATION OF PMRS IN SAP 18
7.3 EVIDENCES 19
8. EVALUATION OF THE ACTION PLAN 21
9. CONCLUSIONS & RECOMMENDATIONS 24
10. ANNEXES 26
10.1 Annex 1: Revision of PMRs 26
10.2 Annex 2: SOLVE CASE 34
10.3 Annex 3: potential problem of broken rotor bar detected by EMD 38

5
1. INTRODUCTION
In the last two years, we have had problems in two different big Fans:
 dopol exhaust gases fan
 raw meal filter fan

In the plant there are three more fans similar to these, with same power level and
driving components, these are:
 clinker cooler filter fan
 raw mill fan
 recycling cement mill fan

One main function of maintenance department is to avoid systematic problems on

equipments, and for that there is a Holcim maintenance strategy to achieve the required
reliability at the lowest sustainable maintenance cost.

Being focused on Big Fans, considering Holcim maintenance strategy and defining
concretely where the problem is, it is necessary to review the preventive maintenance
routines in order to improve their reliability.

2. DESCRIPTION OF THE PROJECT APPROACH / METHODOLOGY

In order to achieve the objectives, the project has been split into different phases:
 Identify main electric components of fans where it is necessary to apply
maintenance. (i. e. transformer, VFD, electric motor, …).
 Define the proper maintenance according to HGRS standards (PMRs, CM) for
each equipment.
 Compare with the current maintenance program to identify:
o Good practices already implemented in the plant.
o Gaps and bad practices compared to the standards.
 Create an action plan to:
o Get the necessary tooling and or instruments to do the maintenance.
o Do the training.
o Update the current preventive maintenance program at SAP.
 Evaluate the results.

6
3. IDENTIFY MAIN COMPONENTS ON “A” FANS

SWITCHGEAR
1

TRANSFORMER
2

VFD
3

4
M MOTOR

4. DEFINE THE PROPER MAINTENANCE ACCORDING TO HGRS STANDARDS

Based on Holcim preventive maintenance strategy for mechanical and electrical
components:
 CONDITION MONITORING
o Walk by inspection
o Transformer oil analysis
o Electrical motor diagnostics
o Thermography
o Vibration analysis
o Partial discharge measurement
o Non destructive testing

REPLACE (PMR)
SERVICING
o Calibration
o Function testing
o Overhauls
these are the best tools for each component.

7
4.1 TRANSFORMER
• Inspection (Preventive Maintenance Routine)
Oil-Filled (3 to 12 months depending on the criticality)
 Check oil level
 Check area for cleanliness
 Analyze winding, top oil and ambient temperature trend
 Check Tank Pressure
 Analyze Transformer load trending
 Visual inspection of bushings for cracks, dirt, burn
 Visual check desiccant (silicone gel) , check moisture by the color change
(depends on type)

• Condition Monitoring (CM)

 Oil Analysis
• Basic 6 parts components: to verify the quality of the oil as an
insulator and heat transfer agent. Yearly.
• Dissolved gas analysis: to verify the operating condition of the
transformer. Yearly.
• Furanic acid analysis: to verify the condition of the paper insulation if
transformer is older than 30 years.
 Thermography (load level  50%)
• Scan cooling system to detect poor circulation.
• Loose connections on terminals.
• Bushing heat from sparks

• Maintenance task (Based on time or Condition)

 Oil filtering (only if the oil test result is above limits)
 Servicing (cleaning, function test of all instruments, insulators).

4.2 VARIABLE FREQUENCY DRIVE

• Inspection (PMR)
 Monthly: Visual inspection and checking the local panel for alarms and
warnings
 1-2 Years:
• Replace the fan filter of cooling system.
• Backup of parameter, update the documentation.
• Cleaning of internal parts.
• Check cable connection, grounding and motor termination.
 2-4 Years:
• Spare parts maintenance: physical inventory, capacitor forming
• Replacement of CPU back-up battery (if equipped)
• Update of Firmware (if available from supplier)
 10-15 Years: plan for replacement of the whole unit.

• Condition monitoring
 6-12 Months: thermography on critical connections if accessible.

8
 • Servicing
 5-8 Years: Testing and / or replacement of DC Link Capacitors.

4.3 ELECTRICAL MOTOR

• Inspection (PMR)
 Weekly - Monthly: Visual inspection.
 Monthly: vibration monitoring.
 Yearly: greasing according supplier specification.
 5 Years (or based on condition): bearing changing.

• Condition monitoring
 Yearly: EMD.

• Servicing
 5 Years (or based on condition): motor servicing (cleaning,…).

4.4 FAN
• Inspection (PMR)
 Weekly: Visual inspection.
 Yearly:
• Wearing inspection.
• Drive alignment checking.

• Condition monitoring
 Monthly: Vibration Analysis.
 Yearly:
• Crack detection on Shaft by UT
• Crack detection on welds by MT or PT
• Thickness measurement of rotor blades by UT

• Servicing
 Yearly: sensors calibration
 Lubrication (according specifications)

9
5. REVISION OF THE CURRENT MAINTENANCE PROGRAM
The revision is going to be made in two different ways:
 Visual inspection where the equipment is, in order to verify the level of safety
conditions, housekeeping, visual indicators, and the evaluation of the inspection
is going to be divided into:
 good practice ().
 to improve ().
 no evidence ().
 Checking the level of compliance on current maintenance instructions if we
compare them with the HGRS standards, in this way we can identify the gaps
and prepare the action plan to solve them.

5.1 TRANSFORMER

5.1.1 Visual Inspection

 Gauges, and oil levels with visual indicators.

 It could be safer checking the gauges from outside the transformer room

10
  It is necessary to avoid the entrance of dust inside the room and maintain properly the filter
condition of cooling air inlets.
 Lack of periodical cleaning.

 Safety indications and recommendations.

5.1.2 Revision of PMRs

The results of the comparation are shown on next table:

GA.361- GA.421- GA.441- GA.471- GA.561-

PMR analysis status at September 2007
VE1 VE1 VE1 VE1 VE4
All PMRs recommended by HGRS
and HCE, are included in the YES YES YES YES YES
Preventive Maintenance Plan?
All PMRs recommended only by
HCE are included in the Preventive YES YES YES YES YES
Maintenance Plan?
PMR not included in the Plant Trafo Oil Analysis
x Maintenance Plan Thermography

See more detailed information of this on annex 1

11
5.2 VARIABLE FREQUENCY DRIVE

5.2.1 Visual Inspection

 cooling system adapted to regional temperature conditions.

 Doors must be closed to let cooling air going on the correct way.

 It is necessary to avoid the entrance of dust inside the room and maintain properly the filter
condition of cooling air inlets.
 Lack of periodical cleaning.

12
  housekeeping, define a place for every thing  identification label
5.2.2 Revision of PMRs

GA.361- GA.421- GA.441- GA.471- GA.561-

PMR analysis status at September 2007
VE1 VE1 VE1 VE1 VE4
All PMRs recommended by HGRS
and HCE, are included in the YES YES YES YES YES
Preventive Maintenance Plan?
All PMRs recommended only by
HCE are included in the Preventive YES YES YES YES YES
Maintenance Plan?

See more detailed information of this on annex 1

5.3 MOTOR

5.3.1 Revision of PMRs

GA.361- GA.421- GA.441- GA.471- GA.561-

PMR analysis status at September 2007
VE1 VE1 VE1 VE1 VE4
All PMRs recommended by HGRS
and HCE, are included in the NO NO NO NO NO
Preventive Maintenance Plan?
All PMRs recommended only by
HCE are included in the Preventive YES YES YES YES YES
Maintenance Plan?
PMR not included in the Plant Grounding Inspection
x Maintenance Plan EMD

13
 See more detailed information of this on annex 1

5.4 FAN

5.4.1 Revision of PMRs

PMR analysis status at September GA.361- GA.421- GA.441- GA.471- GA.561-

2007 VE1 VE1 VE1 VE1 VE4
All PMRs recommended by HGRS and
HCE, are included in the Preventive NO NO NO NO NO
Maintenance Plan?
All PMRs recommended only by HCE
are included in the Preventive YES YES YES YES YES
Maintenance Plan?
Grounding Inspection
Alignment Check
PMR not included in the Plant Thickness Check by UT
x Maintenance Plan Vibration
sensor
calibration

See more detailed information of this on annex 1

14
6. ACTION PLAN
These past years, the solutions to do the preventive maintenance activities have been
as follow:
 Third party services to do the inspection.
 Subcontracting operators for preventive maintenance.
 Receiving support from mechanical and electrical services, but as they are
overloaded, sometimes that support is not possible.
 Accepting that there is nor possible to do some preventive maintenance
techniques, the alternative is considering some maintenance activities into time
intervals.

According with the strict cost reduction program that we are applying at Gádor, it is
necessary to do an alignment between the necessary budget to implement defined
actions of the plan and the available resources ( equipment, budget and manpower) that
there are at the plant.

It is time to bet for simple solutions using only our own resources to meet with the
objectives. Moreover, considering where it is necessary the reliability according with
Holcim Standard,

Personnel
Design OH&S

Operation Spare Parts

Reliability
Planning &
Replacement
Scheduling

Maintenance Problem
Execution Performance Solving
Analysis

It is very obvious to identify the main aspects to consider in the action plan:
 Write Work Instructions explaining how it must be done a specific preventive
maintenance activity (ITOP), and prepare the training to the operators about
how they must proceed with these ITOPs.
 Elaborate reports and trend charts to collect the results of the inspections.
 Update the current preventive maintenance program at SAP.

The next table shows the action plan applied on each equipment, time delivery and
responsible to develop the defined action:

15
 INSPECTION
EQUIPMENT Final Date Resp.
Maintenance Activity GAP Action
INSPECTION & NO TO IMPROVE: Define a summerize table or report to MARCH 09 BFS
SERVICING input the results of the inspection made by third party
services
OIL ANALYSIS PENDANT FOR 2009 BUT MARCH 09 PM
TRANSFORMER DONE IN 2008

THERMOGRAPHY DONE IN 2009 JANUARY 09 PM

INSPECTION YES TO BE DONE: A calendar for planning the replacement MARCH 09 BFS
of Batteries, filter fans and whole units.

VFD
SERVICING NO TO IMPROVE: Define a summerize table or report to MARCH 09 BFS
input the results of the inspection made by third party
services
INSPECTION MEASURE RESISTANCE TO BE DONE: ITOP, report results and trend databAse APRIL 09 BFS
TO GROUND OF THE
MOTOR, RECORD AND
TREND VALUES
EMD PENDANT FOR 2009 TO IMPROVE: Define a summerize table or report to MARCH 09 PM
MOTOR input the results of the inspection made by third party
services
VA VIBRATION COLLECTING Implement the Online System for vibration analysis APRIL 09 BFS / PM
DATA ONLINE IN LAUNCH defining the control parameters
PHASE
INSPECTION & TEST GROUNDING OF TO BE DONE: ITOP, report results and trend databse APRIL 09 BFS
SERVICING EQUIPMENT
WEAR INSPECTION TO IMPROVE: ITOP, report results and trend database MARCH 09 BFS

TO BE DONE: Check the thickness blades by UT MARCH 09 BFS

ALINGMENT CHECK WE CHECK TO IMPROVE: ITOP, report results and trend database MARCH 09 BFS
MISALINGMENT BASED
FAN ON MONITORING
WARNING PARAMETER
SHAFT inspect by UT DONE IN 2008 TO IMPROVE: Define a summerize table or report to MARCH 09 BFS
input the results of the inspection made by third party
services
VA VIBRATION COLLECTING Implement the Online System for vibration analysis APRIL 09 BFS / PM
DATA ONLINE IN LAUNCH defining the control parameters
PHASE
INSPECTION VISUAL MANAGEMENT TO IMPROVE: Try to implement visual aids for the APRIL 09 BFS / PM
inspections like higher gauges, level indicators, flow
indicators, code labels indicators
OVERALL
CLEANING improve the housekeeping and cleanliness of the APRIL 09 BFS / PM
electric rooms

16
7. RESULTS OF THE ACTION PLAN
The results are splitted into three points:
 The level of fulfillment of the action time.
 The implementation of PMRs in SAP.
 The evidences of the action plan.

7.1 FULLFILMENT OF THE ACTION PLAN

By the delivery time, the status of the action plan is as shows the table below because
some activities have been delayed to next planned kiln shutdown, on September 2009,
when 100% of the action plan should be closed.

INSPECTION
EQUIPMENT Final Date Resp. Status
Maintenance Activity GAP Action
INSPECTION & NO TO IMPROVE: Define a summerize table or report to MARCH 09 BFS 100%
SERVICING input the results of the inspection made by third party
services
OIL ANALYSIS PENDANT FOR 2009 BUT MARCH 09 PM 100%
TRANSFORMER DONE IN 2008

THERMOGRAPHY DONE IN 2009 JANUARY 09 PM 100%

INSPECTION YES TO BE DONE: A calendar for planning the replacement MARCH 09 BFS 100%
of Batteries, filter fans and whole units.

VFD
SERVICING NO TO IMPROVE: Define a summerize table or report to MARCH 09 BFS 100%
input the results of the inspection made by third party
services
INSPECTION MEASURE RESISTANCE TO BE DONE: ITOP, report results and trend databAse APRIL 09 BFS 0%
TO GROUND OF THE
MOTOR, RECORD AND
TREND VALUES
EMD PENDANT FOR 2009 TO IMPROVE: Define a summerize table or report to MARCH 09 PM 100%
MOTOR input the results of the inspection made by third party
services
VA VIBRATION COLLECTING Implement the Online System for vibration analysis APRIL 09 BFS / PM 80%
DATA ONLINE IN LAUNCH defining the control parameters
PHASE
INSPECTION & TEST GROUNDING OF TO BE DONE: ITOP, report results and trend databse APRIL 09 BFS 0%
SERVICING EQUIPMENT
WEAR INSPECTION TO IMPROVE: ITOP, report results and trend database MARCH 09 BFS 100%

TO BE DONE: Check the thickness blades by UT MARCH 09 BFS 40%

ALINGMENT CHECK WE CHECK TO IMPROVE: ITOP, report results and trend database MARCH 09 BFS 100%
MISALINGMENT BASED
FAN ON MONITORING
WARNING PARAMETER
SHAFT inspect by UT DONE IN 2008 TO IMPROVE: Define a summerize table or report to MARCH 09 BFS 0%
input the results of the inspection made by third party
services
VA VIBRATION COLLECTING Implement the Online System for vibration analysis APRIL 09 BFS / PM 80%
DATA ONLINE IN LAUNCH defining the control parameters
PHASE
INSPECTION VISUAL MANAGEMENT TO IMPROVE: Try to implement visual aids for the APRIL 09 BFS / PM 30%
inspections like higher gauges, level indicators, flow
indicators, code labels indicators
OVERALL
CLEANING improve the housekeeping and cleanliness of the APRIL 09 BFS / PM 10%
electric rooms

17
7.2 IMPLEMENTATION OF PMRS IN SAP
Considering the scope of this project, the next tables show information about the task
lists of the new Maintenance Plans created in SAP since SEP´07 to do:
 Trafo Oil Analysis.
 Thermography.
 EMD.

18
7.3 EVIDENCES
100% of planned ITOPs have been created, as well checklist reports and trend
databases. On next table, clicking on the proper link is possible having a look the
evidences of the project.

INSPECTION

EQUIPMENT MAINTENANCE EVIDENCE

GAP ACTION
ACTIVITY

INSPECT & SERV No

TO IMPROVE: Define C:\Documents and
a summarize table or
OIL ANALYSIS No Settings\afajardo\My
report to input the
TRANSFORMER results of the
inspection made by
third party services
THERMOGRAPHY No C:\Documents and
Settings\afajardo\My
TO DO: Create a
INSPECTION Yes calendar of
maintenance
TO IMPROVE: Define C:\Documents and
VFD a summarize table or Settings\afajardo\My
report to input the
SERVICING No results of the
inspection made by
third party services
TO DO: ITOP to
measure resistance to
INSPECTION Yes ground of the motor, DELAYED TO SEP 09
record and trend
values
TO IMPROVE: Define
a summarize table or
report to input the
EMD Yes
MOTOR results of the C:\Documents and
inspection made by Settings\afajardo\My
third party services

Yes Implement the Online

On launch System for vibration
VA phase at the analysis defining the C:\Documents and
moment control parameters Settings\afajardo\My
TO DO: ITOP, report
results and trend
FAN Yes database for testing DELAYED TO SEP 09
the ground of the
equipment.

INSPEC & SERV

TO DO: ITOP, report

Yes
results and trend
database for testing
the wear of blades by C:\Documents and
UT Settings\afajardo\My

C:\Documents and
Settings\afajardo\My
19

C:\Documents and
Settings\afajardo\My
 INSPECTION

EQUIPMENT MAINTENANCE EVIDENCE

GAP ACTION
ACTIVITY

Yes, TO IMPROVE: ITOP, C:\Documents and

currently the report results and Settings\afajardo\My
ALIGNMENT CHECK checking is trend database for
based on testing the alignment
condition of driven unit
C:\Documents and
Settings\afajardo\My
TO IMPROVE: Define
a summarize table or
report to input the
SHAFT INSP by UT Yes DELAYED TO SEP 09
results of the
inspection made by
third party services

Yes Implement the Online

On launch System for vibration
VA phase at the analysis defining the C:\Documents and
moment control parameters Settings\afajardo\My
TO IMPROVE: to
implement visual aids
for the inspections like
higher gauges, level
indicators, flow
indicators, code labels
OVERALL INSPECTION Yes indicators
TO IMPOVE: the
housekeeping and
cleanliness of the
electric rooms

20
8. EVALUATION OF THE ACTION PLAN
It is necessary to consider several factors for the evaluation of the action plan, a
possible way to appreciate the added value of the project to the preventive maintenance
for the equipment selected is projecting its evolution over time and this shows three
scenarios:
 June 2007: when the VFD and trafo of the raw meal filter fan were burnout.
 October 2008: when I was receiving PME training course, the capacitor module
of VFD of dopol exhaust gases fan was burnout.
 April 2009: time delivery for the action plan of this project.

The next table shows the evolution of the implementation of the preventive maintenance
routines on “A” fans, from the beginning of the first incident on raw meal filter fan (June
2007).

EQUIPMENT MAINTENANCE ACTIVITY JUN 2007 OCT 2008 APR 2009

WbI 0% 100% 100%

INSPECT & SERV
MKS 100% 100% 0%
B6P 100% 100% 0%
TRANSFORMER
OIL ANALYSIS DGA 0% 100% 60%
FUR 0% 100% 60%
THERMOGRAPHY 0% 100% 100%
WbI 0% 0% 0%
INSPECTION
VFD MKS 100% 100% 80%
SERVICING ABB Rev. 100% 100% 100%
WbI 0% 100% 100%
LUB 100% 100% 100%
INSPECTION
GRD TEST 0% 0% 0%
MOTOR MKS 100% 100% 100%
EMD 0% 0% 100%
Sample 100% 100% 100%
VA
Online 0% 0% 100%
WbI 0% 100% 100%
MKS 100% 100% 40%
INSPEC & WEAR by UT 0% 0% 40%
SERVICING LUB 100% 100% 100%
FAN
ALIGN 0% 0% 0%
SHAFT 60% 40% 0%
Sample 100% 100% 100%
VA
Online 0% 0% 100%

21
The preventive maintenance activities Lubrication (LUB), revisions during the Major Kiln
Shutdown (MKS), VFD revision by suppliers (ABB rev), and a basic level of vibration
analysis (VA) are very well implemented on A fans since time ago.

The most relevant improvements on PM since SEP´07 to OCT´08, Walk by Inspection

(WbI) and Trafo Oil Analysis occurred mainly due to theses events:
 Preventive maintenance improvement and standardization project at HCE from
FEB´07 to DEC´08.
 Problems on raw meal filter fan.

The improvements on “A” fans since OCT´08 to ABR´09: Thermography, EMD, VA

online and wear control on rotor fans by UT have been leaded by the combined effort of
PEMMP HCE and with the action plan of this project.

Due to our strong cost reduction program plant that we are applying since 4thQ 2008,
there is a priority criteria for the costs of the plant, moreover this priority is affecting to
preventive maintenance and the activities are going to be made between two major kiln
shutdown planned by 2009. The most critical on FEB´09 and others on SEP´09. The
impact on this project is as follow.

EQUIPMENT MAINTENANCE ACTIVITY APR 2009 DIC 2009

INSPECT & SERV MKS 100% 100%

B6P 0% 100%
TRANSFORMER
OIL ANALYSIS DGA 60% 100%
FUR 60% 100%
WbI 0% 100%
INSPECTION
VFD MKS 80% 100%
SERVICING ABB Rev. 100% 100%
GRD TEST 0% 100%
MOTOR INSPECTION
MKS 100% 100%
MKS 40% 100%
INSPEC & WEAR by UT 40% 100%
FAN
SERVICING ALIGN 0% 100%
SHAFT 0% 100%

The needed investment since SEP´07 to implement all activities of preventive

maintenance on these “A" fans selected can be divided into three main blocs:
 E: new equipment bought to do the inspections.
 S: new third party services contracted to do the inspections.
 P: new personnel contracted to do Walk by Inspections mainly.

The next table shows the investment distribution defined on this Project:

22
 EQUIPMENT MAINTENANCE ACTIVITY SEP 2007 OCT 2008 DIC 2009

INSPECT & SERV WbI P: 1 Op.

B6P S: 0€ S: 0 € S: 0 €
TRANSFORMER OIL ANALYSIS DGA S: 750 € S: 750 €
FUR S: 750 € S: 750 €
THERMOGRAPHY E: 3.500 €
INSPECTION WbI P: 1 Op.
VFD
SERVICING ABB Rev. S: 5.000 € S: 5.000 € S: 5.000 €
WbI P: 1 Op.
INSPECTION GRD TEST
MOTOR MKS
EMD S: 3.000 €
VA Online E: 50.000 €
WbI P: 1 Op.
INSPEC &
WEAR by UT E: 600 €
FAN SERVICING
SHAFT S: 900 € S: 600 € S: 1.500 €
VA Online E: 50.000 €

Notes: only one person has been contracted to do WbI and the investment on the online
system for vibration analysis on A fans is 50.000 € (fan and motor).

On next graphic is possible to appreciate a clear reduction of PM01 due to the

implementation of new PM02 on “A” fans. The main impact for the project is due to trafo
oil analysis and thermography.
PM01 & PM02 ON "A" FANS FROM JUN´07 TO APR´09

450 140

400
120
350
100
300

250 80
HOURS

Nº WO

200 60

150
40
100
20
50

0 0
PM01 PM02 PM01 PM02 PM02
2007 2008 2009

HOURS WO

23
 PM01 ON "A" FANS FROM JUN´07 TO APR´09

300 8

7
250

200
5
HOURS

Nº WO
150 4

3
100

50
1

0 0
2007 2007 2007 2008 2008
GA.361-VE1 GA.421-VE1 GA.441-AP1 GA.441-VE1

Suma de Trabajo Cuenta de Orden

9. CONCLUSIONS & RECOMMENDATIONS

The lesson learned that we’ve got with this project is to implement preventive
maintenance routines quickly and efficiently is necessary to take into account the
following aspects:
 The development of ITOPs is essential to ensure the quality of inspections,
specifying all necessary elements that there be no mistake. It also becomes a
reference document for training workers in the inspection, therefore have great
value adding photos, diagrams, etc.. on them.
 The result of an inspection should be reflected quantitatively in a report, since it
is essentially a further analysis of the results not only on an individual basis,
because sometimes you need to have the whole number of inspections to make
decisions.
 Having monitored the results of inspections graphically over time is very easy to
observe changes in equipment and anticipate potential problems.

While performing this job, we appreciate the useful techniques that are preventive
maintenance, not only for better knowledge of our equipments but we have helped to
avoid potential failures of equipment as in the case of the exhaust gases fan motor, by
EMD we detected a potential failure on the rotor, the next step is monitoring the motor
by VA to control the evolution of the rotor until next kiln shutdown, where after doing a
revision we will make a decision.

A good recommendation is to expand these PMR to similar equipment that we have in

plant.

24
The obtained feedback from operators, subcontractors, courses, books, .. will be very
useful for the continuous improvement of ITOPs, Checklist, trend graphs, ... since the
development of preventive maintenance is closely related to the evolution of its tools.

25
10. ANNEXES

10.1 Annex 1: Revision of PMRs

LEGEND:

PMR recommended by HGRS and HCE

PMR recommended only by HCE
 PMR included in the Plant Maintenance Plan
x PMR not included in the Plant Maintenance Plan
N. A. Non Applicable

26
TRANSFORMER

GA.361-VE1

GA.421-VE1

GA.441-VE1

GA.471-VE8

GA.561-VE4
# operación tiempo oficio Frec estado del comments
estimado sem equipo

1 limpieza general tanto del transformador como de la sala 15,8 eléctrico 48 parada     
donde está ubicado
2 comprobar funcionamiento de las alarmas y disparos del      THIRD PARTY SERVICE, NO REPORT?
transformador
3 comprobar parámetros del relé de protección del      THIRD PARTY SERVICE, NO REPORT?
transformador con listado existente de dichos parámetros
4 verificar que los avisos de fallo salen en la sala de control     
5 verificar medidas analógicas de potencia e intensidad del     
transformador
6 comprobar el estado de apriete de las bornas     

7.1 inspecciona el correcto funcionamiento del sistema de 1 4 en marcha     

refrigeración por aire forzado
7.2 inspecciona el excesivo calentamiento del transformador.     
Mide la temperatura, graba y realiza tendencias
7.3 comprueba el nivel de aceite de las mirillas N.A.    N.A.
7.4 controla el nivel de silicagel en el deshumidificador     
7.5 comprueba las juntas, fugas de líquido y capa de pintura     
7.6 comprueba el alumbrado de la celda     
7.7 realiza termografías (detección de puntos calientes por fallos      SI HAY INFORME DE REGISTRO
de conexión o sobrecargas) eléctrico

VFD

27
 GA.361-VE1

GA.421-VE1

GA.441-VE1

GA.471-VE8

GA.561-VE4
# operación tiempo oficio Frec estado del comments
estimad sem equipo
o

Variador 1 Electrico anual parada

1 limpieza de tarjetas y tiristores     
2 comprueba apriete de bornas de conexiones     
3 comprobación de condensadores y fugas en tiristores (ABB)     

4 comprobación calidad de voltaje de alimentación (ABB)     

5 inspección estado de los contactores (ABB)     
6 Sustitución ventiladores de refrigeración 0,5 3 parada      based on supplayer recommendation
años
Electrico

MOTOR

28
 GA.361-VE1

GA.421-VE1

GA.441-VE1

GA.471-VE8

GA.561-VE4
comments
tiempo
Frec estado del
# operación estimad oficio
sem equipo
o

Motor 2 Electr/inpec 2 parada

1.1 Comprobar conexiones cajas de bornes del estator y     
estanqueidades.
2.1 Testea el convertidor de señal intensidades y potencias 0,3 instrument 48 parada
2.2 di tel ajuste
Testea t tdel
d RTDi l o el
ió termopar mediante una instrument      CALIBRATION REPORT
simulación
3 Testea los bloqueos de seguridad mediante simulación 0,3 instrument 24 parada     
4 Chequea el estado de los RTD o termopares: daños en 0,3 instrument 48 parada     
cables, conductos y conexiones
5 Comprueba el apriete de los tornillos y tuercas y estado de la 0,3 mecánico 8 parada x x x x x
cimentación
6.1 Comprueba la correcta puesta a tierra del equipo eléctrico 48 parada x x x x x NO ITOP, NO TREND DATA, NO REPORT
6.2 Mide la resistencia a tierra del motor (Rotor y Estator). Graba x x x x x NO ITOP, NO TREND DATA, NO REPORT
valores y realiza tendencias 1
7.1 Limpieza de aletas de refrigeración 1 eléctrico 48 parada     
7.2 Revisión de la regulacion del termico o protección eléctrico     
7.3 Revisar conexiones interruptor de campo eléctrico     
7.6 Comprueba cables , tubos o conexiones dañadas eléctrico     
7.8 Revisar conexiones CCM mecanico     
electrico
8 Giro de 1/3 motor para motores de mas de 500 KW, situados almacen 48 parada N.A. N.A. N.A. N.A. N.A.
1
en almacen.
9 Enviar motor a taller especializado para su limpieza y eléctrico 240 parada      EMD TECHNIQUE LAUNCHED TO REDUCE
regeneracion a los motores de mas de 75 KV con 750 a 1500 THIS RUTINE
rpm x

29
 Motor 2 Electr/inpec 2 en marcha
10.1 Comprueba ruido anormal     
10.2 Comprueba que las protecciones están en su lugar y     
correctamente ancladas
10.3 Comprueba el estado de los tornillos y tuercas y el estado de     
la cimentación
10.4 Comprueba limpieza y refrigeracion aletas.     
10.5 comprueba la temperatura y el nivel de vibración/ruido de los      NO TREND DATA
rodamientos con la mano
10.6 Verifica la limpieza del filtro de entrada de aire. Comprueba la     
lectura del manómetro de presión diferencial (si es aplicable)

10.7 Comprueba que no existen obstrucciones en la entrada de     

aire
10.8 Revisar PT100 control tempertaturas.     
11 Tomar vibraciones con medidor y monitoreo en continuo 0,5 12 en marcha      VIBRATION COLLECTING DATA ONLINE IN
(verificar estado de rodamientos) Electr/inpec LAUNCH
12 Lleva a cabo la toma instantanea de termografía de monitoreo 0,5 12 en marcha     
Electr/inpec
13 Lubrica los rodamientos del motor con la cantidad y tipo de 0,3 engrasador as req en marcha     
grasa prescrita (Según plan)
14.1 Comprueba la calibración de los sensores de vibración 0,3 4 en marcha N.A. N.A. N.A. N.A. N.A.
permanentemente instalados, si es aplicable Electr/inpec
14.2 Inspecciona la holgura del RTD o la conexión de cableado del 4 en marcha     
termopar, si existe Electr/inpec

FAN

30
 GA.361-VE1

GA.421-VE1

GA.441-VE1

GA.471-VE8

GA.561-VE4
comments

tiempo Frec estado del

# operación oficio
estimado sem equipo

1 testea la toma tierra del equipo 0,3 instrument 48 parado y en X X X X X

marcha
2.1 testea la correcta rotación del ventilador después de reparar o 1 instrument 48 parado     
reemplazo de la fuerza motriz
2.2 testea la señal del integrador mediante un test de simulación instrument X X X X X ¿?

2.3 comprueba la calibración del sensor de vibración instrument N.A. N.A. X N.A. N.A.

31
2.4 limpia los caudalímetros con aire a presión en sentido instrument      PRODUCCION
contrario
2.5 testea el RTD o la resistencia del termopar instrument      CALIBRATION REPORT
2.6 inspecciona holguras de las conexiones del RTD o del instrument     
termopar
3.1 lubrica el rodamiento (evita la lubricación incorrecta) 48 parado     
3.2 verifica el estado de los rodamientos y elementos de      EVERY MAYOR SHUTDOWN
transmisión 0,5
4 comprueba la alineación. Comprueba el eje de la unidad a la mecánico 48 parado X X X X X NO REPORT, NO ITOP. ONLY FOR
unidad de accionamiento buscando desalineación REPLACEMENT OR CONDITION
MONITORING WARNING PARAMETERS
0,5 (AV)
5.1 inspecciona el excesivo desgaste de la carcasa del ventilador mecánico 48 parado      NO REPORT, NO ITOP

5.2 inspecciona el excesivo desgaste de la junta del eje del mecánico     

ventilador
5.3 inspecciona el excesivo desgaste de los tornillos de la puerta mecánico     
de inspección del ventilador
5.4 inspecciona el excesivo desgaste de la junta de la puerta de mecánico     
inspección del ventilador
5.5 comprueba el excesivo desgaste de la puerta de inspección mecánico     
del ventilador 1,5
testa el correcto funcionamiento del regulador de presión de mecánico N.A. N.A. N.A. N.A. N.A.
6.1 aire 48 parado
inspecciona el excesivo desgaste de los álabes del ventilador mecánico      NO UT THICKNESS, NO REPORT
6.2
inspecciona el excesivo desgaste de las soldaduras de los mecánico      NO REPORT
6.3 álabes del ventilador
inspecciona el excesivo desgaste de los tornillos de los mecánico     
6.4 álabes del ventilador
inspecciona el excesivo desgaste de las placas finales del mecánico      NO REPORT
6.5 rotor del ventilador (pegaduras)
inspecciona el excesivo desgaste por abrasión de las placas mecánico     
6.6 finales del rotor del ventilador
inspecciona el excesivo desgaste de los tornillos del mecánico      NO REPORT
6.7 ventilador
inspecciona el excesivo desgaste fijaciones de la turbina mecánico      NO REPORT
6.8 (cubo)
inspecciona el excesivo desgaste por abrasión del/los oído/s mecánico      NO REPORT
6.9 de aspiración del ventilador 1,5

32
7.1 comprueba que todas las protecciones y tapas se encuentran 1 1 en marcha     
correctamente anclados
7.2 presta atención a cualquier ruido anormal o vibración     
7.3 comprueba si todos los tornillos están en su lugar     
7.4 mide la temperatura de las carcasas de los rodamientos.      TIS DATABASE
Graba y mide tendencia
7.5 inspecciona los derrames de las juntas de las carcasas     
7.6 reporta y limpia cualquier acumulación de material     
7.7 inspecciona el estado del soporte de rodamiento buscando     
acumulaciones de material
7.8 inspecciona las juntas de los soportes de rodamientos     
7.9 inspecciona la excesiva temperatura del rodamiento (eje)     
7.10 inspecciona el correcto ajuste del regulador de presión de aire N.A. N.A. N.A. N.A. N.A.
mecánico
8 lleva a cabo vibraciones y monitoreado del estado del 0,5 Inspec 4 en marcha      VIBRATION COLLECTING DATA ONLINE
rodamiento en el motor y el ventilador IN LAUNCH
9 lubrica los rodamientos del ventilador con la cantidad y tipo de engrasador en marcha     
grasa especificada
10.1 Comprueba la calibración de los sensores de vibración 0,3 4 en marcha N.A. N.A. N.A. N.A. N.A.
permanentemente instalados, si es aplicable
10.2 Inspecciona la holgura del RTD o la conexión de cableado del     
termopar, si existe instrument

33
10.2 Annex 2: SOLVE CASE

34/44
Company:HOLCIM SPAIN SA Location:GADOR Date of report: 10/02/2008
rd
Participants: attendants to the 3 PEMMP HCE Responsible: BFS

Problem (deviation) definition

What:

Where:

When:
First problem: 18-june-2007 trafo and VFD burnout.

Second problem: 08-september-2007 Trafo burnout because the transformer that we

used to repair the first problem was a used equipment and we didn´t check its
conditions before put on place. Besides, there was not any maintenance plan for
critical spare parts on the system at that time.

How much:
Burnout Equipment: 2 trafos and 1 VFD (wire included).
Clinker production lost: 5 days x 2320 Tn/d = 11600 Tn of Ck.

35/44
Major root causes of the problem

TRAFO: Overcurrent
Manufacturing failure
Low voltage
VFD: SC incoming contact

Overload
TRAFO: arcing
Reduced
TRAFO: Failure Short circuit Lifetime

TRAFO: Low

Failure on POWER DIST: Accelerated

Raw Meal Low capacity trafo paper
filter Fan degradation
TRAFO: SC on 2º

VFD: overload Overvoltage

SWICHGEAR:

TRAFO: Lifetime

Motor

Solutions chosen

SOLUCIONES Imp €

Aceite trafo: prueba básica + gases disueltos anual

Análisis de aceite en trafos de repuesto para asegurar

Sellar vaso expansión en trafos de repuesto para evitar

Realizar prueba de furanos antes de filtrar el aceite para

Instalar interruptor automático de corte en la entrada del

36/44
Implementation of solutions
Solution Action Resp Due Status Comments
date
1 TRAFO OIL ANALYSIS: basics 6 parts test PM & W Closed FREQ: yearly
+ DAG + FAN. A preventive maintenance EM 11/2008
plan has been created for all trafos
(included spare parts)
2 TRAFOS in the Warehouse: OIL PM & W Closed
ANALYSIS to know the condition and seal EM 20/2008
the xxx to prevent them from the moisture.
3 Thermography: A preventive maintenance EM Dec´08 Closed
plan has been created to do thermography
on transformers, MV switchgear and sub
stations
4 Install a Switchgear to protect the VFD EM Dec´08 Closed

Results achieved (cost and benefits)

 The Old trafos that we have in the warehouse for spare part have been analyzed and after
receiving their results, corrective actions have been defined to overhaul them.
 A thermographycal camera has been bought and since we are using it, potential failures have
been detected on electrical components.
 All trafos have been monitored and corrective actions have been taken to prevent similar
failures from the past.

37/44
10.3 Annex 3: potential problem of broken rotor bar detected by EMD

38/44
 Holcim-España,S.A.
Fábrica de GADOR
Departamento de Mantenimiento (Baltasar Fajardo Serrano)

A. EQUIPMENT:
GA.441-VE1.M1 MOTOR OF DOPOL EXHAUST GASES FAN

B. SYMPTOMS

Last April 28th was carried out a planned preventative maintenance routine for next
motors:

EMD routine was done to know the condition of the motors. Due to the plant was
running, only the dynamic test was run, so the analyzed parameters of the motor were:

 Stator.
 Rotor.
 Power cicuit.
 Power source.

Tensión

Corriente

39/44
The next table and chart, shows the results for this motor: according with current
waveform analysis, there is a red level of alarm on the rotor component due to
broken rotor bars problem.

40/44
C. ACTION PLAN:

CONFIRM THE PROBLEM BY VIBRATION ANALYSIS :

This problem on the rotor bar generates an electrical unbalance detectable by high
level of vibration at 1x vibration component, and at 2x and 3x harmonic frequencies:

Other way to confirm the broken rotor bar problem is to find sidebands of 2Fpp (pole
passing frequency) at 1x, 2x, 3x, as shows next drawing.

41/44
42/44
MONITOR THE PROBLEM BY VIBRATION ANALYSIS

Nº Polos 6
Espectro 0 a 400 HZ
Resolución 6400 líneas
mm/s RMS
condición min max
bueno 1,8
tolerable 1,8 4,5
excesivo 4,5 11,2
extremo 11,2 45,0

stma
FECHA Vel. Fg Vent Fg Fd 2Fp Fg mm/s 2Fp
Sinc (Hz) (Hz) (Hz) (Hz) (Hz)
30-abr 749 744 12,40 0,08 1,00 12,54 0,31 1,50 RESOLUCION: 1600 LINEAS
05-may 718 712 11,87 0,10 1,20 11,94 0,72 1,87
07-may 749 744 12,40 0,08 1,00 12,44 0,81 1,31
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00
0,00 0,00 0,00

FECHA ARMÓNICOS (RMS) BANDAS LATERALES DE 2Fp? Si ó NO

2x mm/s 3x mm/s 4x mm/s 5x mm/s 2x mm/s 3x mm/s 4x mm/s 5x mm/s
30-abr 24,80 0,08 37,20 0,09 49,60 0,35 62,00 0,03 N N S 0,11 N
05-may 23,73 0,01 35,60 0,03 47,47 0,65 59,33 0,08 N S 0,02 S 0,03 S 0,02
07-may 24,80 0,06 37,20 0,13 49,60 0,53 62,00 0,26 N N S 0,1 S 0,02
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00

TENDENCIA DE LOS ARMONICOS DE Fg

0,70

0,60

0,50
mm/s RMS

0,40

0,30

0,20

0,10

0,00
09

09

09

09

09

09

09

09
4/

5/

5/

5/

5/

5/

5/

5/

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 DEFINE ALARM LEVELS FOR CONDITION MONITORING

As ISO STANDARD 2372 specifies the RMS vibration velocity for this type of motor:

mm/s RMS
condición
min max
bueno 1,8
tolerable 1,8 4,5
excesivo 4,5 11,2
extremo 11,2 45,0

CHECKING THE CONDITION OF THE ROTOR

If not exceed the yellow alarm level before, next kiln shutdown planned by September,
the rotor of the motor will be checked to find broken bars.
An important failure mode of large electric motors is the cracking and subsequent
heating and breaking of the rotor bars, especially in motors that experience frequent
starts under load. The starting condition places the heaviest stress on the rotor bars
because they are carrying the highest current since the rotor is running at much lower
than synchronous speed. The high currents cause heating and expansion of the bars
relative to the rotor itself, and differences in the electrical resistance of the individual bars
result in uneven heating and uneven expansion. This leads to cracking of the joints
where the bars are welded to the shorting ring. As soon as a crack develops, the
resistance of that bar increases, increasing its heating, and consequently worsening the
crack. At the same time, the adjacent rotor bars experience increased currents because
of the reduced current in the broken bar.

D. FINAL CONCLUSIONS

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