Your reliable partner for smarter maintenance Monthly tips for 2013 We hope youll find this years

calendar useful for more than tracking days and dates. Each month features a major component in FLSmidths industry-leading range of cement plant equipment. Weve also included operating and maintenance advice from experienced FLSmidth specialists and key maintenance tips to ensure reliable performance for each piece of equipment. For more in-depth information, such as brochures and videos, just scan the QR code at the bottom of every page or visit us at www.flsmidth.com. Throughout 2013, well be there for you every day of the year whenever you need a reliable partner for leading cement plant technology and expertise. Sincerely, Per Mejnert Kristensen Group Executive Vice President of Cement FLSmidth

Calendar 2013
February January March
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April

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November

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December

October

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EV hammer impact crusher

Always keep the necessary tools, such as spanners, hydraulic nuts and extraction device safely stored within the department. Proper tools are the key to successful operation.

12+ years of experience with crushers and feeders

n, e s n e r S Henrik uct Manager Prod

JANUARY 2013
Week mon tue wed thu fri sat sun

1 2 3 4 5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

The EV hammer impact crusher is a cost-effective solution for processing abrasive and moderately sticky materials. It reduces quarry size limestone boulders to mill feed in only one stage, achieving reduction ratios of up to 1:100. More than 100 EV hammer impact crushers installed worldwide. Maintenance tips for reliable performance Adjust breaker plates and grates according to wear on a regular basis to avoid excessive power consumption and decreased capacity Replace wear parts such as disks, grates and hammers with original spare parts Turn the hammers when they are 2/3 worn down to reverse the leading and tracing edges Lubricate both sealing and bearings on a regular basis, not only during the yearly maintenance stop

www.flsmidth.com

Scan here to read the EV hammer impact crusher brochure

Stacker and reclaimer

Sticky, abrasive and/or frozen raw materials can damage equipment and slow down production. Inspection of transfer points and adjustment of belt cleaners are small maintenance tasks that can have a huge impact on equipment availability.
19+ years of experience with stackers and reclaimers

, n e s r a L Kasper uct Manager Prod

FEBRUARY 2013
Week mon tue wed thu fri sat sun

5 6 7 8 9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

The circular store has a round base with a ring-shaped pile, continuously being stacked at one end and reclaimed at the other. Matching kiln throughputs of up to 13,000 tpd., the circular blending system is based on well-proven tech nology that provides a high, continuous homogenising effect and fully automatic, continuous operation. More than 650 stackers and reclaimers running globally. Maintenance tips for reliable performance When tightening the stacker belt, move the snub pulley proportionally to avoid the risk of belt slip Perform visual inspection of scraper chain and guide rollers and check if bearings need to be changed Tighten the roller chain for the rake car and make sure the guide rollers are adjusted correctly to ensure smooth rake car operation

www.flsmidth.com

Scan here to read the stacker and reclaimer brochure

ATOX mill
It takes more effort to maintain a mill today than earlier since the material used for grinding is far more abrasive and causes faster wear. This requires more focus on maintenance

30+ years of experience with ATOX raw and coal mills

g, r e b s l o F r e g Jan a n a M Product

march 2013
Week mon tue wed thu fri sat sun

1 2 3 4 5 6 7 8 9 10

The ATOX raw mill saves space and energy and has been proven to deliver reliable operation for crushing and grinding all types of raw materials, coal and pet coke. Its highperfor mance separator and optimised airflow ensure high separation efficiency and low pressure loss for energy savings. More than 460 ATOX raw mills running successfully around the world. Maintenance tips for reliable performance Perform regular visual control of separator and wear parts for the rollers Pay attention to changes in vibration level, temperature, noise level and oil pressure Have vital spare parts in stock to ensure availability of your mill Check hydraulic and lubrication systems

10 11

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

12 13

www.flsmidth.com

Scan here to see the ATOX Mill ANIMATION

Fabric filter
Keep register of measurements of emission levels and differential pressure on a weekly basis to ensure a quick response to any changes. Even a minor change can develop into a costly repair job if not dealt with in time. tensen,
15+ years of experience in filter installation and commissioning

r e e s n i i r g K n E r e g n Pet i n o i s s i Comm

april 2013
Week mon tue wed thu fri sat sun

14 15 16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

FLSmidths fabric filters offer long bag life and cost-effective operation that can deliver emissions below 2.5 mg/Nm3. The filters are available in standard designs as well as highly customised solutions both options provide the highest particulate removal efficiency at the lowest total cost of ownership. More than 4,000 fabric filters installed worldwide. Maintenance tips for reliable performance Perform weekly damper jogging to minimise the risk of mechanical and/or electrical problems with air dampers Ventilate the filter with fresh air to avoid condensation and corrosion risk before annual shutdown Activate cleaning cycle three times before shutdown to avoid increased p when starting up again after an annual kiln shutdown Make a visual inspection of the filter if error messages are received

www.flsmidth.com

Scan here to read the Air Pollution Control brochure

CF silo
Malfunction of the extraction function is usually caused by lack of maintenance of the outlet valve liners or of the air-supply , n e s r system for the silo bottom. a L Lund

Henrik uct Manager Prod

10+ years of experience with CF silo inspections and troubleshooting

May 2013
Week mon tue wed thu fri sat sun

18 19

1 2 3 4 5

The CF (Controlled Flow) silo is a continuously operating system for homogenisation and storage of cement raw meal. Material is extracted simultaneously at different flow rates from a number of outlets in the silo bottom. The CF system, including suitable kiln feed equipment, ensures stable kiln feed composition at minimum power consumption and investment cost. More than 200 CF silos up and running globally. Maintenance tips for reliable performance Check air supply for silo bottom aeration Inspect the air slides on a monthly basis for free material flow when the corresponding valve is open Verify silo roof and related components for damages, as moisture and water leakage can cause lump formations

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www.flsmidth.com

Scan here to read the CF silo brochure

DUOFLEX burner
When changing kiln production and fuel input, the primary air flow must be changed too, in order to keep the momentum constant. Kiln burner momentum is essential for stable kiln operation. n,
17+ years of experience with burners

e s r p e e e J n i g k i n E Er t c u d o r P f e Chi

June 2013
Week mon tue wed thu fri sat sun

22 23

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

The DUOFLEX burner fires rotary kilns with oil, natural gas, pulverized fuels like coal and pet coke or any mixture of these fuels, including solid and liquid alternative fuels. Stable dosing of pulverized fuels is possible with a rotor weighfeeder Pfister DRW with a dosing capacity from a few 100 kg/h up to 50 t/h. More than 450 DUOFLEX burner installations worldwide. Maintenance tips for reliable performance Perform regular visual monitoring of burner pipe refractory condition, flame shape and leaks in fuel and air piping Pay attention to changes in vibration level of the primary air fan. Repair or clean if vibration level is too high Have vital spare parts in stock and keep one spare burner pipe, including refractory, ready for fast replacement For safety and health, keep the burner installation clean and tidy

24 25 26

17 18 19 20 21 22 23

24 25 26 27 28 29 30

www.flsmidth.com

Scan here to read the DUOFLEX Burner brochure

HOTDISC
The required maintenance for the HOTDISC is minimal, however, yearly maintenance focusing on the condition of the lining and the segments will increase its overall processing capability and flexibility. sen,
9+ years of HOTDISC experience

om h T b o r k e a g J a n a M Product

July 2013
Week mon tue wed thu fri sat sun

27

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The HOTDISC ensures high substitution rates with difficult fuels and a guaranteed level of performance. It is to date the best available technology for maintaining kiln availability with alternative fuels. First HOTDISC installed in 2002 today HOTDISCs are running successfully in Canada, Brazil, Norway, Turkey, Mexico, Slovakia, Slovenia and India. Maintenance tips for reliable performance Carry out regular cleaning of excessive grease from slewing ring lubrication Perform regular visual control of the HOTDISC casing, check it for hot areas and redirect cooling air if required Keep an extra set of each segment type in spares inventory

28 29

15 16 17 18 19 20 21 22 23 24 25 26 27 28

30 31

29 30 31

www.flsmidth.com

Scan here to read the HOTDISC brochure

Rotary kiln
After a maintenance stop, we always recommend heating up the kiln for minimum 24-48 hours, as the kiln shell and live ring dont expand equally fast. We often see that heating up time is only 12 hours, which can cause permanent deformation of the kiln shell.

10+ hot kiln alignments per year

, g n e P e h ic n n M r e e n n i i g n E Xinx Service

August 2013
Week mon tue wed thu fri sat sun

31

1 2 3 4 5 6 7 8 9 10 11

With the ideal temperature profile and material retention time, the rotary kiln plays a key role in ensuring optimal quality clinker. The high availability, along with operating temperatures up to 1450C, create a high demand for maintenance. More than 1,000 kilns installed globally. Maintenance tips for reliable performance Do a daily walk-by: see, hear, feel and smell for abnormalities Pay attention to the bearing temperatures and live ring migration from the Central Control Room Perform visual inspection of the kiln seals, kiln shell and weldings Carry out regular housekeeping

32 33

12 13 14 15 16 17 18 19 20 21 22 23 24 25

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www.flsmidth.com

Scan here to see the kiln maintenance animation

FLSmidth Cross-Bar cooler

I always recommend doing a daily walk-by to check for abnormal noises, heat, dust and leakage and once a year sending an oil sample to a laboratory to ensure high quality of the hydraulic oil. se,
Troubleshoots 13-15 coolers per year

Peer Kru Engineer Service

september 2013
Week mon tue wed thu fri sat sun

35

1 2 3 4 5 6 7 8

The FLSmidth Cross-Bar cooler features a stationary grate line with no undergrate spillage or conveying system; separation of the conveying and cooling systems; air distribution plates with mechanical flow regulators; and modular construction. All cross-bars are movable and reciprocate so as to optimise transport efficiency and enable horizontal installation. Hundreds of FLSmidth Cross-Bar coolers reliably working around the world. Maintenance tips for reliable performance Check mechanical/electrical zero point adjustment of drives/pumps and length transducers once a year Inspect the temperature transmitters locally and compare the results with the readings in the Central Control Room Change cylinder sealings every second year to avoid leakages during production campaigns Change the hydraulic filters immediately in case of clogging alarm

36 37

9 10 11 12 13 14 15 16 17 18 19 20 21 22

38 39

23 24 25 26 27 28 29 30
www.flsmidth.com

40

Scan here to see the FLSmidth Cross-Bar cooler animation

OK mill & MAAG planetary gear

We always recommend checking the oil quality by taking oil samples and sending them to the oil supplier. It is often forgotten on site but is crucial for the gears overall performance.

15 to 20 gear inspections and overhauls per year

r, e n g a W r e Rog er g a n a M t Projec

october 2013
Week mon tue wed thu fri sat sun

40 41

1 2 3 4 5 6

The OK vertical roller mill combines the drying, grinding and separation processes into one unit, which simplifies plant layout. The OK mill uses 30-50% less energy than ball mill systems and operates at a low noise level. MAAG vertical planetary gears (WPU, WPV) are designed to drive and support vertical roller mills such as the OK mill. Regular maintenance supports a reliable operation for years. More than 100 OK vertical roller mills and more than 400 MAAG vertical planetary gears running worldwide. Maintenance tips for reliable performance Clean the gears oil filter regularly to detect problems at an early stage Do a daily gear walk-by and check for noise changes Check the water strainer

7 8 9 10 11 12 13 14 15 16 17 18 19 20

42 43

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44

Monitor the gear instrument and benchmark with relevant data

www.flsmidth.com

Scan here to see the OK mill animation

Scan here TO SEE THE MAAG GEAR ANIMATION

CARICAMAT automatic truck loader

Simply performing maintenance regularly and according to the manuals is the key to achieving the highest efficiency from the CARICAMAT.
5+ regular inspections per year

i, n i s e r a V i Pierluig midth Ventomatic FLS

November 2013
Week mon tue wed thu fri sat sun

44 45

1 2 3

The FLSmidth Ventomatic CARICAMAT palletises full bags directly onto truck platforms. It operates with a wide range of different trucks, and is specifically designed for reliably working in the toughest climate and working conditions. More than 450 CARICAMAT automatic truck loaders installed worldwide. Maintenance tips for reliable performance Perform regular visual inspection of the vacuum system and filter Use original spare parts to ensure reliability of the truck loader Follow the preventive maintenance indications as described in the manuals

4 5 6 7 8 9 10 11 12 13 14 15 16 17

46 47

18 19 20 21 22 23 24 25 26 27 28 29 30

48

www.flsmidth.com

Scan here to read the CARICAMAT brochure

ECS/ControlCenter
Its not enough to do a full system back-up every 4-5 years. We always recommend making a full system back-up as often as possible after major changes in order not to lose data and system set-ups.

40+ years of development and experience with control systems

ng, i l l i h c S r e g Jan a n a M Product

december 2013
Week mon tue wed thu fri sat sun

48 49

The FLSmidth ECS/ControlCenter software platform for process control solutions is designed to be an effective roundthe-clock control system and an efficient control engineering platform for greenfield, upgrade and retrofit projects. The ECS/ControlCenter has been continuously improved since the initial versions were launched in the 1970s. Today more than 700 systems running worldwide. Maintenance tips for reliable performance Be sure to keep your control system software continuously updated Keep your operative system fully updated and maintained Always keep your hardware clean and streamlined Ensure that your system has antivirus protection against external threats

2 3 4 5 6 7 8 9 10 11 12 13 14 15

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30 31
www.flsmidth.com
Scan here to read the ECS brochure