CONDITION BASED MONITORING

Transcription

1 Trusted Technology Solid Strength Kesoram Industries Ltd [Cement Division] UNIT: VASAVADATTA CEMENT, SEDAM CONDITION BASED MONITORING

2 Trusted Technology - Solid Strength

3 Trusted Technology - Solid Strength

4 Trusted Technology - Solid Strength

5 Trusted Technology - Solid Strength

6 Trusted Technology - Solid Strength Instillation of Roto Scale for Fly Ash feeding Fly Ash Feeding Roto Scale Started in Unit-3 In Jan Fly Ash Feeding Roto Scale Started on 25 th Dec 2015 at Unit-4 Cement Mill Fly Ash Feeding Roto Scale Platform and Separate Surge Bin Ready at Unit-1 & 2 Cement Mill Started on 22 nd Jan 2016

7 Hot Disc Trusted Technology - Solid Strength

8 Trusted Technology - Solid Strength Various Types of Waste used in Hot Disc Type Of AFR Source Shredded Tyre Chips Imported Tyre & Tyre Waste Imported Goa MSW Goa Plastic Waste From Sunrays Compost Bangalore FRP Waste From Suzlon Mangalore Polyfiber Gujarat Plastic Waste From Moogambigai Mangalore Agriculture Waste Local Coconut Coir Waste Mangalore Shredded Toot Stalks Mangalore Shredded Cotton Stalks In-house generated Dumper Tyre Waste In House Garage Plastic Waste From Paper Mill Dandali MSW from HIL Bangalore

9 Trusted Technology - Solid Strength Total Alternate Fuel Co-processed in Vasavadatta Cement Sedam All Figures in (MT)

10 S. No Trusted Technology Solid Strength Idle running hours optimization and Savings Area For The Year Lime Stone Loading Belts Unit -1 to 4 Coal Mill 1 to 4 and Packing Plant 1to 4. For The Year LAC UNITS / ANNUM Saving (Lac Rs) Unit -4 RABH fan running Optimized With DP Raw Coal Transportation in Power Plant Idle Running of Air Dryers in Cement Plant Idle Running of Air Dryers in CPP Receiver Mounted Compressor Optimization Total

11 S. No Trusted Technology Solid Strength Savings Area LAC UNITS / ANNUM Saving (Lac Rs) 1 Lime Stone Loading Belts Unit -1 & Lime Stone Loading Belts Unit Lime Stone Loading Belts Unit Operation of Coal mill Operation of Coal mill Operation of Coal mill Operation of Coal mill Packing Plants 1 to Total Saving

12 Trusted Technology Solid Strength CONDITION BASED MONITORING 1. Vibration monitoring. 2. Oil and grease analysis. 3. Thermography. 4. Thickness measurement. 5. Ultrasound technique

13 Trusted Technology Solid Strength VIBRATION MONITORING Vibration monitoring of Critical equipments of all four cement plants and Five power plants. So, there are total of 591 equipments/month in route and there are nearly 50 numbers of equipment we monitor off route. Vibration reading of all the equipments is collected and on the basis of vibration trend and its signature a report is generated and will be sent to the concerned department if found abnormal. In addition to the preventive maintenance systems these reports are considered during weekly or annual maintenance work. A feedback report is been taken from all the sections which contains the information like what action the maintenance people have taken to arrest the problem. The same information can be used for further analysis.

14 Trusted Technology Solid Strength VIBRATION REPORT FORMAT

15 Trusted Technology Solid Strength CBM SCHEDULES FREQ. ESS NO. DESCRIPTION MONTHLY QUARTERLY YEARLY EMM091 EMM092 EMM167 EMQ0117 EMQ131 EMY141 EMY142 EMY153 VIBRATION MONITORING MONTHLY ESS THERMOGRAPHY MONTHLY ESS POLYCOM BEARINGS GREASE SAMPLE COLLECTION MONTHLY ESS OIL SAMPLE COLLECTION QUARTERLY ESS POLYCOM GREASE SAMPLE COLLECTION END COVER OPENING QUARTERLY ESS THICKNESS MEASUREMENT YEARLY ESS KILN SHELL THICKNESS YEARLY ESS ULTRASONIC TESTING

16 Trusted Technology Solid Strength CBM INSTRUMENTS

17 Trusted Technology Solid Strength CBM INSTRUMENTS CONDITION MONITORING INSTRUMENTS DETAILS Sl.No. Instruments Name / Model Make 1 CSI 2130 Machinery health analysis Emerson Process Management 2 Thermography Instrument Ti-32 Fluke 3 4 Ultrasound flaw detector "Einstein - II TFT" with color display. Ultrasound Leak detection instrument, (CTRL UL - 101) Modsonic Perma Weld Pvt, Ltd. 5 Ultrasonic Thickness Guage (Edison - 1) Modsonic 6 Nova Strobe DBX Monarch Mechanalysis 7 Digital Tachometer Model-2241 Kusam-Meco

18 Trusted Technology Solid Strength CONDITION BASED MAITENANCE Thermography : Thermal images for Preheater cyclones, feed pipes, gas ducts, cooler hoods at frequency of 4 months. Reports sent to the concerned department for corrective action. Corrective actions like immediate installation of boxes and repair with castable and brick lining during shutdown. Unit 3 PC Duct at Hot Disc side Electrical Cable Cellar

19 Trusted Technology Solid Strength CONDITION BASED MAITENANCE Oil Analysis : - Oil and Grease samples (115 Nos.) at a frequency of Quarterly, sent for analysis to M/s Predict Hyderabad. Corrective actions like Centrifuging, oil top up, oil replacement, bearing/gearbox inspection are carried out.

20 Trusted Technology Solid Strength CONDITION BASED MAITENANCE Grease Analysis: - Grease samples (24 Nos.) at a frequency of 45 days once at Raw mill-3 & 4 and Quarterly once at Cement mill-1,2,3&4 Polycom bearings grease sent for analysis to M/s Predict technologies Hyderabad. As per grease analysis report Raw mill-3 Polycom fixed DE bearing given as Critical condition, So that we have inspected and found that bearing was in damaged condition.

21 Trusted Technology Solid Strength CONDITION BASED MAITENANCE

22 Thickness Measurement: Thickness of Kiln shells, chimneys, ducting, etc in annual Trusted Technology Solid Strength CONDITION BASED MAITENANCE

23 Trusted Technology - Solid Strength Dynamic Balancing:- CASE PLANT SECTION EQUIPMENT Case 1 VC CEMENT MILL-3 BEFORE BALANCING VIBRATION IN mm/s AFTER BALANCING VIBRATION IN mm/s BALANCING WEIGHT IN gms HR SEPARATOR FAN Case 2 KC CEMENT MILL-1 & 2 LNV HT FAN Case 3 KC CEMENT MILL-3 O-SEPA HT FAN Case - 4 VC CEMENT MILL-2 HR SEPARATOR FAN Advantages: Avoided unwanted Mill stoppages due to fan vibration tripping. Transfer of high vibrations to the floors ( fan located at 2 nd floor) Bearing life enhancement due to fan running in minimum vibrations. Oil leakages from the bearing housings. DYNAMIC BALANCING JOBS.xlsx

24 Drive Side Non Drive Side Trusted Technology - Solid Strength Ultra sound Testing: - Testing of the all cooler fans shafts, B/E head drum shafts, DPC head sprocket shafts, Kiln tyres, supporting rollers, Thruster shafts with external party in the annual shutdowns Head Sprocket Defect 1840 mm 840 mm

25 Trusted Technology Solid Strength