Everything you need to maintain your plant

Transcription

1 Everything you need to maintain your plant Services for cement plant maintenance

2 2 Smart maintenance is smart management FLSmidth can help with everything from overcoming daily challenges to strategic planning for a more profitable future As the entire cement industry strives to accomplish more with fewer resources, plant maintenance presents growing technical and management challenges. At FLSmidth, our entire portfolio of support services is dedicated to helping maintenance managers keep availability to an absolute maximum while meeting increasingly tough cost and performance targets. We can help you achieve the high kiln availability your plant needs to be competitive and profitable by helping you identify, prioritise and correct problems before they become a threat to production. The cornerstone of an effective maintenance programme is extensive planning for year-round maintenance and service operations. Our support services can help you realise your

3 3 One source, many capabilities Spare parts Mechanical equipment services Electrical equipment services Troubleshooting Maintenance courses and seminars maintenance strategy by providing expert assistance every step of the way. We have unsurpassed technical insight into the equipment and processes that you can access through audits, inspections and benchmarking. We can also help you become more self-reliant by providing everything from an efficient supply of necessary spare parts to advanced training programmes. Ultimately our aim is to help you achieve your maintenance goals through predicting problems and minimising breakdowns, rather than merely reacting to them. demand for operational reliability within the limitations of realistic budgets. For instance, we can help define your critical spare parts list to ensure fast access to items subject to unpredictable demand. We can also help you identify and spread capital costs so these can be taken into account upfront to avoid nasty financial surprises during the year. All this helps you structure workflow more efficiently and links your maintenance programme more closely with plant purchasing and procurement functions. Planning and budgeting Increased plant availability often hinges on better planning of both regular maintenance and capital budgets. We have the planning expertise to help you balance the growing

4 4 Fix it before it breaks We realise that maintenance staff is under enormous pressure to constantly balance high performance with low cost targets. By investing a little in maintenance service assistance you can avoid a whole variety of far more significant costs due to equipment failure or degradation. Our services are concentrated in the areas of conditionbased and failure maintenance to ensure that you get the most out of planned shut-downs. Preventative maintenance By making the most of preventative maintenance, maintenance managers can hugely reduce the chances of costly unplanned stoppages. FLSmidth can help you maximise planned shutdowns through our extensive condition-based and failure analysis services. Armed with crucial information on the condition of equipment and the reasons for underperformance or even failure, you can better plan and efficiently execute planned stoppages yourself. Predictive maintenance Even in a period of strict cost controls, investing in the upkeep of key equipment is clearly justified. One of the most effective ways to increase availability and reduce total maintenance costs is to invest in predictive, or conditionbased, maintenance that identifies potential problems before they occur. Advanced detection techniques, such as vibration monitoring and analysis, thermographic inspection, ultrasonic testing and others give you a means to accurately determine the condition of equipment.

5 5 FLSmidth s support services are geared towards helping you implement the optimum mix of preventative, predictive and failure maintenance. Not only can we assist you in measuring vital data, but also in analysing the results and providing expert advice about the best course of action. This allows you to foresee repairs, identify the root cause of potential threats and fix equipment before it breaks. Moreover, based on long years of experience, our consultants are able to make subjective evaluations for example, by listening for unusual sounds and visually inspecting components that can provide invaluable warning of potential problems. Troubleshooting and failure analysis Even the best planning in the world is not fail-safe. When unplanned problems occur, as they invariably will, you can trust FLSmidth to respond with the urgency these situations demand. Our technicians can help you accomplish even the most complex repairs in the shortest amount of time to keep your operation up and running. Crucially, we don t just treat the symptoms but get to the bottom of problems and always provide a Root Cause Failure Analysis. This way we re able to turn an emergency situation today into a preventable situation tomorrow. In our experience it s rarely major components, such as the kiln or cooler, that fail. Production problems can stem from a wide range of other essential plant equipment. There are, for example, km of cable in a typical plant, and failure in any one piece in a sequence of electrical equipment can shut down production. Our service consultants are only too aware of this and have decades of experience in diagnosing problems quickly and accurately. We can help you quickly identify and repair malfunctioning equipment, always with a view to minimising future occurrences.

6 6 One source for cement producers With FLSmidth you enjoy outstanding products and services but also benefit from the synergies among our many areas of expertise. Well more than a century of experience in cement plants and technology has taught us that everything in a plant is interlinked, and that problems in one area often affect another. That s why, for example, we understand that an equipment audit may affect spare parts contingency planning and also reveal a need for improved staff training. With FLSmidth you can get it all under one roof, specified to your needs. By using us for specific services, you can also raise your own capabilities through picking up fresh insights and gaining hands-on experience. We constantly compare notes and results to improve our own performance, and we use lessons learned along the way to refine our service offering. All with the aim of helping you ensure the availability of your production lines.

7 7 Spare parts Our original drawings, documentation and long experience in the manufacture and specification of quality spare parts can help ensure optimum spare part management even when it comes to spare parts for older legacy control systems. We have an exacting process to review your specific equipment needs and to verify that the spare parts we provide match your requirements. Additionally, as a one-source supplier we can purchase all your necessary OEM and third-party items. Mechanical equipment services FLSmidth offers a wide range of mechanical inspection programmes like kiln, ball mill, vertical roller mill, grate cooler, gear, auxiliary and material handling equipment audits. In addition we offer predictive maintenance services like ultrasonic crack detection and vibration monitoring. Mechanical equipment services are not only an essential part of an effective maintenance programme, they can provide your team with valuable on-the-job training and equipment insight. Electrical equipment services Inspection of process control equipment and instrumentation comprises a thorough inspection of transducers, measuring equipment, gas analysers, controllers, recorders and other instrumentation. We also provide inspection of various other electrical installations. Electrical equipment services are an essential part of our overall maintenance programme. Troubleshooting Service consultants assist in troubleshooting of cement plant production equipment, including electrical or control equipment problems. Urgent troubleshooting can usually be done at short notice. We always provide a root cause analysis and often propose new ideas or technologies to prevent reoccurrences. Courses and seminars As skilled employees become harder and harder to find, staff training takes on new importance. We set high standards for quality and competence by providing a wide range of training and seminars through FLSmidth s Institute. Our training staff has experience gained in more than 500 plants they know the equipment, where and why typical problems occur and how to solve them. This range of experience makes our staff particularly skilled at recommending courses that are relevant to your specific needs.

8 Project Centre Denmark FLSmidth A/S Vigerslev Allé 77 DK-2500 Valby Copenhagen Tel: Fax: Project Centre USA FLSmidth Inc Avenue C Bethlehem, PA Tel: Fax: info-us@flsmidth.com Project Centre India FLSmidth Private Limited FLSmidth House 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai, Chennai) Tamil Nadu Tel: Fax: indiainfo@flsmidth.com Copyright 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. C ENG