CEMENT RELIABILITY MAINTENANCE SEMINAR

23 – 27 September 2024  |Towneplace Suites by Marriott |  Dallas, Texas

The Cement Reliability Maintenance Seminar aims to provide participants with in-depth knowledge of a cement plant’s components and proper preventive maintenance techniques. The seminar covers various equipment such as kilns, vertical roller mills, coolers, girth gears, ball mills, and crushers. The program focuses on improving equipment availability, reliability, and maintenance cost, optimizing preventive maintenance techniques, and implementing best maintenance practices. The seminar also aims to enhance teamwork, improve maintenance quality and productivity, and keep participants updated with industry developments.

 This seminar covers the main equipment of the plant

KILNS

The kiln's shell is made of mild steel plate, as it's the only viable material for the purpose. Due to the high temperatures inside the kiln, it's important to protect the shell from overheating. Over time, the construction of rotary kiln shells has evolved. Early kilns were made from flat rolled plate, while later kilns were welded. The welded construction reduced the weight of the kilns, but made the shell less rigid. The shape of kilns has also evolved with time. Early kilns were simple cylinders, while later kilns had expanded sections in different parts of the kiln. The expanded sections were favored for various reasons, including an increase in material bed depth and an improvement in gas velocity at the back end. Rotary kilns are supported by tires and rollers, which allow them to rotate with minimal friction. The number of tires depends on the kiln's length, with longer kilns having more tires to limit sagging between supports. Kilns are turned by a girth gear and pinion system or friction drive. The gear meshes with the pinion to rotate the kiln. The turning gear is usually positioned near the middle of the kiln to minimize torsional distortion. Auxiliary drives are also provided to keep the kiln turning in case of main drive failure.

COOLERS

The seminar describes several types of clinker coolers, including: ​ 1. Planetary Coolers: These coolers consist of cooling tubes mounted around the circumference of the kiln shell. ​ They are simple in design and require no excess air, fans, or motors. They have low power consumption and are self-adjusting. 2. Rotary Coolers: These coolers are similar to another kiln and consist of a tube with its own support and drive. ​ They are equipped with ceramic lining and lifters and have special seals at the kiln outlet and cooler inlet. ​ Water injection is used to reduce the clinker temperature. ​ 3. Shaft Coolers: These coolers operate as a fluid bed to avoid agglomeration and ensure even distribution. ​ They require high power consumption, and the cooling air has to be compressed. ​ They are not commonly used in the cement industry. 4. Traveling Grate Coolers: These coolers have yet to be developed to the same high standard of operational reliability as the reciprocating grate cooler. ​ They are used mostly in connection with grate preheater kilns. ​ 5. Grate Coolers: The grate cooler is North America's most common type of clinker cooler. ​ It operates with cooling air moving cross current to the direction of the clinker movement. ​ It can produce clinker discharge temperatures around 80°C. ​ The amount of air needed varies depending on the clinker size distribution and temperature required. ​ 6. Cross-Bar™ Cooler: This newer type of clinker cooler uses wedge-shaped bars suspended above the grates to convey the clinker. ​ It has several innovative features and is claimed to be more efficient at heat recuperation than ordinary reciprocating grate coolers. ​

BALL MILLS

The mechanical components of a tube mill include the feed and discharge arrangement, mill shell, mill heads, mill bearings, mill drive, wear parts, mill inspection/spare parts, and fixation of lining parts. These components work together to ensure the efficient operation and longevity of the tube mill. Regular inspections are necessary to check for damage, and lining plates must be carefully supported and bolted to avoid bending stresses. Wear parts protect the equipment from damage and maintain maximum output at optimum operating conditions.

VERTICAL ROLLER MILLS

Vertical Roller Mills (VRMs) in the cement industry offer several benefits, including: - Lower operating costs - Improved product quality - Flexibility - Better strength development - Lower maintenance costs - Easy installation Compared to ball mills, VRMs use 50% less power when grinding the same clinker, and are more efficient in handling hot feed. The VRM design allows for adjustments to operational parameters, providing better control over the grinding process. VRMs produce cement with higher quality and better strength development, with lower maintenance costs. Their simple and compact vertical mill layout makes them cost competitive and easy to install, even in existing plants.

GIRTH GEARS

Key design considerations for gear units are material, construction, tooth ratings, joint design, mounting, lubrication, guards, noise, safety, selection, and continuous improvement. Ring gears must be designed with the most suitable materials, shape, and construction techniques for each application. Tooth ratings should comply with standards chosen by the customer. Joints must be designed for maximum strength and stability, and mounting method depends on the application. Proper lubricant selection and maintenance are crucial, as is guarding rotating shafts and couplings. High-speed gearboxes may produce harmful noise levels requiring ear defenses. Safety precautions include proper lifting and power isolation. Selection and design are critical for satisfactory machinery performance, and gear units are continuously improved.

CRUSHERS

The purpose of this topic is to provide technical information about the construction, working, and maintenance of crushers for crushing bulk materials. It aims to help improve the reliability and decrease the cost of operating crushers. The document serves as a comprehensive reference for anyone seeking information on crushers for bulk material crushing. It also provides information about different types of crushers, their construction and working principles, design considerations, lubrication requirements, materials used in crusher components, and recommendations for maintenance and troubleshooting.

Highlights

Assessment of plant situation with a focus on equipment availability, reliability, and maintenance cost.

  • Understand the equipment design and its limitations.
  • Optimize and standardize preventive maintenance techniques, improving the overall equipment efficiency and reducing the possible equipment failure.
  • Review and implementation of the best maintenance practices to achieve sustainable and stable run time with the equipment.
  • Eagerness and capacity to learn among the participants.

 

Picture1

Aims of the seminar

This course gives the participants a more in-depth knowledge of a cement plant’s components to learn the proper preventive maintenance, addressing essential cost-efficiency issues by focusing on the root cause and failure mode equipment analysis. The seminar program has been designed to outcome-based knowledge and skill covering real value parameters associated with cement plant maintenance activities, such as:

  • Availability, performance, and department cost
  • Benchmark analysis of the principal KPIs (the key performance indicators) of the cement industry (RF, MTBF, AF, MTTR, FMECA).
  • Comprehensive maintenance.
  • Attendees hands-on activities

 

 

Define accurately and continuously measure student progress and knowledge, graphing and analyzing technical and conceptual data to provide staff and organization with the tools to respond effectively to the needs of the plant and current and future demands.

Help the maintenance staff improve productivity and the workforce’s quality, anticipate and eliminate possible delays, quantify the risk, and prevent its impact through the planning, scheduling, and coordination of maintenance resources, parts, materials, and access to equipment.

 

Learning Outcomes

Continuous education and skill development

The seminar provides continuous education and helps participants develop new skills and stay updated with industry developments. This continuous learning approach ensures that maintenance staff is equipped with the latest knowledge and techniques, leading to improved maintenance quality and productivity.

Continuous education is one of the learning outcomes of the Cement Reliability Maintenance Seminar. ​ Participants in the seminar will have the opportunity to advance their techniques and acquire new skills, allowing them to stay competitive in the industry. The seminar aims to enhance teamwork, improve maintenance quality and productivity, and keep attendees updated with industry developments. ​ By gaining new knowledge and developing new skills, participants can contribute to overall plant performance improvements. ​

Advance techniques and new skills

The seminar will provide participants with advanced techniques and new skills related to cement plant maintenance, allowing them to improve maintenance quality and productivity.

The courses offer theoretical concepts, practical exercises, and case studies to enhance learning. ​ Participants can choose optional topics and engage in group work and structured discussions.

Enhance teamwork

The seminar will focus on improving teamwork among maintenance staff, enabling them to work more efficiently and effectively together.

By attending the seminar, participants will gain a more in-depth knowledge of a cement plant's components and learn proper preventive maintenance techniques. ​ This increased knowledge and skillset can contribute to better collaboration and coordination among team members, leading to enhanced teamwork. Additionally, the seminar program may include hands-on activities and opportunities for attendees to work together, further fostering teamwork.

Improve maintenance quality and productivity

Participants will learn best maintenance practices and techniques to optimize preventive maintenance, leading to improved equipment efficiency and reduced equipment failure.

The seminar program includes a review and implementation of the best maintenance practices. ​ By standardizing and optimizing preventive maintenance techniques, organizations can achieve sustainable and stable run time with their equipment. ​ This can lead to improved maintenance quality and productivity.

Best maintenance practices

The seminar reviews and implements the best maintenance practices to achieve sustainable and stable run time with the equipment. By adopting these practices, maintenance quality can be enhanced, and the risk of equipment failure can be reduced, resulting in improved productivity.

The seminar emphasizes the need to optimize and standardize preventive maintenance techniques to improve overall equipment efficiency and reduce the possibility of equipment failure. ​ Standardizing maintenance practices ensures consistency and reliability in maintenance activities. ​

Equipment design and limitations

Participants will gain knowledge about the design and limitations of different equipment in a cement plant. This understanding will help in optimizing maintenance techniques and ensuring that maintenance activities are

Cement plant equipment typically includes components such as kilns, coolers, ball mills, vertical mills, girth gears, fans, bag houses, bucket elevators, belt conveyors, dust collectors, apron feeders, blowers, and pneumatic transport systems. ​ Each component has its own design and limitations, which we will explore throughout this seminar.

PRELIMINARY PROGRAM

Introduction

  • Welcome remarks
  • Overview of agenda, objectives, and expected outcomes

Maintenance KPIs for the Cement Industry

  • The Plant’s Management Team
  • Maintenance Management
  • Performance Management

Maintenance KPIs for the Cement Industry

  • Key Performance Indicators (KPIs)
  • Key Performance Indicators exercise
  • Inventory and spare parts management
  • Cement Plant Benchmark

Rotary Kiln Maintenance

  • Safety
  • Preheater tower
  • Kiln Process Introduction
  • Kiln Maintenance Introduction – RCA & FMEA
  • Kiln Shell Specification
  • Kiln Shell Deformation
  • Measuring Kiln Shell Deformation
  • Kiln Shell Mechanical Consideration
  • Cutting & Replacement of Kiln Shell Section

Rotary Kiln Maintenance (Kiln Bearings)

  • Kiln Bearing Types
  • Bearing Liners
  • Bearing Lubrication

Rotary Kiln Maintenance (Kiln Axial Balance)

  • Kiln Support Piers
  • Kiln Support Rollers
  • Kiln Axial Balance
  • Kiln Roller Adjustment
  • Kiln Calculation

Rotary Kiln Maintenance (Kiln Tire Deformation and Ovality)

  • Tire Clearances & Tangential Tire
  • Ovality
  • Tire Mounting and Filler Bar Design
  • Correcting Ovality
  • Ovality Case Study

Rotary Kiln Maintenance (Kiln Drives and Kiln Miscellaneous)

  • The Gear and Pinion (Gear Basics)
  • Horizontal & Vertical Axis Deviation
  • Gear Installation and Alignment
  • Lubrication
  • Maintenance and Troubleshooting
  • Kiln Inlet Seal and Outlet Seal
  • Thrust Roller
  • Kiln Preventive Maintenance Checklist

Maintenance Management

  • Maintenance Management
  • What affects Maintenance
  • 12 Areas of Maintenance Management Discipline
  • Maintenance Management Strategy
  • Maintenance Policies

Ball Mill Maintenance

  • Ball Mill Mechanical Elements
  • Mill, Internal Components
  • Mill, External Components
  • Case Study

 

Ball Mill Maintenance

  • Ball Mill Repairs
  • Shell replacement
  • Ball Mill Alignment
  • Ball Mill Drive
  • Case Study – Raw Mill Gear

Understanding Equipment Failure

  • What is Reliability Centered Maintenance (RCM)?
  • The Truth About Machinery and Equipment
  • Areas of Maintenance Management Discipline
  • Typical Causes of Failures
  • Classification of Failures

Vertical Roller Mill

  • Overview
  • Grinding Table Assembly
  • Grinding Rollers
  • Rocker Arms
  • Grinding Table
  • Hydro-pneumatic Spring System
  • Grease Lubrication System
  • Water Spray Systems
  • Mill Body
  • Gearbox
  • Wear Protection

Vertical Roller Mill Hydraulics

  • Hydraulic Spring System – Basics
  • Roller Hydraulic System –Accumulators
  • Grinding Pressure
  • Hydraulic System Basic Concepts

SEPARATOR MAINTENANCE OVERVIEW

  • Separation Theory
  • Ball Mill Separators
  • Vertical Mill Separators

CHANGING THE MAINTENANCE CULTURE FROM REACTIVE TO PROACTIVE

  • Reactive Maintenance and Pro-Active Maintenance
  • Learning the Correct Paradigm
  • Manage Maintenance as a Business
  • Establishing Basic Equipment Condition

CRUSHER

  • Crusher Classification
  • Crushing Theory
  • Crushers Choice Main Criteria

CLINKER COOLERS

  • Introduction to Clinker Coolers
  • Coolers Grates
  • Control-Flow Grate Coolers
  • Fixed Inlet
  • Clinker cooler 3rd Generation
  • Hammer Crusher – Roller Crusher

FAREWELL DINNER

 

Asset Condition Management

  • Lubrication management
  • Life cycle management
  • Spare Parts Management
  • Maintenance Planning and Scheduling
  • Root cause failure analysis

Auxiliary Plant Equipment

  • Air Pollution Control Systems
  • Bucket Elevator
  • Belt Conveyor
  • Pneumatic Transport

Closing Remarks

Certificates

Cement reliability maintenance seminar

enroll now

23 – 27, Sept 2024

Dallas, Texas, USA

Learn more

THE SEMINAR WILL BE HELD AT TOWNEPLACE SUITES BY MARRIOTT DALLAS DOWNTOWN

555 Evergreen St, Dallas, TX 75201

Registration fee per participant: $2,500 USD. Taxes may apply.

The fee includes all training materials, certificate, welcome cocktail, coffee breaks, daily lunches, and farewell dinner.

Payment will be accepted via Credit Card or Purchase Order.

Note: This does not include the cost of your travel expenses, lodging, or personal expenses.

An invoice will be forwarded to you after receiving your registration for a seminar or training course.

Registration is not considered final until payment is received

  • If the participant wishes to cancel his/her participation any time before 61 days of the scheduled seminar date, the participant will
    receive a 100% refund or can decide to receive a credit note of the entire amount, valid for one year from the date it is issued and
    can be used for any future training organized by The Cement Institute, LLC.
  • If the participant wishes to cancel his/her participation any time from 31 to 60 days of the scheduled seminar date, the participant will receive a 50% refund.
  • If the participant wishes to cancel his/her participation any time from 0 to 30 days of the scheduled seminar date, the invoice amount is fully payable.

The Cement Institute reserves the right to change the content, change the dates of the training or cancel seminars and training courses if there are not enough participants to meet the objectives of the seminar or training course as well due to acts of terrorism, extreme weather condition or any event beyond the control of  The Cement Institute, LLC. In case of cancellation, a notification will be sent directly to all applicants.
The Cement Institute, LLC cannot be held responsible for any cost, damage, or expenses that may be the customer due to the event being postponed or canceled. The training fee does not include travel costs, hotel accommodation, or transfer of insurance.

Tel: +1 917 937 8067
Email: training@thecementinstitute.com