Understanding how an effective maintenance program is a critical factor in enabling the organization to gain a competitive and strategic advantage in an intensely competitive market. Increase the knowledge of the participants obtaining the appropriate techniques of technological systems and their reliability systems to improve the plant equipment’s general effectiveness.

 

2 - 6 October 2023 Miami, Florida

Cement Reliability Maintenance Seminar

 This seminar covers the main equipment of the plant

KILNS

Three Pier Standard Kiln - Two Pier Friction Drive Kiln

AGENDA

INTRODUCTION - PLANT SAFETY - KILN RCA & FMECA - KILN SECTIONS (KILN SHELL) REPLACEMENT, IN WHICH DISTORTION CAUSES PROBLEMS - TIRES AND OVALITY - KILN TIRE, DEFORMATION, AND OVALITY - SUPPORTING ROLLER STATION - KILN BEARINGS - KILN ALIGNMENT (IN HOT (RUNNING) AND COLD ENVIRONMENT (KILN SHUTDOWN)) - KILN DRIVES - AUXILIARY EQUIPMENT - PREVENTIVE MAINTENANCE

VERTICAL ROLLER MILLS

Mills technologies

AGENDA

SAFETY - VERTICAL ROLLER MILLS, ADVANTAGES AND DISADVANTAGES - VRMS - VARIATIONS BY SUPPLIER (TABLE DESIGN, ROLLER NUMBER AND DESIGN (SHAPE), EASE OF ROLLER CHANGE, ROLLER TENSIONING ARRANGEMENT) - THE GRINDING TRACKS - MAIN FLOW ACROSS VERTICAL MILLS - HYDRAULIC CIRCUIT FOR GRINDING ROLLERS - GRINDING EQUIPMENT WEAR: TABLE, ROLLERS AND DAM RING - DAM RING FUNCTION AND IMPACT OF ITS WEAR – SEPARATORS

COOLERS

First, Second and Third Generation Clinker Coolers

AGENDA

INTRODUCTION TO CLINKER COOLERS – RECIPROCATING COOLERS GRATES - CONTROL-FLOW GRATE COOLERS - PENDULAR COOLER – PYROFLOOR COOLER - POLYTRACK® COOLER - CROSSBAR COOLER - HAMMER CRUSHER - ROLLER CRUSHER

GIRTH GEARS

Applications and Gear Design

AGENDA

SAFETY - PROOF OF THE GEAR LAW - BASIC THEORY OF GEAR AND TYPES - EPICICLOID GEARS – GEAR INSTALLATION AND ALIGNMENT - LUBRICATION - MAINTENANCE AND TROUBLESHOOTING

BALL MILLS

Grinding Systems and Mill Components

AGENDA

SAFETY - TYPES AND PROCESS - MECHANICAL ELEMENTS OF A BALL MILL - MILL INTERNALS AND EXTERNAL COMPONENTS – LINER INSPECTION AND WEAR TREND - IMPORTANT DATA TO DESIGN A TUBE MILL – BALL MILL ARRANGEMENT – TYPES OF MILL DRIVES – BALL MILL TROUBLE SHOOTING – BALL MILL MAINTENANCE

CRUSHERS

Types and Classification

AGENDA

SAFETY – INTRODUCTION - CRUSHING PROCESS - CRUSHER CLASSIFICATION - MACHINE DESCRIPTION & MAIN PARAMETERS – PREVENTIVE 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.

 

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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
  • Advance techniques and new skills
  • Stay competitive
  • Enhance teamwork
  • Improve maintenance quality and productivity
  • Keep updates with industry developments
  • Improvements in overall plant performance
  • Gain new knowledge
  • Develop new skills

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

2 – 6, October 2023

Miami, Florida, USA

Learn more

THE SEMINAR WILL BE HELD AT COURTYARD MARRIOTT AT DOLPHIN MALL

11275 NW 12th Street, Miami, FL 33172

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