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Challenges

Equipment reliability and predictability are most important to keep a cement plant running 24X7. Below are some solutions to commonly encountered maintenance challenges across various departments of a Cement plant.

Mine  

Mine

Challenge 1: Loosening of bucket elevator bolts

Bucket elevators of mining equipment needs to handle the dual stress of vehicle vibration and excavation. The bolts connections take the maximum part of this load and are prone to frequent loosening.

Solution: Secure bucket elevator bolts with LOCTITE 277 Threadlocker

Challenge 2: Leakages from oil sumps

Gasket failures during operation can lead to the equipment coming to a standstill and necessitate availability of the required gasket size at hand for on the spot servicing.

Solution: Prevent oil leaks and reduce gasket inventory with LOCTITE 587 Gasketing Compounds

Challenge 3: Retaining of large gap bearings in equipment

Under dynamic loads, bearing seat on the shaft gets worn off. Despite high interferences, the gap between the bearing and shaft become large and need remachining to be fitted again, making in-situ repairs impossible.

Solution: Fill bearing and shaft gaps up to 0.5mm without remachining with LOCTITE 660 Retaining Compound

Crusher  

Crusher

Challenge 1: Loosening of Crusher Liner bolts: (raw mill)

Frames subject to high workloads, vibration and impact, causing the loosening of bolts which need to be frequently re-tightened to avoid catastrophic failures.

Solution: Secure bolts with LOCTITE 263 Threadlocker

Challenge 2: Loosening of Adaptor Sleeve:

Crusher adaptor sleeve provides support to the crusher shaft. Under dynamic loads and extreme service conditions, the sleeve can come loose causing reduction in transmitted torque and shaft wear.

Solution: Retain crusher adapter sleeve with LOCTITE 638 Retaining Compound

Raw Mill  

Raw Mill

Challenge 1: Mounting Bearing onto Dust Collector Fan Shaft:

The shaft and bearing assembly is subjected to dynamic rotational loads that can cause loosening of bearing and lead to fretting corrosion. This leads to inefficient torque transmission and decrease in equipment service life

Solution: Fit bearing on shaft with LOCTITE 609 Retaining Compound

Challenge 2: Loosening of Magnetic Separator Bolts

Magnetic Separators rotate at high speeds to separate the ferrous from the non-ferrous substances. This puts huge stress on the bolts which can loosen under shock loads.

Solution: Locking magnetic separator bolts with LOCTITE 263

Challenge 3: Loosening of Vibratory Feeder Bolts:

Vibratory feeder bolts are subjected to heavy vibrations that can easily loosen bolts reinforced with the best of mechanical locking devices.

Solution: Maintain required clamp load in vibratory feeder bolts with LOCTITE 277

Coal Mill  

Coal Mill

Challenge 1: Air Leakage from Air Slides:

Air leaks from air slides can lead to inefficient pulverization of coal and increase costs. Availability of the correct gasket size and material adds to the complexity of repair.

Solution: Seal air slides without worrying about gasket inventory with LOCTITE 587 Flange Sealant

Kiln  

Kiln

Challenge 1: Mounting Bearing onto the Shaft of Cooler Connecting Rods:

Bearings can loosen on shafts due to dynamic rotational loads which reduces torque transmission and reduce equipment performance.

Solution: Retain bearings on cooler connecting rod shafts with LOCTITE 638 Retaining Compound

Challenge 2: Loosening of Cooler Plate Fasteners:

Due to corrosion and shock loads, the fasteners of the cooler plate can reduce the clamp load, increasing vibrations in the machine.

Solution: Lock cooler plate fasteners with LOCTITE 2701 Threadlocker

Challenge 3: Securing Keyways in Drive Gear Box:

High shear stresses on assembly can lead to worn keyways and backlash, reducing the torque transmission capability. Now keyways can be fixed and keys and refitted without further machining.

Solution: Fix keys into keyways with LOCTITE 660 Retaining Compound

Cement Mill  

Cement Mill

Challenge 1: Loosening of Mill Liner Bolts:

Mill Liners are usually used for installations of large vertical grinding mills which are exposed to high loads and vibrations. This can cause the bolts to loosen causing catastrophic machinery failure

Solution: Lock mill liner bolts with LOCTITE 277 Threadlocker

Challenge 2: Retaining Bearing onto Main Shaft of Bucket Elevator and Chutes:

Due to the variety of bulk materials being loaded on bucket elevators, the shaft mounted bearing can loosen leading to reduced transmitted torque and damage to the components.

Solution: Retain bearings on shaft using Loctite 638 Retaining Compound

Challenge 3: Loosening of Separator Mounting Flange Bolts:

Vibration and shock loads can loosen the bolts that keep the flanges bolted. This can lead to misalignment and can cause damage to the separator.

Solution: Reliably lock mounting flange bolts with LOCTITE 270 Threadlocker

Challenge 4: Retaining of Bearing in Elevator Gear Box Housing:

Bearing outer races are prone to spinning within their housings, resulting in damage to the housing. This damage is regardless of whether they have been pressed or shrink fitted in place. Once the clearance increases, the air gap leads to fretting corrosion, causing damage to the parts.

Solution: Fit bearing in housing with LOCTITE 603 Retaining Compound

Electrical Department  

Electrical Department

Challenge 1: Leakage from Transformer Pipe Joints:

Leakage in transformer pipe joints can cause oil spill that increases process fluid cost and clean-up costs.

Solution: Reliably seal transformer pipe joints using Loctite 577

 

Electric motors and generators are the prime drivers of all machinery. Any failure in these, can lead to costly downtime. Proactive maintenance can minimize the risk of such unscheduled breakdowns and increase service life of the motor driven equipment.

Housing and End Plates  

Housing and End Plates

Challenge 1: Loosening of End Plates

Vibration and shock loads can lead to loosening of the through bolts that keep end covers bolted to the housing. This can lead to misalignment and can cause damage to the motor.

Solution: Secure end cover through bolts with LOCTITE 222 Threadlocker

Challenge 2: Loosening of Assembly Screws and Cover Screws

The threaded assemblies can work themselves loose under dynamic loads. This can lead to excessive vibration in the machine and can damage the housing and frame.

Solution: Lock assembly and cover screws with LOCTITE 243 Threadlocker

Challenge 3: Ingression of Moisture and Foreign Particles

The interface between end plates and the housing allow foreign particles to enter the motor housing which can significantly reduce the motor performance.

Solution: Seal the end plate and housing interface with LOCTITE 518 Flange Sealant

Shaft Mountings  

Shaft Mountings

Challenge 1: Loosening of Bearing or Commutator

Electric motors pick up the required rotational speed with a jerk. This repeated jerk can lead to loosening of the shaft mounted component like bearing and commutator. Loosening of cylindrical fittings can reduce transmitted torque and damage the components.

Solution: Mount cylindrical components with LOCTITE 641 Retaining Compound

Challenge 2: Fretting Corrosion on Bearing

The air gap trapped between the bearing and shaft allows corrosion to build up and seize the bearing on the shaft. In such cases, the bearing will have to be replaced with a new one, resulting in downtime and scrap cost.

Solution: Fit bearings on shaft with LOCTITE 641 Bearing Retainer

Mounting Bolt  

Mounting Bolt

Challenge: Misalignment Due to Loose Mounting Bolts

Motor mounting bolts keep the motor frame in place and maintain alignment with the driven equipment. However, the mounting motor bolts can loose clamp loads under vibrational shocks and cause misalignment which can damage the rotational components.

Solution: Fasten mounting bolts with LOCTITE 277 Threadlockers

 

Most industrial centrifugal pumps carry a significant capital equipment value. It is important to extend their service lives and ensure that they run efficiently. Proactive maintenance can reduce the risk of breakdowns and increase pump reliability and longevity.

Bearing Frame & Housing  

Bearing Frame & Housing

Challenge 1: Oil Leaks from Threaded Assemblies

The gaps between threads of drain plugs, oiler nipples, fittings etc. can lead to oil leaks due to constant pressure changes within the bearing housing. Not only do these leaks increase costs but also lead to the seizure of fittings and safety hazards.

Solution: Seal threaded assemblies with LOCTITE 567 Thread Sealant

Challenge 2: Bearing Spinout, Corrosion and Component Damage

Bearings are prone to spinning either on their shafts, or within their housings, resulting in damage to these parts regardless of whether they have been pressed, shrunk or slip fitted in place. The gap that exists between a bearing and shaft is an area where rust can form and cause damage to the parts.

Solution: Fit and seal bearings with LOCTITE 641 Bearing Retainer

Frame Adapter  

Frame Adapter

Challenge 1: Gasket Failure between Bearing Frame and Frame Adapter

Leaks from the frame connection can mean money lost in oil consumption and potential safety hazards. This happens because pre-cut gaskets cannot tackle the gap between flange surfaces. Flange imperfections are potential leak paths that pre-cut gaskets cannot seal and they relax over time to make the gaps large enough for leaks to happen.

Solution: Seal flanges with LOCTITE 518 Flange Sealant

Challenge 2: Fastener Loosening and Corrosion to Frame Adapter Mounting Bolts

Bolts are always under strain caused by torque, vibration, shock, thermal expansion and contraction. The gaps between the engaging nuts and bolts allow these external factors to challenge the clamp load.

Solution: Lock and seal bolts with LOCTITE 243 Threadlocker

Pump Casing  

Pump Casing

Challenge: Corrosion and Seizure of Pump Casing Bolts

The severe pump environments of constant temperature, pressure and humidity changes cause the pump casing bolts to corrode and seize. Seized casing bolts make pump maintenance difficult and create additional labor associated with drilling and tapping the bolt hole.

Solution: Seal and Protect Bolts with LOCTITE 243 Threadlocker

Challenge: Leaks between the Stuffing Box and Casing

The use of cut gaskets has inherent problems. Neither does it occupy all flange irregularities, nor does it maintain elasticity. This leads to creation of leak paths that corrode and damage the flange surfaces.

Solution: Seal flanges with LOCTITE 518 Flange Sealants

Coupling  

Coupling

Challenge: Misalignment and Damage Due to Coupling Loosening

Couplings are held in place by a key and a set screw. If the set screw loosens, the coupling can begin to slide along the shaft and disengage, or it can begin to wallow out the keyway.

Solution 1: Lock set screws in place with LOCTITE 222 Threadlocker (for > ¼") 
Solution 2: Lock set screws in place with LOCTITE 243 Threadlocker (for > ¼")

Pump Base Mounting  

Pump Base Mounting

Challenge: Misalignment Due to Loose Mounting Bolts

Vibration and possible impact shock can work to loosen the mounting bolts. Loose bolts result in a loss of clamp load, which allows the pump to lose its level and aligned configuration.

Solutions: Maintain alignment by securing mounting bolt with LOCTITE 263 Threadlocker

 

Industrial gearboxes play an important role in processing and manufacturing facilities. Reliable operation over a long service life, with minimum maintenance, is a key requirement. Proactive maintenance can minimize expensive downtime, enhance reliability and dramatically cut costs.

Housing  

Housing

Challenge: Damage and Corrosion in Housing due to Bearing Spin

Bearing outer races are prone to spinning within their housings, resulting in damage to the housing. This damage is regardless of whether or not they have been pressed or shrink fitted in place. Once the clearance increases, the air gap leads to fretting corrosion, causing damage to the parts.

Solution: Fit bearing in housing with LOCTITE 641 Retaining Compound

Housing and Cover Assembly  

Housing and Cover Assembly

Challenge 1: Gasket Failure Between Upper and Lower Housing of a Split Gearbox

Oil leakage from failed gasket between upper and lower housings of split case gearbox can increase risk of gearbox running low on oil and increase overall oil consumption, safety hazards and clean-up costs.

Solution: Seal flanges with LOCTITE 518 Gasketing Compound

Challenge 2: Loosening and Corrosion of Housing and Cover Fasteners

Cover fasteners can loosen when exposed to torque, vibration, thermal expansion and shock loads. Once the fasteners become loose, the preload on the gasket is lost and the gasket fails. Additionally, cover fasteners can corrode and seize making gearbox maintenance difficult and hence create additional labour associated with drilling and tapping of the fastener hole.

Solution: Secure cover fasteners with LOCTITE 243 Threadlocker

Lubrication and Cooling System  

Lubrication and Cooling System

Challenge: Leakages from Threaded Fittings

Pressure and temperature changes within the gearbox can lead to leaks from threaded fittings such as oil drain plug, oil inlet, housing ventilation, oil pump, oil filter, oil gauge, coolant pump, pressure and temperature control unit and all pipe work.

Solution: Seal threaded assemblies with LOCTITE 567 Thread Sealant

Shaft Mounted Components  

Shaft Mounted Components

Challenge 1: Spun Bearings on Shaft

Bearings are prone to spinning on the shaft due to dynamic load on the assembly which produces axial loads higher than the original calculations. This bearing spin leads to damage on both shaft and bearing which may necessitate component replacement, causing unplanned downtime and scrap costs.

Solution 1: Fit bearings on shaft with LOCTITE 641 Retaining Compound (gap < 0.15mm)
Solution 2: Fit bearings on shaft with LOCTITE 660 Retaining Compound (gap < 0.5 mm)

Challenge 2: Loosening of Fitted Gears

Gears are prone to loosening on the shaft under dynamic loads, leading to reduction in torque transmitted.

Solution: Fit gears on shaft with LOCTITE 638 Retaining Compound

Gearbox Mounting Bolt  

Gearbox Mounting Bolt

Challenge: Misalignment Due to Mounting Bolt Loosening

Vibration and shock loads can loosen gearbox and motor mounting bolts, leading to misalignment which can cause damage to both the machines.

Solution: Secure Mounting Bolts with LOCTITE 277 Threadlocker

 
 
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