APPLIED TECHNOLOGY MECHANICAL COMPONENTS
Short-term monitoring solution for a cement tube mill
By implementing a temporary monitoring solution for assessing the condition of the trunnion drive end bearing on a cement
tube mill, Schaeffler has helped Sunstate Cement prolong the operating life of its mill, thus avoiding the significant cost of replacing the bearing and the associated downtime
S
unstate Cement is one of Australia’s leading manufacturers and suppliers
of high quality cement products to commercial businesses throughout Queensland and Northern New South Wales. With a production capacity of more than 1.5 million tonnes of cement per year, Sunstate Cement has a long history as a major contributor to Queensland’s largest and most impressive infrastructure projects for over 25 years. The plant primarily produces two types of cement: Flyash blend and GP cement. Each of the three tube mills at the site has a production capacity of 60 to 100 tonnes of cement per hour. During a visual inspection of the trunnion drive end bearing on tube mill No.1, Sunstate Cement engineers discovered that the bearing was in a reasonable condition, despite 28 years of service. A decision was made to extend the service life by rotating the outer ring by 180°, which is a common practice for this type of application. After this rotation, Schaeffler technicians were
a temporary solution that comprised of two FAG SmartCheck online condition monitoring systems (one axial and one radial), as well as a remote wireless network system for communication, monitoring and diagnostics from Schaeffler’s Online Centre in Sydney, Australia. The two FAG SmartCheck units were configured to suit slow speed bearings and were set up to collect vibration data only the when the tube mill was operating, which ensured that just the relevant data was obtained. This temporary solution proposed by Schaeffler was put in place for a period of one month. After this time, a machine condition report was provided by Schaeffler technicians, outlining that the trunnion end bearing was fit for purpose. By implementing the temporary FAG
asked to provide a condition monitoring solution for the trunnion end bearing in order to assure Sunstate Cement that the bearing was still fit for purpose. Due to unpredictable operating times and despite the slow speed of the tube mill, the customer considered collecting vibration data. Schaeffler recommended
SmartCheck monitoring solution, Schaeffler was able to supply a prompt, cost effective monitoring system to assess the condition of the trunnion drive end bearing for continued service. The FAG SmartCheck provided high quality vibration data at slow speeds. Subsequently, Schaeffler technicians analysed the data and made recommendations to the customer for continuation of service for the trunnion bearing. The benefit and value to Sunstate Cement was being given assurance that the bearing was suitable for further operation, thereby avoiding the significantly higher costs of replacing the bearing.
Schaeffler
www.schaeffler.co.uk
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