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
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.
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.
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.
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.
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.
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
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
withLOCTITE
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.
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.
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.
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
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.
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.
Leakage in transformer pipe joints can cause oil spill
that increases process fluid cost and clean-up costs.
Solution: Reliably seal transformer pipe joints
usingLoctite
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 the service life of the
motor driven equipment.
Housing and End Plates
Challenge 1: Loosening of End Plates
Vibration and shock loads can lead to
loosening of the through bolts that keep the
end Plates bolted to the housing. This can
lead to misalignment and can cause damage to
the motor.
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.
Challenge 3: Ingression of Moisture and
Foreign Particles
The interface between the end plates and
housing allow foreign particles to enter the
motor housing which can significantly reduce
the motor performance.
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.
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.
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.
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
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.
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.
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.
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.
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.
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.
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.
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.
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
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.
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.
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.
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.
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.
Food and Beverage processing industry needs to comply with stringent regulations.
Challenges
such as loosening due to vibration, leakages and corrosion, threaten the everyday
performance of processing machinery.
LOCTITE products help to combat the above challenges and increase machine
reliability.
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.
Maximizing productivity and preventing unplanned downtime are critical in the
Mining industry. Proactive maintenance can help protect mining assets in all
phases of operations and reduce common, redundant failures.
From the coke oven plant and sinter plants to the pickling plant and cold rolled
finishing line, reliable equipment is a must. Expensive downtime due to un-
scheduled maintenance can be avoided throughout the steel making process by
utilizing LOCTITE maintenance solutions.
Decanter centrifuges are important equipment in an Oil & Gas plant. The below
sections will help service engineers tackle service and repair challenges to keep
the downtime short and increase equipment longevity.
Thermal Power Plant
Thermal power plant equipment operates in very harsh environments. Proactive
maintenance can help maximize production, extend equipment life and prevent
unplanned plant downtime.
Electric motor is an integral equipment for plant machinery. LOCTITE solutions help
to improve performance and reduce costs by preventing minor issues such as
self-loosening of threaded assemblies which can lead to unplanned downtime.
Prevent Pump Breakdowns with Increased Threaded Fastener Reliability
Frequent pump breakdowns can increase downtime costs and reduce productivity. LOCTITE
threadlockers ensure pump reliability and longevity by filling all gaps between
engaging threads, preventing self-loosening.
Increasing Pump Service Life by Increasing Rotational Component
Relaibility
Industrial pump reliability highly depends on cylindrical components like shaft and
bearing. Proactive maintenance of these essential components can reduce the risk of
breakdowns, preventing downtime costs and increasing pump service life.
Proactive Maintenance of Gearbox to Maximize Productivity
A gearbox failure can lead to costly setback and affect overall plant operations.
LOCTITE threadlockers combat common challenges such as loosening, corrosion and
seizure of fasteners, ensuring high reliability.
Leakages in gearbox can lead to reduce equipment life and amount to expensive
downtime. LOCTITE gasketing compounds ensure 100% flange seal preventing expensive
leaks
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Maintenance
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