cement & lime analysers
  • MHC-Memo in fan motor application gave day 1 payback!
  • Instant CM assessment feature allows 5 out of 24 fan motors to be singled out for strip-down
  • MHC-Memo enables change from policy of fixed time replacement to Condition Based Maintenance (CBM)
 
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'Concrete' benefits for Rugby Cement

  “We have recouped the cost of the MHC-Memo in its first day of use!”   
Nigel Appleyard, Mechanical Engineer

CM plays a major role in the Rugby Cement - South Ferriby Works strategy to reduce costs and maximise plant availability. Critical plant units, including those which are of high capital value, production intensive or where a safety issue exists, have been successfully monitored for a number of years both in-house and by outside condition monitoring consultants using vibration, thermographic and lubricant analysis. However the failure of other numerous smaller items also impacts production output and profitability. It has been customary to replace these items on a fixed time basis or by operating to failure due to the high cost of VA expertise.

Memo Pro and sensor  
One maintenance engineer was on a study course at the University of Manchester as part of the development of his personal skills. The Maintenance Engineering IGDS course involved an objective appraisal of all the capabilities of all CM technologies and as a result Nigel was able to recommend the AE technique as being simple and quick enough to be carried out in-house by available personnel.
 
  • An MHC-Memo was purchased before a planned shutdown at which 24 motors on direct drive fans would normally have been replaced due to the time based maintenance strategy. These fans provide the air for fluidors which transport product from one part of the production process to the next. Whilst this replacement strategy is effective in preventing failures during the following 18 months of running, it has an associated capital cost.

  •  Instead it was decided to carry out a one-off check of each motor prior to the shutdown using the MHC-Memo. This revealed that 19 of the motors were OK and 5 had problems (high Distress® ranging from 11 to 16). These 5 motors were replaced during the shutdown and when stripped,  all had significant bearing damage.
This first application of their MHC Memo instrument is acknowledged to have been a major success since it only took a few minutes to take the measurements yet saved the cost of purchase and fitting of 19 motors without increasing the risk of an in service failure - an important consideration since a single fan failure can result in a loss of up to 5 hours of production by the time the unit is replaced and the production process re-stabilised.

The use of this instrument has since been extended to other plant which, although critical to production, could not be economically monitored by outside CM consultants. The introduction of MHC to Rugby Cement has revealed a highly cost-effective way to maximise efficiency whilst minimising production costs.
 
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