how to improve quality of maintenance and repair works for cement industry equipment

Forecast 2023 -. Transforming Cement Industry with AI driven process efficiency. Cement making is highly resource-driven, with many manual operations and energy-intensive processes. AI shall strengthen the existing processes and make cement manufacturing more robust, environment-friendly and efficient. In the cement industry setup, every …

Cement production can also be enhanced by Industry 4.0 in a number of ways. (See Exhibit 1.) In particular, 4.0 solutions can better manage the enormous energy consumption, rising cost challenges, and overall process complexity that are inherent to the industry. For instance, cement companies today must rely on engineers' gut feel and …

A well-executed remote service offering reduces unnecessary maintenance, improves production efficiency, tracks causes of failures, provides fault diagnosis and recommends …

1) Improve safety and reduce the risk of accidents. A well-maintained facility will help improve equipment reliability, reducing the risk of accidents and improving productivity. Therefore, proactive maintenance is an essential part of an ongoing program.

3-Repair: The detected fault is evaluated according to working schedule of the mill and necessary repair works are done. LABOR-FORCE FOR MAINTENANCE ACTIVITIES. …

In the cement industry, AI offers the chance to come at age-old challenges with a fresh perspective: reducing the cost of operations, while maximizing yield, improving quality and reducing emissions at the same time. It's a balancing act to which AI is ideally suited, as Liran Akavia, COO and co-founder of Seebo, a company that specializes in ...

Our cement solution connects process, discrete, power, information and safety control into one plant-wide infrastructure. An integrated system reduces engineering risks and facilitates operations, maintenance and operational changes. Engineering and operations eficiency: standards and libraries for the cement industry.

Therefore, in addition to proper use and maintenance, it is necessary to replace, repair or improve the parts worn by the cement machinery, arrange necessary maintenance plans to restore the accuracy and performance of the equipment, preserve the quality of the certified products and play the equipment. Performance.

Contents. Concrete literally holds the modern world together. The material and its binding agent cement comprise a key ingredient in the buildings and roads essential for development and in infrastructure critical to sustainable growth. The cement industry also generates about 7 percent of the world's greenhouse gas emissions.

In this way, manufacturers can work towards keeping machines running without spending large amounts of time and money on a calendar-based strategy that over-maintains equipment. Improving a maintenance program will follow along the lines of using more data to drive a more advanced strategy, with each step driving greater machine …

U.S. cement industry in 2009 and 2010 are provided, followed by an assessment of various energy efficiency measures applicable to U.S. cement plants. 2. The U.S. Cement Industry Cement is an inorganic, non-metallic substance with hydraulic binding properties, and is used as a bonding agent in building materials.

In most industries, the cost of maintenance is between 10 and 25 percent of total operating costs. Maintenance efficiency is an important factor in this as typically more than half the cost is labor. Furthermore, improving maintenance efficiency has a positive impact on reliability—so companies can cut costs without risking performance.

These recommended practices are intended as a reference document for use by members of cement industry electrical maintenance departments. The procedures necessary for an efficient maintenance operation are summarized, and detailed information on maintenance procedures for many of the electrical devices more commonly found in the cement …

Asset maintenance in cement plants is critical because: Extensive repair & replacement costs; Chances of industrial safety hazards & accidents; Over maintenance …

It was found that by using the maintenance management system in the cement industry, it was possible to measure and improve about 15 percent …

Senthil et al. describe self-healing material as elements that can achieve self-repair and return to the original condition (Senthil et al., 2019).Self-healing is done to reduce cracks, reduce maintenance expenses, and increasing strength and durability (Devgire, 2019) as shown in Table 2.An experiment by Prabahar et Al. shows that there …

Optimizing the operation of cement mills is essential to maximize productivity, reduce energy consumption, and improve the quality of the final cement product. In this article, we will delve into practical strategies for cement mill optimization, backed by real-world figures and numbers, to enhance efficiency and performance.

Smart concrete: The integration of sensors and smart materials into concrete structures can enable real-time monitoring of structural health, enhancing maintenance efficiency and prolonging the service life of structures ( Onaizi et al., 2021; Singh et al., 2013; Dawood and Mahmood, 2021; Shahbazpanahi et al., 2021 ).

Definition of Road Maintenance: Preserving and keeping each type of roadway, roadside, structures as nearly as possible in its original condition as constructed or as subsequently improved and the operation of highway facilities and services to provide satisfactory and safe transportation, is called Road Maintenance or maintenance of …

By detecting equipment issues early on, operators can carry out maintenance to repair equipment before it breaks down and results in unplanned downtime. Predictive …

Predictive maintenance is a proactive strategy that detects potential issues before breakdowns occur. Monitoring technologies such as vibration and online monitoring systems enable continuous monitoring of equipment health. The importance of equipment condition monitoring cannot be overstated for the maintenance and monitoring of plant …

Over the years technology in the cement industry has developed with a growing focus on sustainable and also cost and energy efficient production. While significant steps may not seem visible on a year to year basis, the medium-term view shows notable progress. The drivers for progress are certainly cost-based, but at the same time the …

The Maintenance Planner's function is to improve the productivity and quality of the workforce by anticipating and eliminating possible delays through the planning, scheduling, and coordination of …

Quality control activities usually include: sampling and testing of concrete and concrete materials; plant and field control of concrete production; evaluation and procurement of …

of quality control policy and requirements which will help Management clarify objectives and make decisions concerning the organization and scope best suited to the organization. Selection of quality level will have an important impact on the degree of risk associated with the business and the type of work which can be accepted.

Availability analysis is used to determine the critical sub-systems that exist in the cement production process so that equipment production capacity utilization can be increased [1]. This ...

MRO (Maintenance, Repair, and Operations/Overhaul) refers to the strategic management of equipment and infrastructure, including proactive maintenance, timely repairs, and efficient asset management, aimed at optimizing performance, minimizing downtime, and ensuring operational excellence. Manaswini Rao. May 29, …

The primary function of a hammer crusher is to break down the material to a specified size, which can then be used in the cement manufacturing process. Hammer crushers are considered essential equipment in cement plants as they help to ensure the quality and consistency of the raw materials used in the production process.

Availability = (total operating time - downtime) / (total operating time) If a power plant has been operating for 24 hours a day for a year, but has been shut down for 50 hours for maintenance, the Availability = (24 x 365 - 50) / (24 x 365) = 98.6%. Pro: Provides a measure of how often the equipment is available for use.

Maintenance of production equipment has a key role in ensuring business continuity and productivity. Determining the implementation time and the appropriate selection of the scope of maintenance activities are necessary not only for the operation of industrial equipment but also for effective planning of the demand for own maintenance …

Equipment Maintenance – Basics, Objectives, and Best Practices. Every piece of machinery in operation experiences wear and tear and eventually fails. Equipment maintenance exists to delay the point of equipment failure and be ready for when it does occur. The choices and actions relating to the supervision and maintenance of property …

Maximizing equipment lifespan: This can be achieved by monitoring the condition of key equipment like shaft kilns, roller presses, ball mills, and conveyor belts with the right sensor technology. Optimizing production processes: Considering that 75% cement plants are integrated clinker and cement production facilities, monitoring key processes ...

and Maintenance 6.1 Introduction Refractories can be a substantial investment for a cement industry, either in new construction or in repair work. Installation of refractories …

The sixth and final step is to learn from your equipment maintenance improvement projects and initiatives and use the feedback to improve your future actions. You need to review and reflect on ...

October 1, 2021. Taxpayers generally must capitalize amounts paid to improve a unit of property. A unit of property is improved if the cost is made for (1) a betterment to the unit of property; (2) a restoration of the unit of property; or (3) an adaptation of the unit of property to a new or different use (Regs. Sec. 1.263 (a)- 3 (d)).

3) Create the equipment maintenance schedule. The equipment maintenance schedule is the center point of any equipment maintenance program. It controls which maintenance actions should …