POLYCOM ROLLER PPT

1. PM Cell Performance
J.K Cement Works, Jharli(HR)

2. PM Cell Team
Lokesh Maratha
Sunil Sharma
Santosh Rathod
HOD -Mechanical
SH -Cement mill & PM cell
Sr.Engineer - Cement mill
& PM cell

3. Key Performance Indicators (KPI)

4. 290
215
264
125
265
230
370
672
0
100
200
300
400
500
600
700
2019-20 2020-21 2021-22 Q1(22-23) Q2(22-23) Q3(22-23) Jan-23 Feb-23
Cement Mill - Mean Time Between Failure ( MTBF )
Hrs.
33 kv
Power Line
Failure in
Dec.22
RP Elevator
pin link
broken in
April.22

5. Cement Mill –Unplanned Stoppage Details
STOPPAGE DETAILS DEC -2022 FREQUENCY HOURS
No any unplanned stoppage 0 0
TOTAL NIL NIL

6. RCFA –Unplanned Stoppage –Feb-2023

7. 96.5
96.1
96.4
93.56
99.3
96.9
99.5
100
90
91
92
93
94
95
96
97
98
99
100
101
102
2019-20 2020-21 2021-22 Q1(22-23) Q2 (22-23 ) Q3 (22-23 ) Jan-23 Feb-23
Cement Mill- Net availability Index ( NAI )
Hrs
.

8. Preventive Maintenance by
Conditioning Monitoring ( CBM )

9. Z-1 Notification status
S/NO Dept.
Notifi.
created
Notifi.
Closed
Notifi
Open
1 Elect. 43 43 0
2 Inst 47 40 7
3 Mech 26 26 0
4
Packing
Plant 18 15 3
5 Process 2 1 1
6 QC 1 1 0
7 Utility 7 7 0
Total 144 133 11
Z-2 Notification status
S/N
O Dept.
Notifi
created
Notifi
Closed
Notifi
Open
1 Elect. 2 2 0
2 Inst 0 0 0
3 Mech 0 0 0
4
Packing
Plant 0 0 0
5 Process 0 0 0
6 QC 0 0 0
Total 2 2 0
Z-3 Notification status
S/N
O Dept.
Notifi.
created
Notific
Closed Notifi Open
1 Elect. o o o
2 Inst 30 30 o
3 Mech 16 16 0
4
Packing
Plant 1 1 o
5 Process 19 15 4
6 QC o o o
Total 66 62 4
SAP PM Compliances Status-Feb-2023

10. Hole in static separator casing,
material leakaging from that
Oil leakage from ball mill fixed
side SS bearing
521BC-100 Belt conveyor
carrying idler damaged
521RF341 rotary feeder body
worn out, due to this
leakages of material
Gravel gate coupling guard
missing
Hole in 511BF-160 bag filter
suction line
Clinker Weigh Feeder belt out 521FN411-Air Slide Blower
coupling shifted
Walk by Inspection ( WBI ) Compliances

11. 43
4
-10
10
30
50
70
90
110
130
150
Normal Caution Critical
521BE-270 elevator chain
elongation increasing
continuously and Ball mill
pinion NDE side bearing
vibration on higher limit,MD-
105 elevator gear box oil
damaged,471FN157 fan
bearing clearance high
471 FAN142 &
611FN201 FAN
BEARING VIBRATION
OBSERVED VERY HIGH
Overall Equipment Health summary report –Feb-23
• Total 49 equipment's covered for
vibration analysis in Feb-23 month.
Vibration
• 521BC-100 snub and head
pulley,491BC-305 tail pulley bearing
replaced after inspection
Inspection
• 521MD-105, 481MD-505 &491MD-310
Chain elongation-0.2 % ,0.7% & 0.02 (
Acceptable )
• 521MD270 Chain elongation – 1.3%(
Causation)
Elongation
• Elevator – 521MD370 ( 86 Shore A ) ,
521MD280 ( 82 Shore A ) , 621MD105
• ( 81 Shore A ) , 622MD 105 ( 83 Shore A )
• 623MD-105(80 shore A) 624MD105 (85
shore A)
Belt hardness
• Cement Mill internal inspection done.
• Polycom Rollers inspection & Wear
measurement .
INSPECTION
& Wear
• 481FN 157 vibration reduced after
balancing.
• 521 FN 155 fan vibration reduced after
balancing.
• 471FN142 & 619FN106 vibration reduced
after bearing changed and coating
cleaned
CBM
corrective
action
2

12. CBM-Equipment health status- Vibration Report
S/N MACHINE NAME STATUS RECOMMENDATIONS Remark
1
BALL MILL PINION
BRG
MARGINAL
Inspect the Pinion DE &NDE bearings for any abnormality/defects.
Vibration on pinion bearing housing was on higher side (Vertical 14 NDE
, Axial -11.4 NDE ), need closed monitoring ,suggest to check bearing
housing clearance and gear coupling. Suggest to check alignment (root
gap/backlash/radial & axial run out)
Inspection done in feb.
3rd
week with FUCS
engineer
2
ROLLER PRESS
(521-RP165)
NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK
3
SEPARATOR DRIVE
(521-SR135)
NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
.
OK
4
RECIRCULATION
ELEVATOR
(521-MD105)
MARGINAL
Inspect the elevator for any abnormality/defect.
Both the side Gearbox input & out oil seal damaged, hence oil leakaging
Excluding this all are ok.
Plan to replace oil seal
ASAP
5
SEPOL FAN
(521-FN155)
NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK
6
MILL ELEVATOR
(521-MD 270)
MARGINAL
Elevator chain elongation is continuing increasing, need closed
monitoring
Under Observations
7
CEMENT SILO
FEEDING ELEVATOR
(521-MD370)
NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK
8
MILL BAGHOUSE
FAN (521FN-288) NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK

13. CBM-Equipment health status- Vibration Report
S/N MACHINE NAME STATUS RECOMMENDATIONS Remark
9
AIR SLIDE BLOWER
(611FN-201)
CRITICAL
Inspect the blower for any abnormality/defects.
Need closed monitoring ,suggest to check bearing clearance and
coupling for damaged. Suggest to check alignment & impeller for
balancing.
Under Observations
10
FAN (CLINKER SILO
TOP)
(471-142)
CRITICAL
Inspect the bag filter fan for any abnormality/defects
Found thick coating in impeller, need to be removed all coating inside
impeller, suggest to check bearing clearance and coupling. Suggest to
check alignment & all base bolts.
Under Observations
11
BAG FILTER FAN
(DBC)-471FN157
MARGINAL
Bearing vibration observed high.
Suggest to check bearing clearance & coupling for any damage , check
alignment & base bolts for looseness & impeller for unbalance.
Under Observations
12
GYPSUM ELEVATOR
(491-MD310)
NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK
13
WT BAG HOUSE FAN
(471-FN208)
NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK
14
CLINKER ELEVATOR
(481-MD 505)
NORMAL No specific maintenance action is suggested now. Please continue
usual operation
OK
15
POLYCOM BH FAN
(521FN307)
NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK
16
BUCKET ELEVATOR
(521MD-280) NORMAL
No specific maintenance action is suggested now. Please continue
usual operation
OK

14. J.K. CEMENT WORKS JHARLI (VIBRATION REPORT)
CEMENT MILL AREA 08.02.2023 Recommendation Status
EQUIPMENT DCS code Position H V A T
mm/sec °C
FAN (CLINKER SILO TOP) 471FN142
MOTOR DE 22.1 22.8 8.8 34.3
Fan is mounted on steel
structure, need to be
strengthening, coating in
impeller,check for
bearing clearance &
Check motor foundation
bolt for looseness
Bearing
Replaced
MOTOR NDE 25 21 3.3 28.2
DE 18.2 19.2 8.1 37.2
NDE
16.1 21.1 6.5 33.6
FAN (DBC) 481FN157
MOTOR DE 11.8 4.2 10 11.8
check for bearing clearance
and check for impeller
balancing
Impeller coating
removed
MOTOR NDE 18.2 5.8 14.1 18.2
DE 8.8 4.6 12.7 8.8
NDE 4.9 9.4 15.1 4.9
FAN (DBC) 481FN512
MOTOR DE 5.2 3.2 2.8 31.9 Vibration
reduced after
balancing
MOTOR NDE 5.4 3.2 2.2 27.8
FAN (BC140) 511FN162
MOTOR DE 4.4 7.2 4.3 33.3
Suggest to change the
bearings and also clean
impeller coating
Bearing
Replaced
MOTOR NDE 5.5 11.8 2 28.1
DE 5.1 7.1 2.8 30.1
NDE 6.6 12.2 3.5 32.2
Cement Mill -Vibration Analysis Report

15. Vibration Monitoring report
J.K. CEMENT WORKS JHARLI (VIBRATION REPORT) -
PACKING PLANT 08.02.2023 Recommendations Status
EQUIPMENT DCS code Position H V A T
mm/sec °C
ELEVATOR 1 621BE105
MOTOR DE 4.6 3.1 3.3 34.2
strengthening required of motor mounted base Completed
MOTOR NDE 6.9 5.1 3.1 28.1
GB I/P 2.2 1.3 2.4 34
GB O/P 2.3 1.7 1.7 36
DE 1.1 1.2 26
NDE 2.2 1.4 1.4 28
ELEVATOR 2 622BE105
MOTOR DE 7.1 2.8 4.1 27.4
Motor foundation bolts need to be checked for
looseness and high vibrations and strengthening
required of motor mounted base
Completed
MOTOR NDE 11.7 9.9 3.5 24
GB I/P 2.8 1.8 2.2 30.3
GB O/P 3.3 2 3.2 32.1
DE 2.1 1.6 23.3
NDE 3.2 1.4 2.1 24.1
ELEVATOR 3 623BE105
MOTOR DE 7.1 5.4 2.6 24.5
Motor foundation bolts need to be checked for
looseness and high vibrations
strengthening required of motor monted base
Completed
MOTOR NDE 12.3 6 1.8 23.1
GB I/P 1.2 2.2 1.8 23
GB O/P 1.3 2.8 1.4 23
DE 1 0.8 22
NDE 1.4 1.2 0.8 23.3
ELEVATOR 4 624BE105
MOTOR DE 9.2 2.9 3.6 34.5
Motor foundation bolts need to be checked for
looseness and high vibrations Strengthening
required of motor monted base
Completed
MOTOR NDE 6.1 3.8 1.2 30.7
GB I/P 1.4 2.4 1.2 26.1
GB O/P 1 1 2.2 36.8
DE 1.1 0.8 0 27.6
NDE 1.3 0 0 30.7
Packing plant -Vibration Analysis Report

16. Corrective action after CBM
Sr No. Notification No. OBSERVATIONS Corrective Action Picture
1 300374539 Gypsum WF endless belt damaged
Weigh Feeder Belt
replaced
2 300378114
521BC100 Head Pulley bearing clearance
high
Bearing Replaced
3 300378116
521BC100 Snub Pulley bearing clearance
high
Bearing Replaced
4 300378135
521MD-105 Recirculation elevator chain
link damage
Damaged link
changed

17. Corrective action after CBM
5 300378484
521FN411 Air slide blower fan coupling
shifted
Coupling adjusted &
fitted properly
6 300378517
High vibration observed in 481FN142 Bag
Filter Fan
Bearing Replaced
7 300378730
521FN-155 Sep. Fan NDE side bearing
temp High
Bearing inspection
done & Oil Replaced
8 300379445
619 FAN106 Bag Filter Fan Bearing
vibration observed high
Bearing Replaced

18. As per recommendation of M/S Fuchs ,Shim to be provided in girth gear NDE pinion for reducing the temp. from
8degree to below 5 degree
Ball Mill spray patten

19. Daily monitoring of operation parameters of the plant equipments
GEAR BOX BEARING TEMP.
(63°C,55°C,54°C,58°C,58°C,68°C)
H V T
DE 0.4 0.1 45
NDE 0.9 0.4 48
DE- 46.7°C
NDE- 47.1°C LOAD-69.2 A
ROLLER PRESS
PRESSURE- L (103BAR),R (101BAR)
SLIDE SHOE TEMPERATURE
BALL MIL
Pinion Bearing temperature
Fresh Feed- 255
LOAD- 113.9A
DAILY EQUIPMENTS PARAMETERS REPORT (28.02.2023)
521 MD-370 PRODUCT ELEVATOR
BOTTOM BRG(62.7°C),
GEAR BOX(56.5°C,58.5°C)
SEPARATOR
RPM- 921
TEMPERATURE-
LOAD- 237A
TOP BRG(51°C),
PRESSURE- PUMP(2.8 BAR)
MOTOR LOAD- M(1157A/908KW),
F(116A/984KW)
Bearing temperature
TPH-270
521-FN-155-SEP FAN
MD-105 RECIRCULATION
ELEVATOR
LOAD- A(*162* A), B(*165* A)
MD-270 BALL MILL DISCHARGE
ELEVATOR
LOAD- 199A / 1788KW
Movable: L-48°C , R- 45.4°C
Fixed: L-53°C, R-48°C
FLOAT(61°C,63°C,62°C,62°C)
FIXED(62°C,62°C,63°C,62°C)
HP PUMPS PRESSURE
LP PUMPS PRESSURE
FLOAT(22BAR)
FIXED(29BAR)

20. Preventive Maintenance by
Total Lubrication management ( TLM )

21. The oil analysis is been
done on quarterly basis
by external agency
‘FACT'. The sample of
lubricants of critical are
tested by FACT, and the
complete report of LCR
& MCR is the basis of oil
replacement.
FIXED SIDE GB OIL
REPORT
MOVABLE SIDE GB OIL
REPORT
Oil analysis details

22. Consolidated Statement of Ferrography & Oil
Analysis Sample and Action status

23. Oil stock details
S/No Lubrication Type
Consumption
Reason for
abnormality
Normal
consumption
Abnormal
consumption
Total Consumption
1 VG-320
15 0
15
2 HP-90
2 0
2
3 VG-68
6 30
36 Oil leakage from line
4 VG-46
0 145
145
Polycom plunger
cylinder replaced
5 VG-100
100 0
100

24. S/N
o
Lubricatio
n Type
Abnormal oil
consumption
Reason for abnormal Consumption Status
1 VG-68 30 +Oil top up in power pack WT, Oil leakage from line Arrested
4 VG-46 145 Oil Leakage from Y Seal – Ball Mill Fixed Side Slide Shoe Bearing. Pending
Oil Abnormal consumption analysis

25.  Product bucket elevator bucket tippling work to resolve bottom
boot problem.
 Separator worn out static vanes replacement work.
 Wagon tippler Steep angle conveyor ( SAC) Side wall replacement
work
 Electrical power cable replaced total =

Reliability Improvement jobs

26. Way Forwards
 Ultrasonic test ( UT test) to be done in All belt conveyors pulley shafts to
avoid any unplanned stoppage due to internal cracks in shafts.
 MPT to be done on Clinker Wagon tippler Apron conveyor Bull gear.
 All chain drive of bag filter rotary air lock to be replaced from Pin bush
coupling for reduction of the grease consumption & reduction of sprocket
/ chain inventory.
 Oil Cosumption to be reduced by monitoring of oil consumption at site &
arresting oil leakages from system.
 Polycom Bearing inspection to be done in Annual shutdown.

27. Thank You