After-Sales Services

To obtain the correct solution you need to know all sides

Parts & Services Division

FLS after-sales services your guarantee for the correct solution

Only few suppliers offer a full range of after-sales services
This is because it requires comprehensive knowledge of all aspects of cement production, something only attained from long established experience in supplying complete cement plants. F.L.SMIDTH is one of the few cement machinery suppliers that offer a full after-sales service programme. The Parts & Services Division (PSD), which is responsible for these activities, naturally benefits from the vast fund of expertise accumulated by F.L.SMIDTH since its establishment in 1882. We are therefore conversant with old as well as new types of equipment, both those designed by F.L.SMIDTH and those provided by most other suppliers to the cement industry. A complete programme of after-sales services means that our consultants are specialists in either spares, surveys or repairs of cement production equipment. We have a full range of options to offer and are able to suggest the one most suitable in your case. Our professional service people are in contact with the whole world - on a daily basis. We operate in all main languages and offer prompt replies to all your enquiries. This is made possible not only by todays efficient and sophisticated means of communication, but also by our comprehensive computer systems that enable rapid and responsive troubleshooting. This is also your guarantee of objective appraisal and recommended improvement of your plant. You deserve a solution that optimises the production process, ensuring maximum reliability and output.

Service with a smile is the FLS specialists hallmark.

Today s efficient means of communication and transport are making the world smaller. This enables us to give you rapid and responsive service.

Spare parts Our spare parts are characterised by the perfect fit. They always match specifications, both geometrically and metallurgically. This is your guarantee of rapid installation and long service life.

Base Stock Before a new production line or plant is commissioned, we supply wear parts and consumable for the initial period of operation as well as any strategic stock of electrical and mechanical parts that you may require.

Training Your training requirement determines our supply of training programme. We offer a range of customised courses, standard courses and training packages in which your own staff are responsible for the actual tuition. Operations and

Production Strategy Planning Our specialists will aim at maximising the lifetime of your plant by computing the most advantageous clinker quality parameters, that can be produced with the existing plant equipment and by computing the corresponding modifications to your existing mine design. Supervision Experienced specialists Supervise the installation of critical equipment ensuring correct erection and efficient operation

maintenance Inspections and analyses of the various plant departments assist in revealing areas that require improvement Technical assistance

We offer technical consultancy - or production and maintenance management services, to improve the run factor and the profitability of your plant. Blending System

Simulation Our specialists establish an integrated model of your mining & raw blending operation. A mining sequence is simulated to minimise the capacity requirements of the mining and blending equipment and ensure that any bottle-necks are eliminated. Possibilities for further minimisation of capacity requirements through modification of the blending logistic will be specified.

Before starting up the plant, spare parts stocks must be adequate to ensure uninterrupted production.

A well-organised stock of spares is your safeguard against sudden failures and prevents major production losses if a breakdown should occur. The initial operation of a new production line or plant requires a special stock of spares. Our specialists know what is needed and draw up a complete list of parts to be included as a separate item in the overall contract. We distinguish between three categories of spare parts: 1. Wear parts and consumables, typically components that are in actual contact with raw materials and transmission parts. 2. Strategic replacement parts that are critical for production and have long lead times, for example kiln supporting rollers. 3. General replacement parts that are not necessarily critical for production. They have short lead times or can be repaired temporarily until a new part is delivered. These are general items such as seals, rubber rings, valves, pressure gauges, etc. If one of the parts at your plant needs replacing it is easy to find it in

the spare parts catalogues that accompany each supply of new equipment. The catalogues contain all parts likely to be replaced during the service life of the machine.

Spare parts catalogues on CD-ROM

Spare parts catalogues have until now been issued on paper, serving as a useful reference manual at cement plants. The introduction of new technology has enabled us to supply spare parts catalogues on CD-ROM. (For plants erected after 1992). This provides the user with additional facilities such as: Searching for a certain component. Within a few seconds the system will identify all the machines that have an identical component. This ensures efficient stock control and minimises the capital investment in spares. Rapid generation of enquiries providing us with exact data enables us to reply within a very short time. The system enables the user to build up his own log for each machine.

Spare parts catalogues are now also available on CD-ROM

The production of clinker, both in tonnage and in energy consumption, depends on the properties of the raw blend input to the plant.

Detailed planning of the raw blend production can boost the financial results of your plant. It therefore pays to focus on the mine even if mining operations only account for 4-10 percent of your total running costs. The mine Changes in the procedure of mining are usually necessary in cases where kiln operations are causing problems change-over to a different type of cement production is being considered combustibles are being replaced with more economical fuel modernisation is taking place to attain more rational operations. Although this is generally accepted it remains a fact that production problems are often caused by inappropriate methods of mining. So we always advise a systematic analysis of mining operations. Not only for the reasons outlined above, but also because a mine that has been in use for many years may no longer be in optimum operating condition, although this is not immediately obvious. It is often advantageous to have someone look at your mining operation with fresh eyes. Our specialists expertise in cement production enables us to effectively determine whether the mining procedure can be successfully revised to save running costs and extend the life of the plant. Logistics If mine operations are modified, the mobile equipment requirement changes too. Choice of mobile equipment is often based on a favourable offer from a machine supplier. Subsequent changes in the equipment requirement are not always taken into account. The end result may be excessive expenditure in new machinery, not to mention unnecessary running costs.

Essential criteria when choosing mobile equipment are equipment capacity, fuel consumption, geological profile of the mine, base course conditions (to estimate the running costs, for example, tyre wear), distance to pre-crusher and distance from pre-crusher to blending store must be included. Whenever the mining procedure is changed or crushers are relocated, and before purchasing new mobile equipment, the implications and consequences of such changes should be deliberated. As an impartial advisor we are able to recommend the most cost-effective selection of equipment for your mine operation. Our philosophy is that you should have the most profitable production plant available. PRO-Service Our complete mine optimisation programme is called PRO-Service and consists of 5 elements: 1. Standard prospecting programme. 2. Evaluation of drill hole requirements. 3. Overall mine design. 4. Optimised production strategy. 5. Production system simulation.

PC-BLEND The strategy for exploitation of the mine is based on analysis of drill hole samples. Once the mining starts the actual contents of the deposit may prove to differ from its anticipated composition. It is therefore necessary to monitor and optimise the mining and production planning on a daily basis. This is where PC-BLEND has proved particularly effective. It is a computer-based program that calculates the sequence and rate of exploiting the different sections of the mine.

Histogramme, showing the capacities required by the crusher during the total production period and how often they are required.

FLS Production Simulator: SIMULOGIC

SYSTEM SIMULATION : Capacity demand

F.L.. Smidth & Co. A/S Denmark Test quarry.

Production line

: HIGH GRADE

Production sector : Crushing Auxiliary storage : HIGH GRADE Days per week Hours per day Tonnage beaiss Surplus tonnage not handled when operation terminates Indentification : 6.0 : 12.0 : Dry

: 0 ton : Demo

Capacity ton/hour (dry)

A mine evaluation and optimisation by FLS specialists can result in a net profit that far outweighs the initial expense. An overall mine evaluation and optimisation consists of a mine site inspection and a report giving a general evaluation of the mine and the raw materials. The report will also pin-point issues of special concern that have been noted during the mine inspection. During the visit the specialist will assist with the definition of raw material production targets, with a study of the geological settings of the mine, with the mapping of the present mine layout and with the organisation of mine operations. This will include spare parts handling in connection with mobile and stationary equipment and with the following operational practices: Drilling Blasting Loading and Transport Crushing Stacking

Invisible factors that have a negative effect on your production plant may be eliminated by a team of FLS specialists acting as consultants or managers. If the run factor of your plant is inadequate or if production stoppages are frequent, we offer to inspect the processes and the mechanical condition of your plant. Based on such analyses we recommend various options for overcoming the difficulties. If these recommendations are insufficient, we offer to enhance the production and maintenance capability of your plant with a team of FLS specialists. They will remain at the plant until the necessary procedures for optimum production are well established. Depending on the current situation, we offer two types of assistance: Technical assistance provided by advisors. Managerial assistance in which case we undertake operational responsibility and make sure that the necessary procedures are implemented. In both cases we establish the necessary working procedures jointly with the plant staff, ensuring that the plant continues to operate at an optimum level after our assignment has ended.

Expert supervision of even minor or short-term installation jobs may prove worthwhile in the long run. Many installation jobs are so specialised that it hardly pays for the individual cement plant to train its own personnel to handle them. Our specialists are constantly carrying out such jobs in all parts of the world, whether related to mechanical or electrical installation, or to the commissioning of control equipment. Their wealth of experience is at your disposal. FLS specialists advise the cement plant staff during the installation process, ensuring that the machinery is safely erected and fitted correctly. Their services are also your guarantee against serious losses resulting from faulty installation. Depending on the type of assignment (installation of a new machine or part of a machine) our technical advisors will be present at your plant from a couple of days to several months.

Before assistance Run factor Planned production stoppages Unplanned production stoppages

After assistance

It is important to find the cause of a problem. Otherwise, it will return, often, twice as large.

Installing new machines and recruiting new staff often creates a need for qualifications that can be acquired by training programmes.

Why use external assistance?

In many cases, production problems appear to be simple and easy to correct. But often, action taken at one point causes an imbalance somewhere else. This may not be immediately obvious, but eventually output will fall and maintenance costs will increase. As the years go by, the cement manufacturer may have accepted such disadvantages. We do not, and with commissioning experience from more than 2,000 production lines, we know how the situation should be. To ensure that you obtain the best possible result assign our specialists to survey part of your production plant or ask us to carry out a complete plant audit.

The data recorded is used for the all-important stress analyses that help to determine the ideal kiln axis. The assessment of the mechanical condition of ball mills includes nondestructive examination (see also table below). The condition of gear units is ascertained by visual inspection and vibration analyses. Historical data is necessary to form a trend survey that will reveal wear tendencies. Large vibration variations are not necessarily an indication of defects. 2. Process evaluation and optimisation Process evaluation and optimisation investigations analyse: Raw materials processing. Kiln operation. Mill operation. Quality control. Both types of investigation are followed up by a provisional report describing the immediate action to be taken. Our specialists final report will contain an overall analysis of the present condition of the plant and will give detailed recommendations for the necessary remedial action.

The purpose of mechanical inspections is to avoid: 1. Machinery breakdown. 2. Unplarmed stoppages. 3. Excessive wear. 4. Uncontrolled maintenance costs

Process evaluation and optimization are necessary if you experience : 1. Falling output. 2. Unsatisfactory quality. 3. High production costs. 4. High maintenance costs.

Training at all levels within the cement plant enables the individuals to make the correct operational decisions within their scope of responsibility. Better understanding of the production, of the actual processes, of preventive maintenance and of the function of the machines, enables the staff to take rapid action if throughput falls, production costs increase or quality begins to decline. The end result is lower maintenance costs, higher run factor, higher output and a more dedicated workforce, all contributing to optimised plant operations. A well-trained staff reduces the need for specialist troubleshooting, which also lowers overheads.

Another use of training is in the circumstances when new technology is being introduced at the plant. New machines are constantly being developed and existing ones are being modified, all of which creates a need for knowing how to implement new technology. To meet these requirements, we offer a complete range of educational services: FLS Standard Courses. FLS Customised Training. FLS Training Packages. FLS Seminars.

Two types of inspection

1. Mechanical inspections: Mechanical inspections comprise analyses of the mechanical condition of all main machinery. The kiln axes are measured by state-of-the-art laser equipment. Other measurements focus on kiln ovality, mechanical balance, crank formation and damage to the surfaces of tyres and rollers and to the roller shafts. Part of inspection programme.

BALL MILL INSPECTIONS

PREVENTIVE
* Deflection measurements and axial

CORRECTIVE
Irregularity Mill output too low:

Probable causes
* unsuitable ball charge composition * badly worn balls * diaphragm unsuitable or clogged * unsuitable worn liners * change of material grindability * large pressure drop in separator due to worn rotor-blades * mill overfilled * separator clogged * feed size too large

movement on mill shell and trunnions * Temperature measurement in bearings * Measurement of mill shell thickness * Crack inspection of mill body * Visual inspection of mill - Externally: - Inlet and outlet - Mill body - Bearing housing - Bearing clearance and lubrication - Girth gear and mill drive * Visual inspection of mill - Internally

As shown by the diagram we undertake a special analysis to match the training programme to your needs.

Mill output too coarse :

2nd generation grate plate for Coolax Grate Cooler Welded tee-piece

3rd generation grate plate for Coolax Grate Cooler Cast in one piece

Original spare parts are easy to purchase, their quality is excellent and you save unexpected expenses. Telephone, telefax, e-mail and Internet have made communication easier and the world smaller. On receiving your enquiry, we immediately direct it to your contact person at F.L.Smidth. A comprehensive computerised system enables us to send you a rapid and appropriate reply.

Todays marketplace
Of course, everyone can find a component that looks like the one originally fitted in the machine. However, it is important to know the special adjustments and settings we had to make to ensure optimum function of the component within the machine. Even in cases where electrical systems are obsolete and no longer available, we are able to suggest the best alternative.

Lead times
We never compromise on quality. This is reflected in lead times, because all necessary production standards must be complied with. So lead times depend on physical and technical limitations. Meanwhile, our efficient shipping and despatch staff make sure that the paper work does not cause any delays. Our sales, shipping and purchasing staff are at the same location. This enables the entire relevant staff to have access to our mutual business. An integrated computer system provides all the necessary information to ensure that you receive the correct parts in good condition. This is your guarantee of rapid support to the highest quality standards. Checking Symetro gear shafts - at an accuracy of one micron.

Automatic updating of spare parts numbers ensures delivery of state-of-the-arttechnology in cases where this requires no adjustments to your existing production plant.

Buy as little as possible

If you are a regular customer with us we shall soon discover whether your plant is using an exceptionally high amount of spares. We do not just supply new parts but also help you to find the cause of such problems. Our spares support service is based on a computer system that records all sales to the individual plant. This system enable us to quickly identify any irregularities in your order.

Why buy original spares?

It is your insurance to obtain a product that matches the quality originally supplied. The spares are completely identical to those previously supplied by F.L.Smidth. This is your guarantee that the parts fit your production plant from the very start. You do not have to worry about adjustments that may weaken the product or allow additional time for replacement of parts. The costs you save easily outweigh the possible extra expense of purchasing original quality spares. Our spare parts lists, control procedures and quality system (ISO 9001) ensure that no errors are made.

F.L.Smidth components for non-FLS equipment

Many of our designs are used successfully at plants not supplied by F.L.Smidth. Tyres with loose supports that facilitate installation and increase the life of the tyres. Supporting rollers based on the anvil concept that has proved to reduce crack formation. Planetary cooler internals whose modular design and low weight make them easy to install and maintain. Varying height of the lifters minimises dust circulation, improving cooling effect and reducing calorie consumption. Mill liners for ball mills such as DUO-3, a standard lining that fits several types and sizes of mill.

No order is too large or too small

We try to make your purchase of spares as easy and trouble-free as possible. An advanced computer system ensures that orders are effected quickly. Irrespective of whether you are ordering a 5 gramme diode or a 116 tonne kiln tyre.

Original spares from F.L.Smidth are different

Our computer system ensures that old spare parts numbers are continuously updated and replaced by those given to new designs. Of course, only if the new parts have the same function and match the existing dimensions.

Spare parts support ranges from 116 tonne tyres to 5 gramme diodes. Spare parts catalogues are now also delivered on CDROM.

Plant inspections

Human Resource Development

Technical assistance / management

Original spare parts

A complete after-sales programme is your guarantee of objective advice and optimum solutions.

F.L. Smidth & Co. A/S l Vigerslev All 77 l DK-2500 Valby l Copenhagen l Denmark Phone : +45 36 18 10 00 l Fax : +45 36 44 11 19 l Tlx : 27050 flssp dk e-mail: psd@flsmidth.com l Website : www.flsmidth.com

Parts & Services Division