Engineering Reliability Specialists

Carbon Plant Ball Mill

Aluminium Smelting Continuous Condition Based Monitoring

DMS currently are the contract supplier for all condition based monitoring services at one of the UK’s leading aluminium smelting plants. Prior to the contract being awarded to DMS, the carbon plant within the

smelting plant had a catastrophic failure on their main gear reducer that drives the Ball Mill.

The Ball Mill was down for a number of days while a replacement gear reducer was installed. DMS were then asked to consider the application in question & provide the client with a solution for continuously monitoring the key components within the drive train.

The “MachineGuard” system proposed was wireless and was specified to monitor the motor drive end bearings, the gear reducer in all three plains on both the input and output lines, and the ball mill pinion support shaft pedestal shaft bearings.

The system was installed during an agreed maintenance window and was initially set up to run on the “MachineGuard” stand alone software on a specific PC in the plant operations room. During the first three months following the installation, the system warned the engineers that the vibration levels on the ball mill pinion support shaft bearings had increased to alarm levels.

At the next available ball mill stoppage an inspection was undertaken to determine the problem in question and it was found that the pedestal shaft bearing top housing had started to work loose, resulting in the increased levels of vibration.

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