Restoring Grout on CMD Gearbox, Auxiliary and GE Induction Motor

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In the world of cement manufacturing, clinker crusher systems are vital to the production process. When a clinker crusher system began experiencing problems, our team was brought in to get it back on track.

 

The Problem and Solution

 

The system in question, known as the Broyeur Klinker 1 (Clinker Crusher 1), is composed of a Polysius ball mill driven by a GE induction motor with powerful 4000HP output, working at 985 rpm. The main gearbox, a CMD JC30SP model, reduces this rotation speed to 16.4 rpm.

However, when the gearbox was replaced in 2007, it became clear that several modifications were needed to ensure it was properly installed. Initial reports suggested that the baseplate used for the installation was not level, horizontal, or at the correct height, which could be the root of the mechanical problems the system was experiencing.

The foundation size was big enough for this type of machinery, so the solution was a proper epoxy regrout, epoxy injection and reinstallation to solve the vibration problem.



Features

Client
Votorantim Cimento
Final user
Asment Temara Plant
Project
Injection Foundation Repairs, Regrout & Realignment, Polyssius Mill Drive Train
Equipment
CMD Jumborex JC30SP 4000 HP @ 985 RPM, GE Induction Motor, Auxiliary turning gear box
Work period
30 Sep – 14 Oct 2015
Location
Temara, Morocco

The Procedure

 

We carefully removed the gearbox from its position, using hydraulic jacks for lifting and a set of rails to move it sideways. We then proceeded to drill three injection holes, each 3.5 metres long and approximately one metre from the centre hole, as part of the injection procedure.

After cleaning all concrete surfaces and protecting anchor bolts, we used our specially designed Alphatec® 800 epoxy grout to regrout and re-install the gearbox. Injecting Alphatec® 342 epoxy resin into the foundation helped seal any cracks within the one metre radius around the area, blocking any oil from penetrating the foundation and sealing all the cold joints. This allowed the foundation to act as a whole, damping any vibration and ensuring the system could operate smoothly.

Using our state-of-the-art, specially designed Alphapads® for fine levelling and laser alignment, we aligned the gearbox to the mill with exceptional accuracy. We repeated this procedure for the auxiliary unit and GE induction motor, ensuring that everything was properly aligned and stable. Finally, we mixed and poured epoxy grout until the baseplates were completely covered.

 

Conclusion

 

Thanks to our team’s precision engineering and careful attention to detail, the clinker crusher system was back up and running smoothly in no time. Our success in this project demonstrates the importance of proper installation, maintenance, and engineering in the world of cement manufacturing.