Case Study: Rugby Cement Works
Summary: Magnom™ Process Unit installed in an off-line lubrication circuit for the main cement kiln transmission
Customer: Rugby Cement
Barrington works
UK
Application(s): Transmissions [Large Scale] Lubrication Oils
Industry(s): Industrial Hydraulics
Notes
Rugby Cement at Barrington (UK) employ a conventional rotary kiln as an integral part of the cement production process. The kiln utilises a girth gear transmission drive with an open lubrication system with synthetic lube oil, supplied by ExxonMobil (ISO VG 3200), spray fed directly onto the gears.
Routine fluid analysis in 2002 evidenced substantial contamination indicating significant wear to the pump and gear teeth. In this instance, the lubrication system had clearly been accumulating and recirculating damaging debris for a significant period of time which inevitably led to a chain reaction of wear and a very real threat of catastrophic failure of the system.
During an ExxonMobil open gear oil cleanliness project with Rugby cement at Barrington in the Autumn of 2002, a two inch nominal bore Magnom™ `Process Unit was fitted on the suction side of the system pump. This was possible due to the negligible pressure drop characteristic of this non barrier magnetic device. The system’s effect was then monitored.
After circa one week’s operation the Magnom™ core was removed for inspection and was found to be laden with contaminant, (2 kg est.). Subsequent analysis showed this to be both ferrous and non ferrous with a significant number of large (5mm+) ferrous particles assumed to originate from the gear teeth.
The unit was cleaned and returned to operation. Periodic inspection and cleaning showed a continuous improvement in system cleanliness with the average size of the ferrous particulate being driven down to well below the 5 micron level, this has subsequently been maintained.
As the first photograph shows - the Magnom is a fully ruggedised unit!
Customer comments
“A highly successful installation – Magnom is ideal for Transmission protection for Kiln Drives, Cement Mills and also for Coal Pulverising Mills common to all Cement Production.”
Benefits
- Protection (life extension) of transmission
- Reduced downtime
- Replacement of existing filtration (disposable)
- Reduced waste disposal requirements
Clearly the Magnom™ technology has played a vital role in system protection and offers significant benefits in extending both asset life but also fluid life with associated cost savings to the plant – both in terms of plant failure but, much more significantly, the heavy premium of plant downtime and lost production.
Installation notes
The Magnom was installed in the vertical position to assist core removal for cleaning.