Clinker Conveyor Condition Monitoring Supports Planned Maintenance
Machine Sentry monitoring provides early fault visibility across a critical cement conveyor motor and gearbox drive
CementProducts used
Machine Sentry Fixed MSF2 Machine Sentry Mobile MSM2 Machine Sentry Next Generation Software
Working to Achieve
AVT Reliability® supports this major EMEA cement producer in maintaining continuous operations by enabling condition-based maintenance through remote vibration monitoring. Using Machine Sentry® fixed vibration sensors, AVT’s Remote Diagnostic Centre (RDC) detected early signs of alignment issues on a critical clinker transport conveyor motor.
The Challenge
The asset monitored was a motor-driven gearbox powering a clinker transport conveyor. It is a critical component of the cement manufacturing process, with no built- in redundancy. A failure in service would result in immediate production stoppage, potentially leading to significant downtime, repair costs, and lost output. Early fault detection was essential to avoid unplanned disruption.
Our Approach
At the time the fault was detected, vibration data was being collected daily and analysed bi-weekly. In response to the developing trend, AVT increased both the data collection frequency (to multiple times per day) and the analysis schedule (twice weekly). The escalated monitoring strategy allowed for real-time tracking of fault development.
Our Findings
In December 2024, AVT’s RDC team observed a rising trend in both velocity and acceleration levels on the motor and gearbox input. These changes followed a recent motor bearing replacement. Spectral analysis revealed a dominant peak at 3x running speed (3x RPM), typically associated with misalignment. As vibration levels continued to increase, the analysis frequency was increased and the Action Note priority was raised from medium to
urgent. Figures showed progressively worsening vibration patterns, prompting AVT to advise realignment of the coupling. The client ultimately decided to replace both the motor and the coupling.
The Solution
During a planned maintenance shutdown, the client installed a new electric motor and coupling. Following installation, vibration levels dropped significantly across both velocity and acceleration readings. The asset was confirmed to be operating within acceptable limits, and Machine Sentry®
monitoring confirmed that the misalignment issue had been resolved.
Follow-Up
The motor and coupling replacement successfully eliminated the vibration anomaly. Had this issue gone unresolved, continued misalignment could have resulted in coupling failure, accelerated bearing wear, or gear damage, leading to costly unplanned downtime. Early detection and timely intervention
enabled the client to maintain full production availability and avoid estimated losses associated with catastrophic failure.
"Increasing monitoring frequency allowed us to stay ahead of the issue. The data made the decision clear, and the asset is now running within normal parameters."
Remote Diagnostic Centre, AVT Reliability®
At a Glance
- INDUSTRY: Cement Manufacturing
- PROCESS: Clinker transport conveyor system
- EQUIPMENT: Electric motor driving gearbox
- PRODUCTS: Machine Sentry® Sensors
- SERVICES: Remote condition monitoring and vibration diagnostics
