Cement plant gearbox oil and vibration monitoring
We monitor oil and vibration continuously on kiln, mill and fan gearboxes. You see the change in the oil before an unplanned kiln stop.
- 1Vibration · Input shaft bearing
- 2Temperature · Input shaft bearing
- 3Vibration · Output shaft bearing
- 4Temperature · Output shaft bearing
- 5Oil sensor · Oil sump
Monitored equipment
Rotary kiln drive gearbox, vertical mill gearbox, ball mill gearbox, fans (gearboxes and bearings), crusher, hydraulic unit, compressor.
| Topic | In this industry |
|---|---|
| Main oil risk | Dust, high heat, contamination |
| Monitoring goal | Continuous monitoring of kiln-line oil |
| Benefit | Lower risk of unplanned kiln stops. |
The right product and monitoring level are defined at the quote stage.
What we measure
In the oil, viscosity, water and moisture, oil ageing, particle contamination (ISO 4406 code) and the wear-metal trend are measured. On the machine, vibration level and temperature are monitored. When a reading moves away from the machine's normal range, the screen changes from green to amber or red. Warning signs and what they mean
What we do not measure: metal identification (which metal a particle is), acid and base number (TAN/TBN) and vibration spectrum analysis (FFT). These tests need a laboratory and a specialist. DataMonitor does not replace them. It works alongside them. The system watches for warning signs and gives early warning. It does not diagnose faults.
Cement FAQ
How often should kiln drive gearbox oil be changed?
There is no single correct interval. It depends on the gearbox manufacturer's recommendation and the measured condition of the oil. The interval should follow test results rather than the calendar. Changing too often wastes time, and changing too late shortens oil life (US USBR FIST 2-4).
How can oil condition be monitored in a dusty cement plant?
Sensors on the oil line show how dust and heat are affecting the oil. The particle counter reports contamination as an ISO 4406 code. The oil sensor shows viscosity, water and ageing. When the code or the ageing trend rises, an alarm prompts you to check the filter and seals. So you change the oil by its condition rather than by the calendar.
What is measured on mill and fan gearboxes?
In the gearbox oil we track viscosity, water, ageing, particle contamination (ISO 4406) and the wear-metal particle trend. On fan and gearbox bearings we measure vibration level (RMS velocity) and temperature. The overall vibration level is a simple indicator rather than a full analysis (NASA RCM Guide). Reading it together with the oil data gives a clearer picture.
A quote for your machine
The machine, the oil in use and the problem are discussed by phone. The right product and monitoring level are defined. The price is sent as a written quote.
- Product recommendation for your machine
- Written quote
- Installation and alarm set-up included