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Operation Background
The Cementos San Marcos plant, which officially began operations in 2012, is located in the municipality of Yumbo, in the town of San Marcos Valle del Cauca, Colombia. Currently, the plant has a production capacity of 12,700 tons per month of Portland Cement. Since 2016, it has had a Loesche 3.2+2 primary mill with a Santasalo vertical reducer of 1800 kW.
The Case
The Santasalo gearbox of the Loesche mill had been running at a reduced load for some time due to incipient damage to the bevel gear pair and planetary stage. This situation evolved into the catastrophic failure of the input gear set bevel gear-pair, ring gear, and sun shaft.
Technical Solution
ABS inspected all components in detail and concluded that, for an optimal solution, it recommended manufacturing a new bevel gear spar and planetary stage gear set using state-of-the-art materials and heat treatments and defining an optimized gear microgeometry that would increase the gearbox reliability. Cementos San Marcos decided to follow the recommendation and entrusted ABS with the manufacture of the entire gearbox transmission set and the on-site supervision of the assembly of its components with specialized engineers from our factory in Italy, MGS Gears.
Execution of the work
ABS programmed the following sequence of works:
- The inspection of all the components associated with the failure.
- Dimensional survey on site.
- Ship the damaged parts to the MGS Gears factory in Italy for analysis and dimensional survey.
- Advisory service for the assembly of the parts and verification of fine adjustments to guarantee the reliability of the gearbox.
Once all the gearbox parts were manufactured and tested in our factory in Italy, they were sent to the plant in Colombia, and the assembly was planned, establishing 12 days of joint work between ABS and Cementos San Marcos. It is worth highlighting the magnificent collaborative environment between both teams and the level of intensity, precision, and detail necessary to achieve the adjustments and tolerances required by the AGMA standard.
Another success story
When you have the experience, capacity, and predisposition to collaborate with highly qualified professionals and work actively to integrate and analyze the different visions, there is only one result: the achievement of the objectives set in the estimated time. Cementos San Marcos now has wholly refurbished equipment, repowered and ready to perform at full capacity and with full guarantees.
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Manufacture of the Loesche 3,2+2 Cement Mill vertical gearbox transmission set and supervision of assembly on location
ABS and MGS GEARS, Technical Excellence for the Heavy Industry
For over 20 years, we have been offering products and engineering solutions for all types of industrial applications drives such as Ball Mills, Rotary Dryer Furnaces, Bucket Elevators, using gearboxes and components capable of adapting to any assembly requirement, space availability, and required torque and ratio, etc. We count on a wide range of special bearings and power transmission solutions for the CEMENT industry to help optimize your production processes and extend the life of your industrial equipment.”
