Hansford ensures efficiency in Cement industry through real-time vibration monitoring

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Published: 06th February 2017
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What is the company?

Hansford Sensors, a leading global supplier and manufacturer of industrial accelerometers, ancillary equipment and loop powered sensors, has wide range of industry applications for vibration monitoring. They design, develop and manufacture vibration sensors for world's leading companies at competitive prices with outstanding customer and technical support. Vibration Sensors is estimated to carry a potential of $34 billion by 2020.

Which industries does it serve?
In the Metals industry, their vibration sensors and vibration transmitters protect cooling towers and rolling mills. In the Food and Beverage industry their accelerometers monitor fans, ovens, mixers, conveyors and centrifuges. In Pharmaceuticals, vibration sensors protect the whole motor and fan components in air handling units. In the Marine applications, the vibration sensors help to avoid the machine delays and failure by monitoring turbochargers, cargo pumps, and ventilation fans. In Wind Power, the accelerometers help to keep turbines working in any kind of weather and prevent damage. In Paper mills, industrial accelerometers are built to withstand aggressive conditions for total reliability. In the Coal & Quarry sector, vibration sensors are used to monitor pumps, crushers and conveyors. Finally in the Cement sector, their vibration sensors are used in critical condition monitoring systems on mills, kilns, silos and crushers.

What is the recent achievement?
Very recently the company has launched the multi-sensor switch box which would help for easy data collection. It helps to collect the vibration data from remotely placed accelerometers. The HS-SRM with a stainless steel enclosure and a slant roof top is a new addition to its multi-sensor switch boxes line.
Application of Vibration Sensors in Cement Industry

Cement manufacturing is a standout amongst the most demanding industrial situations, with high centralizations of dust, extremes of temperature and serious mechanical weights on working equipment. The commonly manufactured Portland cement causes sullying at all phases of production, from the procurement of crude materials to final stage of packing and loading. This tough operating condition makes the techniques such as condition monitoring and predictive maintenance feel important, with vibration monitoring being a primary tool used by plant, process and maintenance engineers.

Vibration sensors would be installed on cement manufacturing assets such as crushers, kilns, conveyor belt, seperators, elevators, screens, raw mills and blowers. Cement manufacturing applications utilize 4-20mA accelerometers associated with PLC systems. Every sensor is hard-wired to a sealed nearby intersection box and later multicore cable is utilized to associate with a PLC. This empowers the accelerometers to be utilized for alarm, real time monitoring and critical analysis.

The determination of the right sensor is vital for accuracy and optimum performance. For instance of sensor installation on a conveyor, crusher and screen, a side-entry model may be favored more than a top-entry component to avoid debris harming the sensor connections. On the other hand, for hazardous locations, safe accelerometers are needed, while for equipment in sumps the submersible sensors are required.

What is the result?
The results of frequently gathered and analyzed data can lead to huge improvement in plant effectiveness, driving to decrease maintenance costs and enhance efficiency. As an instance, an accelerometer or vibration transmitter mounted on a cooling fan can give data to recognize small and potential critical changes in operating conditions. These may be created by inaccurately deployed bearings, a detachable bearing that was not correctly locked down, or a matrix coupler running dry or any mix of those or different issues.

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