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April 24, 2024

From Shake to Steady: Buzzi Unicem USA Case Study

RDI Technologies

From Shake to Steady: Buzzi Unicem USA is one of the leading cement manufacturing companies in the US. Headquartered in Bethlehem, PA, Buzzi Unicem nationally recognizes the importance of maintaining and enhancing the occupational Health and Safety of their employees, contractors, and suppliers across all 7 cement plants and 34 cement terminals. They aim to eliminate injuries and occupational illnesses entirely.

From Shake to Steady:

Buzzi Unicem USA is one of the leading cement manufacturing companies in the US. Headquartered in Bethlehem, PA, Buzzi Unicem nationally recognizes the importance of maintaining and enhancing the occupational Health and Safety of their employees, contractors, and suppliers across all 7 cement plants and 34 cement terminals. They aim to eliminate injuries and occupational illnesses entirely.

They exemplified their commitment to safety when they encountered foundation concerns with a raw mill at their Festus, Missouri, site. Their collaboration with RDI Technologies underscores a commitment to informed decision-making, ensuring operational stability and security. The partnership resulted in a 73% reduction in vibration levels.

The Importance of Proactive Maintenance:

In the industrial landscape, proactive maintenance is the cornerstone of reliability and safety. Buzzi Unicem USA was proactive in identifying the foundation concerns with a raw mill at their Festus, Missouri, site. Recognizing the criticality of the situation, they reached out to RDI Technologies for assistance. They sought a solution to address vibration and movement issues. If Buzzi Unicem had not addressed the problems, the raw mill could have been shut down for a period of time, needed more costly fixes performed, and could have put their employees at health and safety risk.

RDI Technologies Services:

Buzzi Unicem USA’s proactive approach led them to contract RDI Technologies for a Motion Amplification® service visit. Scott Burkhart, Director of Services, and Jim Bricco, Senior Service Engineer, utilized the Iris M™ System, Motion Amplification®, Shaft Inspection, and Motion & Phase Map. They identified key vibration frequencies through meticulous analysis, primarily linked to mill and motor speeds. Noteworthy base movement, associated with mill speed, was identified, prompting a set of comprehensive recommendations.

Recommendations and Implementation:

Based on the data collected, RDI Services recommended securing all hold-down bolts on pedestals and scheduling Motion Amplification follow-up recordings post-foundation repairs for commissioning and baselining purposes. Buzzi Unicem USA diligently implemented these recommendations.

The Results:

The implementation of RDI Services’ recommendations yielded significant improvements:

  • Total Displacement Reduction: From 57 mils to 15.5 mils.
  • Elimination of South and West Side Mill Vibrations.
  • Achieved Similar Relative Phase among the Motor and Gearbox of the Raw Mill.

 

Conclusion:

The collaboration between Buzzi Unicem USA and RDI Technologies exemplifies the power of proactive maintenance in ensuring operational reliability and safety in industrial settings. By leveraging advanced technologies and expertise, Buzzi Unicem addressed immediate concerns and laid the foundation for long-term stability and efficiency in their raw mill. This case study is a testament to the value of informed decision-making and proactive maintenance practices in industrial operations.

 

View the Case Study & Motion Amplification Video

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