Condition monitoring systems(CAM) by Imco Alloys

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An international company of repute with over a decade in research and development, manufacturing and marketing of wear resistant solutions to a wide range of industries in India and abroad. Solutions include various applications for crushing hammers, impact blades, rotors, cutter and liners used in different industries such as Sugar, Steel, Cement, Power Stations, Refractory, brick and tiles, Mining, etc. IMCO caters to more than 2000 mills in India and abroad, we export specialized applications to Thailand, Mauritius, China, Australia, Africa, Indonesia, France etc. Team of skilled, highly professional, enthusiastic engineers within reach of our customers.

We bring to you the following:

1. I & A ( Inspection & Analysis) of all critical Mill parts

Entire Mill Area including preparatory devices like Choppers ,Levellers, Fibrisors & Sugar Mill rollers .This includes Shafts & their journal Areas, Rotor bodies, Motors, Anvil , Firbizor hammers, Knife bodies, Rollers, Pinion,Liners, Couplings and other related components. The process involves a thorough inspection of the dismantled components by IMCO experts for visual, dimensional, mechanical, electrical as well as non destructive tests like IT , MPT or DPT as and where required.

2.Recommendations & report submissions:

Based on the condition of the components IMCO will submit a comprehensive report with recommendations for repair, reconditioning or replacement.

3. R&R: Reconditioning and /or Replacement job :

Based on acceptance of proposal ,Components /equipment to be reconditioned or replaced,jobs to be done at factory or IMCO’s state of the art workshop in Ambernath as required and reconditioned or new equipment to be readied for installation with dynamic balancing for rotary equipment.

4. Re-Installation of equipment:

Installation to be done by plant with supervision of critical components by IMCO experts . This includes dynamic balancing of rotary equipment after installation, checking of electricals,etc.

5. Installation & Commissioning & calibration of thresh-hold values:

Installation monitoring equipment at critical locations on the machinery and threshold limit calibrations to be done with the recommendations of the plant team over a period of one month after the plant starts running.

6. Real time monitoring at given frequency

Data will be monitored in real time over as per the threshold limits and frequencies set for each data point.

Predictive Maintenance for Rotating Equipment

Problem

No access to real-time insights on vibration of rotors
No access to full life cycle and remote monitoring for predictive maintenance.
Threshold values – No real time alerts in case the threshold values are breached
Unscheduled downtime and breakdown

Solutions

COINs are installed on machinery from which insights are required.
Temperature and Vibration sensors in COIN will record any irregularities (upper and lower threshold values) at regular intervals and shares this data real-time over the cloud via our Wi-Fi or Ethernet gateway.
The manual process of monitoring the health of machines every 15 to 20 days is eliminated using our solutions
We can analyze historical data to identify the root cause and location of frequently occurring issues.

Benefits

Predict asset failures in advance (FFT)
100% uptime without breakdown
Periodic reports for better planning
Higher Productivity
Lower Operational Cost & Economical

COIN- Our Flagship Product

Communication speed - 1 Mbps. Suitable for high speed & high data applications. Self-learning and self-healing capabilities.( out of network if the battery is down for whatever reasons the system reconnects by the shortest avl route- keeps on hunting.
Self Healing- the coin that was down will start and hunt and self heal on its own.
Range - 180 ft per node max subject to interference. Range increases with more nodes in the mesh. ( coin to coin is node to router) if coins are not able to connect to the gateway the additional coin will act as a booster.
Machine learning and edge computing on every node. Studying vibration patterns to formulate with algorithms will keep on comparing and if the difference is within range). Edge computing is a processing happening on every coin – load . This reduces lag.
D type battery

Advantages of Condition & Monitor

Avoid breakdown.
Predict failures in advance.
Get periodic reports for better planning.
Get higher productivity.
Lower operations and maintenance cost.
Keep your plant perfect.

Benefits	Features	Advantages
No Need of Maintenance, Calibration	Calibrated for life	No downtime, No periodic service
Readings in Deg Celsius or Fahrenheit	Units as per your needs	Easy readings
No data Loss in case of power down	COIN + Gateways has onboard flash memory	Always stay connected to machines
Wide Temp. range of operating conditions across winter/ summer	Temp from -40 to +80 Deg C	Any existing + other machines operating in other conditions can be covered.
% RH wide range in Winter & summer	% RH from 0-95%	Any existing + future machines can be covered ( RH will be measured within an area covering 1-3ft in radius from the sensor).
Will cover all your vibrations patterns	Vibration – from 0 to 16 g (m/s2) available, can give Velocity, Displacement, Acceleration	No need to have additional sensors/ Hardware ( velocity of vibration (time required),displacement ( height of the vibration),Acceleration (G value)
Always up to date software	Can be updated via internet Hardware has onboard microprocessor +	Cutting edge technology in Industry 4.0
Remote connected	Hardware has onboard microprocessor + Networking ability