Field Assembly of a Custom Cement Mill Bearing Support System

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ABS completed the field assembly, installation, and commissioning of an ACB custom split bearing support system for a Plug&Grind® XL cement mill, working closely with the customer’s maintenance and engineering teams.

The intervention included dimensional verification, controlled assembly of the split housings and bearing components, mill positioning and precision alignment, lubrication system preparation, and final commissioning. The installed solution is designed to reduce downtime for future bearing replacements by up to 70% and has since accumulated more than 6,000 operating hours with stable and reliable performance.

Sector: Cement Industry

Equipment: Plug&Grind® XL Modular Cement Mill

Field Scope: Assembly, installation, alignment, lubrication, and commissioning of the complete split bearing support system.

Criticality: High — technically demanding field intervention requiring precise component assembly and mill alignment to ensure reliable operation under continuous production conditions.

Key Factors:

• Up to 70% less downtime — the split configuration enables significantly faster future bearing replacements
• 15-day field intervention — structured execution under demanding site conditions
• Complete split-system assembly — installation of the custom housings, SRB, and STRB
• Mill positioning and precision alignment — controlled leveling and preparation for final drivetrain alignment
• Successful commissioning — correct lubrication, alignment, and stable initial operation confirmed
• 6,000+ operating hours — stable and reliable performance under continuous production conditions

This project involved the field assembly of a custom-engineered bearing support system for a Plug&Grind® XL modular cement mill. The custom-engineered ABS solution replaced the original bearing arrangement with a fully integrated split system comprising custom split housings, a split spherical roller bearing (SRB) on the fixed side, and a split toroidal roller bearing (STRB) on the free side. Specifically engineered to simplify future maintenance, the new configuration enables bearing replacement without removing the shaft or dismantling the support housings, helping reduce future maintenance downtime and improve long-term maintainability. The field assembly of the complete split bearing support system required detailed dimensional verification, controlled assembly of the housing and bearing components, precise mill positioning and alignment, and preparation for commissioning. Executed in close collaboration with the customer’s maintenance and engineering teams, this technically demanding field intervention demonstrated ABS’s capability to deliver complex engineered installations under real operating conditions.

Over approximately 15 days, ABS field engineers and technical specialists carried out the installation under demanding site conditions, following a structured execution plan that included:

• Site inspection and work area preparation.

• Trunnion inspection and precision dimensional verification.

• Surface condition assessment and fit verification.

• Installation of the custom split bearing housings.

• Field assembly of the split spherical roller bearing (SRB) and split toroidal roller bearing (STRB).

• Integration of the complete split bearing support system.

• Mill positioning and precision alignment.

• Lubrication system preparation.

• Final installation checks, assembly verification and preparation for commissioning.

ABS and customer teams preparing the custom split bearing housing for installation.

Controlled field assembly of the ACB Split Spherical Roller Bearing (SRB) and custom housing.

ACB Split Spherical Roller Bearing (SRB) assembled within its custom-engineered housing during field installation.

ACB custom split bearing support system positioned on the Plug&Grind® XL cement mill during field installation.

Following completion of the bearing assembly, the mill was lifted and positioned on the existing support rails. Final bolting and leveling were carried out after confirming the condition of the base surfaces and completing minor cleaning and adjustments where required. Threaded leveling bolts were used to achieve precise vertical positioning, while additional shims were prepared in case further adjustment was required during final placement. Because the internal liners had not yet been installed, final drivetrain alignment was deferred until the mill reached its final operating configuration, ensuring accurate coupling geometry under operating conditions.

Plug&Grind XL cement mill being positioned with ACB split bearing support systems

ACB Bearing Support System on Plug&Grind XL Mill

Field positioning and alignment of a Plug&Grind XL cement mill by ABS

All bearing and housing components were handled following strict cleanliness and alignment protocols throughout the assembly process. Component seating and alignment were progressively verified as the split bearing elements and custom housings were installed. The controlled assembly process ensured proper seating and seamless integration of the custom split housings and bearing elements, demonstrating the robustness and maintainability of the engineered bearing support system.

Both bearings were pre-lubricated using high-performance grease suitable for extreme loads and moderate rotational speeds. Double labyrinth seals were installed and verified on site to ensure long-term contamination control.

The lubrication system was completed by aligning the lubrication lines and adapting the fittings to ensure minimal flow resistance and maintain proper operating pressure throughout commissioning.

Following successful commissioning, the bearing support system entered service as planned. Initial operation confirmed correct lubrication, proper alignment and stable system performance.

Since commissioning, the system has accumulated more than 6,000 operating hours, maintaining stable and reliable performance under continuous production conditions. Routine maintenance inspections have confirmed that the system continues to operate as expected.

At ABS, engineering does not end with design or manufacturing. It continues through field execution and commissioning, ensuring every engineered solution is successfully installed, commissioned and validated for long-term operation. This integrated approach improves  maintainability, supports long-term equipment reliability and maximizes the performance of critical rotating equipment.

ACB Split Bearing Support System in Operation