Sample Factory

Rotary Kiln #1 Hot Kiln Alignment

18-23 March 2012
ROTARY KILN SERVICES - TYRE, ROLLER THRUST ROLLER ON SITE MACHINING AND GRINDING - HOT KILN ALIGNMENT
BOSB Birlik Sanayi Sitesi 5. Cadde No:32 34520 Beylikduzu Istanbul TURKEY Phone: +90212 879 23 29 Fax: +90212 861 53 02 E-Mail: bilgi@ozekmakina.com
www.rotarykiln.eu
Sample Factory
Page
1
www.rotarykiln.eu
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3
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Foreword
Description of Measurements
Written Report
Basic Inspection
7
8
9
10
11
12
Coordinating System, Symbol and Terms
Axial Deviations
Slope of Axis, Tyre and Rollers
Suggested Alignment
Shell Heat Map
Roller Bed Temperatures
13
14
15
16
17
18
19
Under-tyre Gaps and Relative Movements
Tyre and Roller Movements
Roller Operating Angles
Roller Skew Positions
Roller Shaft Conditions
Roller and Shaft Positions and Lubrication
Roller Surface Wear
20
21
22
23
Wobbling
Ovality
Shell Deformation
Shell Sections
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
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2
FOREWORD
As a main component of today's cement factories; rotary kilns have became an expensive-to-stop unit because of the increasing
demand, competition and production continuity policy. However, rotary kilns are mainly made of steel and work in hot conditions
which deforms the initial design of the kiln. By the help of technological improvements, many variables of rotary kilns can be
observed and some other important variables should be observed by alignment professionals for an on-time intervention and better
maintenance.
Rotary kiln alignment reports mean a technical photo of the rotary kilns which work on the presicion stability condiditons and these
reports help to undertand and solve the problems when it is resolvable by preventive maintenance.
Ozek Makina improves its rotary kiln service experience with technological add-ons and presents presicion hot kiln alignment
services and targets to provide clean, easy and understandable reports.
We believe, the main saving for the rotary kiln is having an annual kiln analyse which helps for a better preventive maintenance and
durable working life.
Best Regards,
Ali ZEK
Mustafa ZEK
Zeki ZEK
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
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3
SCOPE
KILN
Basic inspection of working conditions.
Establishing the coordinate system.
Determining the horizontal and vertical axis deviations.
PIERS
Determining the roller skews and axial movement.
Measuring the roller and tyre diameters.
* Determining the concave, convex or conical wear.
Calculating the roller working angles.
Determining the surface conditions of tyre and roller.
Inspecting the roller bed lubrication efficiency.
Measuring the independent roller and tyre slopes.
Measuring the tyre relative movement.
Measuring the under-tyre gap.
Measurement of tyre wobbling.
GEARS
Basic inspection of girth and pinion gears.
Inspection of tooth condition.
6 point backlash measurement.
Lubrication efficiency.
Individual slope measurement.
Girth gear wobbling measurement.
SHELL
Measuring the shell deformation.
Calculation of shell run-out and eccentricity.
Measurement of shell and roller bed temperatures.
Design of the shell deformation map.
Analyse of measurements.
Preparing of the report.
Presentation of report.
ALIGNMENT SUPERVISION
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
4
WRITTEN REPORT
All measurements are taken on site during kiln's normal working
conditions on 18-23 March 2012 by Ozek Makina alignment team.
Piers are numbered starting from the discharge. When you look from
the discharge, office side is accepted as left and mill side is right. The
manhole line is starting point for all diametral measurements.
AXIS
As a result of axial deviation measurements, it is observed that the
middle pier is out of axial line, 6 mm to office side and 1 mm up. As it is
described in suggested alignment page, it is adviced to move the piers
to axial bas eline by 0,5 mm movement on numbered bearings
maximum 2 mm a day.
SLOPE
Kiln axial slope and individual tyre, roller and gear slopes are
measured during the rotation and it is observed that all piers have
parallel slopes except feed pier mill side roller.
As it is described in slope of axis page, it is recommended to add 4 mm
shims under the feed pier, mill side roller (discharge side.)
SHELL
High shell deformation is observed between girth gear and middle pier,
feed side of discharge tyre and discharge hood. (Please see shell
deformation page.) It is advised to keep track regularly on these
sections.
Local shell deformations cause local brick problems and hot spots on
shell but also crank on whole shell. Eccentricity is caused by the crank
and distributes unequal loads on rollers.
Unstable shell temperature can effect the shell itself, bricks and
undertyre gaps.
It is observed that bed temperatures are in tolerance during
measurements.
It is observed that under tyre gaps and roletive movement is in
tolerance.
TYRES AND ROLLERS
All diameters of tyres and rollers are measured on site and it is
observed that working angles are in tolerance to distribute the loads on
rollers equally.
Cracks on feed pier rollers may cause marks and cracks on tyre
surface in future.
Feed and discharge tyres has 3 mm conical wear which may cause
alignment failure and low tyre/roller contact.
Middle pier tyres and rollers are newly machined and in good condition
Feed pier tyre's thrust roller working side is in good condition. The
contact between thrust roller and tyre is acceptible. Hydraulic thrust
roller has 0-50 bar press. Kiln is working on down side and feed side
thrust roller does not work usually.
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
5
ALIGNMENT
4 rollers are carrying the kiln up and 2 rollers are carrying it down. It is
recommended to increase the contact surfaces of middle pier rollers
and tyre if necessary.
No eccentricity is observed on shaft miles. Discharge rollers have
eliptical wear and causes unequal load distribution.
Roller beds are in good condition and good lubrication efficiency
except feed pier mill side roller feed side bed.
All roller diamaters are measured on 5 different points and wear
problems are observed in discharge rollers.
All tyre and girth gear wobbling conditions are measured and it is
obesrved that the values are in tolerance.
GEARS
All teeth of girth and both pinion rollers are in good condition.
Lubrication efficiency is acceptible. Backlash values are between 11-
16 mm. Both side baclash values are equal.
There is high vibration and sound noise in motor area caused by the
kiln crank and eccentricity.
SUGGESTIONS
Shell temperature should be kept stable.
Kiln should work in up and down positions in equal times.
Dry lubrication graphite blocks should be checked regularly.
Discharge seal should be maintained in first shut down.
All 1,5 mm movements on rollers takes the kiln center 1 mm down or
up depending on the movement.
Measurement plates should be placed on roller beds before alignment
movements.
Cracks on the tyre stop blocks of feed tyre should be maintained in first
shut down.
WRITTEN REPORT
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
6
BASIC INSPECTION
Feed seal is in good condition.
There are cracks on both rollers of feed pier which
causes unequal load distribution and marks on tyre
surface.
Hydraulic thrust roller has a pressure between
0 - 50 bars.
Shell surface has spots caused by brick problems
and build-up.
The teeth of girth gear and pinion are in good
condition. Backlash is in 11-16 mm range.
Backlash measurements are same at both sides.
Discharge seal leaks clinker out which causes wear
on roller and tyre surfaces of discharge pier.
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
7
COORDINATING SYSTEM, SYMBOLS AND TERMS
1. Pier
2. Pier
3. Pier
Girth Gear
s

dy
dz
ds
c
Under tyre gap
Roller operating angle
Slope
Horizontal axis deviation.
Vertical axis deviation
Roller skew
Backlash
Manhole line is starting point for
all diametral measurements.
Office side
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
8
AXIAL DEVIATIONS
X
Y
Z
4555 mm
+0 mm
+0 mm
X
Y
Z
0 mm
+0 mm
+0 mm
O
f
f
i
c
e

S
i
d
e
M
i
l
l

S
i
d
e
X
Y
Z
2507 mm
+6 mm
+1 mm
The tolerance of axial deviation is 1,5 mm for this kiln.
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
%3,5
%3,6
%3,6
%3,6
%3,9
%3,6
%3,7
4 mm shim
In tolerance
Out of tolerance
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SLOPE OF AXIS, TYRE AND ROLLERS
Tyre and roller slopes are also
measured by the slope sensors
which is mounted on the sides
of t yr es and r ol l er s dur i ng
rotation.
This helps us to double check
the slope data and get better
results.
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Slope differences between tyre and rollers causes conical wear on both surfaces and wear on shaft and bed because of unequal loads. Max 0,2 difference
accepted in tolerance for this kiln. ( If it is 2 m between two alignment bolts, %0,1 difference means 2mm shim.)
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10
SUGGESTED ALIGNMENT
7,5 mm
4,5 mm
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
It is suggested to align the pier by moving 0,5 mm every bed in order. (Numbers on beds show the order.) A bed should be moved Max. 2 mm a day.
The move which takes the tyre center down should be choosen for start.
100 C
200 C
300 C
400 C
500 C
600 C
Max
Min
358
214
Max
Min
356
174
Max
Min
218
118
Max
Min
218
110
Max
Min
244
132
Max
Min
232
134
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11
SHELL HEAT MAP
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
12
ROLLER BED TEMPERATURES
33 39 30 34 38 33
30 37 32 35 36 26
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
13
UNDER-TYRE GAPS (UTG) AND RELATIVE MOVEMENT (RM)
UTG
RM
9
15
UTG
RM
8
15
UTG
RM
7
12
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
14
TYRE AND ROLLER DIAMETER
1970 1973 1960
1975 1964 1976
5661 5669 5653
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
15
ROLLER OPERATING ANGLES
Feed Pier Middle Pier Discharge Pier
5945' 5832' 6006'
Sample Factory
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
www.rotarykiln.eu
For an equal load distribution, it is expected to have 60 2 roller operating angles.
Page
16
ROLLER SKEW POSITIONS
+
3

m
m
-
2

m
m
+
2

m
m
Middle Pier Feed Pier Discharge Pier
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Page
17
ROLLER SHAFT CONDITIONS
Feed Pier Middle Pier Discharge Pier
Max
0,1 + 0,0 mm
Max
0,4 + 3,9 mm
Max
0,1 + 0,0 mm
Max
0,1 + 0,0 mm
Max
0,2 + 0,6 mm
Max
0,1 + 0,0 mm
Shaft Ovality + Roller Ovality
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
The deviation created by non-cylinder roller form and curvature shaft mile causes unequal loads on rollers, bed wear and unefficient lubrication.
Deviation under 1 mm is acceptible.
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ROLLER AND SHAFT POSITIONS AND LUBRICATION
Feed Pier Middle Pier Discharge Pier
Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Shaft
Lubrication

Sample Factory www.rotarykiln.eu

Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
ROLLER SURFACE WEAR
0
.
0
-
1
.
0
-
1
.
0
-
1
.
5
-
1
.
0
-
1
.
0
-
0
.
5
-
0
.
5
0
.
0
0
.
0
Feed Pier Middle Pier Discharge Pier
Page
19
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
The diametral difference in 5 different points. Machining the concave rollers does not effect the kiln axis.
The rollers of feed and middle pier are machined and do not have diametral deviation.
WOBBLING
Max 0,8 mm Max 0,9 mm Max 2,9 mm Max 0,7 mm
Looking from discharge
Manhole
Page
20
Max
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Wobbling is mainly caused by shell crank and ovality. It is expected to be under 2 mm.
Middle pier tyre has a 2,9 mm wobbling. 16,17,18 and 39,40,41 numbered under tyre pads should be checked.
Page
21
OVALITY
A
B
C
ORT
%0,32
%0,46
%0,34
%0,37
A
B
C
ORT
%0,32
%0,48
%0,42
%0,41
A
B
C
ORT
%0,14
%0,22
%0,18
%0,18
A
B
C
ORT
%0,15
%0,21
%0,20
%0,19
A
B
C
ORT
%0,32
%0,32
%0,40
%0,35
A
B
C
ORT
%0,42
%0,38
%0,39
%0,40
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
The ovality tolerance for a 4,60 m diameter shell is %0,5. Rapid changes in ovality diagrams signs fractures and cracks on shell.
Page
22
SHELL DEFORMATION
1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 16 18 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 46 45
5
10
15
20
25
mm
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
By measuring the shell deformation on 47 sections of the kiln shell; deformation, run out and rotation center are calculated to draw the shell deformation diagram. It is shown that;
21-36, 5-10, 0-2 sections has bigger run out and eccentricity which causes crank on shell, wobbling and unequal load distribution on tyres and rollers. ( Run Out , Eccentricity )
Looking from Discharge
Page
23
Section :
Deform ratio 1:1 , Manhole at down position.
2 SHELL SECTIONS
Sample Factory www.rotarykiln.eu
Rotary Kiln #1 Hot Kiln Alignment
18-23 March 2012
Rotation
Center