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

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Sample Factory Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

2 3 4 6

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

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 1

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

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 2

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

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 3

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 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. 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.

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 4

WRITTEN REPORT
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 1116 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.

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 5

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.

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.

Shell surface has spots caused by brick problems and build-up.

Discharge seal leaks clinker out which causes wear on roller and tyre surfaces of discharge pier.

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 6

COORDINATING SYSTEM, SYMBOLS AND TERMS

1. Pier Girth Gear

2. Pier

3. Pier

Manhole line is starting point for all diametral measurements. s dy dz ds c Under tyre gap Roller operating angle Slope Horizontal axis deviation. Vertical axis deviation Roller skew Backlash Office side

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 7

AXIAL DEVIATIONS

X Y Z

0 mm +0 mm +0 mm

Office Side

X 2507 mm Y +6 mm Z +1 mm

Mill Side

X 4555 mm Y +0 mm Z +0 mm

The tolerance of axial deviation is 1,5 mm for this kiln.

Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012 Page 8

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SLOPE OF AXIS, TYRE AND ROLLERS

In tolerance Out of tolerance 4 mm shim

Tyre and roller slopes are also measured by the slope sensors which is mounted on the sides of tyres and rollers during rotation. This helps us to double check the slope data and get better results.

%3,9 %3,6

%3,6

%3,6

%3,7 %3,5 %3,6

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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SUGGESTED ALIGNMENT

4,5 mm

7,5 mm

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.
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SHELL HEAT MAP

Max 358 Min 214 Max 356 Min 174 Max 232 Min 134 Max 218 Min 118 Max 218 Min 110

Max 244 Min 132

600 C

500 C

400 C

300 C

200 C

100 C

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 11

ROLLER BED TEMPERATURES

33

33

39

38

30

34

30

26

37

36

32

35

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 12

UNDER-TYRE GAPS (UTG) AND RELATIVE MOVEMENT (RM)

UTG 8 RM 15

UTG 7 RM 12

UTG 9 RM 15

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 13

TYRE AND ROLLER DIAMETER

1970

1973

1960

5669 1975

5661 1964

5653 1976

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 14

ROLLER OPERATING ANGLES

5945'

5832'

6006'

Feed Pier

Middle Pier

Discharge Pier

For an equal load distribution, it is expected to have 60 2 roller operating angles.

Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012 Page 15

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ROLLER SKEW POSITIONS

+3 mm

Feed Pier

Middle Pier

Discharge Pier

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

+2 mm
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-2 mm

ROLLER SHAFT CONDITIONS

Shaft Ovality + Roller Ovality

Max 0,1 + 0,0 mm

Max 0,1 + 0,0 mm

Max 0,2 + 0,6 mm

Max 0,1 + 0,0 mm

Max 0,1 + 0,0 mm

Max 0,4 + 3,9 mm

Feed Pier

Middle Pier

Discharge Pier

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

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Shaft Lubrication

Feed Pier

Middle Pier

Discharge Pier

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Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012

Page 18

ROLLER SURFACE WEAR

-1.5 -1.0 -0.5 -1.0 -0.5 -1.0 0.0 -1.0

0.0

0.0

Feed Pier

Middle Pier

Discharge Pier

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.
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WOBBLING
Looking from discharge

Max

Manhole

Max 0,8 mm

Max 0,7 mm

Max 2,9 mm

Max 0,9 mm

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.
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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

The ovality tolerance for a 4,60 m diameter shell is %0,5. Rapid changes in ovality diagrams signs fractures and cracks on shell.
Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012 Page 21

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SHELL DEFORMATION

25

20

15

10

mm 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

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 )
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SHELL SECTIONS

Section :

Looking from Discharge

Rotation Center

Deform ratio 1:1 , Manhole at down position.

Rotary Kiln #1 Hot Kiln Alignment 18-23 March 2012 Page 23

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