Training to cover preventive maintenance practices

Basic Topics are:

Basic design fundamentals, Inspection and Trouble
Shooting
Shell Tires, mounting styles and hardware
Rollers, thrust Rollers and bases
Gear, Pinion and other drives
Inlet and Outlet Seals
Alignment –multi pier laser / conventional 2 pier
alignment.
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Alignments
Alignment is the most important way to increase life span of industrial equipment

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Alignment can be done on any rotating equipment
such as:
 fans, fans to motor, kilns, etc. Alignment allows
mechanical machinery to run smoothly.
 Incorrect alignment occurs when the centerlines
of the motor and the driven equipment shafts are
not in line with each other.
 Misalignment produces excessive vibration,
noise, coupling and bearing temperature
increases, and premature bearing or coupling
failure.

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 In practice, proper alignment is difficult to
achieve without using alignment equipment

 such as dial indicators or laser alignment tools

to check and correct for misalignment.

 The proper shaft alignment procedure is to

secure the driven equipment first, and then install
the coupling to the equipment.

 When doing a kiln alignment it is critical to know

tolerances and possible mismatches with
equipment. mekonnen zergaw 5
 . Forexample not everything will be perfect. Kiln
piers, kiln ovality, kiln bearings, tire wear, tire pads all
come into play

 Alignment of gears is essential to transfer power

without excessive wear.

 Kiln misalignment can lead to maintenance and

operational problems.

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Frequent kiln alignments will
 lower maintenance and
 operational costs by minimizing refractory loss due to
mechanical stresses,
 reduce kiln drive horsepower,

 Increase life of gearing, riding rings, carrying rollers,

filler bars, bearings and other kiln components.

 Alignments will also prevent shell cracking that can

sometimes be caused by misalignment.

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Performing kiln alignments while the kiln is
shutdown and cold.

 This allows for accurate dimensional data and

pier sightings without the affects of radiant heat
and vibration associated with hot alignments.

 Aligns kilns to the original vertical and

longitudinal centerlines as well as the design
slope.

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Rotary Kiln Hot Kiln Alignment,
Maintenance
A global leading company specializing in hot kiln
alignments and adjustments and kiln inspections, to
provide specialty services including;

 kiln alignment,

 measurement of roller parameters,

 kiln adjustment program and schedule,

 kiln thrust and mechanical balance,

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 mechanical balance of the hydraulic
system pressure,
 drive mesh inspection,
 tire & girth gear wobbling, girth gear radial
run-out,
 accurate measurement of kiln shell profile
together with kiln shell 3D model,
 mechanical & temperature (or thermal)
crank formation,
 tire migration & shell ovality test,
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 loads, pressures and stresses analysis,

 stiffness matrix, advanced kiln modeling,

 Comprehensive test of kiln mechanical

parameters.

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preventative maintenance service on rotary
kilns extends the life of the kiln between
shutdowns..
By recording and logging daily reports including;
 shell temperature,

 support roller bearing temperatures,

 rotary kiln burner conditions,

 shell cooling fans, submerged air fans and girth

gear monitoring, a detailed history of kiln should
be recorded
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The inspection & maintenance
service includes;
 kiln inspection,

 corrective action reporting,

 support roller condition monitoring,

 thrust roller condition monitoring,

 rotary kiln float adjustments,

 inlet and discharge

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 burner condition and recommended adjustments,

 complete maintenance package, daily lubrication of

all rotary equipment, riding ring inspection, girth gear
and pinion drive

 daily inspection and main drive gearbox daily visual

inspection and

 Monthly oil inspection with samples sent for wear

analysis.

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Rotary Kiln Monitoring & Maintenance
Services
 including but not limited to tyre and support roller
resurfacing and in-production mechanical
analysis (hot kiln” alignments)

 decrease operating costs and reduce energy

usage, while increasing production levels and
profit margins.

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Preventative & Corrective Maintenance

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 Preventative maintenance on rotary kilns is
critical to extend the life of the kiln between
shutdowns.

 Preventative and corrective maintenance is to

supply a dedicated team of experts that will
reduce kiln downtime and increase running
periods between shutdowns of the rotary kiln.

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 Shutdown turnaround periods are also shorter
due to the identification and repairs done to the
rotary kiln in the “hot” state.

 The refractory demolition and installation team

working inside the rotary kiln are also able to
continue with the work unhindered by the
mechanical maintenance team working outside
the kiln shell if kiln shutdowns are undertaken on
a turnkey basis.

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undertake recordings and logging of daily reports
including;
 shell temperatures,
 support roller bearing temperatures,
 rotary kiln burner conditions,
 shell cooling fans,
 submerged air fans and girth gear monitoring,
create an individual history for each rotary kiln to
prepare corrective maintenance procedures in
conjunction with the client.

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Monitoring of a Rotary Kiln
 The advantages of daily monitoring of critical
items and components on a rotary kiln can lead
to substantial costs savings.

 The items that should be monitored on a daily

basis and corrected with immediate detection of
a fault are the following:

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 Shell temperatures – provides an indication of the
condition of the refractory lining and slag/ash ring
build up inside the rotary kiln.

 Girth gear and pinion condition – if gear rooting is

occurring this will result in an increase in the
amperage of the rotary kiln, which in turn will result in
an increase in electricity consumption and related
operating cost.
 Mechanical failure and or excessive damage to drive
mesh will also occur

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 Support roller monitoring for possible bearing
failure - the collapse of a rotary kiln support roller
bearing could cause immense damage to inlet
seals and girth and pinion gears, which will result
in loss of production.

 Rotary kiln inlet and discharge seals – if not

monitored correctly and the seal is damaged,
excess air will enter the rotary kiln which will
result in excessive fuel being required to correct
the air-fuel mixture to fire the rotary kiln.

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 If not corrected this will lead to excessive costs and
unburned fuel creating a pollution problem.
 There is furthermore possible damage to the
electrostatic precipitators.

 Main drive gearboxes – if not checked daily and faults

identified for immediate planned correction, could
lead to downtime, resulting in a major financial loss of
the operating company.

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Focus on preventative and corrective maintenance
as a means to properly maintain and monitor rotary
kilns.

 Damage to rotary kilns can be eliminated

or controlled if proper inspections and
regular maintenance is carried out.

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 Frequent rotary kiln maintenance and monitoring
will prevent premature kiln component failure,
which will extend the life expectancy of the
mechanical and refractory life cycles.

 An integrated rotary kiln monitoring and

maintenance service on planned manner is
crucial to minimize breakdown.

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Inspection and repairs includes to
the following equipment:
 Support rollers,

 Riding ring,

 Girth gear and pinion,

 Kiln shell deformation,

 Kiln shell ovality,

 Kiln shell temperatures,
 Thrusters and the kiln float,
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 Slip on riding rings and contact shoes,

 Girth gear and pinion contact areas,

 Rotary kiln creep, measurement and adjusting,

 Replacement of all major components of a rotary

kiln on a breakdown basis,

 Setting of the rotary kiln to allow it to follow the

proper float pattern.

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Rotary Kiln Condition Monitoring
 Monitor the rotary kiln on a daily/weekly basis
and report to the technical head any unforeseen
problems.

 This monitoring is an early warning system to

allow the technical head to be able to make an
informed decision regarding the perceived
problem.

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The following will be monitored.
All recordings will be logged and used for
reference points.
 By monitoring the kiln shell, this will create an
early warning system for refractory wear and
possible damage to the refractory inside the
rotary kiln.
 The wear on the refractory inside the rotary kiln
can create “hot spots” on the kiln shell.
 This will create enormous damage to the rotary
kiln itself and leads to distortion of the kiln shell.

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 The monitoring of shell temperatures will give an
early warning system regarding slag / ash build
up inside the rotary kiln.
 The build-up of slag / ash is dangerous for the
safe operation of a rotary kiln, it will create a
“back pressure” affect within the rotary kiln and
damage to inlet seals and other mechanical
items will occur.
 It also has an effect on the production of the
rotary kiln by retarding the steady flow of material
down the length of the rotary kiln.
 To remove the slag build-up inside the kiln is a
costly and very dangerous exercise; it could also
lead to premature shutdown of a rotary kiln.

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Support Roller Bearing Monitoring
 The collapse of a support roller bearing can
cause immense damage to a rotary kiln.

 The girth gear will settle into the pinion gear and
chipping, pitting and burring to the teeth of the
gears will occur.

 The amperage of the main drive motors will

increase and the cost of electricity will become
very costly.

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It is recommended that the following parameters
should be monitored on a weekly basis:

 Bearing temperature

 Correct lubrication

 Grease spillage

 Plummer block seals

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Kiln Support Rollers inspection and
maintenance will do the following:

 Support roller surface monitoring

 Riding ring surface monitoring
 Changing of support rollers
 Setting of support rollers
 Grinding of support rollers. This will be done
without stopping the rotary kiln, therefore no loss
in production

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 Support roller bearing inspection
 Support roller plumber block seals inspection.
 Damaged plumber block seals create/allow
grease to get onto support roller surface and this
creates kiln slipping and does not give a true
reflection as to how the kiln is actually riding.

 This will put excessive wear on the thrust rollers

and can lead to damaged bearings and
excessive wear to thrust rollers.

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Kiln Support Rollers Maintenance
 The support roller is a critical part of a rotary kiln.
 The entire kiln and production life cycle depends on
the support roller.
 The correct monitoring and maintenance is critical to
increase the life cycle between shutdowns.
 The changing of a support roller is a costly exercise in
the loss of production and mechanical parts.
 Therefore the correct monitoring and lubrication
should be of the highest standard

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In cement plant the Rotary kiln supporting roller
bearing temperature is rising in one of the tire at
each time. Explain me why and how it rises.
How to control it? give me the solution?
Answer:
 There may be many causes for the rising in temp
of bearings of a rotary kiln.
1. Axial force of riding wheel oversize.
2. Oil selection is improper, oil viscosity is not
enough
3. Kiln body local high temperature radiation
reduce lubricating oil viscosity, oil film becomes
thin
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 .
4. Radial force of riding wheel oversize, resulting in
increasing the friction between axle and bearing
bush.
5. check if the roller shaft or the bearing has
developed pitting marks. These can break the
lubrication film and raise the temp.

6. In the bearings, cooling water interrupt for a long

time, resulting in temperature increment.

7. Also check ELEVATION VIEW allignment. If kiln's

centreline is down from the reference slope it will
added additional load on the bearings of that pier
resulting in high temp.
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rotary kiln tire ring | Thrust roller
kiln

Rotary kiln shell:

 It is the main body of the rotary kiln, rotary kiln
shell plate thickness of about 40mm steel,
 tires near the ring, because the load is relatively
large, rotary kiln here to be thicker steel shell.

 Kiln shell with a layer of 200mm internal puzzle

about the bricks.

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 Kiln shell in operation, because of the
relationship between temperature and load-
bearing, rotary kiln will be elliptical shell-type
deformation, which would put pressure on the
brick kiln, brick kiln affect the life.

 In the rotary kiln about one meter long tail where

the cone, the feed from the machine room to
warm up the material can be more smoothly into
the rotary kiln.

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Rotary kiln tire ring
 support rollers, bearings, tires are used to
ring to support the weight of the rotary kiln
used.
 Tire ring is set in the kiln shell, between it
and the kiln shell is not fixed,
 rotary kiln shell and tire ring plus a piece of
iron between the separated ring and the
tire to retain a certain gap between the kiln
shell, not too much not too small.
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 If the gap is too small, the expansion of the
rotary kiln shell limited by the tire ring, brick kiln
easy to destroy.
 If the gap is too large, the kiln shell and the
relative movement between the tire ring,
 friction is more interest, but also make an
elliptical deformation of the rotary kiln shell is
more serious.
 the kiln shell relative motion between the ring is
estimated to the kiln shell with elliptical
deformation.

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 Rotary kiln shell and tire ring exists between thermal
conductivity differences, it is necessary to help with
the surrounding air outside the kiln shell heat balance
reduces the temperature difference between the two.
 Otherwise the kiln shell expansion will be limited tire
ring.
 In the open kiln, the kiln shell heating rate higher
than the tire ring, rotary kiln workers must control the
heating rate 50 ℃/ h, so beneficial to protect the kiln
brick.
 Rotary kiln shell to reduce the thermal radiation of the
tire ring, resulting in roller temperature is too high,
between the two are added with insulation board to
reduce heat radiation..
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Thrust roller rotary kiln:

 a roller thrust is to restrict wearing or wear when

the rotary limit switch.
 Support the tire because the wheel wider than
the rotary kiln tire, for the wheel and tire can be
moved up and down, wear uniform.
 In the fetal face with thrust ring roller. Thrust
roller just play the role of blocking, wheel itself is
not power.
 Rotary kiln tire is by wearing wheel deviation,

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 the wheel and the center line of a certain
angle rotary kiln, rotary kiln to roller to
force the body upward, move on to the
rotary kiln shell.

 Sometimes sprinkle some of the raw

material powder or clean the wheel,
increasing the friction coefficient,

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Inlet & Discharge Seals
 Damage to inlet / discharge seals can lead to
excessive fuel being used.

 The kiln operator has difficulty controlling his/her

air fuel mixture ratio.

 Damaged seals will increase the cost of fuels

used at the rotary kiln, be it, oil or gas fired.

 The damaged seals will also create a dust and

pollution problem.

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Rotary Kiln Girth Gear & Pinion

 The girth gear and pinion is the unit that turns the
rotary kiln.

 This section with the support rollers is critical to the

life of the kiln.

 Therefore the proper maintenance is critical at this

point.

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During shutdown phase the following should be
inspected and corrective action taken (all settings to
be done to accommodate the hot state of the rotary
kiln) to minimize any breakdowns during the running
phase of the rotary kiln;

 Rooting of girth gear and pinion

 Pitting/chipping of girth gear and pinion
 Correct mesh alignment of girth gear and pinion
 Rotary kiln main drive gearboxes to be inspected
and drive gears to be checked
 Alignment of drive couplings

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During normal running of the
rotary kiln
the following must be inspected on a daily basis;
 Correct lubrication of girth gear and pinion
 Girth Gear/Pinion lubrication pump. Ensure that the
pump is working
 Lubrication spray nozzles
 Meshing of pinion and girth Gear
 Rooting of girth gear and pinion.
 If any deviation from recommended practice is
noted, these should be corrected before kiln start up

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 It may be argued that the expense of kiln
maintenance procedures is quickly returned in profit
increases.
 Rising energy costs, increasing labour costs, and
lost production through equipment failure are serious
problems that the cement processing industries are
facing as they struggle to survive in today’s
competitive markets

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 Efficiently planned and executed maintenance
schedules do not only reduce operating costs but
can also directly influence profit margins.
 Many cement processing plants are however
reluctant to spend money on kiln maintenance. The
issue that faces today’s plant manager is whether
planned kiln maintenance is just an operating
expense that can be postponed if the budget is tight
or should be perceived as an investment that
increase the profitability of a company.

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