KILN GEOMETRY MONITORING SYSTEM

KGM-System is a remote system of monitoring geometric parameters for industrial rotary kilns with over 2 supports. Its main aim is to detect operational irregularities which may result in mechanic damages.

Data collected by the system are monitored 24/7 both at the CCR level and at any place around the world. Continuous review of various kiln geometric parameters allows to set respective alarms and undertake proper steps in case of irregularities. Moreover, devices save the measured data on a thumb drive (or a hard drive) so that off line analyses are possible at any stage and so that root-causes can be located (production or mechanic-related)..

KGM-System has been fit in various sensors allowing indirect measurement and calculation of selected geometric parameters of the kiln, such as:

  • Shaft deflection of support rollers
  • Values of under-tire clearance
  • Axial kiln position
  • Kiln rotary speed
  • Radial run-out of girth gear
  • Axial run-out of girth gear and tires
  • Peripheral temperature of the shell and tires
  • Mechanic position of support rollers

MEASUREMENT SYSTEM

The system is composed of a multichannel measurement module i.e. multi-box collecting measurement data from connected sensors. Data is send via RS485 (up to 1200 m) to a monitoring unit which saves and stores all data in device's internal memory. Measurements collected can be displayed on a screen directly connected to a monitoring unit or send to a network and visible via a WWW website (following logging in) on computers with Internet access (from any place around the world).

Information about alarming events (situations) are stored as logs, send to an e-mail and displayed on a WWW website.

Scheme of a measurement system has been presented below:

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Modular set up allows to connect various measurement sensors adjusted to your needs.

MODULE 1: Controlling

Main, superior part of the whole system. Its main tasks cover i.e.:

  • verification of operation efficiency of measurement modules,
  • identification and reporting of potential defects,
  • inspection of kiln operation mode based on rotary speed (obtained from one of the measurement modules),
  • switching the system in a standby mode (in case of absence of kiln rotation),

In case of normal kiln operation, based on indications of one of the measurement modules (Z1.1), the controlling module initiates the operation of all measurement modules, collects data collected by them and sends them (via Internet) to a specific SQL data base located on an external server.

Moreover, the controlling module holds a control panel available via the Internet where the service personnel can declare basic operation fittings of the entire system, i.e.:

  • kiln rotary speed below which an object is determined non-operational (not subject to monitoring)
  • frequency of initiating measurements (during the day or an hour)
  • number of kiln rotations where data are collected for analysis.
MODULE 2: Shaft deflection of support rollers

Value of shaft deflections of support rollers at individual supports indicate presence of cranks in kiln shell. This crank is non-other than straight-line deviations of kiln shell (rotation axis does not overlap with the geometric centre of individual shell segments) which shift the excess load on individual support rollers with each kiln rotation, i.e. "dog leg".

We can differentiate 2 types of shell's crank:

  • Mechanic/constant crank – caused with plastic deformations of the kiln shell or errors in the course of building or renovating the kiln.
  • Thermal crank – caused by uneven temperature distribution/temperature expansion at the kiln shell circumference.

Load deviations due to the crank are very high and overload tires and rollers the outcome of which are cracks in the tires, support rollers and shafts.

When a crank presses a specific roller - the distance between a sensor and running surface of the roller diminishes. Half rotation of kiln later makes the crank to reverse, with the stress being reduced at this support - distance from the sensor increases.

To measure the outcome that the crank has on the roller the sensor needs to be located under the roller in the line of the force. This means that on the other side than the contact of the roller and the tire.

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Due to high rigidity of the support roller shafts, deflection values are really minor (a few tenths of a millimetre), hence small and precise sensors with a short measurement range are applicable here to provide the required high accuracy.

The required number of sensors – 6 (U1.1, U1.2, U2.1, U2.2, U3.1, U3.2) - measurement range: 0 - 6 mm, high temperature resistant, measurement accuracy: 0.01mm.

MODULE 3: Sub-ring clearance and kiln rotation speed

Under-tire clearance value is specified based on comparing the rotation speed of the tire and kiln's shell. Using magnetic marks (switch flag) of rotation and sensors measuring the speed of the kiln, the system computes the real value of under-tire clearance. In case of exceeding the tolerance assumed, the system will automatically inform the user about any inaccuracies.

The required number of sensors - 4 (C1.1, C2.1, C3.1, Z1.1) - single sensors, measuring scope up to 25 mm, resistant to high temperature and dust.

 

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MODULE 4: Axial position of kiln/Axial run-out of girth gear
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The real axial position of the rotary kiln is measured using two sensors with an increased scope and located on both sides of the girth gear or on the trust rollers' housing. Two sensors are necessary to increase the measuring scope, keeping high accuracy.

In case of installing sensors on both sides of the girth gear the system provides axial run-out value of that component.

The required number of sensors - 2 (W1.1, W1.2) - measuring scope up to 50 mm, resistant to high temperature and dust.

MODULE 5: Radial run-out of girth gear
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Value of radial run-out is measured by a single sensor located perpendicularly to the girth gear (pointed radially).

Based on a precise measurement of the distance to each tooth and applying an innovative interpolation method, the system provides values of radial run-out of the girth gear.

The necessary number of sensors - 1 (R1.1) - linear sensor, resistant to high temperature and dust, measuring scope up to 25 mm.

MODULE 6: Axial run-out of tires

The real value of axial run-out for each tire is measured using current sensors with an increased scope up to 80 mm. Based on a precise measurement of the distance to the tires's side surface (located in the measurement range) and internal calculation algorithm, the axial run-out value is computed.

Exceeded tolerance for this parameter very often is a symptom of crank's presence (mechanic or thermal) running through a specific support i.e. "crank shaft".

The necessary number of sensors - 6 (W1.1, W2.1, W3.1) - sensors resistant to high temperature and dust, increased measurement scope.

MODULE 7: Peripheral temperatures (OPTION)

A symptom of thermal crank's presence in the kiln's shell is an uneven peripheral temperature. To monitor this parameter - the KGM System anticipates installation from 2 to 4 industrial fixed pyrometers (per 1 support) located possibly close on both sides of the ring. The aim of the measurement is to detect temperature differences in the shell's (and tire's) circumference over 80 degrees Celsius which together with other parameters allow to get a picture as to the type and size of the crank in the kiln's shell.

The necessary number of sensors - from 6 to 12 (T1.1, T1.2, T1.3, T1.4, T2.1, T2.2, T2.3, T2.4, T3.1, T3.2, T3.3, T3.4 - fixed pyrometers, measuring scope up to 500 degrees Celsius.

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MODULE 8: Mechanic location of support rollers (OPTION)

It allows to monitor the direction of axial forces generated by support rollers. Inductive sensors located inside the roller housing measure the distance (or position) up to the head of the roller's shaft.

The necessary number of sensors – 6 (P1.1, P1.2, P2.1, P2.2, P3.1, P3.2) - linear or single inductive sensors, with measurement scope up to 25 mm, resistant to high temperature.

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MODULE 9: (OPTION)

Possibility to install and connect additional measurement modules adjusted to user's needs.

 

INSPECTION OF ROTARY KILNS

Hot kiln alignment - the main area of our actions shall be to conduct mechanical inspection and to specify activities (regulations, exchanges, repairs, modifications, etc.) which should be performed to attain and maintain high effectiveness of the rotary kiln's operation.

MEASUREMENT TECHNOLOGY

We hold a specialist hardware and software used for professional measurements. Application of relevant tools allows for effective diagnosis and monitoring of machinery and equipment operation.

INDUSTRIAL AUTOMATICS

We developed high precision measurement systems to allow to monitor current status of equipment and to plan maintenance activities. Hence, malfunctions and breakdowns can be reduced both in respect of their intensity and frequency.

INDUSTRIAL MEASUREMENTS AND CONTROL

We provide a wide scope of measurement services addressed to many industry branches. Highly precise measurements are the starting point for analyses and regulations supporting the work of machinery and equipment.