INSPECTION OF ROTARY KILNS, HOT KILN ALIGNMENT

Operation measurement, diagnosis, and optimisation of heavy duty equipment. Kiln alignment.

Our services provide continuous operation of machinery keeping maximum efficiency throughout the service period. Regular inspections help to avoid unplanned standstills and to keep high efficiency as well as possibly highest effectiveness of the rotary kiln.

KEY BENEFITS:

Lower number of unplanned standstills

Longer longevity of kiln components

Higher effectiveness of kiln's operation

Flexibility - resolving problems on the spot

Adjustments performed during regular kiln's operation

Recommendations connected with planning components exchange

Sharing knowledge and experience with personnel responsible for kiln maintenance and operation

HAVEC Engineering holds a unique capability of supporting its clients all around the world. This is possible thanks to experienced specialists and an innovative measuring technology.

This service provided by our company is part of the Preventive Maintenance Strategy of keeping kiln's operation. The aim of this strategy is to identify current causes of problems and to implement effective solutions. Return on investment following comprehensive inspection of the rotary kiln takes place after the first unplanned standstill of the kiln.

Our alignment methods are based on advanced measurement techniques, high quality of measurement machinery and state-of-the-art software. The service is performed in dynamic conditions, during day-to-day kiln operation, which does not intervene in the production process.

 

KILN ALIGNMENT – NEW APPROACH

As part of the Preventive Maintenance Strategy, periodic alignment of the rotary kiln helps to locate problems long before a malfunction. Instead of a cost-related (standard) repair of damages, HAVEC Engineering identifies and eliminates their causes. If only outcomes are being dealt with it is highly probable that they will re-appear and that damages will multiply (deepening the damages).

Based on our experience, a decisive majority of damages is caused by one of the following four reasons:

Non-alignment of the kiln

Crank's occurrence (mechanic, thermal)

Excessive ovalisation

Incorrect kiln axial balance

Apart from the said inaccuracies, in the course of comprehensive kiln inspection also the following elements are acknowledged:

Geometry of the drive system

Overall mechanic condition

Engineering analysis

 

  • 1

    MAIN REASONS

  • 2

    SYMPTOMS

  • 3

    DAMAGES

MAIN REASONS/SYMPTOMS

Non-alignment of the kiln

Excessive ovalisation

Crank's occurrence

Incorrect kiln axial balance

High temperature of the bearing

Support roller shaft

 

 

Thrust ring

     

Crank

Kiln shell

 

Support roller shaft

 

 

Mechanical wear

Support roller and tire

   

Between the tire and shell

 

   

Damages to the lining

Between supports

   

 

Under the tire

   

EXCHANGE OF KEY COMPONENTS

Knowledge of real mechanic status of the rotary kiln allows to facilitate the planning process of key components exchange. Comprehensive inspection of the kiln will depict elements for and fix priorities of repair actions. Such information is crucial when forming and planning the budget.

 

INCREASE OF PERSONNEL' TECHNICAL COMPETENCES

Knowledge and experience exchange between our engineers and workers responsible for kiln maintenance and operation are extremely crucial. In the course of each inspection we work together to achieve better outcomes. Such cooperation helps to develop knowledge of the technical personnel.

FLEXIBILITY

HAVEC Engineering, if possible, provides solutions to problems on the spot making sure improvement of kiln's parameters will be as expected. We are ready to supervise the recommended adjustment. A summary meeting is organised before leaving the facility to present an up-to-date, final report. It contains i.e.:

Results of measurements

Guidelines to carry out adjustments

Crucial conclusions

Recommendations

This documentation is the grounds to conduct the planning process of the soonest kiln standstill and helps to create a detailed schedule of works. This helps to perform any crucial repairs in the shortest time possible.

HOT KILN ALIGNMENT – SCOPE OF SEVICE

  1. Setting up the surveying bases for the kiln – reference base.
  2. Measurement of kiln axis position in horizontal plane.
  3. Measurement of kiln axis in vertical plane.
  4. Measurement of kiln inclination.
  5. Measurement of under-tire clearance parameter and tires’ migration.
  6. Measurement of supports displacement: settlement and cyclic transverse movement.
  7. Measurement of rollers’ operating angles.
  8. Measurement of rollers’ axis position (in horizontal plane) in relation to kiln axis.
  9. Measurement of rollers’ inclination In relation to kiln axis.
  10. Measurement of foundation frame axial slope.
  11. Measurement of rollers’ and tires’ mechanical wear (profiles).
  12. Measurement of shell profile – circularity deviation of cross section
  13. Measurement of shell profile – eccentricity of cross section.
  14. Measurement of girth gear radial run-out.
  15. Measurement of tires’ and girth gear axial run-out.
  16. Measurement of temperature distribution of kiln shell and tires.
  17. Measurement of rollers’ shaft deflection (indication of hidden mechanical crank formation).
  18. Measurement of thrust roller position in reference to kiln axis.
  19. Measurement of root clearance and backlash parameters.
  20. Measurement of kiln drive system geometry: gear, pinion, shafts, reducer, main motor, auxiliary motor.
  21. General mechanical inspection of drive mesh, bearings and shafts condition, lubrication efficiency, inlet and outlet sealing, thrust unit, adjustment equipment, covers and housing.
  22. Calculations of axial deviations in horizontal and vertical plane and kiln slope
  23. Recalculation of kiln mechanical parameters: current loads on piers, pressure on bearings, Hertz pressures, bending stress in the shell, stress in the tires, calculation of stiffness matrix, optimization of kiln vertical axis position considering load distribution.
  24. Preparation of optimal version of adjustment program and schedule
  25. Supervision over adjustment procedure carried out by technicians of the Cement Plant (if necessary).
  26. Control survey of final kiln axis position and rollers skewing after the adjustments.
  27. Preparation of shell polar diagrams and shell 3D animation model.
  28. Preparation of completed report of measurements and adjustments
  29. Preparation of recommendations for future preventive maintenance actions, routines, necessary repairs and replacements.
  30. Presentation and submission of the report and shell animation to the Customer.

HAVEC Engineering deals with providing innovative solutions supporting operation of heavy duty machinery, in individual rotary kilns.
contact@havec.eu

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.