Cement Industry

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Comprehensive Hot Kiln Alignment & Inspection

Kiln Inspection & Alignment

Rotary kiln alignment is well known preventive maintenance tool which is recommended after every two years of operation. The rotary kilns are affected by mechanical and technological stresses causing components wear and as consequence misalignment. Every kiln operator wishes to have high run-time factor and no unexpected fails and stoppages. Therefore, the managers prefer preventive routines than costly repairs. Our vast experience in this field is appreciated by cement, paper and steel manufacturers in many countries.

Our scope of works and quality of services fits the highest available standards. The kiln axis survey and adjustment, rollers position and profiles, shell deformation analysis and 3D modelling, radial and axial run-out of tires and girth gear, shell crank detection, kiln thrust balancing, drive mesh inspection, finally complete recalculation of kiln mechanical parameters, all is covered in one comprehensive kiln inspection report. We do alignment and inspections in order to safe cost of maintenance and our goal is to adjust existing equipment and improve the kiln condition and operation.

We also perform Recalculation of Kiln mechanical parameters and understand the usual behaviors of kilns about bearing overloads (hot bearings), shell cracks, roller shaft cracks, frame cracks. There are cases of an uneven distribution of support loads with simultaneous dimensional overdesign for stress in the kiln shell. This technique has been known by producers for many decades but it is not widely offered.

Scope of Services:

  • Measurement of kiln axis position in horizontal and vertical plane.
  • Measurement of tire migration and calculation of under-tire clearance.
  • Measurement of rollers’ axis position, rollers’ skewing and operating angle.
  • Measurement of rollers’ inclination and foundation frame axial slope
  • Measurement of rollers’ profiles (mechanical wear of running surface)
  • Measurement of thrust rollers position in reference to the kiln axis
  • Measurement of tires and shell temperatures
  • Calculations of axial deviations in horizontal and vertical plane and kiln slope
  • General mechanical inspection of drive mesh, bearings and shafts condition, lubrication efficiency, inlet and outlet sealing, thrust unit, adjustment equipment, covers and housing.
  • Check for kiln thrust and mechanical balance.
  • Preparation of op6mal version of adjustment program and schedule
  • Preparation and submission of completed report including results of survey, short- and long-term recommendations for preventive maintenance actions.
  • Minor adjustments of rollers and kiln mechanical balance.

Kiln shell profile and shell crank survey

  • Measurement of kiln shell permanent deformations (circularity deviation and eccentricity of cross sections)
  • preparation of shell polar diagrams and shell animation model (unique full 3D rotating shell)
  • Measurement of tires and girth gear wobbling
  • Measurement of rollers’ shaft cyclical deflection (indication of kiln shell mechanical crank)
  • Measurement of kiln shell temperatures distribution (indication of shell temperature crank)
  • Kiln shell 3D animation model

Kiln shell ovality test (direct survey of elastic deformation of the kiln shell)

Kiln drive system geometry: girth gear, pinion, shafts, reducer, engine

Recalculation of kiln mechanical parameters

  • Current loads on piers
  • Pressure on bearings
  • Hertz pressures on roller-tire contact
  • Bending stress in the kiln shell
  • Stress in the tires
  • Stiffness matrix, optimization of kiln vertical axis position considering load distribution

Supervision of adjustment action to be carried out by technicians of the Plant

  • Supervision of adjustment works
  • Thrust control and correction whenever necessary
  • Control survey and reporting of actual state after adjustment