Sample-Report-Kiln-Alignment.pdf

Sample Factory

Rotary Kiln #1 Hot Kiln Alignment

18-23 March 2012

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: [email protected]

www.rotarykiln.eu

Sample FactoryPage

1www.rotarykiln.eu

2346

ForewordDescription of MeasurementsWritten ReportBasic Inspection

789

101112

Coordinating System, Symbol and TermsAxial DeviationsSlope of Axis, Tyre and RollersSuggested AlignmentShell Heat MapRoller Bed Temperatures

13141516171819

Under-tyre Gaps and Relative MovementsTyre and Roller MovementsRoller Operating AnglesRoller Skew PositionsRoller Shaft ConditionsRoller and Shaft Positions and Lubrication Roller Surface Wear

20212223

WobblingOvalityShell DeformationShell Sections

Rotary Kiln #1 Hot Kiln Alignment18-23 March 2012

Page2

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 ÖZEKMustafa ÖZEK

Zeki ÖZEK

Sample Factorywww.rotarykiln.euRotary Kiln #1 Hot Kiln Alignment

18-23 March 2012

Page3

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


18-23 March 2012

Page4

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

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.

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 conditionFeed 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.


18-23 March 2012

Page5

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 11-16 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.

WRITTEN REPORT


18-23 March 2012

Page6

BASIC INSPECTION

Feed seal is in good condition.There are cracks on both rollers of feed pier whichcauses unequal load distribution and marks on tyre

surface.

Hydraulic thrust roller has a pressure between0 - 50 bars.

Shell surface has spots caused by brick problemsand build-up.

The teeth of girth gear and pinion are in goodcondition. Backlash is in 11-16 mm range.

Backlash measurements are same at both sides.

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


18-23 March 2012

Page7

COORDINATING SYSTEM, SYMBOLS AND TERMS

1. Pier

2. Pier

3. Pier

Girth Gear

s

α

η

dy

dz

ds

c

Under tyre gap

Roller operating angle

Slope

Horizontal axis deviation.

Vertical axis deviation

Roller skew

Backlash

Manhole line is starting point forall diametral measurements.

Office side


18-23 March 2012

Page8

AXIAL DEVIATIONS

X

Y

Z

4555 mm

+0 mm

+0 mm

X

Y

Z

0 mm

+0 mm

+0 mm

Offic

e S

ide

Mill

Sid

e X

Y

Z

2507 mm

+6 mm

+1 mm

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


18-23 March 2012

%3,5

%3,6

%3,6

%3,6

%3,9

%3,6

%3,7

4 mm shim

In tolerance

Out of tolerance

Page9

SLOPE OF AXIS, TYRE AND ROLLERS

Tyre and roller slopes are alsomeasured by the slope sensorswhich is mounted on the sidesof t y res and ro l le rs dur ingrotation.

This helps us to double checkthe slope data and get betterresults.


18-23 March 2012

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 differenceaccepted in tolerance for this kiln. ( If it is 2 m between two alignment bolts, %0,1 difference means 2mm shim.)

Page10

SUGGESTED ALIGNMENT

7,5 mm

4,5 mm


18-23 March 2012

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.

100 °C

200 °C

300 °C

400 °C

500 °C

600 °C

Max

Min

358

214Max

Min

356

174

Max

Min

218

118Max

Min

218

110

Max

Min

244

132

Max

Min

232

134

Page11

SHELL HEAT MAP


18-23 March 2012

Page12

ROLLER BED TEMPERATURES

33° 39° 30° 34°38°33°

30° 37° 32° 35°36°26°


18-23 March 2012

Page13

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

UTG

RM

9

15

UTG

RM

8

15

UTG

RM

7

12


18-23 March 2012

Page14

TYRE AND ROLLER DIAMETER

Ø1970 Ø1973 Ø1960

Ø1975 Ø1964 Ø1976

Ø5661Ø5669 Ø5653


18-23 March 2012

Page15

ROLLER OPERATING ANGLES

Feed Pier Middle Pier Discharge Pier

59°45' 58°32' 60°06'

Sample FactoryRotary Kiln #1 Hot Kiln Alignment

18-23 March 2012www.rotarykiln.eu

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

Page16

ROLLER SKEW POSITIONS

+3 m

m

-2 m

m

+2 m

m

Middle PierFeed Pier Discharge Pier


18-23 March 2012

Page17

ROLLER SHAFT CONDITIONS


Max0,1 + 0,0 mm

Max0,4 + 3,9 mm

Max0,1 + 0,0 mm

Max0,1 + 0,0 mm

Max0,2 + 0,6 mm

Max0,1 + 0,0 mm

Shaft Ovality + Roller Ovality


18-23 March 2012

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.

Page18

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


18-23 March 2012

ROLLER SURFACE WEAR

0.0

-1.0

-1.0

-1.5

-1.0

-1.0

-0.5

-0.5

0.0

0.0


Page19


18-23 March 2012

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.

WOBBLING

Max 0,8 mm Max 0,9 mmMax 2,9 mmMax 0,7 mm

Looking from discharge

Manhole

Page20

Max


18-23 March 2012

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.

Page21

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


18-23 March 2012

The ovality tolerance for a 4,60 m diameter shell is %0,5. Rapid changes in ovality diagrams signs fractures and cracks on shell.

Page22

SHELL DEFORMATION

1234567891011121315 141618 17192021222324252627282930313233343536373839404142434447 46 45

5

10

15

20

25

mm


18-23 March 2012

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 )� �

Looking from Discharge

Page23

Section :

Deform ratio 1:1 , Manhole at down position.

2SHELL SECTIONS


18-23 March 2012

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Sample-Report-Kiln-Alignment.pdf

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