Exemplary Documentation

TECHNICAL DOCUMENTATION
RESULTS OF DEVIATION MEASUREMENTS AND GEOMETRY OF ROTARY KILN No 1
AT
EXEMPLARY CEMENT PLANT
PERIOD OF SURVEY: 30 of March - 16th of April, 2004

th
FINAL REPORT ON KILN No 1

AT EXEMPLARY CEMENT PLANT I. SCOPE OF WORK: 1. Measurement of kiln axis deformation in horizontal and vertical plane with accuracy +/- 1.0 mm 2. Measurement of rollers horizontal skewings and rollers inclinations with accuracy +/- 0.5 mm
3. Measurement of undertyre clearances 4. Measurement of rollers operating angles 5. Measurement of shell radial and axial deformations (shell profile) 6. Measurement of drive pinion deviations 7. Measurement of supporting rollers mechanial wear 8. Measurement of drive gear run out and wobbling 9. Measurement of tire wobbling 10. Measurement of roller shaft deflections 11. Elaboration, presentation and submission to the Client the complete measurement report.
II.
SURVAY OF ROTARY KILN 1. All measurements were taken by GEOSERVEX Hot Kiln Alignment Team Bydgoszcz, Poland from 30.03.2004. to 16.04.2004. 2. After completing all measurements for the kiln, technical documentation was presented to cement plant representatives and the adjustment program and schedule was discussed and agreed.
III.
RESULTS OF MEASUREMENTS 1. Kiln axis kiln axis in horizontal plane is deviated by 19 mm on second pier and 11 mm on third pier and require adjustment kiln axis in vertical plane is deviated by 12.0 mm on second pier and require adjustment undertire clearances are slightly too large for tires No 1,2,4 and it's incorrect for tire No 3 where it rise up to 14 mm. The clearance should be corrected by inserting shims at the nearest kiln stoppage. Too large clearance may cause too high shell ovality and as a result refractory loss. kiln slope is 2.50 % and it's correct.
2. Roller's parameters and kiln thrust rollers skewing are correct, it's values are small and do not cause high axial forces rollers inclinations are correct for all rollers kiln thrust is correct, kiln is well balanced hydraulic system pressure is around 40-50 Bar and it's correct rollers operating angles are correct on piers No 2,3,4 and exceeds tolerance for pier No 1, however it should not cause any problems with kiln's operation roller's mechanical wear is not high comparing to other older kilns however it exceeds value of 1 mm for radius
3. Drive station drive pinion axis is deviated by 3.5 mm in horizontal plane and by 2.0 mm in vertical plane (reduced for regulation bolts distance), this deviation is higher than expected for this parameter gear rim eccentricity is 4 mm what causes 8 mm change of root clearance gear rim eccentricity is caused by kiln shell eccentricity at the gear (see cross section No 24), however the gear eccentricity is smaller than eccentricity of shell in this zone gear rim wobbling is not high and equal +/- 1.6 mm
drive gear rim and pinion are mechanically worn, all root's working surfaces are damaged, root clearance and backlash are both incorrect there is very high vibration caused by improper mesh of the drive the pinion should be replaced as soon as possible the gear rim should be also replaced and it can not be installed in opposite position (after turning it by 180 degrees) because the roots are worn both sides, the gear replacement should be performed with consideration on eccentricity reduction
4. Kiln shell survey of shell deviation was taken in 35 sections shown on the draft maximum deviations of the shell (eccentric) rise up to 64 mm (section No 16) and it exceed tolerance several times, there is a huge "banana" formation in this zone deviations of the shell surface (circular deviations) exceed tolerance for cross sections No 5 and No 16 to No 32. deviations of the shell surface (circular deviations) from section No 17 to No 22 is critically high and rise up to +/- 35 mm, replacement of this shell portion should be taken under consideration if any refractory loss had place in this zone tire wobbling is +/- 1.8 mm for tire No 1, +/- 0.5 mm for tire No 2, 0.3 for tire No 3 and 0.7 mm for tire No 4, tire No 1 wobbling only slightly exceeds tolerance roller shaft deflections doesn't exceed value of 0.11 mm (eccentricity) while the tolerance given by kiln producer (FLS) is 0.15 mm roller shaft deflection are caused by mechanical crank of the shell however the crank formation in the shell is smaller than that which is normally considered dangerous
IV.
ADJUSTMENT OF THE KILN 1. Kiln axis should be adjusted to proper position in horizontal and vertical plane by shifting rollers on first and second piers what has been discussed and agreed with plant representatives. 2. It has been agreed that vertical adjustment axis on second pier should remains 6 mm over straight line connecting remaining axis points (Adjustment program, VERSION I ) , what is recommended by the kiln producer (FLS) 3. It has been agreed that the adjustment should be done in small steps by plant crew according to adjustment program prepared by Geoservex 4. First 16 steps (first day of adjustment) has been performed under supervision of Geoservex team, there was no problems with shifting of the rollers, reference system is clearly marked on foundation frames
V.
CONCLUSION The kiln should be adjusted to proper positions of the axis. The most critical point for kiln operation is drive station. The drive gear rim and pinion mesh is critically incorrect and may cause serious problems for the future. There is no possibility to solve this problem by adjusting rollers. It is strongly recommended to replace this worn components as soon as possible. The kiln shell deformations is very high in several places. This deformations has serious influence on refractory life-time. If refractory loss had place in a zone where shell deformations are serious , this part of shell should be replaced.
VI.
THANKS 1. The GEOSERVEXs Hot Kiln Alignment team would like to thank officialy the plant mechanical crew for help and assistance during measurements and adjustment of the kiln 2. We would like to thank Cementos Goliat Plants Management for choosing our company as the Hot Kiln Alignment Service deliverer. We aprieciate Your confidence to us and we hope for long time cooperation with Your company. 3. In case of any problems with the kiln geometry please contact our company by fax or mail for free consulting.
GEOSERVEX Dipl. Eng. Zbigniew Krystowczyk (M. Sc.) Place of measurements: Date: 16.04.2004.
GEOSERVEX
ENGINEERING MEASUREMENTS ENTERPRISE LTD POLAND
TECHNICAL DOCUMENTATION
RESULTS OF DEVIATION MEASUREMENTS GEOMETRY OF ROTARY KILN N o 1
AND
Date of survey : 05.04.2004.
Index Table of Contents

Table of contents Measurement Data Axial Deviations in Horizontal Plane Axial Deviations in Vertical Plane Rollers Skewing in Horizontal Plane Rollers Skewing in Vertical Plane Drive Pinion Axis Deviations Drive Gear Run Out Tyre Wobbling Roller Shaft Deflection Shell Deformations Adjustment Program and Schedule Control Check Measurement x y z
GEOSERVEX - POLAND
Symbol and Terms
axial coordinates horizontal coordinates vertical coordinates undertire clearance rollers operating angle slope of axis horizontal axis correction vertical axis correction skewing correction ovalization reference axis real axis regulation axis
s a h
Dy Dz ds
Measurement Data
GEOSERVEX - POLAND
Coordinates " x " feed [m] feed
Coordinates " y " [ mm ]

= = = =
Coordinates " z " feed [ mm ]

= = = =
x4 = x3 = x2 = x1 =
discharge
101.98 66.04 31.94 0.00
y4 y3 y2 y1
discharge
0.0 + 11.0 + 19.0 0.0
z4 z3 z2 z1
discharge
0.0 0.0 + 12.0 0.0
Undertire clearance " s " feed [ mm ]

= =
rollers operating angle " a " feed [o
Slop of axis
, , , , ,
s4 s3
8.0 14.0 8.5 8.0
o a 4 = 58 40
h=
2.50 %
a 3 = 58 o 29 a 2 = 59 16 a 1 = 62 53
discharge
o o
s2 = s1 =
discharge

Kiln No 1
Date of survay: 05.04.2004.
Axial Deviations
In Horizontal Plane
DEFORMATION SCALE : 1:1
GEOSERVEX - POLAND
0.0 mm
+ 11.0 mm
+ 19.0 mm
0.0 mm
S o u t h side
F E E D
reference line
real axis
North side
D I S C H A R G E

Kiln No 1
Precision of finding kiln axis: +/- 1 mm
Axial Deviations
In Vertical Plane
DEFORMATION SCALE :
GEOSERVEX - POLAND
s
4
a
1:1
a = 58
40
a = 58
29
a = 59
16
a = 62
53
s = 8 mm
s = 14 . 0 mm
s = 8. 5 mm
s = 8 . 0 mm
z
F E E D
0.0 mm
0.0 mm
kiln slope = 2.50%
+ 12.0 mm
0.0 mm
reference lin e
D I S x C H A R G E

Kiln No 1
Rollers Skewing
In Horizontal Plane
GEOSERVEX - POLAND 5
1.5 mm
1 .0 mm
0.0 mm
1.5 mm
S o u t h side
F E E D
k iln a x is
North side
D I S C H A R G E
1.0 mm
1.0 mm
0.0 mm
2.5 mm

Kiln No 1
Rollers skewing (Sh) are reduced for screw distance
Rollers Skewing
In Vertical Plane
GEOSERVEX - POLAND
z
F E E D
reference lin e
Measured value of roller vertical skewing
D I S x C H A R G E
South side
0.0 mm
North side
0.0 mm
1.0 mm
0.5 mm
0.5 mm
1.0 mm

Kiln No 1
1.0 mm
0.0 mm
Rollers skewing (Sv) are reduced for screw distance
Adjustment Program
In Horizontal Plane
DEFORMATION SCALE : 1:1
GEOSERVEX - POLAND
0.0 mm
0.0 mm
S o u t h side
0.0 mm
25.0 mm
F E E D
reference line
real
y North side
axis
D I S C H A R G E
adjustm e
nt axis
+/- 1.5 mm tolerance zone

Kiln No 1
Adjustment Program
In Vertical Plane VERSION I
DEFORMATION SCALE :
GEOSERVEX - POLAND
s
8
a
1:1
z
F E E D
0.0 mm
0.0 mm
adjustment a xis
kiln slope = 2.50%
4.0 mm
0.0 mm
D I +/- 1.5 mm S tolerance zone x C H A R G E
6.0 mm reference lin e

Kiln No 1
Adjustment Program
In Vertical Plane VERSION II
DEFORMATION SCALE :
GEOSERVEX - POLAND
s
9
a
1:1
z
F E E D
0.0 mm
0.0 mm
kiln slope = 2.50%
9.0 mm
0.0 mm
D I +/- 1.5 mm S tolerance zone x C H A R G E
adjustment a
xis
reference lin e

Kiln No 1
Adjustment Schedule
In Horizontal Plane VERSION I
25.0 mm
S o u t h side
25.0 mm
7.0 mm
7.0 mm
F E E D
reference line
North side
D I S C H A R G E
25.0 mm
7.0 mm
7.0 mm

Kiln No 1
25.0 mm
Adjustment Schedule
In Horizontal Plane VERSION II
15.5 mm
15.5 mm
25.0 mm
S o u t h side
25.0 mm
F E E D
reference line
North side
D I S C H A R G E
25.0 mm

Kiln No 1
15.5 mm
15.5 mm
25.0 mm
Pinion Axis in Reference to Kiln Axis
GEOSERVEX - POLAND
12
IN HORIZONTAL PLANE
South side
F E E D
kiln axis
pinion axis
3.5 mm
D I S C H A R G E
North side
2010 mm
CAUTION! Values of pinion axis deviations are calculated for regulation bolts distance IN VERTICAL PLANE
F E E D
kiln axis
2.50 %
pinion axis
D I S C H A R G E
2.0 mm
Kiln No 1
2010 mm
Rollers Mechanical Wear DISCHARGE Pier I

max. radius = 877 mm 0.0 - 1.5 - 1.5 - 2.5 - 1.5
[mm] deviation
GEOSERVEX - POLAND
13
max. radius = 890 mm 0.0 0.0 - 1.5 - 1.5 - 1.5

[mm] deviation
max. radius = 649.5 mm 0.0 - 1.0 0.0 0.0 - 1.0

[mm] deviation
Pier II
max. radius = 655 mm - 1.5 - 0.5 - 0.5 - 0.5 0.0

[mm] deviation
max. radius = 747 mm 0.0 - 1.0 - 1.0 - 1.5 - 1.0

[mm] deviation
Pier III
max. radius = 750.5 mm 0.0 0.0 0.0 - 0.5 - 0.5

[mm] deviation
max. radius = 647 mm - 0.5 0.0 - 0.5 - 1.0 0.0

[mm] deviation
Pier IV
max. radius = 647.5 mm - 0.5 - 1.0 0.0 - 1.0 - 0.5

[mm] deviation

Kiln No 1
F EED
Drive Gear Run Out and Wobbling
GEOSERVEX - POLAND
14
(viewing from feed end)
14 13 12 11 10 max. wobbling line 9
15
16
17
18
19
20 21 22 23
geometric cetre
Y
24 25
8 7 6 5 4
rotation axis
26 27 28 29
GEOMETRIC CENTRE COORDINATES Y Z
EXCENTR
+ 2 mm + 3 mm 4 mm
32
31
30
manhole line
PIER. IV
PIER. III
D I S C H A R G E
point No 25
point No 9

Kiln No 1
1.6 mm
1.6 mm
Tire No I Wobbling
GEOSERVEX - POLAND
15
14 13 12 11 10 9 8 7 6 5 4
15
16
17
18
19
20 21 22 23 24 25 26 27 28 29
32
31
30
ma x. wo bb lin
manhole line
TIRE II
gl ine
TIRE I D I S C H A R G E
point No 14
point No 30

Kiln No 1
1.8 mm
1.8 mm
Tire No II Wobbling
GEOSERVEX - POLAND
16

16 17 18
14 13 12 11 10 9 8 7
15
19
20 21 22 23 24 25 26 27
w x.
ob
in bl
li
ne
6 5 4 3 2 32 31 30 29
28
manhole line
TIRE III
TIRE I I
D I S C H A R G E
point No 22
point No 6

Kiln No 1
0.5 mm
0.5 mm
Tire No III Wobbling
GEOSERVEX - POLAND
17
14 13 12 11 10 9 8 7 6 5 4
15
16
17
18
19
20 21 22 23 24 25 26 27 28 29
32
31
30
manhole line
ma x. wo bb lin gl ine
TIRE IV
TIRE III
D I S C H A R G E
point No 14
point No 30

Kiln No 1
0.3 mm
0.3 mm
Tire No IV Wobbling
GEOSERVEX - POLAND
18
14 13
15
16
17
18
19
20 21 22 23 24 25 26
max.
12
wobb
ling l
ine
11 10 9 8 7 6 5 4 3 2 32 31 30 29 28
27
manhole line
TIRE IV TIRE III
point No 10
point No 27
0.7 mm
D I S C H A R G E
0.7 mm

Kiln No 1
Tyre and Roller Diameters
GEOSERVEX - POLAND
19
f = 1294 mm
f = 1494 mm
f = 1299 mm
f = 1755 mm
S o u t h side
F E E D
f = 4659 mm
f = 4672 mm
f = 4764 mm
North side
f = 4947 mm
D I S C H A R G E
f = 1295 mm
f = 1500 mm
f = 1310 mm
f = 1780 mm

Kiln No 1
Precision of finding diameters: +/- 2 mm
Adjustment Schedule
Step by Step - Days 8 - 9
1 mm 11 12 1 mm 10 1 mm 3 1 mm 1 2 4 1 mm 1 mm 1 mm
GEOSERVEX - POLAND
21
afternoon
Caution! Adjustment shoud be made in following order day 8 - perform steps 1 to 16 day 9 - perform steps 1 to 8 and 9,10,13,14
9
1 mm
m or ni ng
S ou th side
F E E D
reference line
y
5 1 mm 7 1 mm 13 14 1 mm 16 1 mm 8 1 mm 6 1 mm
North side
D I S C H A R G E
morning

Kiln No 1
1 mm 15 1 mm
a fternoon
Adjustment Schedule
Step by Step - Days 1 - 7
GEOSERVEX - POLAND Caution! Adjustment shoud be made in following order days 1 to 6 - perform steps 1 to 16, each day day 7 - perform steps 1,2,5,6
9 1 mm 3 1 mm 1 1 mm 2 1 mm 4 1 mm 11 1 mm 10 1 mm 12 1 mm
20
afte rnoon
morning
S o u t h side
F E E D
reference line
North side
6 1 mm 8 1 mm 14 13 1 mm 15 1 mm 7 1 mm 5 1 mm
D I S C H A R G E
morning

Kiln No 1
1 mm 16 1 mm
a fternoon
GEOSERVEX - POLAND
ROLLER SHAFT DEFLECTION Date of survay: 09.04.2004.

Pier No III - NORTH roller
EXEMPLARY CEMENT PLANT KILN No 1
digital gauge readings [0.001 mm]
-60 -40 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 -20 0 20 40 60
No of point on circumference
Eccentricity: 0.05 mm Total value of deflection: 0.10 mm Maximum deflection angle: 205 deg
GEOSERVEX - POLAND
ROLLER SHAFT DEFLECTION Date of survay: 09.04.2004.

Pier No III - SOUTH roller
EXEMPLARY CEMENT PLANT KILN No 1
digital gauge readings [0.001 mm]
-100 -50 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 50 100
No of point on circumference
Eccentricity: 0.09 mm Total value of deflection: 0.18 mm Maximum deflection angle: 238 deg
Drive Mesh Visual Inspection
GEOSERVEX - POLAND
22

Kiln No 1
Drive Mesh Visual Inspection
GEOSERVEX - POLAND
23

Kiln No 1
Mechanical Inspection (visual)
GEOSERVEX - POLAND
17
Tire No I Too big clearance between tire and stopping blocks.
Photo # 1
Lower stopping block

Too big clearance
Upper stopping block
Thickness of stopping block is very low
Photo # 2
Photo # 3
EXEMPLARY CEMENT PLANT KILN No # DATE
GEOSERVEX - POLAND
18
Tire No I Undertire shims are damaged Small thickness shim should be installed UNDER big shim
Photo # 4
Rollers are lubricated by grease what cause components wear-out
Photo # 5
GEOSERVEX - POLAND Drive station
19
Photo # 6
Weld-joints
Drive station
Cracks
Photo # 7

Drive station
GEOSERVEX - POLAND
20
Crack
Photo # 8
Drive pinions foundation frame is loosed and it move by 5 mm
Photo # 9

Girth Gear Fastening
GEOSERVEX - POLAND
21
Girth gear fastening blocks are corroded, plates are loosed, weld joints are ckacked
Photo # 10
Photo # 11
Some fastening bolts have felt down
Photo # 12
GEOSERVEX - POLAND
22
Shell section between V and VI tire
The shell has been overheated
Photo # 13
Photo # 14
GEOSERVEX - POLAND
23
Sixth pier is permanently covered by clinker dropping from the coolers
Photo # 15
Photo # 16
Clinker stock wall is damaged and kiln piers are surrounded by clinker
Photo # 17
GEOSERVEX
ENGINEERING MEASUREMENTS ENTERPRISE LTD POLAND
TECHNICAL DOCUMENTATION SHELL PROFILE MEASUREMENTS KILN No 1 EXEMPLARY CEMENT PLANT
Date of survey : 06.04.2004.
F E E D
P - IV
101.98 m 97.80 m
108.96 m 107.71 m 104.93 m 102.53 m 101.10 m
88.96 m
80.11 m
70.74
71.61 m
P - III
66.04
66.80 m 65.06 m 62.60 m
53.78 m
44.93 m 42.00 m 39.06 m 36.08 m 34.78 m 31.94 m
( VIEW FROM THE AIR )
Kiln No 1
Date of survey : 7.04.2004
P -II
32.86 m 31.04 m 29.57 m 28.68 m
25.62 m 20.14 m manhole 12.38 m 9.71 m 6.98 m 3.99 m 0.93 m 0.00 m 1.78 m 4.22 m
SHELL SECTIONS LENGHTS ( HOT CONDITION )
P-I
D I S C H A R G E
F E E D
108.85 m
35 34
104.50 m
P - IV
101.98 m 98.00 m 94.80 m 91.90 m 89.20 m 86.00 m 83.05 m 80.30 m 77.20 m

70.74
33 32 31 30 29 28 27 26 25 24 23
74.40 m 71.40 m 67.85 m 62.80 m 59.60 m 56.70 m 54.00 m 51.00 m 48.10 m 45.10 m 42.20 m 39.30 m 36.30 m 34.60 m
P - III
66.04
( VIEW FROM THE AIR )
13 22 21 20 19 18 17 16 15 14 12
Date of survey : 7.04.2004
P -II
31.94 m
11 10
EXEMPLARY CEMENT PLANT Kiln No 1
29.80 m 28.50 m
9 8 7
25.90 m 22.90 m 19.90 m 15.60 m 12.10 m 9.50 m 6.70 m 3.70 m 0.00 m
SECTIONS POSITION DRAFT FOR KILN SHELL DEVIATION SURVEY
manhole 4.40 m
D I S C H A R G E
5 4 3 2
P-I
PIER No I
SUMARY DIAGRAM OF SHELL DEFORMATION

AXONOMETRIC VIEWING

KILN No 1
8 9 11 10 PIER No II Date of survey: 07.04.2004 7
D I S C H A R G E
12 13
PIER No III
29 30 31 32 33
28
27
26
25
24 22 21 20 19 18 17 15
DRIVE 23
manhole discribing kiln position - in the bottom

14
PIER No IV 34
Z
16
35
rotary
axis
F E E D
No of section Y geom.centre Z geom.centre Excentr
35 +8 -5 9
34 +3 -3 4
P- IV
33 0 +2 2
32 0 +3 3
31 -1 +5 5
30 -2 +8 8
29 -4 +9 10
28 -3 + 10 10
27 -1 +9 9
26 -1 +9 9
25 -1 +8 8
24 -1 +7 7
23 -2 +7 7
P- III
22 +9 - 13 16
21 + 13 - 24 27
20 + 26 - 34 43
19 + 34 - 41 53
18 + 37 - 45 58
17 + 37 - 47 60
16 + 42 - 48 64
15 + 33 - 33 47
14 + 26 - 19 32
13 + 16 - 11 19
12 + 10 -6 12
P- II
11 -7 +5 9
10 -9 +7 11
9 -9 + 11 14
8 - 10 + 17 20
7 - 12 + 18 22
6 - 10 + 24 26
5 -8 + 24 25
4 -6 + 18 19
3 -4 + 14 15
2 -2 +8 8
P- I
1 0 -4 4
Unit mm mm mm
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20
RADIAL DIAGRAM OF SHELL DEFORMATION

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
( CIRCULAR DEVIATIONS )
21
VIEWING FROM FEED END
20 10
0
+ +
20
12
+
20 +
- 10
-1 0
- 10
- 10
0
- 10
10
10
10
-1
22
+ 20 + 10
+1
-1
11
+ 20
0 -2
0 -2
- 20
- 20
- 20
- 20
+2
-2
-1

23
KILN No 1
0 +2
-2
0 +1
-1
-2
SECTION No 11
24
DEFORMATION SCALE 1:1
-2
0 -1
-1 0
+ 20
+ 10
+ 10
0 -2
- 10
10
+ 20
-2 0
- 10
- 20
- 20
+ 10
rotation axis
+ 20
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
+ 10
+ 20
- 20
- 10
geometric centre
- 20
+ 10
+ 20
- 20
+ 10
0 -2
8
+ 20
26
+ 20
GEOMETRIC CENTRE COORDINATES Y - 7 mm 5 mm 9 mm
- 10
20
-1
+ 10
-1
-2
-2
0 +1
-1
0 +2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1 0
+1
27
Z ECCENTR
-2
0 +2 0
0
+ 10
+ 20
28
Date of survey: 07. 04. 2004
20
29
Caution: Manhole discribing kiln position - in the bottom (point No 1)
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
10
- 10
- 10
0
- 10
10
10
10
-1
22
+1
-1
11
+ 20
0 -2
0 -2
- 20
- 20
- 20

23
KILN No 1
+ 20 + 10
- 20
+2
-2
-1
0 +2
-2
0 +1
-1
-2
+ 10
-2 0
- 10
10
+ 20
rotation axis
SECTION No 12
24
-2
0 -1
-1 0
+ 20
+ 10
0 -2
- 10
- 20
- 20
+ 20
+ 10
+ 10
- 10
9
- 10
- 20
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
GEOMETRIC CENTRE COORDINATES Y 10 mm - 6 mm 12 mm
- 10
20
-1
+ 10
-1
-2
-2
0 +1
-1
0 +2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1 0
+1
27
Z ECCENTR
-2
0 +2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
-1 0
- 10
- 10
0
- 10
10
10
10
-1
22
+ 20 + 10
+1
-1
11
+ 20
0 -2
0 -2
- 20
- 20
- 20
- 20
+2
-2
-1

23
KILN No 1
0 +2
-2
0 +1
-1
-2
-1 0
rotation axis
SECTION No 13
24
-2
0 -1
+ 20
+ 10
+ 10
0 -2
- 10
10
+ 20
-2 0
- 10
- 20
- 20
+ 10
+ 20
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2
-2
0 +1
-1
0 +2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1 0
+1 0
27
Z ECCENTR
-2
+2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
10
- 10
- 10
0
- 10
10
10
10
-1
22
+1
-1
11
+ 20
0 -2
0 -2
- 20
- 20
- 20
- 20
+2
-2
-1

23
KILN No 1
+ 20 + 10
0 +2
-2
0 +1
-1
-2
-1 0
rotation axis
SECTION No 14
24
-2
0 -1
+ 20
+ 10
+ 10
0 -2
- 10
10
+ 20
-2 0
- 10
- 20
- 20
+ 10
- 10
32
9
- 10
- 20
mm
+ 20
+ 10
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2
-2
0 +1
-1
0 +2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1 0
+1 0
27
Z ECCENTR
-2
+2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
10
- 10
- 10
0
- 10
10
10
10
-1
22
+1
-1
11
+ 20
0 -2
0 -2
- 20
- 20
- 20

23
KILN No 1
+ 20 + 10
- 20
+2
-2
-1
0 +2
rotation axis
-2
0 +1
-1
-2
SECTION No 15
24
-2
0 -1
-1 0
+ 20
+ 10
+ 10
0 -2
- 10
10
+ 20
-2 0
Y
- 20
- 10
- 20
47
+ 20
+ 10
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2
-2
0 +1
-1
0 +2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1 0
+1 0
27
Z ECCENTR
-2
+2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
10
- 10
- 10
0
- 10
10
10
10
-1
22
+1
-1
11
+ 20
0 Z -2
0 -2
- 20
- 20
- 20
- 20
+2
-2
-1

23
KILN No 1
+ 20 + 10
0 +2
-2
0 +1
-1
-2
- 10
10
+ 20
Y rotation axis
SECTION No 16
24
-2
0 -1
-1 0
+ 20
+ 10
+ 10
0 -2
-2 0
- 10
- 20
- 20
64 m
+ 20
+ 10
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2 0
0 -2
0 +1
-1
+2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1
+1
27
Z ECCENTR
-2
0 +2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
-1
-1 0
- 10
- 10
0
- 10
10
10
-1
22

23
KILN No 1
+ 20 + 10
+1
-1
11
+ 20
0 -2 Z
0 -2
- 20
- 20
- 20
- 20
+2
-2
-1
0 +2
-2
0 +1
-1
-2
+ 10
-2 0
Y rotation axis
SECTION No 17
24
-2
0 -1
-1 0
+ 20
+ 10
0 -2
- 10
10
+ 20
- 10
- 20
- 20
60
+ 20
+ 10
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2 0
0 -2
0 +1
-1
+2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1
+1
27
Z ECCENTR
-2
0 +2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
-1 0
- 10
- 10
0
- 10
10
10
10
-1
22
+1
-1
11
+ 20
0 -2
-2 0
0 -2 Z
- 20
- 20
- 20
- 20
+2
-2
-1

23
KILN No 1
+ 20 + 10
0 +2
-2
0 +1
-1
-2 0
0 -1
+ 10
-2 0
- 10
10
+ 20
Y rotation axis
SECTION No 18
24
-1 0
+ 20
+ 10
0 -2
- 10
- 20
- 20
58
+ 20
+ 10
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2 0
0 -2
0 +1
-1
+2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1
+1
27
Z ECCENTR
-2
0 +2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
-1 0
- 10
- 10
0
- 10
10
10
10
-1
22
+1
-1
11
+ 20
0 -2
0 -2
- 20
- 20
- 20
- 20
+2
-2
-1

23
KILN No 1
+ 20 + 10
0 +2
rotation axis
-2
0 +1
-1
-2
SECTION No 19
24
-2
0 -1
-1 0
+ 20
+ 10
+ 10
0 -2
- 10
10
+ 20
-2 0
- 10
53
- 20
- 20
+ 20
+ 10
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2 0
0 -2
0 +1
-1
+2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1
+1
27
Z ECCENTR
-2
0 +2 0
0
+ 10
+ 20
28
20
29
GEOSERVEX - POLAND
14
16 15
+ 20
+2 0
17
+ 20
18 19
+ 20

20
+ 20 + 10
13
+
+ 10
+1 0
0
0
+ 10
+ 10
+2 +1
21
20 10
0
+ +
20
12
+
20 +
- 10
-1 0
- 10
- 10
0
- 10
10
10
10
-1
22
+1
-1
11
+ 20
0 -2
0 -2
- 20
- 20
- 20
- 20
+2
-2
-1

23
KILN No 1
+ 20 + 10
0 +2
rotation axis
-2
0 +1
-1
-2
SECTION No 20
24
-2
0 -1
-1 0
+ 20
+ 10
+ 10
0 -2
- 10
10
+ 20
-2 0
- 10
- 20
43
- 20
+ 20
+ 10
+ 10
- 10
- 10
- 20
9
- 10
- 20
25
- 10
- 20
- 20
+ 10
+ 10
+ 20
+ 20
- 20
- 10
geometric centre
- 20
+ 10
0 -2
8
+ 20
26
+ 20
- 10
20
-1
+ 10
-1
-2 0
0 -2
0 +1
-1
+2
10
3 2 1 32
+ 20
+ 20
+ 20
+ 20
31
+2
+ 10
+ 10
+ 10
+ 10
manhole
30
20
10
+1
- 10
- 10
+1 0
+2 0
10
20
-1
-1
-2
- 10
- 20
- 20
- 20
- 20
- 10
-2 0
-1 0
-1 0
-2
-1
+1
27
Z ECCENTR
-2
0 +2 0
0
+ 10
+ 20
28
20
29
REFERENCE LIST
Year/m 2005/04 2005/04 2005/04 2005/04 2005/04 2005/03 2005/03 2005/03 2005/03 2005/03 2005/03 2005/03 2005/03 2005/02 2005/01 2005/01 2005/01 2005/01 2004/12 2004/12 2004/11 2004/11 2004/11 2004/11 2004/10 2004/10 2004/10 2004/09 2004/08 2004/08 2004/07 2004/07 2004/06 2004/06 2004/05 2004/05 2004/05 2004/04 2004/04 Kind of works
Rotary Dryers Alignment Hot Kiln Alignment Hot Kiln Alignment Cement Mill Alignment Hot Kiln #4 Alignment Hot Kiln Alignment Hot Kiln #1 Alignment Hot Kiln #1 Alignment Hot Kiln #2 Alignment Hot Kiln #5 Alignment Kiln #2 Renovation Supervision Hot Kiln Alignment Hot Kiln #1 Alignment Coal Mill Alignment Hot Kiln #1 Alignment Hot Kiln #3 Alignment Hot Kiln #4 Alignment Hot Kiln #1 Alignment Cement Mill #3 Alignment Hot Kiln Alignment Hot Kiln #1 Alignment Hot Kiln #2 Alignment Hot Kiln #1 Alignment Hot Kiln #2 Alignment Hot Kiln Alignment Rotary Cooler Alignment Centering of Drive Gear Hot Kiln Alignment Hot Kiln #1 Alignment Hot Kiln #2 Alignment Hot Kiln #3 Alignment Hot Kiln #4 Alignment Alignment of Power Turbine Alignment of Power Turbine Hot Kiln Alignment Hot Kiln #2 Alignment Measurements of Furnance#4 Hot Kiln Alignment Kiln Renovation Supervision
Plant name Clinton San Juan Kryvyi Rih Cement Kryvyi Rih Cement Rudniki Nasice Runiki Dniprocement Dniprocement VAC Gorazdze Odra Gorazdze Gorazdze Adana Cimento Adana Cimento Adana Cimento Mardin Cimeto Gorazdze Kryvyi Rih Cement Dniprocement Dniprocement Hanil Hanil Odra Anwil-Wloclawek IP Kwidzyn Afyon Cimento Kutayha Magnesit Kutayha Magnesit JECHEON-SI JECHEON-SI Borowo Bydgoszcz Jaroszw Hejocsaba
Glogow Coper Plant
Company name ADM Clinton Essroc Heidelbergcement Heidelbergcement CEMEX NEXE Grupa CEMEX Heidelbergcement Heidelbergcement Heidelbergcement Heidelbergcement Cement Odra Heidelbergcement Heidelbergcement OYAK OYAK OYAK OYAK Heidelbergcement Heidelbergcement Heidelbergcement Heidelbergcement Hanil Cement Hanil Cement Cement Odra ORLEN
International Paper
Country USA* Puerto Rico* Ukraine Ukraine Poland Croatia Poland Ukraine Ukraine Hungary Poland Poland Poland Poland Turkey Turkey Turkey Turkey Poland Ukraine Ukraine Ukraine Korea Korea Poland Poland Poland Turkey Turkey Turkey Korea Korea Poland Poland Poland Hungary Poland USA* USA*
Mason City IOWA
SET-Italcementi Kumas Kumas Asia Cement Asia Cement BE&K Europe Power Plant Jaroszw Cement Holcim KGHM Holcim Holcim
2004/04 2004/04 2004/04 2004/04 2004/04 2004/04 2004/03 2004/03 2004/03 2004/03 2004/03 2004/03 2004/03 2004/03 2004/02 2004/02 2004/02 2004/02 2004/02 2004/02 2004/01 2004/01 2004/01 2004/01
Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004
Hot Kiln Alignment Kiln Renovation Supervision Rotary Cooler Alignment Hot Kiln #1 Alignment Hot Kiln #3 Alignment Hot Kiln #4 Alignment Hot Kiln #1 Alignment Hot Kiln #2 Alignment Cement Mill #2 Alignment Hot Kiln Alignment Cement Mill #4 Alignment Kiln #2 Renovation Supervision Hot Kiln #4 Alignment Hot Kiln Alignment Kiln #1 Renovation Supervision Hot Kiln #1 Alignment Kiln Renovation Supervision Hot Kiln Alignment Kiln #1 Renovation Supervision Kiln #2 Renovation Supervision Hot Kiln #1 Alignment Hot Kiln #2 Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln #1 and 2 Alignment Hot Kiln Alignment Kiln Erection Supervision Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment
Jaroszw Jaroszw Anwil-Wloclawek Rudniki Rudniki Rudniki Goliat Malaga Goliat Malaga Goliat Malaga Picton Goliat Malaga Gorazdze Odra Arrigorriaga Gorazdze Gorazdze Kryvyi Rih Cement Kryvyi Rih Cement Dniprocement Dniprocement Dniprocement Dniprocement Arrigorriaga Hanil Denizli Beli Izvor Kujawy IOWA Mason City NUH Cimento Sung Shin Dong Hae Sam Chok Monselice Broceni Trbovlie Nowiny Sankarnagar Jaypee Bela Jaypee Rewa Chilamkur Limassol Vassiliko Nazareth
Jaroszw Cement Jaroszw Cement ORLEN CEMEX CEMEX CEMEX

Cem.RezolaItalcementi Cem.RezolaItalcementi Cem.RezolaItalcementi
Essroc
Cem.RezolaItalcementi
Heidelbergcement Cement Odra

Poland Poland Poland Poland Poland Poland Spain Spain Spain USA* Spain Poland Poland Spain Poland Poland Ukraine Ukraine Ukraine Ukraine Ukraine Ukraine Spain Korea Turkey Bulgaria Poland USA* USA* Turkey Korea Korea Korea Italy Latvia Slovenia Poland India India India India Cyprus Cyprus USA*
Heidelbergcement Heidelbergcement Heidelbergcement Heidelbergcement Heidelbergcement Heidelbergcement Heidelbergcement Heidelbergcement

HANIL CEMENT Denizli Cimento Holcim Lafarge Heidelbergcement Holcim NUH Sung Shin Cement Ssang Yung Tong Yang Major Italcementi Readymix Lafarge Dyckerhoff The India Cement Jaypee Bela Cem. Jaypee Rewa Cem. The India Cement The Cyprus Cem. Vassiliko Cement Essroc
Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004 Before 2004
Hot Kiln Alignment Hot Kiln Alignment Kiln Renovation Supervision Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment Hot Kiln Alignment
Speed Bessemer Bessemer Frederick Mason City Mason City Logansport St. Lawrence Ponce Picton
Essroc Essroc Essroc Essroc Holnam Lehigh Essroc Holcim CEMEX Essroc
USA* USA* USA* USA* USA* USA* USA* Canada* Puerto Rico* Canada*
* - jointly with HKA Corp. New York City; USA

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TECHNICAL DOCUMENTATION

RESULTS OF DEVIATION MEASUREMENTS AND GEOMETRY OF ROTARY KILN No 1

EXEMPLARY CEMENT PLANT

PERIOD OF SURVEY: 30 of March - 16th of April, 2004

FINAL REPORT ON KILN No 1

EXEMPLARY CEMENT PLANT

Date of survey : 05.04.2004.

Index Table of Contents

Symbol and Terms

Coordinates " x " feed [m] feed

Coordinates " y " [ mm ]

Coordinates " z " feed [ mm ]

101.98 66.04 31.94 0.00

0.0 + 11.0 + 19.0 0.0

0.0 0.0 + 12.0 0.0

Undertire clearance " s " feed [ mm ]

rollers operating angle " a " feed [o

8.0 14.0 8.5 8.0

EXEMPLARY CEMENT PLANT

EXEMPLARY CEMENT PLANT

Precision of finding kiln axis: +/- 1 mm

kiln slope = 2.50%

EXEMPLARY CEMENT PLANT

Precision of finding kiln axis: +/- 1 mm

EXEMPLARY CEMENT PLANT

Rollers skewing (Sh) are reduced for screw distance

Measured value of roller vertical skewing

EXEMPLARY CEMENT PLANT

Rollers skewing (Sv) are reduced for screw distance

+/- 1.5 mm tolerance zone

EXEMPLARY CEMENT PLANT

Precision of finding kiln axis: +/- 1 mm

kiln slope = 2.50%

6.0 mm reference lin e

EXEMPLARY CEMENT PLANT

Precision of finding kiln axis: +/- 1 mm

EXEMPLARY CEMENT PLANT

Precision of finding kiln axis: +/- 1 mm

EXEMPLARY CEMENT PLANT

EXEMPLARY CEMENT PLANT

Pinion Axis in Reference to Kiln Axis

Rollers Mechanical Wear DISCHARGE Pier I

max. radius = 890 mm 0.0 0.0 - 1.5 - 1.5 - 1.5

max. radius = 649.5 mm 0.0 - 1.0 0.0 0.0 - 1.0

max. radius = 655 mm - 1.5 - 0.5 - 0.5 - 0.5 0.0

max. radius = 747 mm 0.0 - 1.0 - 1.0 - 1.5 - 1.0

max. radius = 750.5 mm 0.0 0.0 0.0 - 0.5 - 0.5

max. radius = 647 mm - 0.5 0.0 - 0.5 - 1.0 0.0

max. radius = 647.5 mm - 0.5 - 1.0 0.0 - 1.0 - 0.5

EXEMPLARY CEMENT PLANT

Drive Gear Run Out and Wobbling

(viewing from feed end)

14 13 12 11 10 max. wobbling line 9

EXEMPLARY CEMENT PLANT

(viewing from feed end)

EXEMPLARY CEMENT PLANT

(viewing from feed end)

EXEMPLARY CEMENT PLANT

Tire No III Wobbling

(viewing from feed end)

EXEMPLARY CEMENT PLANT

(viewing from feed end)

EXEMPLARY CEMENT PLANT