Hail Cement Company - Kiln bricks fallin

Equipment/Item no. Kiln Location: Kiln

Name
Hatem Abdulaziz
Participant

Problem Definition Kiln tripping due to Main drive high load

What Kiln feed tripping due to main drive tripped with high load
When 26.10.2017
Where Kiln
Significance
Safety
No Injuries
( potential injury )
Reliability
Revenue (Production) 3.42 Hrs (855 tones)
Revenue loss
Frequency 1st time at Kiln.

No. Possible Root Cause(s)

1 Unstable operation of Thruster pump ( up , and down with short ti

2 Hanged coating and build ups at inlet or unstable coating at kiln

Friction between Lip plate loaded with castable with sector plates
3
Electrical Malfunction at Kiln main drive
4
Coating build-ups and collapse due to High SO3
5
Changing of flame momentum due to changing of Main burner Pr
outlet pressure ( by decreasing fan speed).
6
7
No. Most Probable Root cause
 Changing of flame momentum due to changing of Main burner Pr
1 outlet pressure ( by decreasing fan speed).
Hanged coating and build ups at inlet or unstable coating at kiln
2

No. Agreed Action Plans

1 Checking thickness at each possible kiln entry

2 Control So3 not to exceed 0.3 at kiln feed
3 Control Volatalization Cycle and Alkali / Sulphate ratio

Waiting for a reply from Refratechniq regard the bricks and the
4 possible reason for it , and if any new suggestion regard new type.

5 Adjusting the vibration of girth gear

Prepared by : Hatem abdulaziz

 - Kiln bricks falling

RCA Meeting
Date : 26.10.2017
Time : 12:18 PM
Designation
Production Supervisor

ped with high load

ause(s) Category
nd down with short time) Medium

able coating at kiln Medium

ble with sector plates Medium

Low

SO3 Low

ng of Main burner Primary fan

High

ot cause Category
ng of Main burner Primary fan
High

able coating at kiln

Medium

Action by Target date Status

Production SD Pending
QC / Quarry In progress
QC / Hashim In progress

Production Pending

Mech. / PME SD Pending

Hatem abdulaziz
 Coating load

Collapse of
Falling of Hanged caoting at kiln
coating at inlet

Thermal,
chemical Change Changing of Kiln Unstable coating at
coating profile begining of operation
 Main drive tripping with
overload

Mechanical Failure

Thruster pump
Friction between Lip operation
plate and sector plate
High vibration of girth
gear reached to (11-
Unstable coating at 13 mm/s) with speed
begining of operation Unstability, fast kiln 3.55 RPM
movement

Falling of cating
 Electrical failure

Main drive
malfunction

n of girth
to (11-
th speed