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Introduction
INSPECTION
MAIN FEATURES
Ensures high kiln availability Reduces maintenance costs Short payback time Performed during normal kiln operation Extended lifetime of refractory lining and other key kiln components Backed up by F.L.Smidths in-house engineering departments Based on more than 120 years of experience in kiln design Performed by highly experienced F.L.Smidth kiln specialists
Kiln inspections
Regular kiln inspection is required to ensure optimum availability of the kiln installation and to verify that the kiln operates within the load and stress parameters laid down by the kiln designer. Todays state of the art methods of inspection performed during normal operation of the kiln are based on advanced measuring techniques and evaluated by highly experienced kiln specialists. Although the vast majority of cement plants employ a very experienced maintenance staff, it is not economically and technically viable for the individual plant to invest in the measuring instruments and develop the computer software required, acquire and maintain the skills necessary to perform these advanced inspections, process the data and evaluate the results. Therefore it is an accepted practice in the cement industry worldwide to call on an outside company to carry out these comprehensive kiln inspections at regular intervals.
F.L.Smidth
F.L.Smidth is the world's largest supplier of rotary kilns, spare parts and services to the cement industry. With more that 120 years of experience as kiln designers, F.L.Smidth possesses a huge technical know-how on rotary kilns and employs a group of highly experienced field engineers, who work daily as kiln specialists at cement plants all over the world backed up by the entire F.L.Smidth organisation. The Hot Kiln Alignment method was introduced into the cement industry in 1981 allowing a full inspection of the kiln to be performed during normal operation. Since then, F.L.Smidth has continuously updated and improved the method, measuring instruments and computer software to provide our clients with the best possible tools to evaluate the consequences of the kilns present operating condition in respect of the availability.
MECHANICAL
KILN
Symptoms
Hot bearings
On bearing On thrust journal collar Kiln axis
Cracks
In kiln shell Kiln axis Kiln shell ovality In supporting roller shaft Kiln axis
Wear
On suppt. roller and tyre Kiln axis Kiln shell ovality Between tyre and kiln shell
Lining loss
Between the tyres Under the tyres Kiln axis Kiln shell ovality Kiln crank
Root causes
Kiln crank
Corrosion
F.L.Smidth to tailor an inspection to meet his specific needs. The results of the F.L.Smidth inspection are presented in a written report and/or on a CD-Rom, with recommendations of measures to be taken. Additionally, any adjustments to the kiln recommended by F.L.Smidth can, at the clients request, be supervised and verified by an F.L.Smidth field engineer in continuation of the inspection.
Benefits
The comprehensive kiln inspection performed on a regular basis in co-operation with F.L.Smidth provides the client with the knowledge necessary to prolong the lifetime of the refractory lining and expensive kiln components and reduces the risk of unscheduled stoppages, thus ensuring high kiln availability. Empirically, the payback time of a comprehensive kiln inspection is very short as the expenditure on this inspection is very marginal as compared with the cost of refractory lining and components to be replaced as a result of avoidable mechanical failures as well as the cost of the consequential production losses incurred.
Elements
Kiln axis
The kiln axis is defined by the position of the supporting rollers. It determines the distribution of the kiln weight load between the supports and thus the distribution of the longitudinal bending stresses in the kiln shell. Misalignment of the kiln axis may result in overloading of supports, excessive stresses in kiln shell, tyres and supporting rollers as well as bearing overload. The kiln axis is measured during normal kiln operation using two electronic theodolites, connected to a computer calculating the horizontal and vertical kiln axis by specially developed software. Additionally, the Comprehensive kiln inspection includes a complete recalculation of the kiln, based on the axis measured and the present load conditions, to determine the optimum kiln axis, taking both load distribution on the supports, the stress levels in kiln shell and tyres, and the kiln axis into consideration.
Axial balance
Although a rotary kiln is always in axial balance, the axial balance can be established either between large forces or preferably, in order to ensure the availability, between small forces. The state of axial balance is defined by the degree of parallelism between the kiln axis and the axes of the individual supporting rollers determining the magnitude and directions of the axial frictional forces between the tyres and supporting rollers and on the thrust roller(s). Large axial forces may result in hot supporting roller bearings, failure of the thrust device(s) or damaged end seals.
Elements
Kiln crank
A kiln crank, whether mechanical or thermal, can cause excessive, extra, cyclic loads between supporting rollers and tyres and stresses in the kiln shell. A mechanical crank is caused by a permanent deformation in the kiln shell, whereas a thermal crank is caused by temperature variations along the circumference of the kiln shell, and so it is present only during operation of the hot kiln. Excessive crank formation can lead to failure of contact surfaces, supporting roller shafts, tyres, kiln shell and lining. The kiln shell is checked for crank formation by measuring the variations in the deflection of the supporting roller shafts, which has to stay within certain limits.
Kiln drive
An examination of the kiln drive constitutes another important element of a kiln inspection. The condition of the kiln drive is determined by measurering of the axial and radial wobbling of the girth gear as well as evaluation of the mesh and root clearance between the girth gear and pinion(s). Further, the condition of the tooth profiles, the lubrication of the gears, as well as the stud bolt connections between the girth gear and the spring plates and the welds between the spring plates and the kiln shell are examined. To complete the examination of the kiln drive, the operating temperature and vibration levels of the main gear unit are checked.
General inspection
The general inspection of the kiln comprises a visual examination of the condition of other key kiln components not included in any of the above activities, but the possible poor condition of these components can also pose a threat to the availability of the kiln.
Inspection types
Comprehensive kiln inspection Inspection of two-support kiln Hot kiln alignment check
) Included in the standard inspection
*) Optional
Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice. 12-04-258 Bazement Grafisk Design ApS
DENMARK
www.flsmidth.com
Up-to-date addresses of worldwide subsidiaries and sales offices are available from our website
USA
F.L.Smidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Tel: +1 800-523-9482 Fax: +1 610-264-6170 E-mail: info-us@flsmidth.com
INDIA
F.L.Smidth Ltd. Capital Towers 180, Kodambakkam High Road Nungambakkam Chennai 600 034 Tel: +91 44-52 191234 Fax: +91 44-2827 9393 E-mail: indiainfo@flsmidth.com
F.L.Smidth A/S Vigerslev All 77 DK-2500 Valby Copenhagen Tel: +45 36 18 10 00 Fax: +45 36 30 18 20 E-mail: info@flsmidth.com
Inspection modules