8 application of preditive maintenance in kiln maintenance

8/13/2019 8 Application of Preditive Maintenance in Kiln Maintenance

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APPLICATIONSOF

PREDICTIVE MAINTENANCEIN

MAINTENANCE OF KILNS


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PREDICTIVE MAINTENANCE - 1 Under Predictive Maintenance, some

parameters are measured to determine thecondition of the machine and to take

appropriate corrective actions. Predictive Maintenance helps to know the

trend of the health of any equipment over a

period of time Enables timely corrective actions to be taken

to avoid unplanned, sudden and avoidablebreakdowns.


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PREDICTIVE MAINTENANCE - 2 The terms predictive maintenance and condition-

based maintenance are used synonymously. Better control over the machine Reduction in unscheduled stoppage of the

machines to a great extent Management could plan the stoppage of the

machines in a much better way utilizing all theorganizational resources in the most effectivemanner.

Predictive maintenance adds value to the customerby:

Improving the uptime of the machines, Reducing cost and arranging products 4


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OBJECTIVES OF PREDICTIVEMAINTENANCE

Helps in determining that there exists a problem. It monitors the degrading condition of the

machine. Trending degradation permits planning for

repairs.

Trending degradation permits scheduling repairs. Limits the extent of damage of machine save money in costly repairs as well as in loss of

opportunity to produce.


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PARAMETERS TO MEASURE UNDERPREDICTIVE MAINTENANCE OF CRK -1

Temperature Vibration measurements:

Amplitude, Velocity and Frequency of the vibrations.

Presence of contaminants, if any, such as: Dust, Dirt, Metal wear particles,

Soluble and insoluble acidic bodies in lubricating oils.


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PARAMETERS TO MEASURE UNDERPREDICTIVE MAINTENANCE OF CRK -2

Cracks in shell or supporting rollers Alignment of kiln

Ovality of kiln shell Thrust on supporting roller bearings Thickness of the refractory lining Thickness of the shell plate in different zones. Current


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EQUIPMENTSUSED IN

PREDICTIVE MAINTENANCE


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PORTABLE ULTRASOUNDTHICKNESS GAUGE

Specifications

Thickness range 0

100mm

Purpose

To measurethickness of kiln shell


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ULTRASONIC FLAW DETECTIONTEST KIT

Specifications

Should be able todetect cracks andmetallurgical flaws inferrous and nonferrous materials

Purpose

To detect cracks inshell, tyres andsupport rollers.


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OIL SPECTROMETER

Specifications

Suitable for oilanalysis of industriallubricants havingviscosity range from20 - 700 Centistokesat 40C.

Purpose

To determine thecondition of thelubricant for furtheruse.


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NON-CONTACT THERMOMETER

Specifications

Infrared laser typenon-contactthermometer, range0 - 500C.

Purpose

To measure surfacetemperature of shell,tyre, support roller,girth gear toothflanks.


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DIGITAL OPTICAL PYROMETER

Specifications

Range 0 - 600C.

Purpose

To measure surfacetemperature of:

shell, tyre, support roller, girth gear tooth

flanks.


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PORATABLE INFRAREDTHERMOMETER

Specifications

(-)30 - (+)1600C

Purpose

To measure flametemperature


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DIGITAL VERNIER CALLIPER

Specifications

Measurement range0 - 100 mm, leastcount 0.01 mm

Purpose

To measurethickness of girthgear and piniontooth


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SHELL TESTER

Specifications

Kiln shell ovalitytester, portable withtemperatureresistant magnets,mechanicalrecording device.

Purpose

To test shell ovalityand determining therequired thickness ofchair pads.


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ELECTRONIC EQUIPMENT FOROVALITY MEASUREMENT

Specifications Purpose

Kiln shell ovality tester,portable.

To test shell ovalityand determining therequired thickness of

chair pads.


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DIGITAL LEVELING INSTRUMENT

Specifications

Least count /sensitivity 0.1mm/meter

Purpose

To determine topand bottom deadcenter of the kilnshell, other levelingworks.


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KILN THRUST MEASUREMENTEQUIPMENT

Specifications

Mobile hydraulicthrust measuringequipment with highpressure jack.

Purpose

To adjust setting ofthe support rollersand checking thecondition of thebearings of thesupporting rollers.


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MICROLOG DATA COLLECTOR WITHFFT ANALYZER AND PROCESSOR

Specifications With accelerometer of

magnetic base,

accelerometer cable,dynamic balancing andstroboscope set withfacility to download the

data to any P4 processorequipped PC. The datacollector / analyzershould cover frequency

range of 0.2 Hz to 20 KHz.

Purpose Data collection,

machinery vibrationanalysis andmonitoring e.g. girthgear and motors.Should do earlydetection of bearingdefects or gear toothwear, electric motormonitoring and fieldmachinery balancing.


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ENGINEER'S STETHOSCOPE

Specifications

Portable stethoscope

Purpose

For detectingabnormal sound inmachine inoperation


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LASER ALIGNMENT CHECKINGEQUIPMENT

Specifications

Laser couplingalignmentequipment withaccessories.

Purpose

To do alignment ofcouplings of motorand fan or any othercouplings.


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LINOMETER

Specifications

Portable thicknessmeasuringequipment.

Purpose

For measurement ofrefractory brickthickness.


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SHOCK PULSE METER

Specifications 0 100 db

Purpose To measure the

value of shock pulsesin ball and rollerbearings


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CASE STUDIES OF SIDHEE CEMENT


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VIBRATION MEASUREMENTS OF KILNDRIVE AT SIDHEE CEMENT


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VIBRATION ANALYSIS OF MAIN KILN DRIVE GEARBOX OF4200TPD 4.3M DIA KILN AT SIDHEE CEMENT PLANT


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BREAKDOWN ANALYSIS ROLLER SHAFTSHEARED OFF AT GSCL


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GIRTH GEAR AND PINION TEMPERATURE ON21.01.08 AT GSCL


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GIRTH GEAR AND PINION TEMPERATURE ON18.05.08 AT GSCL


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CONTACT PATTERN EARLIER BETWEEN GIRTH GEAAND PINION AT GSCL


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CONTACT PATTERN LATER BETWEEN GIRTH GEAR ANPINION AT GSCL


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ROOT CLEARANCE AND BACKLASH BETWEEN GIRTH GEAAND PINION ON 07.08.06 AT GSCL


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ROOT CLEARANCE BETWEEN GIRTH GEAR ANDPINION ON 14.10.07 AT GSCL


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ROOT CLEARANCE AND BACKLASH BETWEEN GIRTH GEAAND PINION ON 06.06.08 AT GSCL


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TECHNICAL AUDIT REPORT OFBREAKDOWN AT GSCL - 1

1.0 Name of Machine:

2.0 Department & Machine ID:3.0 Source of supplier:

4.0 Brief technical details: (Write technicalspecification, dimension, material of constructionetc.)

5.0 Date of Installation:6.0 Date of last repair / maintenance:7.0 Brief details of last repair / maintenance:

8.0 Time and Date of occurrence of the problem:


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9.0 Time and Date of Restarting the machine afterrepair:

10.0 Total time of stoppage of machine :11.00 Brief details of Breakdown: (State what

happened? (Damage to men, machine or building).Support with drawings and photographs)

12.00 Details of investigations carried out and fieldmeasurement.

13.00 What were the last readings of fieldmeasurements?14.00 Were any early signals noticed before occurrence

of the actual failure or damage?


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15.00 Analyze and establish of reason (s) for the failure/ damage, which may include:i. Poor Material

ii. Long operating lifeiii. Wrong operationsiv. Negligence in maintenance.v. Deficiency in system design.vi. External factors like-heavy rains, earthquake,lightening, accident etc.vii If any official is found responsible or thefailure/damage.

TECHNICAL AUDIT REPORT OF


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16.00 What actions were taken to restore the machine?17.00 Details of materials used with cost:18.00 Details of manpower used:19.00 What lessons can be drawn from the failure/damage?

20.00 What actions should be taken to make the m/c workingefficiently and safely?21.00 What steps should be taken to avoid similar failures in

future?

Report prepared by Concurred by Approved by22.00 Remarks of the controlling authority.Joint President (Works)Cc: Director (Operations/Projects)


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TREND OF KILN TYRE MIGRATION ATGSCL

8 application of preditive maintenance in kiln maintenance

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