Mechanical Kiln Inspection

The condition of the kiln is essential for its run factor

The rotary kiln is among the most important machines at a cement plant. Smooth, uninterrupted operation of the kiln is essential for plant profitability. It is therefore important that the maintenance strategy includes regular kiln inspections. For such inspections, FLS Plant Services team of kiln experts offer the cement industry their extensive know-how and expertise in kiln design, erection and commissioning. Their expertise derives from the installation of a great number of kiln systems and from trouble shooting and service assignments at many plants of different makes around the world. FLS Plant Services is therefore your ideal patner offering specialist expertise based on long-standing and worldwide experience. FLS Kiln inspection is carried through without any disturbance of clinker production. The programme includes visual inspection which requires particular competence and expert knowledge. It also comprises all necessary measurements including, of course, the traditional kiln axis measurement to produce a thorough description of the mechanical situation.

Before leaving the plant inspected, the FLS specialist submits his recommendation regarding any immediate action needed as well as a preliminary report documenting the kiln axis ascertained. The final report submitted from FLS Head Office contains all measurements and observations made during the inspection as well as comments regarding any implications. The kiln is completely recalculated on the basis of current plant data to ascertain fatigue loading in the kiln shell and load distribution on the supports, which is necessary to specify the optimum kiln axis. The report contains clear conclusions and recommendations as to any specific action to be undertaken in the shorter or longer term. Overleaf is an outline of the FLS kiln inspection service.

Kiln inspection

A kiln inspection is a strategic action. Its primary goal is to give an in-depth and realistic analysis of the mechanical condition of the kiln. It must provide a sound basis for the planning of spare parts purchases and maintenance activities to ensure optimum plant profitability. Kiln inspection is a job for experts. Supported by advanced instruments and methods they must have wide experience in all aspects of kiln operation to draw the right conclusions from their observations at the plant and to combine them with the large number of measurements carried out. Facilities for making complete kiln calculations are also necessary to assess load conditions, residual life, consequences of adjustments, etc. It is the condition of the kiln in operation that matters. Modern kiln inspection therefore takes place while that the kiln is hot and working, without interrupting clinker production. The visual inspection is supported by a range of measurements focusing on the four potential threats to trouble-free kiln operation. l kiln alignment l kiln ovality l kiln crank l kiln balance

Hot kiln ovality

kiln shell ovality is due to the clearance between kiln shell and tyre. Increasing ovality causes increasing fatigue stresses in the kiln shell and increasing mechanical loads on the lining. It eventually reduces lining life and causes cracks in the shell.

Measuring of Kiln shell ovality.

Hot kiln crank

Hot kiln alignment

FLS plant Services offers a unique technique of kiln alignment developed in collaboration with a Danish university. It uses computer-controlled, electronic theodolites one of which is equipped with a laser unit.

Cranks are dangerous because they are invisible until they become very large. They cause varying and potentially very high additional loads on supporting rollers, tyres and kiln shell.

Changes in the air temperature along the kiln cause refraction of the laser beam. The beam is therefore not used as a reference line along the kiln but perpendicular to the kiln to mark points to be measured over short distances. This technique has proved extremely accurate.

Measuring kiln crank

Hot kiln balance

Skewing of supporting rollers may create very large axial forces. Part of the kiln inspection programme aims at attaining an equilibrium of such forces a low level to avoid the risk of supporting roller bearings running hot.

Kiln inspection programmes

FLS Plant Services offers a wide range of kiln inspection programmes. The programmes range form comprehensive kiln inspection to simple kiln axis measurements. Services offered include machining of tyres and supporting rollers and straightening of warped kilns.

Plant Services

The FLS Mechanical kiln Inspection programmes incorporate F.L.Smidths cutting-edge technology and extensive know-how. Performed by experts the inspection programmes are an unsurpassed instrument in planning maintenance and ensuring maximum plant profitability. For further details please contact: Measuring of supporting roller diameter

Based on the measured kiln axis and the weight of the lining and coating, the kiln is completely recalculated. From this recalculation emerges the optimum Kiln axis, i.e. the axis which will equalise the support loads and minimise the stresses in the kiln shell.

Vigerslev All 77 . DK-2500 Valby . Copenhagen Telephone : +45 36 18 10 00 . Telefax: +45 36 44 11 19 E-mail: info@flsmidth.com . Internet:http://www.flsmidth.com