Rotary kiln diagnostics

Rotary kiln diagnostics

Machinery reliability plays a key role in plant economic performance. SKF is a leading supplier of products and services in the area comprising rolling bearings, seals, mechatronics, lubrication systems and reliability solutions. SKF thus significantly contributes to increasing the productivity of rotating machinery and reducing the operation-related costs. Examples of such machinery are rotary kilns, dryers and pelletizers. Any downtime or operation at low levels resulting from an unsatisfactory mechanical condition of these large machines has a massive impact on the economic performance of the entire plant. One of the most reliable methods of determining the mechanical condition of a rotary kiln is the measurement of its geometric parameters such as kiln axis, axes of the supporting rollers and ovality.

SKF offers a comprehensive set of diagnostic services enabling to establish the prevailing mechanical condition of the kiln in full operation. The next step is to localize the critical parts and to optimize them. Regular application of the rotary kiln diagnostic services serves as an effective tool for failure prediction and improved maintenance planning. All measurements included in the individual diagnostic modules are carried out while the kiln is in operation. As a result, any optimization recommendations reflect the real operating conditions including high temperatures and dynamics of the kiln and are not burdened with a kiln shell thermal expansion error. As the diagnostic measurements are performed on machinery in full operation, the service has no influence on the plant production levels.

Benefits of regular kiln diagnostics

extended lifetime of the refractory lining and elimination of the lining loss caused by the rotary kiln mechanical instability energy savings enhanced lifetime of the shell, tyres, stop-blocks, support rollers, shafts and bearings reduced wear of a gear ring, pinion and drive elimination of cracks and overheating of the kiln shell Considering the operating savings and a reduced risk of unexpected breakdowns and failures, the return on investment in the rotary kiln diagnostics service is very short.

Typical kiln failure symptoms

Hot bearings On bearing journal On thrust journal collar Cracks In kiln shell Na radilnch kladkch Mechanical wear On support roller and tyre Kiln geometry Between tyre and kiln shell Lining loss Between tyres Under tyres

Kiln geometry

Kiln geometry

Kiln geometry

Kiln geometry

Kiln shell ovality

Kiln shell ovality

Kiln shell ovality

Root cause

Kiln crank

Kiln crank

Kiln crank

Kiln crank

Axial balance

Axial balance

Lubrication

Corrosion

Lining quality

Diagnostics modules:
Modul A Kiln geometry analysis
The high reliability and the ability to predict breakdowns of a rotary kiln critically depend on its geometry. Changes such as sinking of foundations, uneven mechanical wear or an inadequate repair can lead to overloading of individual components. This condition then gradually develops into a full-fledged damage and production loss. Rotary kilns should be therefore carefully aligned in order to reduce to minimum torsion and stress in the kiln shell, i.e. the factors cause excessive mechanical wear and can negatively influence the lifetime of refractory lining, rollers, bearings and other components. Analysed elements: - kiln axis (spatial course) - kiln slope - roller operating angles - deviation of supporting roller axes from the kiln axis (spatial) - diameters and profiles of the supporting rollers - diameters and profiles of the tyres - tyre and gear ring wobbling - thermal differences

Deviations for the distance

Sample analysis presentation

Modul B Kiln shell profile

Kiln shell profile analysis is used to determine the plastic (permanent) deformation of the kiln shell, either along the entire length of the kiln or along a particular segment. Although such deformation may not affect the distribution of loads on the supporting rollers, it can have negative impact on the refractory lining lifetime. The analysis of the measurement results is used to select critical parts of the kiln to be replaced or repaired.
Sample analysis presentation

Modul C Advanced diagnostics

- kiln shell thermal scanning - inspection and diagnostics of the kiln drive section (gearing, gear clearance, vibrations, alignment) - online condition monitoring

OPTIMAL Module Customized combination of diagnostic services

For customer comfort and ease of use, SKF provides the four rotary kiln diagnostics modules described above. In order to achieve optimal results in particular cases, it is often necessary to select a different combination of analyses. These customer-specific solutions come under the heading of the OPTIMAL module.

Sample analysis presentation

Analysis types

Analysis

Mechanical wear (profile, diameter) of rollers and tyres

Supporting roller axes deviation from the kiln axis

Kiln axis / Kiln slope / Roller operating angles

Pier declinations (kiln crank)

Drive section analysis

Thermal scanning

Kiln shell profile

Tyre wobbling

Modul Modul A Modul B Module Optimal

Service included in the module Service NOT included in the module Optional service

The outputs from the diagnostics

Electronic and printed version of the measurement report Diagnostic results are presented to and consulted with the customer Recommendations for optimalization activities Upon agreement, supervision over implementation of the optimisation measures

Report

Bearings all types and sizes

Power transmission products

Seals

Tools and instruments

Lubricants

Lubrication systems

Vibration analysis

Filters

Optical measurements

Seals

Bearings and units

Lubrication systems

Mechatronics

Services

Contact in Czech Republic Lucie Stavaov Project manager - Optical measurement SKF Loiska, a.s. Technologick 372/2 708 00 Ostrava - Pustkovec, esk Republika Tel: +420 597 305 968 Mobile: +420 737 208 265 Fax: +420 597 306 024 lucie.stavarova@skf.com www.skf.cz

Contact in Italy Gianluca Gaziano Platform Champion - Reability Systems SKF Industrie S.p.A. Service Division Via Pinnerolo 54 I - 10060 Airasca (TO), Italy Tel: +39 011 9852 920 Fax: +39 011 9852 252 gianluca.gaziano@skf.com

Service is provided in cooperation with Czech and Italian division SKF.

SKF is a registered trademark of the SKF Group SKF Group 2008 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein. Publication 6654 EN November 2008