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    8 Application of Preditive Maintenance in Kiln Maintenance

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    ayaskant751001
    This document discusses predictive maintenance techniques for kilns. It begins by defining predictive maintenance and its benefits, such as enabling timely repairs to avoid breakdowns. It then lists objectives like determining problems and monitoring degradation to plan repairs. Various parameters for predictive maintenance of kilns are outlined, like temperature, vibration, and thickness measurements. Equipment used for predictive maintenance is also described, such as ultrasound tools, oil analyzers, and alignment instruments. Finally, case studies from Sidhee Cement and GSCL applying these techniques are presented.

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    8 Application of Preditive Maintenance in Kiln Maintenance

    Uploaded by

    ayaskant751001
    585 views41 pages
    This document discusses predictive maintenance techniques for kilns. It begins by defining predictive maintenance and its benefits, such as enabling timely repairs to avoid breakdowns. It then lists objectives like determining problems and monitoring degradation to plan repairs. Various parameters for predictive maintenance of kilns are outlined, like temperature, vibration, and thickness measurements. Equipment used for predictive maintenance is also described, such as ultrasound tools, oil analyzers, and alignment instruments. Finally, case studies from Sidhee Cement and GSCL applying these techniques are presented.

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    KILN MAINTENANCE

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    This document discusses predictive maintenance techniques for kilns. It begins by defining predictive maintenance and its benefits, such as enabling timely repairs to avoid breakdowns. It then lists objectives like determining problems and monitoring degradation to plan repairs. Various parameters for predictive maintenance of kilns are outlined, like temperature, vibration, and thickness measurements. Equipment used for predictive maintenance is also described, such as ultrasound tools, oil analyzers, and alignment instruments. Finally, case studies from Sidhee Cement and GSCL applying these techniques are presented.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    585 views41 pages

    8 Application of Preditive Maintenance in Kiln Maintenance

    Uploaded by

    ayaskant751001
    This document discusses predictive maintenance techniques for kilns. It begins by defining predictive maintenance and its benefits, such as enabling timely repairs to avoid breakdowns. It then lists objectives like determining problems and monitoring degradation to plan repairs. Various parameters for predictive maintenance of kilns are outlined, like temperature, vibration, and thickness measurements. Equipment used for predictive maintenance is also described, such as ultrasound tools, oil analyzers, and alignment instruments. Finally, case studies from Sidhee Cement and GSCL applying these techniques are presented.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 41

    APPLICATIONS OF PREDICTIVE MAINTENANCE IN MAINTENANCE OF KILNS

    PREDICTIVE MAINTENANCE - 1
    Under Predictive Maintenance, some parameters are measured to determine the condition 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 avoidable breakdowns.

    PREDICTIVE MAINTENANCE - 2
    The terms predictive maintenance and conditionbased 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 the organizational resources in the most effective manner. Predictive maintenance adds value to the customer by: Improving the uptime of the machines, Reducing cost and arranging products
    4

    OBJECTIVES OF PREDICTIVE MAINTENANCE


    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.

    PARAMETERS TO MEASURE UNDER PREDICTIVE 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.

    PARAMETERS TO MEASURE UNDER PREDICTIVE 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

    EQUIPMENTS USED IN PREDICTIVE MAINTENANCE

    PORTABLE ULTRASOUND THICKNESS GAUGE


    Specifications
    Thickness range 0 100mm

    Purpose
    To measure thickness of kiln shell

    ULTRASONIC FLAW DETECTION TEST KIT


    Specifications Purpose
    Should be able to To detect cracks in detect cracks and shell, tyres and metallurgical flaws in support rollers. ferrous and non ferrous materials

    OIL SPECTROMETER
    Specifications
    Suitable for oil analysis of industrial lubricants having viscosity range from 20 - 700 Centistokes at 40C.

    Purpose
    To determine the condition of the lubricant for further use.

    NON-CONTACT THERMOMETER
    Specifications
    Infrared laser type non-contact thermometer, range 0 - 500C.

    Purpose
    To measure surface temperature of shell, tyre, support roller, girth gear tooth flanks.

    DIGITAL OPTICAL PYROMETER


    Specifications
    Range 0 - 600C.

    Purpose
    To measure surface temperature of:
    shell, tyre, support roller, girth gear tooth flanks.

    PORATABLE INFRARED THERMOMETER


    Specifications
    (-)30 - (+)1600C

    Purpose
    To measure flame temperature

    DIGITAL VERNIER CALLIPER


    Specifications
    Measurement range 0 - 100 mm, least count 0.01 mm

    Purpose
    To measure thickness of girth gear and pinion tooth

    SHELL TESTER
    Specifications
    Kiln shell ovality tester, portable with temperature resistant magnets, mechanical recording device.

    Purpose
    To test shell ovality and determining the required thickness of chair pads.

    ELECTRONIC EQUIPMENT FOR OVALITY MEASUREMENT


    Specifications
    Kiln shell ovality tester, portable.

    Purpose
    To test shell ovality and determining the required thickness of chair pads.

    HOT KILN EQUIPMENT ALIGNMENT EQUIPMENT


    Specifications
    Optical theodolite with optically alignable spirit level and computer.

    Purpose
    For alignment of the kiln during operating condition.

    DIGITAL LEVELING INSTRUMENT


    Specifications
    Least count / sensitivity 0.1 mm/meter

    Purpose
    To determine top and bottom dead center of the kiln shell, other leveling works.

    KILN THRUST MEASUREMENT EQUIPMENT


    Specifications Purpose
    Mobile hydraulic To adjust setting of thrust measuring the support rollers equipment with high and checking the pressure jack. condition of the bearings of the supporting rollers.

    MICROLOG DATA COLLECTOR WITH FFT ANALYZER AND PROCESSOR


    Specifications
    With accelerometer of magnetic base, accelerometer cable, dynamic balancing and stroboscope set with facility to download the data to any P4 processor equipped PC. The data collector / analyzer should cover frequency range of 0.2 Hz to 20 KHz.

    Purpose
    Data collection, machinery vibration analysis and monitoring e.g. girth gear and motors. Should do early detection of bearing defects or gear tooth wear, electric motor monitoring and field machinery balancing.

    ENGINEER'S STETHOSCOPE
    Specifications Purpose

    Portable stethoscope For detecting abnormal sound in machine in operation

    LASER ALIGNMENT CHECKING EQUIPMENT


    Specifications
    Laser coupling alignment equipment with accessories.

    Purpose
    To do alignment of couplings of motor and fan or any other couplings.

    LINOMETER
    Specifications
    Portable thickness measuring equipment.

    Purpose
    For measurement of refractory brick thickness.

    SHOCK PULSE METER


    Specifications
    0 100 db

    Purpose
    To measure the value of shock pulses in ball and roller bearings

    CASE STUDIES OF SIDHEE CEMENT

    VIBRATION MEASUREMENTS OF KILN DRIVE AT SIDHEE CEMENT

    VIBRATION ANALYSIS OF MAIN KILN DRIVE GEARBOX OF 4200TPD 4.3M DIA KILN AT SIDHEE CEMENT PLANT

    BREAKDOWN ANALYSIS ROLLER SHAFT SHEARED OFF AT GSCL

    GIRTH GEAR AND PINION TEMPERATURE ON 21.01.08 AT GSCL

    GIRTH GEAR AND PINION TEMPERATURE ON 18.05.08 AT GSCL

    CONTACT PATTERN EARLIER BETWEEN GIRTH GEAR AND PINION AT GSCL

    CONTACT PATTERN LATER BETWEEN GIRTH GEAR AND PINION AT GSCL

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

    ROOT CLEARANCE BETWEEN GIRTH GEAR AND PINION ON 14.10.07 AT GSCL

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

    TECHNICAL AUDIT REPORT OF BREAKDOWN AT GSCL - 1


    1.0 Name of Machine: 2.0 Department & Machine ID: 3.0 Source of supplier: 4.0 Brief technical details: (Write technical specification, dimension, material of construction etc.) 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:

    TECHNICAL AUDIT REPORT OF BREAKDOWN AT GSCL - 2


    9.0 Time and Date of Restarting the machine after repair: 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 field measurement. 13.00 What were the last readings of field measurements? 14.00 Were any early signals noticed before occurrence of the actual failure or damage?

    TECHNICAL AUDIT REPORT OF BREAKDOWN AT GSCL - 3


    15.00 Analyze and establish of reason (s) for the failure / damage, which may include: i. Poor Material ii. Long operating life iii. Wrong operations iv. 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 the failure/damage.

    TECHNICAL AUDIT REPORT OF BREAKDOWN AT GSCL - 4


    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 working efficiently and safely? 21.00 What steps should be taken to avoid similar failures in future? Report prepared by Concurred by Approved by 22.00 Remarks of the controlling authority. Joint President (Works) Cc: Director (Operations/Projects)

    TREND OF KILN TYRE MIGRATION AT GSCL

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