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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

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Kiln Area Maintenance checklist


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Kiln Area Maintenance checklist

Kiln inlet seal

Finding:

The track under the graphite block fabricated into 2 non machined
quarters

Worn out in kiln inlet cone, shovel, shelf and shelf plate.

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cement kiln

kiln graphite block

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

worn out kiln shelf plate

Recommendation:

Fabricate a machined tack under the graphite block into 2 machined


halves

Change kiln inlet cone, shovel, shelf and shelf plate

Outlet kiln shell

Finding:

5. 5. The outlet section till meter 5, need to be changed due to deformation


under the nose ring and tire at outlet side
6. 6. High deformation in the old jacket
7. 7. Lamella seal plates have been missed its elasticity as a result of
insufficient sealing at kiln outlet so energy &production capacity will be
loosed
8. 8. Worn out of lamella seal plates

old jacket before repair 

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9. 9. The erected retaining ring is not matched the original design. 12 pieces
chamfered at both sides and also three holes have been drilled per each
part

cement kiln plates

11.High deformation under tire, outlet side, grinded by removing about 2 cm

deformation kiln shell

Important Note:

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

Because of deformation at kiln outlet and repeated fallen down of bricks,


the ring plate beside nose ring plate transferred 80 cm towards the kiln inlet
and change the original design to be a castable between the nose ring plate
and ring plate to avoid the deformed part and in spite of that the castable
fallen down several times.

Now they will back again to the original design, that is good, but the outlet
section still has a deformation so an outlet section is a mandatory to be
fabricated to avoid any expected repeated damage due to fallen down of
bricks again

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As per original design the ring plates, six pieces, should be chamfered
at castable side, straight at brick side and machined to be sure full contact
with the kiln inner diameter to avoid any material attack through any
expected gaps or grooves in case of none machined outside ring plate nor
grinding inner diameter of kiln shell outlet section.

Recommendation:

It is recommended to prepare an outlet section complete with new jacket,


ring plates and nose ring plates as per original design to avoid fallen down
brick again

Action has been taken

Deformed jacket has been repaired and erected again

Percentage about 40% of the total outlet lamella seal’s quantities hasn’t
been changed and it was erected again.

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

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new quantities of lamella seal fabricated form stainless steel thick 3 mm


which isn’t suitable for that application “Not have the spring steel properties”

old jacket kiln

Grate Cooler1&2

Finding:

Worn out most of grates and side plates of grate 1 and grate 2

There are two deformed movable beams, one at chamber 1”grate1” and

the other at chamber 3 “grate2”

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

grate cooler cement kiln

Recommendation:

Change all grates and side plates of grate 1 and grate 2

Change the deformed movable beams. No off 2, one at chamber 1 and


the other at chamber 2

Action has been taken:

Worn out plates of grate 1 and 2 have been repaired by stainless steel
strips

Clinker Crusher

finding:

Grate basket worn & some deformed & missed

Liners worn.

No concrete under crusher



High wear in Grizzly bars

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

Recommendation

Replace or repair grate basket completely.

Replace or repair liners

Concrete foundation must be repaired

clinker crusher

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worn liners grate cooler

grate cooler cement kilwn

Action has been taken 

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

Grizzly bars have been repaired

Upper plates of grizzly bars have been repaired

grizzly bars grate cooler cement kiln

Pan conveyor

Finding:

1- The free bearing of the drive sprocket have bad grease and the clearance
of it is 1mm.

2- There is a metal flow in the drive sprocket segments.

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3- The bolts of the drive sprockets segments which fix it with hub is very
loose and some bolts not exist.

4- The driven sprocket bearings have clearance 0.3mm and the shafts have
wear, where there is 0.4 mm clearance between bearing inner race and shaft,
also the bearings condition is bad.

5- The fixation bolts which connect the buckets and chain links is very loose.

6- There are some bolts connect the chain links together need to be
retighten.

7- The pan conveyor rollers have defected bearings (approximately 100


rollers).

8- There are a worn out and defected rails with length 30 m.

9- The coupling elements have high wear.

Recommendation:

1- Replace the free bearing for the drive sprocket due to high clearance.

2- Remove the metal flow in the drive sprockets segments.

3- Erect the missed bolts and re-tightens the loose bolts for the drive
sprocket and it’s recommended to erect counter nuts for this bolts.

4- Replace the bearings of the driven sprockets and replace the broken
housing.

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5- Repair the shaft of the driven sprocket due worn out, where there is a
clearance between the bearing inner race and shaft (0.4 mm).

6- Replace all loose fixation bolts which connect the buckets and chain links
together.

7- Check the rails alignment.

8- Re-tight the bolts which connect the links together due to looseness.

9- Replace bearings of 100 roller, and check their shafts if they need replace.

10- Replace the worn out, deformed and defected pan conveyor rails.

11- Replace the coupling element due to high wear and replace its rings
keepers.


clinker panconveyor sprocket
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cement kiln clinker cooler panconveyor

Action has been taken

1- The worn out, deformed and defected rails have been replace with length

30m approximately.

2- About 200 buckets have been replaced with its bolts.

3- About 9 rollers have been changed

4- Loosen bolts have been performed

1-Main Burner

Main burner hoses

Finding:

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

cement kiln main burner

There is a high leakage due to worn out in pipe’s thread inlet to the main
burner and also worn out in hose end

Very low leakage in quick fitting

Recommendation:

Change the deformed hose

Prepare a set of hoses as spare

Prepare a quick fitting as a spare

Action has been taken:

Thread pipe connection 10 cm length has been welded at the pipe inlet to
the main burner as a male thread and the hose has been assembled to it

2-Grate cooler

Cooler grate 1&2


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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

Finding:

The disposing of scrap material is done by turning the kiln and thrown it
away through the cooler plates, crusher and collecting it from pan conveyor.
That may damage the cooler gate plates, crusher, pan conveyor and also
affecting the hydraulic circuit operation

Disposing of scrap has been performed due to heating up, as a result of


that one of the waste components which is AL2O3-80% bricks chemically
interact with spinal bricks “basic refractories are located at meter 37” ,so that
partial corrosion in spinal bricks and fallen down sticky material upon cooler
plates has been occurred

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There is a contact between deformed movable beam, chamber 3


grate2&chamber1 grate 1 and fixed beam When the two grates 1&2 have
been put into operation

Two movable plates have been stucked in grate 2

Repeated stop of grate 1 or grate 2 or both of them at grate cooler’s


loading specially in return stroke

Important note:

Cold run for grate 2 has been performed for five hours before heating up
and all bolts have been retighten. All hydraulic parameters are in normal
condition

Cold run for grate 1 has been performed for four hours before heating up
and all bolts have been retighten. All hydraulic parameters are in normal 
condition
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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

Both grates 1&2 have been put in to operation for 3 hours during heating
up before kiln feeding.

All hydraulic parameters are in normal condition

Recommendation:

It is recommended to dispose of scrap through a dust chute beside the


handrail and discarding the waste through trucks to open yard.

Change both deformed movable beams and replace the two movable
stucked plates

All hydraulic circuit components should be checked and reviewed

Action has been taken:

The stroke of the grate 2’s piston, chamber 3, has been readjusted again
to be little bit less than 7 cm to avoid the contact between the movable beam
and the next fixed beam. Also the same for chamber 1 grate 1 but the stroke
has been readjusted to be little bit more than 7 cm

grate1

The cooler plates and two movable beams have been repaired

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grate2

grate cooler repair

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deformation beam grate cooler

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removing waste

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waste scraps grate cooler

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anchors kiln

All hydraulic circuit has been reviewed. For grate 1, two return valves have
been reviewed. Proportional valve, oil circuit block with valve block and
pump has been replaced. For grate 2, proportional valve has been changed
and also readjusting the two

check valves direction in proper position

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proportional valve grate cooler

Proposal for housekeeping the waste and scrap of overhaul inside the kiln:

Short run proposal: fabrication a chute in the first floor in front of the kiln
door beside the handrail. Remove the waste and scrap from inside kiln by a
mini loader, thrown away through that chute, collecting it from the ground
and discarding the waste through trucks to open yard

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Long run proposal: In addition to the short run proposal, a manhole


should be fabricated in the

kiln section in case if there is any necessity to change that kiln section

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6/3/2018 Kiln Area Maintenance checklist - INFINITY FOR CEMENT EQUIPMENT

proposal to install new chute

if you have any inquiry about the Kiln Maintenance please don’t hesitate to
contact us

Email : project20062015@gmail.com

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2 Comments

Happy \
December 8, 2016 at 1:11 am Reply

well done

Valentina
January 4, 2017 at 3:21 pm Reply

thank you Mark

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