Вы находитесь на странице: 1из 8
Rotary kiln diagnostics

Rotary kiln diagnostics

Rotary kiln diagnostics
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 opera- tion 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 diagnos- tic 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 ro- tary kiln diagnostic services serves as an effective tool for failure prediction and improved mainte- nance planning.

All measurements included in the individual diag- nostic modules are carried out while the kiln is in operation. As a result, any optimization recom- mendations 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.

measurements are performed on machinery in full operation, the service has no influence on the plant

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 Cracks Mechanical wear Lining loss On bearing On thrust In kiln shell Na
Hot bearings
Cracks
Mechanical wear
Lining loss
On bearing
On thrust
In kiln shell
Na radiálních
On support
Between tyre
and kiln shell
Between
Under tyres
journal
journal collar
kladkách
roller and
tyres
tyre
Kiln geometry
Kiln
Kiln
Kiln
Kiln
geometry
geometry
geometry
geometry
Kiln
Kiln
Kiln
shell ovality
shell ovality
shell ovality
Kiln crank
Kiln crank
Kiln crank
Kiln crank
Axial balance
Axial balance
Lubrication
Corrosion
Lining
quality
Root cause

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 compo- nents.

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
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.

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

vibrations, alignment) - online condition monitoring OPTIMAL Module Customized combination of diagnostic

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.

of analyses. These customer-specific solutions come under the heading of the OPTIMAL module. Sample analysis presentation

Sample analysis presentation

Analysis types

Analysis Modul Modul A Modul B Module Optimal Kiln axis / Kiln slope / Roller
Analysis
Modul
Modul A
Modul B
Module Optimal
Kiln axis / Kiln slope / Roller operating angles
Supporting roller axes deviation from the kiln axis
Mechanical wear (profile, diameter) of rollers and tyres
Tyre wobbling
Pier declinations (kiln crank)
Kiln shell profile
Thermal scanning
Drive section analysis
Report

Service included in the moduleprofile Thermal scanning Drive section analysis Report Service NOT included in the module Optional service The

Service NOT included in the modulesection analysis Report Service included in the module Optional service The outputs from the diagnostics Electronic

Optional serviceincluded in the module Service NOT included in the module The outputs from the diagnostics Electronic

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

Seals Lubricants Bearings – all types and sizes Power transmission products Tools and instruments Vibration
Seals Lubricants Bearings – all types and sizes Power transmission products Tools and instruments Vibration
Seals Lubricants Bearings – all types and sizes Power transmission products Tools and instruments Vibration

Seals

Seals Lubricants Bearings – all types and sizes Power transmission products Tools and instruments Vibration analysis

Lubricants

Bearings – all types and sizes

Power transmission products

Bearings – all types and sizes Power transmission products Tools and instruments Vibration analysis Filters Lubrication

Tools and instruments

and sizes Power transmission products Tools and instruments Vibration analysis Filters Lubrication systems Optical
and sizes Power transmission products Tools and instruments Vibration analysis Filters Lubrication systems Optical

Vibration analysis

products Tools and instruments Vibration analysis Filters Lubrication systems Optical measurements Bearings

Filters

Lubrication systems

instruments Vibration analysis Filters Lubrication systems Optical measurements Bearings an d units Lubrication Seal

Optical measurements

Bearings an d units Lubrication Seal s sy stems Mechatronics Ser vices
Bearings
an d units
Lubrication
Seal s
sy stems
Mechatronics
Ser vices
Contact in Czech Republic Lucie Stavařová Project manager - Optical measurement SKF Ložiska, a.s. Technologická

Contact in Czech Republic Lucie Stavařová Project manager - Optical measurement

SKF Ložiska, a.s. Technologická 372/2 708 00 Ostrava - Pustkovec, Česká 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

or consequential arising out of the use of the information contained herein. Publication 6654 EN •