ADVANCED MAINTENACNE

TECHNIQUES

For

ROTARY KILN
&
ATOX RAW MILL
 CONTENTS

▪ Introduction to maintenance Types

▪ Kiln Maintenance
▪ Major Factors influencing maintenance
▪ Maintenance Components

▪ ATOX Raw Mill Maintenance

▪ Maintenance Techniques
▪ Condition based maintenance
 Introduction to Maintenance Types

▪ Reactive Maintenance

▪ Preventive Maintenance

▪ Predictive Maintenance

▪ Reliability Centered Maintenance

 MAINTENACNE TECHNIQUES

Reactive Maintenance

▪ Allow machinery to run to failure.

▪ Unplanned breakdown resulting in production loss

▪ Repair or replace damaged equipment when obvious problems

occur.

▪ Common for small parts/ equipment that don’t affect production

process
 MAINTENACNE TECHNIQUES

Preventive Maintenance

▪ Schedule maintenance activities at predetermined time intervals.

▪ Normally recommendations from OEM are followed e.g. oil

replacement, overhauling , routine maintenance checkups, etc.

▪ Repair or replace damaged equipment before obvious problems

occur.
 MAINTENACNE TECHNIQUES

Predictive Maintenance

▪ Schedule maintenance activities when mechanical or operational

conditions warrant.

▪ Actually based on operating behavior of equipment that is

recorded through condition monitoring techniques measuring
actual conditions e.g. Operating Temp, Vibrations, etc.

▪ On basis of abnormalities maintenance is planned and executed

to eliminate risk of unplanned Breakdown
 MAINTENACNE TECHNIQUES

Reliability Centered Maintenance

▪ Utilizes predictive/preventive maintenance techniques with root

cause failure analysis to detect and pinpoint the precise
problems

▪ Advanced installation and repair techniques, including potential

equipment redesign or modification are applied to avoid or
eliminate problems from occurring.
ROTARY KILN

Objective
24 hr continuous
operation
MAJOR FACTORS INFLUENCING
MAINTENANCE
MAJOR FACTORS INFLUENCING
MAINTENANCE
MAJOR FACTORS INFLUENCING
MAINTENANCE

Mechanical Stability
Kiln mechanical stability is based on four major aspects. Kiln
maintenance plans are directly affected by these.

▪ OVALITY

▪ KILN AXIS

▪ AXIAL BALANCE

▪ KILN CRANK
 MECHANICAL STABILITY
Kiln Shell OVALITY

▪ The ovality is defined by the degree of deformation of the kiln shell

and determines the distribution of the cyclic, circumferential
bending stresses in the kiln shell at supports.

▪ Excessive ovality can result in

▪ Circumferential bending fatigue
in the kiln shell up to damage
▪ Refractory lining failures.
 MECHANICAL STABILITY

Kiln Shell OVALITY

▪ The ovality is checked on the basis of the tyre migration.

▪ Increase in migration leads to more ovality
▪ Migration is controlled by maintaining gap between tyre and
shell. V=migration
Pi=22/7
 MECHANICAL STABILITY

KILN AXIS/ALIGNMENT

▪ The Kiln axis is the line connecting the crossing points of the
neutral planes for bending in vertical and horizontal plane
over the kiln support.
▪ It determines the distribution of the kiln weight load between
the supports

Misalignment of the kiln axis may result

in
▪ Overloading of supports
▪ Excessive stresses in kiln shell, tyres
▪ Supporting roller Bearing overload.
 MECHANICAL STABILITY

AXIAL BALANCE

▪ The state of axial balance is defined by the degree of

parallelism between the kiln axis and the axes of the individual
supporting rollers determining the magnitude and directions
of the axial frictional forces between the tyres and supporting
rollers and on the thrust roller(s).

▪ Large axial forces may result in

▪ Hot supporting roller bearings
▪ Failure of the thrust device(s)
▪ Damaged end seals.
 MECHANICAL STABILITY

HOT KILN ALIGNMENT

Hot kiln alignments ensure that your kiln keeps operating at
maximum efficiency throughout its entire service life. An
alignment helps you avoid any unforeseen breakdowns and
maintain full kiln availability and productivity – resulting in
optimum kiln performance and maximum production.
Kiln alignment is part of a preventative
maintenance strategy that identifies the
actual cause behind problems and
recommends a more efficient solution. A
kiln alignment also helps diagnose potential
causes of failure before problems occur.
 MECHANICAL STABILITY
Kiln CRANK
▪ If, during rotation of kiln support load vary cyclically with kiln
rotational frequency then Kiln is said to have a crank.
▪ A kiln crank can cause excessive, extra, cyclic loads between
supporting rollers and tyres and stresses in the kiln shell.

Types of CRANK
Mechanical CRANK
Permanent deformation in the kiln shell is mechanical crank
▪ Due to bad alignment during erection
▪ Sudden Kiln stop and not rotated for a longer period

Thermal CRANK
Caused by temperature variations along the circumference of the
kiln shell
▪ Due to Damages lining/uneven coatings along the kiln axis
▪ Present during operation only
 MECHANICAL STABILITY

Effects of CRANK
▪ Excessive crank formation can lead to
▪ Failure of contact surfaces, supporting roller shafts, tyres,
kiln shell and lining.
▪ In extreme cases tyre is lifted from rollers

The kiln shell is checked for crank formation by measuring the

variations in the deflection of the supporting roller shafts, which
has to stay within certain limits.
MAINTENANCE COMPONENTS

Following are the major parts/component must be considered

during maintenance plan of Kiln

▪ KILN INLET/OULET SEAL

▪ KILN SHELL

▪ KILN SUPPORTING ROLLERS AND TYRES

▪ THRUST ROLLER

▪ KILN DRIVE
 KILN INLET/OULET SEAL
To Control False air infiltration in pyro process
Types of seal
▪ Lamella seal
▪ Pneumatic slide seal
▪ Graphite block seal –Latest innovation
 KILN INLET/OULET SEAL
Maintenance:
▪ During operation gap between kiln rotating part and stationary seal
should be checked and adjusted
▪ During Planned shutdown replacement of worn-out seal parts must
performed to avoid loss of fuel in terms of extra heat generation due
to false/cold air infiltration
PREVENTIVE PREDICTIVE

-Replacement after life achievment- Measurement of thickness of worn-

02yrs normally out portion and calculate further
usable life
-Induce some maintenance
cost -Plan for replacement /even after
achieving 02 yrs. life

-Resulting in saving
maintenance cost
 KILN SHELL

Kiln shell condition to be analyzed every 02years by HOT Kiln

Alignment services for better control on its operation.

Operation:
• As steel starting losing its strength above 400C ,so during operation
shell temperatures must observed and recorded to avoid shell
deformation damage. e.g. in case of red spot (if
uncontrolled/expanding)
• In case of sudden breakdown Kiln should be started without any
delay to save Shell from permanent deformation
 KILN SHELL
Maintenance:
• Measurement of Shell thickness annually to check wear and tear
• In Case of Shell Crank , steps should be taken as per
recommendations by HOT Kiln Alignment reports

PREVENTIVE PREDICTIVE
Optimizing operation to maintain HOT Kiln Alignment
normal shell temperature -To check Kiln Shell Crank, Ovality,
-Temperature monitoring of shell Alignment
-Thickness measurement in shutdown -Execute a plan to remove any
-Acceptable normal approach abnormality
-Most reliable technique to
ensure life and continuous
operation
 KILN SUPPORTING ROLLERS AND
TYRES
As supporting rollers are bearing kiln weight (vertical and partial Axial).

Maintenance:
• Lubrication of Roller/tyre surface with graphite block to avoid wearing
• Condition of lubrication oil to check periodically
• Cooling system for bearing checked
PREVENTIVE PREDICTIVE
Routine inspection -Oil sampling to check condition
-Graphite blocks for surface and predict usable life(more than
lubrication between roller and tyre running hours)
-Oil replacement after achieving -Ultrasonic testing of roller
running hours surface for any crack and tackle
-Oil circulation condition any abnormality by planning
-Normal approach -Reliable approach
 KILN THRUST ROLLER

Thrust roller hold the kiln axially and also perform floating of kiln
with help of hydraulic system installed.

Maintenance:
• Lubrication of Roller surface with graphite block to avoid wearing
• Condition of lubrication oil to check periodically

PREVENTIVE PREDICTIVE
Routine inspection -Oil sampling to check condition and
-Graphite blocks for surface lubrication predict usable life(more than
between roller and tyre running hours)
-Oil replacement after achieving running
hours -Kiln axial balance to be check by
-Pressure variation to be observed detail HOT Kiln Alignment and
perform adjustment (if needed)
 KILN DRIVE

Kiln drive for 3-Base Kiln is containing girth gear

Maintenance:
• Lubrication of Gear pinion
• Condition of lubrication oil to check periodically
• Cooling system for gearbox to be checked

PREVENTIVE PREDICTIVE
Routine maintenance -Measurement of Root Clearance and
-Lubrication system of Girth gear Backlash
-Measurement of vibration periodically -Measurement of Gear wobbling-
-Oil replacement after achievement of Rectify if abnormal
running hours -Oil sampling of gear oil to predict
usable life –saving maintenance cost
ATOX RAW MILL

Objective

21 hr continuous
operation
 29

Maintenance of Atox Mill

 • Maintenance Techniques

▪ Systematic and planned mill maintenance

▪ Condition based mill maintenance

▪ Activities during mill stoppage and based on overall planning

30
 Systematic and planned mill maintenance

Consists of daily routines carried out by the plants own personnel,

which is the best means of getting to know the condition of the
machines.

▪ Cleaning

▪ Visual Monitoring

▪ Lubrication

31
 32

Systematic and planned mill maintenance

.1 Lubrication
.2 Cleaning
.3 Inspection and adjustment
.4 Checking of condition
.5 Replacement (incl. lubricants)
.6 Performance test
Pos. Text 1 2 3 4 5 6
00 ATOX mill S M
01 Grinding roller T M
21 Wear segment * M T
20 Scraper M
38 Grinding roller segment M T
61 Shaft seal 4AT
69 Shaft seal 4AT
74 Tensioning rod seal M
81 Spherical plain bearing T
85 Rubber buffer M
Hydraulic equipment T
Sealing air fan, filter S 4AT
* for grinding track

D = per 8-hour operation A number in front of the letter

indicates the frequency of
S = weekly
procedure.
M = monthly
A = yearly
For example, 2M = twice a
T = see text in instruction month.
manual
 Condition based mill maintenance

The basic principle of conditioning based maintenance is that a

machine is not overhauled until its condition indicates that it is
necessary.

Inspection
During stable operation:

Measurements and visual observations.

During stoppage:

Inspection, trial tests, measurements.

33
 Condition based mill maintenance
Sluice During operation

Seals

Seals

Vibration measurements

34
 Condition based mill maintenance
During operation
Gradually change in
▪ Vibration level ?
▪ Temperature ?
▪ Noise level ?
Vibration measurements ▪ Oil Pressure ?

Amplitude
(m/s2)

Frequency (Hz) 35
 Condition based mill
Separator drive unit, Gear,
maintenance
Hydraulic/ electric
During operation

Hydraulic
Lubrication of rollers system
Lubrication station Cylinders
Int/Ext. leakage
Pump station

Lubrication of gear Lubrication

station

36
 Condition based mill maintenance
During stoppage

Lubrication of rollers Hydraulic

Trial test Flow/Temp. system
Trial test
Lift/lower roller
Accumulator

Lubrication of gear Trial test Meshing Contact prints

37
 38

Condition based mill maintenance

During stoppage

Measurement of roller and table wear profile.

Measurement of roller and table wear profile.
During stoppage
Typical wear profile on roller

39
Measurement of roller wear profile.
During stoppage
Measurement of roller and table wear
profile.

When to replace worn segments?

▪ 33 % left of wear segment.
▪ Broken segment.
▪ High vibration and over limited value.
▪ Appearance of big cracks.
▪ Reduction of output.
▪ Over-limit pressure on cylinder 41
 Condition based mill maintenance
During stoppage

Replacement/ reversing
of Roller wear parts/
Hard facing

Lining

Scrapers
Nozzle ring

Densit lining
42
Roller segment Hard facing
During stoppage
Table segments Hard facing
During stoppage
Dam ring and nozzle ring
During stoppage
 Condition based mill maintenance
During stoppage
Sluice Repl. of
wear parts
Bolted connection

Sealing air system

Absorbers
Seals Repl. of Shaft seals
wear parts
Bearing clearance

Tension system
Bearings Connections
Grinding table Connections to
Sealings
gear box
46
 47

Seal parts

Wear sleeve
 48

Support for
maintenance

Spherical plain
bearings
 49

Spherical plain bearings and buffer

Gap

Spherical plain bearings

Buffer elements
 50

Air sealing and oil connections

 51

Rotary sluice
.1 Lubrication
.2 Cleaning
.3 Inspection and adjustment
.4 Checking of condition
.5 Replacement (incl. lubricants)
.6 Performance test
Pos. 1 2 3 4 5 6
Text

00 Sluice M A A

04 Bucket wheel M
09 Bearings T

10 Geared motor
See separate instruction manuals for pos. 10, 11
11 Safety coupling
and 12.
12 Worm gear unit

16 Baffle plate M A

D = per 8-hour operation A number in front of the

S = weekly letter indicates frequency
M = monthly of procedure. For instance
A = yearly 2M = twice a month.
T = see text in instruction manual
 52

Rotary sluice
Separator lubricationBearing
SEPERATOR
condition During stoppage
Separator
Vibrations Compensators

Bolted connections

Top seal Clearance

Wear
Rotor and louvres
Clearance, Wear

53
Separator:
Bearing condition. Gearbox and bearing lubrication.

54
Separator:
Rotor and louvres Clearance, Wear

55
Separator:
Top seal Clearance, Wear

56
Condition based mill maintenance
57

During stoppage
Separator:
Top seal Clearance Wear
 58

Separator:
Rotor and louvres Clearance, Wear
 Condition based mill maintenance
During stoppage

Separator:
Rotor vanes worn out

59
 60

Separator:
Wear protection
 61

Condition based mill maintenance

During stoppage
Grinding table connections to gear box
Spline

Meshing Contact prints

Correct Incorrect
Condition based mill maintenance
During stoppage

Pins

Gear shaft

62
Condition based mill maintenance
63

During stoppage

Air seals

Oil seals
Condition based mill maintenance
During stoppage
Air seals

Grease

Oil seals

Grease
64
 65

Condition based mill maintenance

During stoppage

Air sealing system

 Condition based mill maintenance
During stoppage

Crack Examination:
▪ Welded structures
▪ Roller Segments
▪ Mill housing
▪ Gear box

66
 KEY POINT

Activities during a maintenance stop

▪ Scheduled annual plant shutdowns for repair
▪ Replacement of defective components ascertained during regular
inspections.

67
THANKS