Kiln Preventive Maintenance BY NAK

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Kiln Preventive Maintenance BY NAK

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Daily Inspections

1-Conduct a walk-by inspection of the kiln.

A)Are there any shell discolorations or hot spots?

B)Check and record the temperature profile of kiln shell and tires.

2-Inspect each pier.

A)Does any tire lift off the roller during any portion of the kiln rotation?

B)Is there any unusual bearing movement?

C)Is there adequate lubricant in the support roller bearings?

D)Is there evidence of recent damage or unusual wear to the support pads, stop blocks, or tire/roller surfaces?

E)Are there any unusual sounds or vibration?

F)Are there any unusual sounds or vibration?unusually warm?

G)Is the bearing lubricant level adequate?

H)Is there enough cooling water available for the bearing housings? Any leaks?

I)Clean pier of dust and buildup that may contaminate roller surface or seize the graphite block.

3-Check condition of nose ring area.

A)Are any castings loose damaged or missing?

B)Are the nose brick worn, damaged or Missing

4-Check the condition of the drive system.

A)Is there adequate gear lubrication?

B)Any unusual sounds from the drive system?

C)Is there any noticeable vibration?

D)Is the reducer lubricant level adequate?

5-Check oil levels of roller and thrust bearings. Make sure fill pipe/level indicator is not plugged.

6-During start up measure tire creep. During shut down apply graphite solution to rollers.

Weekly Inspections

1-Start up the emergency drive engine and run it for at least 30 minutes.

A)Check the water level and cables of the emergency engine battery.

B)Check the fuel level of the emergency engine.

c)Check the lubrication system of the gearbox and drive system.

2-Check graphite block lubrication

A)Are holders clean and free of product or dirt contamination?

B)Is the graphite block free and loose in its holder?

C)Is the graphite providing an adequate supply of lubrication.

3-Check creep or gap of tires on all piers.

a)Has level of creep increased since the last inspection?

b)Has the tire developed a wobble?

c)Lubricate between the filler bars and tire ID after creep measurements.

4-Check the condition of the tire on each pier.

a)Is there any spalling, ridging or unusual wear on the tire face (visible tapers, convex or concave wear)?

b)Since the last inspection, has the tire position changed relative to the stop blocks?

c)Are there any broken welds or cracks on any parts of the support pad components, stop blocks or adjacent kiln shell?

d)Is the tire centered over the carrying rollers?

5-Check the condition of the carrying rollers on each pier.

a)Are the rollers thrusting uphill or downhill?Hard or light?

b)Is there spalling, ridging or unusual wear on the roller face (visible tapers, convex or concave wear)?

c)Are the bearing seals working properly?

d)Is the roller shaft receiving adequate lubrication ?

e)Do tires and rollers have full-face contact?

f)Is there any movement between the pier and support frame?

g)Are there any loose anchor bolts on the support frame?

h)Is there progressive cracking of the concrete or grout on the pier?

6-Check the condition of the thrust rollers.

a)Is the kiln against the uphill or downhill thrust roller?

b)Is there spalling , ridging or unusual wear on the roller surface?

7-Check the condition of the drive system.

a)Does the gear housing show any signs of contact with the gear?

b)Has the pattern of gear/pinion contact changed?

c)If applicable, are there any loose or missing flange bolts?

d)If applicable, is there any visible cracking or looseness of spring-plate components?

e)Is there adequate gear lubrication?

f)Are there any unusual sounds coming from the drive system?

g)Is there any noticeable vibration, where from?

h)Are the motor, reducer and pinion bearing base bolts tight?

8-Clean the pier tops of dirt, oil product spillage.

9-Check condition of discharge and feed end seals.

a)Is there any leakage of excess air or product?

b)What is the condition of the seal support?

c)Is there any visible kiln runout?

Monthly Inspection

1-Check for pitch line separation of gear and pinion.

2-Check for pitch line run-out of gear and pinion.

3-Check condition of welds on gear flange or spring plates.

4-Lubricate the drive coupling.

5-Perform vibration analysis on kiln drive.

6-Take samples for oil analysis (drive and suspect thrust or support rollers).

7-Check feed and discharge hoods for metal damage or corrosion.

Three Month Inspection

1-Measure shell ovality.

2-Determine and perform support roller adjustments to optimize kiln and roller thrust.

3-Weekly and monthly kiln inspections.

Annual Inspection

1-Change gear lubricant and clean sump and gear area if needed.

2-Change oil in thrust roller bearings.

3-Inspect kiln shell for cracks under rings.

4-Check alignment of gear and pinion.

5-Inspect drive coupling grid members.

6-Check the kiln alignment, (as needed).

7-Inspect refractory for cracking, crushing or unusual wear, especially around tires.

8-Clean and inspect gear.

a)Check gear teeth for abnormal wear.

b)Change gear lubrication.

c)Check drive train couplings for wear and replace if needed.

d)Check and repair welds on gear flange or spring plates and gear if needed.

e)Check for loose nuts or bolts on gear mounting flange or loose spring plate pins.

f)Inspect, clean, repack and change lubrication on pinion bearings.

g)Check brush rigging and electrical components of drive motor.

h)Take samples of reducer, main gear, thrust rollers and problem support roller bearings oil and send to a laboratory to detect oil contamination.

9-Clean and inspect roller bearings.

a)Remove covers and drain lubricant.

b)Check for bearing wear, shaft condition, and bearing liner thickness.

c) Flush with new bearing lubricant.

10-Clean and protect the bearing adjustment screws.

 

HELLO!!! IF YOU NEED TO DOWNLOAD LAFARGE HOLCIM , , … ETC + MOST IMPORTANT CEMENT BOOKS AND MANUALS AND IMPORTANT EXCEL SHEETS , THAT CONTAIN ALL IMPORTANT CALCULATION FORMULAS PLEASE CLICK HERE 

 

 

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