ENGINEERING MEASUREMENTS ENTERPRISE LTD. TECHNICAL REPORT RESULTS OF DEVIATION MEASUREMENTS AND GEOMETRY OF ROTARY KILN GEOCEMENT PLANT

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1 GEOSERVEX s.c. Zbigniew i Boleslaw Krystowczyk office@geoservex.com.pl office: ul. Kościuszki /19A 8-9 Bydgoszcz, POLAND tel: (+48) 34 6 fax: (+48) 34 6 EU VAT ID No: PL ENGINEERING MEASUREMENTS ENTERPRISE LTD. TECHNICAL REPORT RESULTS OF DEVIATION MEASUREMENTS AND GEOMETRY OF ROTARY KILN AT GEOCEMENT PLANT Period of survey: February 1

2 Index 1. Cover Page 1. Index 3. Written Report 3 4. Coordinating System, Symbols and Terms. Measurements Data 8 6. Axial Deviations in Horizontal Plane 9. Axial Deviations in Vertical Plane 1 8. Rollers Skewing in Horizontal Plane Rollers Skewing in Vertical Plane 1 1. Adjustment Program Control Check after Adjustment in Horizontal Plane Control Check after Adjustment in Vertical Plane Base Plates Elevation Skewing Corrections in Vertical Plane 1 1. Position of Supporting Rollers (up - down) Recoendation for Future Thrust Correction Tires ans Shell Temperatures 18. Tires and Rollers Diameters Rollers Mechanical Wear. Roller Shafts Condition and Lubrication Efficiency 3 1. Tires and Girth Gear Wobbling 4. Girth Gear Runout 8 3. Deflection Values Changes of Roller Shaft 9 4. Drive Axial Position 3. Thrust Roller Position 3 6. Shelltest 38. Mechanical Inspection Sections Position Diagram for Kiln Shell Deviation Survey 9. Shell Profile - Axonometric View 3 3. Radial Diagrams of Shell Deformation 31. Kiln Mechanical Parameters Rotary Kiln Inspection February 1 Page

3 FINAL REPORT OF ROTARY KILN ALIGNMENT AND INSPECTION AT GEOCEMENT PLANT. I. SCOPE OF WORK: 1. Setting up the surveying bases around the kiln.. Measurement of kiln axis deformation in horizontal and vertical plane. 3. Measurements of rollers axis position, rollers skewing, inclination and operating angles. 4. Measurements of rollers profiles (mechanical wear of rollers profiles).. Measurements of rollers shafts deflection (indication of shell crank formation). 6. Measurements of thrust roller position in reference to the kiln axis.. Measurements of tires and shell temperatures. 8. Measurements of tire migration (circumferential tire movement) and calculation of shell ovality. 9. Measurements of shell profile (circularity deviation and eccentricity of cross sections), preparation of shell polar diagrams and shell 3D animation model. 1. Measurement of tires and girth gear wobbling and run-out. 11. General mechanical inspection of drive mesh, bearings and shafts condition, lubrication efficiency, inlet and outlet sealing, thrust unit, adjustment bolts and housing. 1. Calculation of axial deviations in horizontal and vertical plane and the kiln slope. 13. Preparation of optimal version of adjustment program and schedule. 14. Supervision over adjustment procedure carried out by technicians of the Cement Plant. 1. Control survey of final kiln axis position and rollers skewing after the adjustment. 16. Preparation of completed report on measurement and adjustment. 1. Preparation of recoendation for future preventive maintenance actions, routines, necessary repairs and replacements. 18. Presentation and submission of the report to the Customer. 19. Optional 1: Shelltest elastic shell deformation survey, shell ovality check.. Optional : Measurement of kiln drive assembly geometry. 1. Optional 3: Recalculation of kiln mechanical parameters (current loads on piers, pressure on bearings, Hertz pressures, bending stress in the shell, stress in the tires, calculation of stiffness matrix, optimization of kiln vertical axis position considering load distribution). 3

4 II. SURVEY OF THE ROTARY KILN No All measurements have been taken by GEOSERVEX Hot Kiln Alignment Team Bydgoszcz, Poland from February 1, 1 to February 9, 1.. After completing all measurements for the kiln, technical documentation has been presented to the cement plant representatives. 3. Coordinating system: Piers are numbered from outlet to inlet side Left and right sides are orientated, looking from inlet to outlet end Starting point for all measurements is a reference line; shim placed on this line is shown as shim No. 1 ( see page ). III. RESULTS OF MEASUREMENTS 1. Kiln axis, tire migration. Kiln axis position in horizontal plane is within the tolerance and does not require any correction at the moment, but the kiln axis in vertical plane is 3. lower and requires some adjustment. Measurement data is shown on page 8 and kiln axes deviations are shown on pages 9 and 1. Under-tire clearance values are shown on pages 8 and 1, the clearance at tires No. III and No. I slightly exceeds recoended value, which is 3 to 6. Kiln slope is 3. % and it is correct (See page 8 and 1).. Rollers parameters and the kiln thrust Skewing of rollers is not high. Rollers inclination is within the tolerance only for two rollers ( see rollers inclination and rollers skewing correction drawings on pages 1 and 1 ). Rollers operating angles are correct for all stations ( see page 8 and 1 ). No angle exceeds the tolerance (6 o +/- 1 o 3 ). Rollers mechanical wear is quite low ( see page ). Also diameters of all rollers are not far from nominal values. The rollers low wear is a result of proper lubrication routine. 3. Drive station The drive system has been working with a lot of vibrations caused by improper girth gear and pinion meshing ( the girth gear teeth are worn out ). Gear wobbling is +/- 1.4 and slightly exceeds the tolerance (+/- 1 for a brand new kiln). Gear radial run-out is +/-. and is acceptable at the moment. 4

5 4. Kiln shell Survey of shell deviation has been taken at 3 cross sections shown on page. Maximum shell eccentricity is 14 at section No. 1, second biggest eccentricity is 11 at cross-section No. ( The tolerance for shell eccentricity and shell local deformations given by most kiln producers is 1 for the eccentricity and 1 for local deformations ). Some shell cross-sections radial deformations are quite significant and they do exceed the acceptable range, take a look at sections No. 1,13 and 14 in this report. Tires wobbling is not high for stations No. II and III, but the tire wobbling at the first station exceeds the tolerance. The kiln shell has been examined for mechanical and thermal hidden crank formation presence. Mechanical crank formation can be examined by measuring of roller shaft deflection change. The measurement results are shown on pages None of roller shaft deflection exceeds the tolerance (.3 for total deflection ).. Shell-test measurement The expected maximum ovality for a kiln of this diameter would be,8%. Suary graph is shown on page 39. For all measured piers ovality results are quite low. The measured ovality for pier No. I was,3%, creep value was approximately. For pier No. II measured ovality was,3%, creep was around 1. The ovality at pier No. III was,%, creep value was. All presented ovality values are perfectly within the tolerance. For more details see pages Mechanical inspection (visual) The kiln is in satisfactory mechanical condition. All rollers bearing condition is good. Lubrication system is complete and works properly, there is proper oil film on all shafts. Rollers shaft condition is also good. Rollers housing and adjustment bolts are well maintained. Rollers and tires are in good condition, the graphite lubrication device works properly, shiing bolts and nuts were inspected and they are complete. The contact between tires, supporting rollers and thrust roller is acceptable.. Adjustment The adjustment has been carried out in stages within three days ( February - 1 ). The above mentioned adjustment has been made due to the fact that the kiln axis in vertical plane required adjustment and the girth gear and pinion meshing was improper and it was necessary to decrease vibrations appearing at the inlet side pier. The whole adjustment has produced the desired result and the vibration level has been significantly reduced ( please, see page 13 for more details ).

6 IV. CONCLUSION We have been informed about the kiln tendency for high amperage, especially during start-up, in our opinion the main reason for this was: kiln axis misalignment in vertical plane, improper girth gear and pinion meshing and also shell deformation crank. To prolong the life of shell and refractory lining is important to: - correct tire clearance regularly, - monitor tire creep, temperature of tire and shell, - avoid rapid heating and cooling of kiln, - check alignment of kiln every two years. According to our measurements some geometrical parameters such as kiln axes in horizontal and vertical plane do not require any further correction, however, some actions should be performed in the future to improve the kiln operation. Actions to be taken in the nearest future: - skewing correction in vertical plane and bearing thickness check ( page 1 ), - repair works on outlet seal, a lot of material drops on pier No. I, which has a bad influence on tire and rollers surface ( page 1 ), - thrust roller position correction ( move towards the right side of the kiln viewing from inlet side - page 3 ). - thrust correction (only if necessary) according to our proposal described on page 19, - careful monitoring of under-tire clearances at all tires, the most recoended clearance value is 3 to 6. Actions to be taken later: - take under consideration the girth gear reversal and centering, - consider shell section replacement between cross-sections No.1 and 14, due to significantly big shell local deformations which may cause frequent lining problems. Geoservex, Hot Kiln Alignment Team would like to thank the Plant Crew and Management for cooperation and assistance during our visit. In case of any problems with the kiln geometry do not hesitate to contact us. GEOCEMENT Plant: 9 th of February 1. 6

7 Coordinating System, Symbols and Terms y z INLET x Tire No. III Drive Gear LEFT SIDE Tire No. II Tire No. I x y z axial coordinates horizontal coordinates vertical coordinates Pier No.III x s undertire clearance a rollers operating angle RIGHT SIDE Pier No.II h slope of axis Pier No.I OUTLET dy dz horizontal axis correction vertical axis correction ds skewing correction c root clearance Starting point for all measurements. Reference line. reference axis real axis adjustment axis Rotary Kiln Inspection February 1 Page

8 Measurements Data Coordinates " x " Coordinates " y " Coordinates " z " OUTLET [ m ] OUTLET [ ] OUTLET [ ] x1 = 4.1 y1 =. z1 =. x = 9.8 y = - 4. z = +. x3 =. y3 =. z3 =. INLET INLET INLET Undertire clearance " s " OUTLET [ ] s1 = s = s3 = Rollers operating angle "a" OUTLET. a 1 = o, a = o, 9 6. a 3 = o, 9 48, [ o ] Slope of axis h = 3. % INLET ( Average ) INLET Rotary Kiln Inspection February 1 Page 8

9 Axial Deviations in Horizontal Plane DEFORMATION SCALE : 1 : left side I N L E T tolerance zone +/- 1. reference axis real axis x O UT L E T right side y Precision of finding kiln axis: +/- 1 Rotary Kiln Inspection February 1 Page 9

10 Rotary Kiln Inspection February 1 Axial Deviations in Vertical Plane DEFORMATION SCALE : 1 : 1. Precision of finding kiln axis: +/- 1 tolerance zone +/- 1. reference axis. I NL E T z s =. s = 4. s =. a 3. % real axis a = 9 o 48 a = 9 o 6 a = 9 o 4 +. s Page x 1 O UT L ET

11 Rollers Skewing in Horizontal Plane 1... left side I N L E T kiln axis O UT L E T right side... Rollers skewing (Sh) are reduced for bolts distance Rotary Kiln Inspection February 1 Page 11

12 Rotary Kiln Inspection February 1 Page 1 Rollers Skewing in Vertical Plane I NL E T O UT L ET Rollers skewing (Sv) are reduced for bolts distance kiln axis. adjustment bolts distance Caution! Roller skewing value is reduced for adjustment bolts distance 3. % 4. left side 1... right side %.

13 Adjustment Program left side I N L E T O UT L E T right side Rotary Kiln Inspection February 1 Page 13

14 Adjustment Schedule dy 8. dz. ds 4. dy 8. dz. ds left side I N L E T O UT L E T right side dy dz ds dy dz ds Rotary Kiln Inspection February 1 Page 13a

15 I NL E T Adjustment Schedule - Step by Step left side right side The number of adjustment steps - in red colour Rotary Kiln Inspection February st Day 1st Day nd Day Page O UT L ET 13b

16 Control Check - Axial Deviations in Horizontal Plane DEFORMATION SCALE : 1 : left side I N L E T tolerance zone +/- 1. reference axis real axis x O UT L E T right side y Precision of finding kiln axis: +/- 1 Rotary Kiln Inspection February 1 Page 14

17 I NL E T Rotary Kiln Inspection February 1 Control Check - Axial Deviations in Vertical Plane DEFORMATION SCALE : 1 : 1 Precision of finding kiln axis: +/- 1 real axis reference axis tolerance zone +/- 1.. a 3. %. z a = 9 o 44 a = 6 o a = 9 o 4 s =. s = 4. s =. -. s Page O UT L ET x 1

18 Base Plates Elevation OUTLET PIER No. I ( ) -.3 PIER No. II.. PIER No. III (3. %) % (3. %) % ( ) % (3. %) 3.1 % (3. %) ( ) ( ) -. INLET measured elevation (. ) - theoretical elevation deviation 3. % - measured slope (3. %) - theoretical slope Rotary Kiln Inspection February 1 Page 16

19 Rotary Kiln Inspection February 1 Skewing Correction in Vertical Plane I NL E T 3 shim to be placed under housing Rollers skewing (Sv) are reduced for bolts distance kiln axis. adjustment bolts distance Caution! Roller skewing value is reduced for adjustment bolts distance 3. % 4. left side right side 3. %. Page 1 O UT L ET

20 Position of Supporting Rollers (up - down) Distance between Trust Collars and Retaining Blocks gap contact contact gap contact gap left side I N L E T O UT L E T right side contact gap gap contact gap gap contact shaft roller shaft bearing resistance ring contact Rotary Kiln Inspection February 1 Page 18

21 Recoendation for Future Thrust Correction Perform only if necessary kiln up kiln up.. left side I N L E T kiln up kiln axis O UT L E T right side Rotary Kiln Inspection February 1 Page 19

22 Recoendation for Future Thrust Correction Perform only if necessary kiln down. left side I N L E T kiln down kiln axis O UT L E T right side. kiln down Rotary Kiln Inspection February 1 Page 19a

23 Tires and Shell Temperature Unit: [ C] Emission factor:.9 PIER III inlet side outlet side minimum 3 maximum difference 3 PIER II inlet side outlet side minimum 16 maximum difference 34 1 PIER I inlet side outlet side minimum maximum difference 3 33 I N L E T O UT L E T Date : February 3, 1 Rotary Kiln Inspection February 1 Page

24 Diameters of Tires and Rollers in Normal Physical Conditions ( o C) f = 1994 f = 98 f = I N L E T f = 884 f = 93 f = 883 O UT L E T f = 1996 f = 3 f = 1999 Rotary Kiln Inspection February 1 Page 1

25 Rollers Mechanical Wear deviation [] OUTLET deviation [] roller axis P - I roller axis max. radius = 1. max. radius = 11. DEFORMATION SCALE 1 : roller axis max. radius = 11. roller axis P - II P - III roller axis roller axis max. radius = max. radius = 998. INLET max. radius = 999. Accuracy of measurements +/-. Rotary Kiln Inspection February 1 Page

26 Roller Shafts Condition and Lubrication Efficiency OUTLET shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good shaft condition: good lubrication: good INLET Rotary Kiln Inspection February 1 Page 3

27 Tire Wobbling Tire No. III (VIEWING FROM INLET SIDE) Z Maximum wobbling line Y Caution: reference line describing kiln position - at the bottom TIRE No. III TIRE No. II TIRE No. I I NL E T O U T L E T.4.4 (Point No. 1) (Point No. 8) Rotary Kiln Inspection February 1 Page 4

28 Tire Wobbling Tire No. II (VIEWING FROM INLET SIDE) Z Maximum wobbling line Y Caution: reference line describing kiln position - at the bottom TIRE No. III TIRE No. II TIRE No. I I NL E T O U T L E T.9.9 (Point No. ) (Point No. 18) Rotary Kiln Inspection February 1 Page

29 Tire Wobbling Tire No. I (VIEWING FROM INLET SIDE) Z Maximum wobbling line Y Caution: reference line describing kiln position - at the bottom TIRE No. III TIRE No. II TIRE No. I I NL E T O UT L E T.. (Point No. ) (Point No. 4) Rotary Kiln Inspection February 1 Page 6

30 Girth Gear Wobbling Girth Gear (VIEWING FROM INLET SIDE) 8 Z max. wobbling line Caution: reference line describing kiln position - at the bottom TIRE No. III 1 GIRTH GEAR 1 TIRE No. II TIRE No. I I NL E T O U T L E T (Point No. 3) (Point No. 19) Rotary Kiln Inspection February 1 Page

31 Girth Gear Runout Girth Gear (VIEWING FROM INLET SIDE) Z geometric centre z 1 y axis of rotation 4 Y Caution: reference line describing kiln position - at the bottom GEOMETRIC CENTRE COORDINATES Coordinate Y Coordinate Z -.. ECCENTRICITY. Rotary Kiln Inspection February 1 Page 8

32 Roller Shaft Deflection Value Change PIER No. III LEFT ROLLER Unit: [] No. of point: Measurement Method View from inlet side 1 3 Left Side Starting point line - start of survey Starting point line - end of survey change value of deflection Eccentricity: Total deflection value:.8 (tolerance.1 ).8 Maximum deflection at point No.: 8 Rotary Kiln Inspection February 1 Page 9

33 Roller Shaft Deflection Value Change PIER No. III RIGHT ROLLER.3. Measurement Method View from inlet side.1 Unit: [] No. of point: 1 3 Right Side Starting point line - start of survey Starting point line - end of survey change value of deflection Eccentricity: Total deflection value:.6 (tolerance.1 ).3 Maximum deflection at point No.: 3 Rotary Kiln Inspection February 1 Page 3

34 Roller Shaft Deflection Value Change PIER No. II LEFT ROLLER Unit: [] No. of point: Measurement Method View from inlet side 1 3 Left Side Starting point line - start of survey Starting point line - end of survey change value of deflection Eccentricity: Total deflection value:.9 (tolerance.1 ).8 Maximum deflection at point No.: 14 Rotary Kiln Inspection February 1 Page 31

35 Roller Shaft Deflection Value Change PIER No. II RIGHT ROLLER Unit: [] No. of point: Measurement Method View from inlet side 1 3 Right Side Starting point line - start of survey Starting point line - end of survey change value of deflection Eccentricity: Total deflection value:.46 (tolerance.1 ).9 Maximum deflection at point No.: 1 Rotary Kiln Inspection February 1 Page 3

36 Roller Shaft Deflection Value Change PIER No. I LEFT ROLLER.1.1. No. of point: Measurement Method View from inlet side Unit: [] Left Side 1 3 Starting point line - start of survey Starting point line - end of survey change value of deflection Eccentricity: Total deflection value:.8 (tolerance.1 ).1 Maximum deflection at point No.: 3 Rotary Kiln Inspection February 1 Page 33

37 Roller Shaft Deflection Value Change PIER No. I RIGHT ROLLER.1.1. No. of point: Measurement Method View from inlet side Unit: [] Right Side -.1 Starting point line - start of survey Starting point line - end of survey change value of deflection Eccentricity: Total deflection value:.8 (tolerance.1 ).1 Maximum deflection at point No.: 8 Rotary Kiln Inspection February 1 Page 34

38 Axial Deviations of Drive in Horizontal Plane Line Parallel to Kiln Axis - 3. OUTLET Kiln Axis. LEFT SIDE INLET Precision of finding Drive misalignment: +/-. Rotary Kiln Inspection February 1 Page 3

39 Axial Deviations of Drive in Vertical Plane Line Parallel to Kiln Axis -. OUTLET Kiln Axis LEFT SIDE INLET Precision of finding Drive misalignment: +/-. Rotary Kiln Inspection February 1 Page 36

40 Thrust Roller Position in Horizontal Plane OUTLET 3 thrust roller slope 3.4% thrust roller axis incorrect kiln axis TIRE No. III INLET Rotary Kiln Inspection February 1 Page 3

41 SHELLTEST Measurements results Rotary Kiln Inspection February 1 Page 38

42 SHELLTEST Measurements results Date of measurement: 1..1 No. of the Tire and side of measurement Mean ovality from three measurements Distance from the ring center Tire III Inlet side Tire III Outlet side Tire II Inlet side Tire II Outlet side Tire I Inlet side Tire I Outlet side.3 % 1.3 m. %. m.9 % 1.3 m.34 % 1.3 m.3 % 1.3 m. % 1.3 m Ovality limits as a function of the kiln diameter 1..8 Ovality (%) Shell diameter (m) Rotary Kiln Inspection February 1 Page 39

43 SHELLTEST - MEASUREMENT PIER No. III INLET SIDE 1.3 m view from inlet side 1 Average ovality =.3 % C B Shell diameter = 483 Creep = INLET OUTLET 1 1 measuring points A ref. line A B C wr =. % wr =.6 % wr =. %. 6.. Rotary Kiln Inspection February 1 Page 4

44 SHELLTEST - MEASUREMENT PIER No. III OUTLET SIDE. m view from inlet side 1 Average ovality =. % C B Shell diameter = 483 Creep = INLET OUTLET 1 1 measuring points A ref. line A B C wr =.3 % wr =.13 % wr =. %. 3.. Rotary Kiln Inspection February 1 Page 41

45 SHELLTEST - MEASUREMENT PIER No. II INLET SIDE 1.3 m view from inlet side 1 Average ovality =.9 % C B Shell diameter = 483 Creep = 1 INLET OUTLET 1 1 measuring points A ref. line A B C wr =.8 % wr =.3 % wr =.8 % Rotary Kiln Inspection February 1 Page 4

46 SHELLTEST - MEASUREMENT PIER No. II OUTLET SIDE 1.3 m view from inlet side 1 Average ovality =.34 % C B Shell diameter = 483 Creep = 1 INLET OUTLET 1 1 measuring points A ref. line A B C wr =.43 % wr =.6 % wr =.34 % Rotary Kiln Inspection February 1 Page 43

47 SHELLTEST - MEASUREMENT PIER No. I INLET SIDE 1.3 m view from inlet side 1 Average ovality =.3 % C B Shell diameter = 483 Creep = INLET OUTLET 1 1 measuring points A ref. line A B C wr =.3 % wr =.3 % wr =.34 %.. 8. Rotary Kiln Inspection February 1 Page 44

48 SHELLTEST - MEASUREMENT PIER No. I OUTLET SIDE 1.3 m view from inlet side 1 Average ovality =. % C B Shell diameter = 483 Creep = INLET OUTLET 1 1 measuring points A ref. line A B C wr =.6 % wr =.3 % wr =.4 % 6... Rotary Kiln Inspection February 1 Page 4

49 Mechanical Inspection (Visual) Girth Gear and Pinion (Teeth inspection) The Girth Gear Teeth - worn out at a point of contact The Pinion Teeth - good condition Rotary Kiln Inspection February 1 Page 46

50 Mechanical Inspection (Visual) Pier No. III Tire - running surface in good condition Running surface of both rollers - satisfying condition Left Roller Right Roller Rotary Kiln Inspection February 1 Page 4

51 Mechanical Inspection (Visual) Thrust Roller Running surface - good condition Pressure around 4 Bar Rotary Kiln Inspection February 1 Page 48

52 Mechanical Inspection (Visual) Pier No. II Tire - running surface in good condition Running surface of both rollers - satisfying condition Left Roller Right Roller Rotary Kiln Inspection February 1 Page 49

53 Mechanical Inspection (Visual) Pier No. I Tire running surface - good condition Gap between The Tire and Left Roller Running surface of both rollers - good condition Left Roller Right Roller Rotary Kiln Inspection February 1 Page

54 Mechanical Inspection (Visual) Inlet Inlet sealing works properly Outlet Outlet sealing does not work properly Rotary Kiln Inspection February 1 Page 1

55 Sections Position Diagram for Kiln Shell Deviation Survey (layout) P - III DRIVE P - II P - I I N L E T O U T L E T m refrence line describing kiln position - at the bottom Rotary Kiln Inspection February 1 Page

56 Shell Profile Axonometric View Starting point at bottom - P - III DRIVE P - II P - I No. of section 1 Y geom.centre Z geom.centre Eccentricity P- III - 6 DRIVE Unit No. of section Y geom.centre Z geom.centre Eccentricity P- II P- I Unit Rotary Kiln Inspection February 1 Page 3

57 Shell Profile Axonometric View Starting point at 9 P - III DRIVE P - II P - I No. of section 1 Y geom.centre Z geom.centre Eccentricity P- III - 6 DRIVE Unit No. of section Y geom.centre Z geom.centre Eccentricity P- II P- I Unit Rotary Kiln Inspection February 1 Page 4

58 Shell Profile Axonometric View Starting point at 18 P - III DRIVE P - II P - I No. of section 1 Y geom.centre Z geom.centre Eccentricity P- III - 6 DRIVE Unit No. of section Y geom.centre Z geom.centre Eccentricity P- II P- I Unit Rotary Kiln Inspection February 1 Page

59 Shell Profile Axonometric View Starting point at P - III DRIVE P - II P - I No. of section 1 Y geom.centre Z geom.centre Eccentricity P- III - 6 DRIVE Unit No. of section Y geom.centre Z geom.centre Eccentricity P- II P- I Unit Rotary Kiln Inspection February 1 Page 6

60 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 1 Deformation Scale - 1 : geometric centre z axis of rotation y GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

61 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. Deformation Scale - 1 : geometric centre z y axis of rotation GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

62 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 3 Deformation Scale - 1 : geometric centre z y axis of rotation GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

63 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 4 Deformation Scale - 1 : geometric centre z y axis of rotation GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

64 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

65 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 6 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC - Rotary Kiln Inspection February 1

66 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. Deformation Scale - 1 : axis of rotation z y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

67 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 8 Deformation Scale - 1 : axis of rotation z y 1 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

68 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 9 Deformation Scale - 1 : axis of rotation z y 1 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

69 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 1 Deformation Scale - 1 : axis of rotation z y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

70 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 11 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

71 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 1 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

72 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 13 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

73 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 14 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

74 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 1 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

75 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 16 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

76 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 1 Deformation Scale - 1 : z axis of rotation y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC - Rotary Kiln Inspection February 1

77 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 18 Deformation Scale - 1 : axis of rotation z y 1 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

78 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 19 Deformation Scale - 1 : axis of rotation z y 1 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

79 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. Deformation Scale - 1 : axis of rotation z 1 y 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

80 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 1 Deformation Scale - 1 : axis of rotation z y 1 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

81 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. Deformation Scale - 1 : axis of rotation z y 1 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

82 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 3 Deformation Scale - 1 : axis of rotation z 1 y 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

83 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 4 Deformation Scale - 1 : z axis of rotation 1 y 9 6 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC + 1 Rotary Kiln Inspection February 1

84 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. Deformation Scale - 1 : z axis of rotation 1 y 9 6 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC + 11 Rotary Kiln Inspection February 1

85 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 6 Deformation Scale - 1 : z axis of rotation 1 y 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

86 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. Deformation Scale - 1 : axis of rotation z y 1 9 geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

87 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 8 Deformation Scale - 1 : axis of rotation z y geometric centre GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

88 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 9 Deformation Scale - 1 : geometric centre z y axis of rotation GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

89 Radial Diagram of Shell Deformation (Circular Deviations) CROSS SECTION No. 3 Deformation Scale - 1 : geometric centre z y axis of rotation GEOMETRIC CENTRE COORDINATES Caution: Hatch Line describing kiln position at the bottom VIEWING FROM INLET SIDE Coordinate Y Coordinate Z ECCENTRIC Rotary Kiln Inspection February 1

90 Kiln Mechanical Parameters The kiln mechanical parameters has been calculated with consideration of actual thickness and weight of kiln shell, refractory lining, coating, material flow, as well as all dimensions of kiln components. All results represents the case of kiln straight axis. To illustrate consequences for the kiln we calculate load capacity utilization of particular parameter referring to its design limit. LOAD DISTRIBUTION FOR ROLLERS AND TIRES BEARINGS TIRES Specific load Utilization Bending stress Utilization Hertz pressure Utilization (design limit 4.4 MPa) [ % ] (design limit 6 MPa) [ % ] (design limit 44 MPa) [ % ] Support No Support No Support No All above parameters, particularly specific load of bearings, tires bending stress and Hertz pressure between tires and rollers are within tolerance. Utilization of design limit is close to 1% for support No. 1 what is related with mass concentration in this zone (coating). The kiln is not overloaded but support No. 1 is close to upper tolerance limit for bearing load and Hertz pressure between tire and rollers. Therefore we recoend to pay special attention on coating accumulation. In case of high thickness of coating or coating ring formation support No. 1 may be temporarily overloaded. STIFFNESS MATRIX Change of reaction in [%] by lowering particular support by 1 No. 1 No. No. 3 Support No Support No Support No The stiffness matrix illustrates kiln shell characteristics. The result illustrates change of reaction of all supports when particular support is lowering by 1. Considering maximum reaction value of 18% the kiln is classified as flexible. It means the kiln is not very much sensitive for change of kiln axis position and reactions on supports do not change drastically. Anyway, it is recoended to pay attention on the kiln alignment and under-tire clearance s changes to avoid overload in the future.

91 Kiln shell bending stress reaches 16 MPa and it is within designed limits ( MPa). It looks there is large spare limit for shell bending stress. However, it has to be considered that above result represent straight kiln in static condition without any shell deformation or crank formation. All above results lead to conclusion the kiln should be aligned for straight axis, there is no need to optimize loads and stresses by changing axis position. TIRE MIGRATION, SHELL RELATIVE OVALITY, NIES OVALITY FOR TIRES SHELL TIRES Rel. ovality Utilization Migration Nies ovality Utilization (design limit.3%) [ % ] (recoended: 1 /rev) (design limit.%) [ % ] Support No Support No Support No Tires migration is almost within tolerance (1- /rev) for all supports. Therefore relative ovality of kiln shell is also within design limit. Nies ovality for tires are within tolerance and the utilization is below 1%. However, the migration and ovality is just at the tolerance limit and it is recoended to pay attention on tire migration in the future. In case it increases, shiing should be considered. Generally, the kiln mechanical parameters are within design limits. The kiln is definitely not overloaded in terms of support loads, bearing pressures, tire stress and Hertz pressures between tires and rollers. Also the kiln shell bending stress is within designed limit. However, it should be considered that all the design limits correspond to static condition and in fact all parameters are frequently much higher due to cyclical load change during kiln operation (crank effect). It is recoended to monitor the bearings condition and temperatures frequently. Technical drawings of calculation results are attached at the end of this report.

92 Kiln Mechanical Parameters Rotary Kiln Inspection February 1

93 Kiln Mechanical Parameters Rotary Kiln Inspection February 1

94 Weight distribution [t/m] Rotary Kiln Inspection February 1

95 Vertical Displacement of the Kiln Shell [] Rotary Kiln Inspection February 1

96 Longitudinal Bending Stress of the Kiln Shell [MPa] Rotary Kiln Inspection February 1

97 Shear Stress of the Kiln Shell Rotary Kiln Inspection February 1

98 Von Mises Stress (Reference Stress) of the Kiln Shell [MPa] Rotary Kiln Inspection February 1

99 Bending Stress of Tires [MPa] Rotary Kiln Inspection February 1