8 Application of Preditive Maintenance in Kiln Maintenance
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Transcript of 8 Application of Preditive Maintenance in Kiln Maintenance
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APPLICATIONSOF
PREDICTIVE MAINTENANCEIN
MAINTENANCE OF KILNS
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PREDICTIVE MAINTENANCE - 1 Under Predictive Maintenance, some
parameters are measured to determine thecondition of the machine and to take
appropriate corrective actions. Predictive Maintenance helps to know the
trend of the health of any equipment over a
period of time Enables timely corrective actions to be taken
to avoid unplanned, sudden and avoidablebreakdowns.
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PREDICTIVE MAINTENANCE - 2 The terms predictive maintenance and condition-
based maintenance are used synonymously. Better control over the machine Reduction in unscheduled stoppage of the
machines to a great extent Management could plan the stoppage of the
machines in a much better way utilizing all theorganizational resources in the most effectivemanner.
Predictive maintenance adds value to the customerby:
Improving the uptime of the machines, Reducing cost and arranging products 4
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OBJECTIVES OF PREDICTIVEMAINTENANCE
Helps in determining that there exists a problem. It monitors the degrading condition of the
machine. Trending degradation permits planning for
repairs.
Trending degradation permits scheduling repairs. Limits the extent of damage of machine save money in costly repairs as well as in loss of
opportunity to produce.
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PARAMETERS TO MEASURE UNDERPREDICTIVE MAINTENANCE OF CRK -1
Temperature Vibration measurements:
Amplitude, Velocity and Frequency of the vibrations.
Presence of contaminants, if any, such as: Dust, Dirt, Metal wear particles,
Soluble and insoluble acidic bodies in lubricating oils.
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PARAMETERS TO MEASURE UNDERPREDICTIVE MAINTENANCE OF CRK -2
Cracks in shell or supporting rollers Alignment of kiln
Ovality of kiln shell Thrust on supporting roller bearings Thickness of the refractory lining Thickness of the shell plate in different zones. Current
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EQUIPMENTSUSED IN
PREDICTIVE MAINTENANCE
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PORTABLE ULTRASOUNDTHICKNESS GAUGE
Specifications
Thickness range 0
100mm
Purpose
To measurethickness of kiln shell
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ULTRASONIC FLAW DETECTIONTEST KIT
Specifications
Should be able todetect cracks andmetallurgical flaws inferrous and nonferrous materials
Purpose
To detect cracks inshell, tyres andsupport rollers.
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OIL SPECTROMETER
Specifications
Suitable for oilanalysis of industriallubricants havingviscosity range from20 - 700 Centistokesat 40C.
Purpose
To determine thecondition of thelubricant for furtheruse.
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NON-CONTACT THERMOMETER
Specifications
Infrared laser typenon-contactthermometer, range0 - 500C.
Purpose
To measure surfacetemperature of shell,tyre, support roller,girth gear toothflanks.
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DIGITAL OPTICAL PYROMETER
Specifications
Range 0 - 600C.
Purpose
To measure surfacetemperature of:
shell, tyre, support roller, girth gear tooth
flanks.
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PORATABLE INFRAREDTHERMOMETER
Specifications
(-)30 - (+)1600C
Purpose
To measure flametemperature
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DIGITAL VERNIER CALLIPER
Specifications
Measurement range0 - 100 mm, leastcount 0.01 mm
Purpose
To measurethickness of girthgear and piniontooth
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SHELL TESTER
Specifications
Kiln shell ovalitytester, portable withtemperatureresistant magnets,mechanicalrecording device.
Purpose
To test shell ovalityand determining therequired thickness ofchair pads.
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ELECTRONIC EQUIPMENT FOROVALITY MEASUREMENT
Specifications Purpose
Kiln shell ovality tester,portable.
To test shell ovalityand determining therequired thickness of
chair pads.
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DIGITAL LEVELING INSTRUMENT
Specifications
Least count /sensitivity 0.1mm/meter
Purpose
To determine topand bottom deadcenter of the kilnshell, other levelingworks.
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KILN THRUST MEASUREMENTEQUIPMENT
Specifications
Mobile hydraulicthrust measuringequipment with highpressure jack.
Purpose
To adjust setting ofthe support rollersand checking thecondition of thebearings of thesupporting rollers.
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MICROLOG DATA COLLECTOR WITHFFT ANALYZER AND PROCESSOR
Specifications With accelerometer of
magnetic base,
accelerometer cable,dynamic balancing andstroboscope set withfacility to download the
data to any P4 processorequipped PC. The datacollector / analyzershould cover frequency
range of 0.2 Hz to 20 KHz.
Purpose Data collection,
machinery vibrationanalysis andmonitoring e.g. girthgear and motors.Should do earlydetection of bearingdefects or gear toothwear, electric motormonitoring and fieldmachinery balancing.
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ENGINEER'S STETHOSCOPE
Specifications
Portable stethoscope
Purpose
For detectingabnormal sound inmachine inoperation
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LASER ALIGNMENT CHECKINGEQUIPMENT
Specifications
Laser couplingalignmentequipment withaccessories.
Purpose
To do alignment ofcouplings of motorand fan or any othercouplings.
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LINOMETER
Specifications
Portable thicknessmeasuringequipment.
Purpose
For measurement ofrefractory brickthickness.
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SHOCK PULSE METER
Specifications 0 100 db
Purpose To measure the
value of shock pulsesin ball and rollerbearings
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CASE STUDIES OF SIDHEE CEMENT
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VIBRATION MEASUREMENTS OF KILNDRIVE AT SIDHEE CEMENT
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VIBRATION ANALYSIS OF MAIN KILN DRIVE GEARBOX OF4200TPD 4.3M DIA KILN AT SIDHEE CEMENT PLANT
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BREAKDOWN ANALYSIS ROLLER SHAFTSHEARED OFF AT GSCL
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GIRTH GEAR AND PINION TEMPERATURE ON21.01.08 AT GSCL
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GIRTH GEAR AND PINION TEMPERATURE ON18.05.08 AT GSCL
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CONTACT PATTERN EARLIER BETWEEN GIRTH GEAAND PINION AT GSCL
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CONTACT PATTERN LATER BETWEEN GIRTH GEAR ANPINION AT GSCL
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ROOT CLEARANCE AND BACKLASH BETWEEN GIRTH GEAAND PINION ON 07.08.06 AT GSCL
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ROOT CLEARANCE BETWEEN GIRTH GEAR ANDPINION ON 14.10.07 AT GSCL
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ROOT CLEARANCE AND BACKLASH BETWEEN GIRTH GEAAND PINION ON 06.06.08 AT GSCL
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TECHNICAL AUDIT REPORT OFBREAKDOWN AT GSCL - 1
1.0 Name of Machine:
2.0 Department & Machine ID:3.0 Source of supplier:
4.0 Brief technical details: (Write technicalspecification, dimension, material of constructionetc.)
5.0 Date of Installation:6.0 Date of last repair / maintenance:7.0 Brief details of last repair / maintenance:
8.0 Time and Date of occurrence of the problem:
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TECHNICAL AUDIT REPORT OFBREAKDOWN AT GSCL - 2
9.0 Time and Date of Restarting the machine afterrepair:
10.0 Total time of stoppage of machine :11.00 Brief details of Breakdown: (State what
happened? (Damage to men, machine or building).Support with drawings and photographs)
12.00 Details of investigations carried out and fieldmeasurement.
13.00 What were the last readings of fieldmeasurements?14.00 Were any early signals noticed before occurrence
of the actual failure or damage?
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TECHNICAL AUDIT REPORT OFBREAKDOWN AT GSCL - 3
15.00 Analyze and establish of reason (s) for the failure/ damage, which may include:i. Poor Material
ii. Long operating lifeiii. Wrong operationsiv. Negligence in maintenance.v. Deficiency in system design.vi. External factors like-heavy rains, earthquake,lightening, accident etc.vii If any official is found responsible or thefailure/damage.
TECHNICAL AUDIT REPORT OF
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TECHNICAL AUDIT REPORT OFBREAKDOWN AT GSCL - 4
16.00 What actions were taken to restore the machine?17.00 Details of materials used with cost:18.00 Details of manpower used:19.00 What lessons can be drawn from the failure/damage?
20.00 What actions should be taken to make the m/c workingefficiently and safely?21.00 What steps should be taken to avoid similar failures in
future?
Report prepared by Concurred by Approved by22.00 Remarks of the controlling authority.Joint President (Works)Cc: Director (Operations/Projects)
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TREND OF KILN TYRE MIGRATION ATGSCL