ABC Company – Kiln #1 Somewhere, KY July 12, 2018 · 2018-08-07 · • The alignment to the kiln...

ABC Company – Kiln #1 Somewhere, KY

July 12, 2018 Company ABC Company Attention John Smith

IKD Job # FS1234 Equipment/Make Kiln #1/Allis Chalmers

PRMS 98765 Design Slope 0.3125 in/ft

Plant Code ABC123-45 Unit diameter 10’-5”

Customer P.O. 987654321 Unit length 265’

Crew Onsite TZ, JT, NN, FG, CV, AF # of Piers 4

Dates Onsite 6/12/ - 6/18/18 Analyzed by TZ, MA

The New Hot Kiln Alignment

IKD Plant Code: ABC123-45 Proposal #: 98765

July 12, 2018

Mr. John Smith Maintenance Planner ABC Company 123 Rotary Drive Somewhere, KY 23191

Phone: (555) 555-5555E-Mail: [email protected]

SUBJECT: Kiln Axis SurveyTM + Options 1 to 6

Dear Mr. Smith:

Thank you for the opportunity for Industrial Kiln and Dryer Group to perform a Kiln Axis SurveyTM on the Allis Chalmer Kiln #1. During the course of our work, we have completed the following:

Work Scope • Kiln Axis Survey

o The shell rotating center will be located on all piers using proprietary opticalmethodology

o Horizontal and vertical misalignments will be measuredo Kiln slope are determinedo Base slopes are measuredo Shell ovality at each pier are measuredo Temperatures of the tire face and shell uphill and downhill of each pier are takeno Creep is measured at each piero Thrust orientation is notedo General inspection is performed

• Bearing Adjustments and Thrust Neutralization are performed (Option 1)• Tire/Roller Face Diameter measurements are taken (Option 2)• Gear Radial (Eccentricity) and Axial (Wobble) Runouts are taken (Option 3)• Tire Wobble is measured (Option 4)• Roller Shaft Bending is taken at each pier (Option 5)• Kiln Shell Profile is completed (Option 6)

Recommendations

• The alignment to the kiln axis is relatively good. Tire 2 is vertically 0.39 inches too low. Therollers at Tire 2 are moved in 0.25 inches which raised the unit about 0.14 inches.

• The kiln axis however is skewed compared to the base centers at the feed and dischargeend. The biggest difference is 2.06 inches at the discharge end. We recommend correctingthis on the next shut down.

mailto:[email protected]

ABC Company – Somewhere, KY July 12, 2018

• Tire 1 (DS), 3, and 4 (FD) have very high taper from 0.283 inches to 0.374 inches. These tires along with rollers need to be grinded to avoid point contact loads.

• Gear has a radial runout of 0.110 inches. Please monitor the gear and check for wear during next shut down.

• Bearing seals are needed for Pier 1, 2 and 4. Large amounts of oil are leaking from each bearing cap.

• Investigate Pier 3 left roller chunks missing.

Executive Summary We performed a Kiln Axis Survey on the Allis Chalmers Kiln #1 at the ABC Company plant in Somewhere, KY. Kiln Axis Survey The kiln has a design slope of 0.313 in/ft or 5/16 in/ft. We found the kiln measured slope to be 0.312 in/ft. The kiln is horizontally within tolerance of ± 0.125 inches. The vertical misalignment shows Tire 2 to be 0.39 inches too low. Base slopes in general are quite high at a maximum of 0.337 in/ft. This could be pier settling over time. One thought here is the high amount of oil leakage at the pier. Oil pooling from downhill bearings may cause loosening at downhill side of pier which could lead to high base slopes. Creep, Temperatures, Ovality. Pier 4 (FD) has a creep of 0 in/rev which is of concern. The tirepads may be too tight or there is significant enough grease buildup to obstruct movement. Please clean the tirepads first to see if creep occurs. If creep does not occur, please investigate the tire pads. Ovality should be under 0.32% for this diameter kiln. The measured ovalities are all below this value. The temperatures show no discernable problems and follow typical kiln trends. Dogleg Measures at Pier and Shell There is no dogleg measured at each Pier via roller shaft bending measurement. The shell runout measure shows two bends one at between Pier 1 and Pier 2 and the other between Pier 3 and Pier 4. If process is not affected and no brick loss is observed, normally these bends are of no concern. Tire/Roller Profile Pier 1, 2, and 4 Tires have very high differentials ranging from 0.283 inches to 0.374 inches. We recommend grinding at each tire and roller. Tire Wobble/Gear Runout Tire wobble are all below the maximum tolerance of 0.157 in. Gear runout is measured at 0.110 in. We recommend close monitoring of gear for additional wear. Sincerely, Carlos Velez Kiln Axis Specialist Industrial Kiln and Dryer Group

Sarah Garner Key Account Specialist Industrial Kiln and Dryer Group

Tom Zhang, PhD, PE Engineer Industrial Kiln and Dryer Group


TABLE OF CONTENTS Page Work Scope 1 Recommendation 1 Executive Summary 2 Table of Contents 3 Kiln Axis Survey 4 Orientation 4 Survey Summary 4 Horizontal Misalignment 4 Elevation Misalignment 5 Kiln Slope 6 Base Slope 6 Thrust Orientation 7 Adjustments 7 Ovality, Creep, and Temperature 8 Tire/Roller Face Diameter 9 Tire Wobble 13 Gear Runout 13 Roller Shaft Bending 14 Kiln Shell Profile 15 Inspection Observations 18


Kiln Axis SurveyTM Unit Orientation

All references to this kiln will be made from the discharge end looking toward the feed end. Therefore, rollers will be refered to left and right according to the above reference. Discharge Pier will be refered to as Pier #1 and follow an ascending order of Piers. Survey Summary The unit design slope or agreed slope is 0.312 in/ft or 5/16 in/ft. Looking at the overall system slope, the system is 0.312 in/ft. The overall system slope is good. Pier 2 elevation is 0.39 in too low which needs correction. Horizontal Misalignment

The horizontal misalignment via the kiln axis is within tolerance of 0.25 inches. However the system itself is quite a bit off compared to the base centers at a max of 2.06 inches. We recommend setting the unit back on the bases on next shut down.

Tire 3

Tire 2

Tire 1

Plan ViewDischarge

LEFT RIGHT

Feed

Tire 4


Elevation Misalignment

Tire 1

Tire 2

Tire 3

Tire 4

0

500

1000

1500

2000

2500

3000

-0.25 -0.15 -0.05 0.05 0.15 0.25

Loca

tion

(in)

Horizonal Misalignment (in)

Horizontal Misalignment Limit Kiln Centerline

Tire 3

Tire 2

Tire 1

Plan ViewDischarge

LEFT RIGHT

Feed

Tire 4

Tire 1

Tire 2

Tire 3

Tire 4

-0.5

-0.4

-0.3

-0.2

-0.1

0

0.1

0.2

0.3

0.4

0.5

0 500 1000 1500 2000 2500 3000

Vert

icle

Mis

alig

nmen

t (in

)

Kiln Location (in)

Elevation Misalignment Limit Kiln Centerline


Kiln Slope

Base Slope

Base Slope Left (in/ft) Right (in/ft) Pier 1 0.323 0.337 Pier 2 0.321 0.335 Pier 3 0.313 0.315 Pier 4 0.328 0.322

Tire 4Tire 3Tire 2Tire 1

Elevation View

0.3

0.302

0.304

0.306

0.308

0.31

0.312

0.314

0.316

T1 T1 to T2 T2 to T3 T3 to T4 T4

Slop

e (in

/ft)

System Slope (in/ft) Tire 1 to Tire 4 Measured Slopes Design Slope


Thrust Orientation

Adjustments

A small adjustment was made to at least elevate Pier 2 to alleviate some of the elevation misalignment. Also uphill thrust of 0.006 inches total was added to the unit to neutralize the thrust.

With a 0.25 inch move inward will raise the unit about 0.14 inches. This brings the overall vertical misalignment to 0.25 inches too low at Pier 2.

Unit ThrustPier 1 Pier 2 Pier 3 Pier 4

+Y

+XPlan View

Adjustments Upturning side: LeftPier 1 Pier 2 Pier 3 Pier 4

0.250" 0.253"

0.253" 0.250"Plan View


Ovality, Temperatures, Creep

The creep measurements show Pier 4 has no creep. This is concerning due to the amount of lubrication built up between the tire, tirepad, and shell. Removal of grease and general housekeeping should help. Some creep here is better than no creep.

An ovality of 0.32% is the limit for this unit. The average ovality data shows good overall health of the shell. No discernable temperatures problems were seen on the unit. The temperatures follow the normal trend of increasing as it gets towards to discharge end of the kiln.

0.00

0.10

0.20

0.30

0.40

Tire 1 Tire 2 Tire 3 Tire 4

Ova

lity

(%)

Ovality Measurements Avg Tolerance

0

200

400

600

800


Tem

pera

ture

(°F)

Temperature Measurements Shell DH Tire Face Shell UH

0.00

0.50

1.00

1.50


Cree

p (in

/rev

)

Creep Measurements Creep (in/rev) Plan for Repad


Tire/Roller Face Diameter

1060

1062

1064

1066

1068

1070

DH MD-DH MD MD-UH UH

Diam

eter

(mm

)

Pier 1 - Left Roller

4060

4062

4064

4066

4068

4070

4072


Diam

eter

(mm

)

Pier 1 - Tire

1060

1062

1064

1066

1068

1070


Diam

eter

(mm

)

Pier 1 - Right Roller


1060

1062

1064

1066

1068

1070


Diam

eter

(mm

)


4060

4062

4064

4066

4068

4070

4072


Diam

eter

(mm

)

Pier 2 - Tire

1060

1062

1064

1066

1068

1070


Diam

eter

(mm

)



1043.51044

1044.51045

1045.51046

1046.51047

1047.5


Diam

eter

(mm

)


4062

4064

4066

4068

4070

4072

4074

4076


Diam

eter

(mm

)

Pier 3 - Tire

104310441045104610471048104910501051


Diam

eter

(mm

)



1048.51049

1049.51050

1050.51051

1051.51052

1052.5


Diam

eter

(mm

)


403640384040404240444046404840504052


Diam

eter

(mm

)

Pier 4 - Tire

1038

1039

1040

1041

1042

1043


Diam

eter

(mm

)



Tire Wobble

The tire wobble overall are well below the 0.118 inches (3 mm) tolerance band which is good.

Gear Runout The measured eccentricity or runout of this gear is 2.8 mm. This exceeds the calculated tolerance.

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140


Tire

Wob

ble

(±in

) Tire Wobble Measurement

Measurements Limit

0

0.5

1

1.5

2

2.5

3

Eccentricity (mm)

Mea

sure

s (m

m)

Gear Eccentricity Limits


Roller Shaft Bending One of the concerns was the possibility of a dogleg at the Pier 2. We use a proximity sensor which effectively is a noncontact dial indicator. This sensor is at the 7 o’clock or 5 o’clock of the roller depending on which side is viewed. If a dogleg or crank is present in the unit, the roller will deflect. This deflection will be picked up by the proximity sensor. Below a set of results are shown indicating approximate movement along with the tolerance table of dogleg.

From the results, no indication of dogleg is seen. The results are very good.

0

0.05

0.1

0.15

0.2

0.25

Pier 1 Pier 2 Pier 3 Pier 4

Valu

es (±

mm

)

Roller Shaft Bending Values Left Roller Right Roller Limit

0

50

100

150

200

250

300

Pier 1 Pier 2 Pier 3 Pier 4

Angl

e (°

)

Peak Angles Left Roller Right Roller


Kiln Shell Laser

Using an optical laser, a shell profile is created from Pier 1 to Pier 4. The red is a high point and the blue is a low point. The profile shows bends in the shell between Pier 1 and Pier 2 along with a second bend between Pier 3 and Pier 4. Normally if these bends in the shell don’t affect process or brick loss, the unit can be run indefinitely this way. The roller shaft bending or dogleg measurement at each pier is more critical.

0

5

10

15

20

25

0 10 20 30 40 50 60 70

Tota

l Run

out (

±mm

)

Kiln Location (m)

Total Runout (±mm) - Inlet @ 0 m


0

50

100

150

200

250

300

350

400

0 10 20 30 40 50 60 70

Peak

Ang

le (°

)

Kiln Location (m)

Peak Angle (°) - Inlet @ 0 m

0

2

4

6

8

10

12

14

0 10 20 30 40 50 60 70

Ecce

ntric

ity (m

m)

Kiln Location (m)

Eccentricity (mm) - Inlet @ 0 m


General Inspection Pier 1

Discharge pier right side has some bearing leakage.

Pier 2

Pier 2 rollers on left and right has leaking bearing seals. This should be fixed on next shut down.


Pier 3

Pier 3 left roller has two pits/cracks that look out of place especially for a relatively new roller. Something such as debris getting between the tire and roller may have caused this.

A large chunk of Pier 3 uphill side is separated. Please monitor for further damage.


Pier 4

Pier 4 Right Roller has lots of lubricant overall on the roller and tire. There exists point contact between the tire and roller on the uphill side where pitting is occurring.

Pier 4 access has a hole with weak wooden plank. This is a safety hazard.


Pier 4 Tire has a large buildup of grease between the tire and tirepads. The creep here is 0 in/rev. This could be a reason for the low creep. This is fixed through general cleaning and fixing the bearing seal leakage.

ABC Company – Kiln #1 Somewhere, KY July 12, 2018 · 2018-08-07 · • The alignment to the kiln...

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Transcript of ABC Company – Kiln #1 Somewhere, KY July 12, 2018 · 2018-08-07 · • The alignment to the kiln...