APPLICATIONS OF PREDICTIVE MAINTENANCE IN MAINTENANCE OF KILNS

PREDICTIVE MAINTENANCE - 1
Under Predictive Maintenance, some parameters are measured to determine the condition 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 avoidable breakdowns.

PREDICTIVE MAINTENANCE - 2
The terms predictive maintenance and conditionbased 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 the organizational resources in the most effective manner. Predictive maintenance adds value to the customer by: Improving the uptime of the machines, Reducing cost and arranging products
4

OBJECTIVES OF PREDICTIVE MAINTENANCE

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.

PARAMETERS TO MEASURE UNDER PREDICTIVE 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.

PARAMETERS TO MEASURE UNDER PREDICTIVE 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

EQUIPMENTS USED IN PREDICTIVE MAINTENANCE

PORTABLE ULTRASOUND THICKNESS GAUGE

Specifications
Thickness range 0 100mm

Purpose
To measure thickness of kiln shell

ULTRASONIC FLAW DETECTION TEST KIT

Specifications Purpose
Should be able to To detect cracks in detect cracks and shell, tyres and metallurgical flaws in support rollers. ferrous and non ferrous materials

OIL SPECTROMETER
Specifications
Suitable for oil analysis of industrial lubricants having viscosity range from 20 - 700 Centistokes at 40C.

Purpose
To determine the condition of the lubricant for further use.

NON-CONTACT THERMOMETER
Specifications
Infrared laser type non-contact thermometer, range 0 - 500C.

Purpose
To measure surface temperature of shell, tyre, support roller, girth gear tooth flanks.

DIGITAL OPTICAL PYROMETER

Specifications
Range 0 - 600C.

Purpose
To measure surface temperature of:
shell, tyre, support roller, girth gear tooth flanks.

PORATABLE INFRARED THERMOMETER

Specifications
(-)30 - (+)1600C

Purpose
To measure flame temperature

DIGITAL VERNIER CALLIPER

Specifications
Measurement range 0 - 100 mm, least count 0.01 mm

Purpose
To measure thickness of girth gear and pinion tooth

SHELL TESTER
Specifications
Kiln shell ovality tester, portable with temperature resistant magnets, mechanical recording device.

Purpose
To test shell ovality and determining the required thickness of chair pads.

ELECTRONIC EQUIPMENT FOR OVALITY MEASUREMENT

Specifications
Kiln shell ovality tester, portable.

Purpose
To test shell ovality and determining the required thickness of chair pads.

HOT KILN EQUIPMENT ALIGNMENT EQUIPMENT

Specifications
Optical theodolite with optically alignable spirit level and computer.

Purpose
For alignment of the kiln during operating condition.

DIGITAL LEVELING INSTRUMENT

Specifications
Least count / sensitivity 0.1 mm/meter

Purpose
To determine top and bottom dead center of the kiln shell, other leveling works.

KILN THRUST MEASUREMENT EQUIPMENT

Specifications Purpose
Mobile hydraulic To adjust setting of thrust measuring the support rollers equipment with high and checking the pressure jack. condition of the bearings of the supporting rollers.

MICROLOG DATA COLLECTOR WITH FFT ANALYZER AND PROCESSOR

Specifications
With accelerometer of magnetic base, accelerometer cable, dynamic balancing and stroboscope set with facility to download the data to any P4 processor equipped PC. The data collector / analyzer should cover frequency range of 0.2 Hz to 20 KHz.

Purpose
Data collection, machinery vibration analysis and monitoring e.g. girth gear and motors. Should do early detection of bearing defects or gear tooth wear, electric motor monitoring and field machinery balancing.

ENGINEER'S STETHOSCOPE
Specifications Purpose

Portable stethoscope For detecting abnormal sound in machine in operation

LASER ALIGNMENT CHECKING EQUIPMENT

Specifications
Laser coupling alignment equipment with accessories.

Purpose
To do alignment of couplings of motor and fan or any other couplings.

LINOMETER
Specifications
Portable thickness measuring equipment.

Purpose
For measurement of refractory brick thickness.

SHOCK PULSE METER

Specifications
0 100 db

Purpose
To measure the value of shock pulses in ball and roller bearings

CASE STUDIES OF SIDHEE CEMENT

VIBRATION MEASUREMENTS OF KILN DRIVE AT SIDHEE CEMENT

VIBRATION ANALYSIS OF MAIN KILN DRIVE GEARBOX OF 4200TPD 4.3M DIA KILN AT SIDHEE CEMENT PLANT

BREAKDOWN ANALYSIS ROLLER SHAFT SHEARED OFF AT GSCL

GIRTH GEAR AND PINION TEMPERATURE ON 21.01.08 AT GSCL

GIRTH GEAR AND PINION TEMPERATURE ON 18.05.08 AT GSCL

CONTACT PATTERN EARLIER BETWEEN GIRTH GEAR AND PINION AT GSCL

CONTACT PATTERN LATER BETWEEN GIRTH GEAR AND PINION AT GSCL

ROOT CLEARANCE AND BACKLASH BETWEEN GIRTH GEAR AND PINION ON 07.08.06 AT GSCL

ROOT CLEARANCE BETWEEN GIRTH GEAR AND PINION ON 14.10.07 AT GSCL

ROOT CLEARANCE AND BACKLASH BETWEEN GIRTH GEAR AND PINION ON 06.06.08 AT GSCL

TECHNICAL AUDIT REPORT OF BREAKDOWN AT GSCL - 1

1.0 Name of Machine: 2.0 Department & Machine ID: 3.0 Source of supplier: 4.0 Brief technical details: (Write technical specification, dimension, material of construction etc.) 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:

TECHNICAL AUDIT REPORT OF BREAKDOWN AT GSCL - 2

9.0 Time and Date of Restarting the machine after repair: 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 field measurement. 13.00 What were the last readings of field measurements? 14.00 Were any early signals noticed before occurrence of the actual failure or damage?

TECHNICAL AUDIT REPORT OF BREAKDOWN AT GSCL - 3

15.00 Analyze and establish of reason (s) for the failure / damage, which may include: i. Poor Material ii. Long operating life iii. Wrong operations iv. 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 the failure/damage.

TECHNICAL AUDIT REPORT OF BREAKDOWN 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 working efficiently and safely? 21.00 What steps should be taken to avoid similar failures in future? Report prepared by Concurred by Approved by 22.00 Remarks of the controlling authority. Joint President (Works) Cc: Director (Operations/Projects)

TREND OF KILN TYRE MIGRATION AT GSCL