1. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 1
Kiln Condition Report (Line 1)
(March 2015)
Contents
1 Executive Summary .................................................................................................. 1
2 Resume of Recommendations............................................................................... 2
3 Kiln Condition .............................................................................................................. 3
3.1 Support Rollers Condition................................................................................... 3
3.2 Migration.................................................................................................................... 4
3.3 Kiln Crank.................................................................................................................. 5
3.4 Kiln Support Bearing Temperature.................................................................. 6
3.5 Kiln Pinion Temperature ...................................................................................... 7
3.6 Girth Gear spray Pattern..................................................................................... 9
3.7 Visual Inspection.................................................................................................. 10
1 Executive Summary
Kiln running during the month except interval 13 to 17 February 2015 due
to red spot at M25.
Found Diesel Oil in Main burner’s natural gas inlet port.
Scuffing of kiln pinions and girth gear is under monitoring.
Wear of support rollers (station 3) increased when measured in the last
shutdown.
Temperature difference of kiln pinions tooth is within acceptable limits.
Spray pattern distribution of both systems is good.
Thermal crank measurements of Kiln shell show that the thermal crank
beside each tyre is within accepted limits.
2. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 2
2 Resume of Recommendations
Grind both right and left side support rollers at station no.3.
Required repair the kiln shovel next overhauling shutdown.
Required to change natural gas nozzle tip next overhauling shutdown.
3. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 3
3 Kiln Condition
3.1 Support Rollers Condition
Wear on kiln supporting rollers had measured by using filler and straight
edge during at April 2014
1 2 3 4 5 6 7 8 9 10
Station
no. I
Left roller 0 0.05 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.05
Right roller 0 0.05 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.05
Station
no. II
Left roller 0 0.05 0.1 0.1 0.05 0.05 0.05 0.05 0 0
Right roller 0 0.05 0.1 0.1 0.05 0.05 0.05 0.05 0 0
Station
no. III
Left roller 0.05 0.05 0.1 2.1 3.5 3 2.5 2 0.1 0.05
Right roller 0.05 0.05 2 2 3 2 2 2 0.1 0.05
Dim. in mm
Above measurements shows high wear at kiln support rollers of station III.
4. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 4
3.2 Migration
The kiln supports are designed so that there will be a minimum diameter
difference between hot kiln tube and live-ring, this difference causes the
relative motion which is called the kiln migration
So, we measured it in the 3 support stations and compared it with the
reading in the CCR and we found them closed to the CCR reading.
Kiln support station
Hand measured migration
(mm/rev.)
CCR migration
(mm/rev.)
Station 1 8.2 10.3
Station 2 7.3 8.2
Station 3 11.3 11.3
Migration at stations no.2&3 was high so added 2mm shims at both
stations in order to maintain the migration at both stations within
acceptable ranges at April 2014.
5. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 5
3.3 Kiln Crank
The kiln shell may in itself be bent in the longitudinal direction.
If this bending extends over a section of the length that covers at least
one of the supports, the kiln is said to be cranked
In most cases, such cranks develop as a result of irregular thickness of the
coating causing uneven heating of the kiln shell in the burning zone of the
kiln. This type of crank, called a “thermal crank”, can be reduced by
changing the composition of the raw materials and/or the burning process
and by choosing the right type of lining.
Our main concern is not to have a temperature difference of kiln shell on
same area more than 100 degrees (especially on the tyres heavy sections)
Below measurements are showing the temperature difference beside each
tyre from inlet and outlet sides.
Tyre no.
Inlet side Outlet side
Temperature Difference Temperature Difference
I 39.9 56.8
II 28.6 22.3
III 6.8 9.1
Above measurements taken on 27 March 2015 shows that the thermal
crank beside each tyre within accepted limits.
6. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 6
3.4 Kiln Support Bearing Temperature
One of the important measurements is
measuring the temperature of the thrust collar
and supporting roller shaft in order to indicate
the condition and loads by means of T
7. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 7
3.5 Kiln Pinion Temperature
A scheduled routine measurement for kiln pinions temperature is done on
a weekly basis.
We use a hand pyrometer (Fluke 63) and readings are in degree
centigrade, in additional to thermograph images to detect any abnormal
loads.
Reading
date.
Right hand pinion Left hand pinion
1.2.2015 54 56 56.8 55.8 55 56.1 58.8 56.5 54.3 54.5
8.2.2015 60.1 61.2 60.7 60.1 59.7 62.2 63.6 63.4 62.1 62.1
23.2.2015 62.2 63.2 65.1 65.6 64.3 67.6 68.4 65.5 63.1 63.0
9.3.2015 52 52.6 52.8 51.6 51.2 50.4 51.2 51.4 51.4 51.2
8. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 8
Backlash and root clearance measurement was performed at April 2014
Left pinion,Measuringofbacklash and root clearance (mm)
Pos.No 1 2 3 4 5 6 7 8 9 10 11 12 Avg.
Backlash in 2.2 2 3 3.8 2.75
Backlash out 3 2 2.5 3.8 2.80
Root clear.in 3.2 2.1 5.8 7.4 4.60
Root clear.out 3 2.2 5.8 7.4 4.60
Right pinion,Measuringof backlash and root clearance (mm)
Pos.No 1 2 3 4 5 6 7 8 9 10 11 12
Backlash in 3.5 2.4 2.5 4 3.10
Backlash out 3.5 3 3 4 3.37
Root clear.in 4.9 4 4 5.9 4.70
Root clear.out 4.5 3.3 3.9 5.6 4.30
9. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 9
3.6 Girth Gear spray Pattern
The spray lubrication print was taken for system A and B, pattern for both
systems are OK.
10. Ramliya Cement Plant (Egypt)
Preventive Maintenance Department
Inspection Section
Page 10
3.7 Visual Inspection
We have checked main burner and found
Damaged in cooling air ring.
Damaged in natural gas nozzle tip ,found oil in natural gas channel
Damage in castables at 50 cm of Jacket
Also, during kiln stoppage
Changed Shell Bricks at in many places Meter 25, Meter 29 and Ring after
nose ring.
Found Damaged Castables on tip of one Z-Plate of Kiln inlet.
Damaged Kiln inlet shelf made contact with Castables of Z-Plate
Damaged Kiln Shovels need repair next Kiln Shutdown.
