Kiln Failure List Comments E

8.

Final comments

Practice shows that failure occurrence and consequences are still considerable in spite of rotary kiln experiences of 100 years. The failure collection presented in chapter 7 does cover many incidents which have ever happened on kiln.

The listed attributes of the exposed failures like features, consequences, causes, etc. substantiate actual experiences and are valid in general. It was our intention to give herewith hints to the interested plant personnel at how to cope with – or better – at how to prevent failures. By the occurrence of serious failures, detailed investigations are not only suggested ; they are a MUST.

Prevention of failures is better than cure. Therefore we earnestly suggest:

-

A failure Risk Survey (FRS) on existing installation

-

Quality assurance for new or replacement machinery

Adequate maintenance and operations practice naturally from the essential basis of any successful and trouble free kiln Operations Manager

To assist our group factories in the presented measures we understand as a chance of corporation and as our contribution to the mutual efforts of “cost leadership”.

2

LITERATURE [1]

Bipl. Ing. Walter H. Duda Cement Data Book, Chapter 19 Bauverlag GmbH

[2]

B. Saxer HMC/VA Analysis of Stresses and Strenght Figures of Kiln Tyres Presentation at IEEE-Meeting 1984 in Anaheim, California HMC-Report No. VA 84/ 5114/ E

[3]

B. Saxer HMC/VA Gleitalger von Drehofen Laufrollen, Analyierrung der Betriebssicherheit Sicherheit HMC- Report No. VA 85/ 5236/ D

[4]

B. Saxer HMC/VA Reliability Assessment of Geardrives HMC – Report No. VA 87 / 5341/ E

[5]

W. Burgi HMC/ VA Quality Assurance for Equipment and Machinery 28th Technical Meeting 1984 HMC-Report No. VA 84/ 5089/E W. Burgi HMC/ VA Experience with Quality Inspection 30th Technical Meeting 1984 Report, Session 26 D. Ritchie, AATS Quality Assurance for AATS Projects 28th Technical Meeting 1984 HMC-Report No. VA 84/ 5090/E N. Boller, Ciminas Quality Assurance for Equipment and Machinery, Ciminas Extension 28th Technical Meeting 1984 HMC-Report No. VA 84/ 5096/E

[6]

N.K. Andresen Mechanical Monitoring and Maintenance of Rotary Kilns and Cooler Zement -Kalk –Gip8/1986

[7]

Bob Chapman Mechanical Analysis of Rotary Kilns

3

[8]

Pit and Quarry, October 1986 Rock Products, October 1986 R. Haas Assessment of Mechanical Failures of Kiln HMC- Report No. VA 86 /5298/E

[9]

“Shellest” Kiln Deformation Test Device Instruction Manual HMC-Report No. VA 80/ 4698/ D/ E/ S

[10]

A. Pozun Detection and Correction of Wrapping in Rotary Kilns Zement –Kalk -Gips 12/ 1966

[11]

H. Erni, B. Saxer, F. Schneider HMC Deformation of Rotary Kilns and their Effect on Lining Life Zement –Kalk -Gips 5/ 1979

P. Hunter Continuous, Automatic Measurement of the Relative Movement of Riding Rings on Rotary Kilns 26th Technical Meeting 1980 HMC – Report No. VA 80/ 4776/ E

A. Huart Ciments d‘Obourg Device for Measure of the Tyre Creep and the Tyre Clearance HMC News No. 126 October 1974

[12]

R. Haas HMC /VA Kiln Drive Repair Repair, Measurement, Observations HMC –Report No. VA 86/ 5294/ E

[13]

U. Hess HMC /VA Weakpoint and Failure Management 30th Technical meeting 1987 Report, Session 28

[14]

P. Ellemann, P.W. Nielsen

4

[15]

New Method of Straightening Warped Rotary Kiln Zement – Kalk-Gip 9/1980 Auswechseln eines Ofenschusses in enier nordameerikanischennn Zementfabrik Zement -Kalk – Gips 8/1957 FL Smidth Large Rotary Kilns FLS – newsfront 1971 T. Sander, Dundee Cement Ersatz enies Ofenschusses in Dundee

[16]

H. Pisters, U. Spilhagen, M. Becke Experiences with a new System for Monitoring the Shell Temperatures Zement – Kalk – Gips 3/1984

[17]

Riding Ring Creep, an Important Factor in Kiln Operation HMC/ VA Pamphlet

[18]

P. Kunne, Alsen – Breitenburg Experience with a Kiln Tyre Conditioning Device in Lagerdorf 28th Technical Meeting 1984 HMC-Report No. VA 84 / 5052/ E

[19]

W. Bonn, B.Saxer HMC Shelltest Measurements on Large Rotary Kilns Zement –Kalk- Gips 7/1976

[20]

O. Domenichini, Cementeria di merone Anderung an eniem Ofenauslaufschuss HMC News No. 121, May 1979

[21]

B. Saxer, F. Schneider HMC/ VA Vigier Cement AG Reuchenette Ausmaurungsprobleme am Auslauf von Ofen 3 HMC – Report No. VA 86/ 5334/ D

[22]

F. Schneider, a. Obrist HMC/Va Features of Modern Clinker Coolers 28th Technical Meeting 1984 HMC – Report No. VA 84/ 5060/ E

5

[23]

E. Kotter, P. Bartha Untersuchungen zum Problem der Ofenmantel – Korrosion Refre Kollegium 1986

[24]

G. Bougard, Ciemts d’Obourg Correcting the Outside of a Riding ring at Kiln no. 9 in Obourg HMC News No. 78. October 1979

G. Sartori, SCC Roche Wiederinstandellung enies Ofenlaufringes und der beiden Tragrollen an eniem Ofen in Roche HMC New No. 98/ 1972

[25]

H. Buchmann Damage to Large Machine Parts and Possibilities of Reconditioning them Zement -Kalk- Gips 2/1983

A. Wildi Cementwerke Vigier Laugringeparatur am KHD – Warmetauscher Ofen in Reuchenette HMC News No. 186/ 1979

P.S. Munk, Dundee Cement Laufringreparaturen im werk Clarksville HMC News No. 11/ 1984 M.W. Balzli, Cimento Ipanema Schweissreparatur eines Laufringreisses im werk sorcaba, Brasilien HMC New No. 11/ 1984

[27]

D.M. Skeen, AATS Experience with Failures of Kiln Rollers in the Anglo Alpha Group HMC News No. 7/8/1984

[26]

Th. Ubelhart Experience with a Toothed Riding Ring at Orizaba 30th Technical Meeting 1987 Report Session 24

[28]

Mitsuo Nakagawa, Akira Asano, Mastake Fukushima, Akira Hashi, Hitachi Ltd.

6 Effect of Maintenance on Back-up Roll Life Iron and steel Engineer, August 1982 [29]

W. Burgi HMC/ VA Fracture of a kiln Roller Shaft HMC – Report No. VA 80/ 4703/ E

[30]

J.D. Hotchkiss, M.I. Plant Machining Kiln Roller Journals in Site Using a Portable Rotary Lathe Cement Technology May/ June/ 1972

[31]

B. Saxer HMC/ VA Dynamic Problems on Girth Gear Drives 30th Technical Meeting 1987 Report Session No. 22

R. Haas HMC/ VA Typical Gear Failures (Maintenance Course Paper) HMC – Report No. VA 84/ 83/ E

German Standard DIN 3979 Tooth Damages on Gears DK 621.833.05.004.64:001.4

[32]

R. Munk Planetary Coolers for Large Rotary Kilns Zement – Kalk – Gips 11/1975

W. Bonn, Th. Lang. HMC Burning Processes Zement –Kalk-Gips 3/1986

A. Schmid Shadenetwicklung und Reparatur am Drehofen 3 in Untervaz FENZA-POST 1/1984

[33]

U. Meyer Improvement of Planetary Cooler support at Apaxco 30th Technical Meeting 1987 Report, Session 25.