Hot Alignment 2009

I- INTRODUCTION
I-1 ASEC Kiln Alignment System Overview
Kiln shell is physically carried by tyres, which are mechanically supported by

the rollers mounted on kiln stations. As the kiln is in operation, the shell
condition varies from day to day operation and accordingly its center of
rotation varies.
ASEC system measures rotary kilns quickly, precisely and without

interrupting the operation, thus avoiding the associated cost of kiln shutdown.
ASEC alignment system determines and establishes the true center of the
mechanical elements that rotates the kiln shell, allowing the shell to straighten
its center of rotation accordingly during normal hot operation condition.
ASEC alignment system is an extension of cold alignment techniques, as it

preserves the mechanical condition of the kiln driving system. As a result, the
necessary adjustment can be made to keep the locus of the centers of rotation
in a straight line. Having the mechanical rotating elements aligned
geometrically, the kiln shell center of rotation will lay on the correct and
actual tyres center line, allowing long period of good operation before the
occurrence of any changes for tyre/shell gap or tyre/roller diameters due to
uneven wear.
ASEC kiln alignment method depends on a new technology to determine the

true centers of each supporting station, which will establish the axis of
dynamics of rotation, achieving the correct geometric center of rotation.
The procedure is based on simple geometric calculations of the tyre centers
and tyre/shell gaps (Ovality & Creep) taking into consideration the actual
tyre/rollers diameters and kiln roller bases actual levels, regardless of the
changes caused by foundation settlements.
Ovality is a measurement showing a kiln ability to support refractory. Rotary
kiln refractory brick linings depend on the principle of the continuous arch to
Page No.1
stay in place. Naturally, any forces on that arch, such as flexing kiln shell, will
act to deteriorate the mechanical stability of that arch.
The girth gear/pinion meshing, the tooth bottom clearance and backlash of the
kiln drive system is also taken into account in the calculation. Girth
gear/pinion correct meshing is an important result of the procedure.
Obtaining the shell profile is extremely useful when considering the

installation of a new shell section. The shell profile can pin point the most
serious shell deformation and help to determine shell cut points. Identifying of
the shell is important when assessing shell repair or section replacement costs.
Periodic profile analysis allows management to spot any trends of
deterioration
.
I-2 Criteria pointing the necessity for kiln alignment system:
1. Bearings over-heating.
2. Cracks in the kiln shell.
3. Refractory lining problems.
4. Tyres lifting off the supporting rollers.
5. Abnormal operation of the thrust roller system
6. Foundation settlements.
7. Increasing relative movement of floating tyres.
8. High or fluctuating drive motor current requirement.
9. Temporary or permanent knocking or vibrations in the kiln drive system.
10. Serious deformation of the kiln shell.
11. Big radial run out at the kiln inlet or outlet.
12. Uneven wear of the supporting rollers and/or tyre surfaces.
13. After grinding of supporting roller and/or tyre surfaces.
14. Before and after repairs (replacement of tyre bearing shell section,
turning around the girth gear etc.
15. As an important part of the preventive maintenance program.
Page No.2
II- ASEC
PERSONNEL
II-ASEC Personnel
ASEC has provided a qualified well-trained team as per the contract with enough
experience in similar jobs, they are:
Mr. Hassib Aly Specialized Maintenance manager
Mr. Mohammed Abdel-Moneim Measurements Section Head
Mr. Mahmoud Fawzy Surveying Engineer
Mr. Helal Mohmed Ahmed Technician
Mr. Alaa Foaad Saleh Technician
Page No.1
III- EQUIPMENT
DESCRIPTION
Circumference Measuring Device (C.M.D.)
The CMD is an electronic device manufactured and developed by ASEC.
It is used to measure the

diameter of rollers and tyres
of the rotary kilns while in
rotation..
The device consists of a

known diameter wheel (150
mm ) to be in contact with
the roller or the tyre while in
rotation.
Circumference Measuring Device (C.M.D.)

The electronic circuits
calculate precisely the number of rotations of that wheel during one exact revolution
of the tyre or roller.
The ratio between the number of rotations of the wheel and the roller or tyre is the
same ratio of diameters, and hence the diameter of a roller or tyre is calculated.
Total Station
The total station, which

ASEC uses, is Trimble
5601 DR type, and is
manufactured in U. S. A.
This type has a very high

accuracy LASER device
less than 1 mm in distance
measurement, and less
than 1 second in angle
Page No.1
measurement for 100 meters
distance
The total station is used to

measure the coordinates in three
dimensions of the supporting
rollers center of rotation while
the kiln is in rotation, and hence
calculating the kiln center of
rotation at the supporting points,
which is the basis of the kiln hot
alignment.
The total station Trimble 5601 DR
Kiln Shell Measuring Device
This device is specially

developed to measure the
kiln shell surface profile as
well as the temperature
profile at the same time;
the device has mainly two
main parts: DISTO and
Temperature Pyrometer
The ASEC Shell Measuring Device

Page No.2
The DISTO is a LASER device used to measure the distances, while the Pyrometer
is an infrared device used to measure the temperature
The shell profile measurement gives a comprehensive idea about the kiln axis of
rotation between the supporting points of the kiln as well as the permanent
deformation of the kiln shell along the whole kiln length.
Grinding Machines
ASEC developed and fabricated special grinding machines which are designed for
the rollers grinding
With a special attachment the same machine can be easily adapted for the grinding
of kiln tyres as shown in the photos below
The machines can adapt any kiln condition according to the International Standards
and can also fit any size of kilns rollers and tyres
The grinding machine mounted The grinding machine mounted

on the kiln roller on the kiln tyre
Page No.3
ASEC developed and fabricated
another grinding machine used for
grinding all types of the tyres thrust
faces, also it can withstand the
movement of the kiln uphill and
downhill during the grinding
process as shown in the photo
below.
Grinding Wheels
For grinding of tyres and rollers ASEC uses specially developed grinding wheels
They are specially designed to be
used for kiln tyres and rollers.
The advantage of these wheels is
that they dont need any coolant
as the air entering through the
slots of the wheel blades naturally
cools them.
Other types of grinding

wheels, which ASEC uses,
is shown below where they
suit highly deformed tyres
and rollers surfaces as these types are much faster

while the first type has higher surface finish.
Page No.4
IV- KILN
Measurements
Kiln No. 1
Station I (inlet) Left Roller

Date 27/04/2009
Surface Measured
Average Temperature: 50
0
C
A B C D E
Distance From Inlet 100 300 450 600 750
Measured Diameter 1599.61 1598.34 1597.88 1599.82 1600.17
Measured Temperature 41 50 55 51 53
Deviation From Nominal 0.39 1.66 2.12 0.18 -0.17
Maximum Diameter Deviation 2.29
Surface Thickness 124.805 124.17 123.94 124.91 125.085
% Of Nominal thickness 99.84% 99.34% 99.15% 99.93% 100.07%
Surface Profile Before Grinding
1600.50
1599.00
1597.50
1596.00
100 300 450 600 750
Grinding Plan
Expected Diameter After Grinding. 1597.88
Maximum Guranteed Diameter Deviation 1
Surface Thickness 123.94
% Of Nominal thickness 99.15%
% Of Thickness Removed 0.51%
Page No. 1
Kiln No. 1
Station I (inlet) right Roller

Date 27/04/2009
Surface Measured
Average Temperature: 50
0
C
A B C D E
Deviation From Nominal 1.03 0.74 0.38 0.62 0.57
1600.50
1599.00
1597.50
100 300 450 600 800
Grinding Plan
Page No. 2
Kiln No. 1
Station I (inlet) Tyre

Date 27/04/2009
Surface Measured Average

Temperature: 84 0C
A B C D E
Deviation From Nominal -5.28 -4.59 -4.38 -3.58 -3.19
5768.00
5767.00
5766.00
5765.00
5764.00
100 260 420 550 700
Grinding Plan
** Measured diameters are bigger than design diameters
Page No. 3
Kiln No. 1
Station II Left Roller

Date 27/04/2009

Temperature: 42 0C
A B C D E
2253.31
1802.65
100 400 550 700 950
Grinding Plan
** Measured diameters are bigger than design diameter due to thermal expansion
Page No. 4
Kiln No. 1
Station II right Roller

Date 27/04/2009
Surface Measured
Average Temperature:
52 0C
A B C D E
Deviation From Nominal 0.84 -0.02 -1.14 -0.38 0.69
2002.00
2001.00
2000.00
1999.00
1998.00
150 400 550 700 1000
Grinding Plan
Maximum Guranteed Diameter Deviatio 1
Page No. 5
Kiln No. 1
Station II Tyre
Date 27/04/2009

Temperature: 117 0C
A B C D E
5880.00
5879.00
5878.00
100 300 500 700 900
Grinding Plan
** Measured diameters are bigger than design diameters
Page No. 6
Kiln No. 1
Station III (outlet) Leftt Roller

Date 27/04/2009
Surface Measured
76 0C
A B C D E
1601.00
1600.00
100 300 450 600 750
Grinding Plan
Page No. 7
Kiln No. 1
Station III (outlet) right Roller

Date 27/04/2009
Surface Measured
73 0C
A B C D E
1602.00
1601.00
1600.00
150 300 450 600 800
Grinding Plan
**Measured Diameters are bigger than nominal diameters due to the thermal expansion
Page No. 8
Kiln No. 1
Station I (outlet) Tyre

Date 03/06/2007
Surface Measured
140 0C
A B C D E
5778.02
5765.90
100 300 425 550 750
Grinding Plan
Measured diameters are bigger than design diameters
Page No. 9
Kiln Tyres Migration Measurements
Material Flow
T1 T3
Date 27/04/2009
T2
Tyre I (Inlet) Tyre II Tyre III (Outlet)

TEMP T1 T2 T3 T1 T2 T3 T1 T2 T3
160 83 146 197 109 205 291 168 304
Average
25.7 27.3 36.8
Migrationp(mm)
Average Hot gap(mm) 12.3 13.2 11.8
Tyre II (Inlet)
M1 M2 M3
H1 H2 H3
25.5 25.5 26
H1 H2 H3
M1 M2 M3 12.5 12 12.5
Tyre II
H3 M1 M2 M3
H1 H2
27.5 27.5 27
H1 H2 H3
M1 M2 M3 13 13 13.5
Tyre III (Outlet)

M1 M2
H1 H2
36.5 37
H1 H2
12 11.5
M1 M2
Page No. 10
V- PROCEDURE
&
JOB HITORY
Job History
Referring to the requisition from ASEC Misr Qena technical management project to
perform the tracking job of foundation settlement and hot alignment job, ASEC
specialized maintenance department was in site at 13th Apr. 2009 to make a
reconnaissance job. And found that the Bench Mark which the tracking job is
performed related to it was established on the foundation base indicating doubtable
results of tracking job.
ASEC specialized maintenance department team was in site at 25th Apr. 2009
morning to check up the Bench Mark level, and to take the kiln measurements, and
found that the level of the Bench Mark is raised up by 4mm indicating false tracking
job. So, we established new Bench Mark in suitable place near to the kiln area. And
its level was chained from known level construction point.
The kiln axis measurements were taken as well, and the relevant report was
submitted.
ASEC specialized maintenance team will supervise the correction of kiln axis of
rotation, and the adjustment of the kiln movement according to submitted report.
Page No. 1
VI- KILN SHELL
PROFILE
-Introduction
The objective of the kiln shell profile measurement is to stand on the condition of the kiln shell
and to determine the permanent deformation in the shell as well as the deviation in the kiln axis
of rotation from the geometrical kiln axis, and hence to know the defected parts of the shell
that are required to be replaced to guarantee the normal and efficient operation of the kiln. The
measurements were taken using the LASER DISTO instrument each 2 meters along the kiln
length and were carefully analyzed.
One of the most dangerous phenomena happening in the kilns is the "CRANK" which can be
detected by the analysis of the DISTO readings.
For a new kiln erected in the correct way, the cross-sectional axis and the axis of rotation of
the kiln shell coincide. If this coincidence of the axes should later turn out to be established
forcibly by the supports, the kiln is said to have a crank. Cranks can get so big that the kiln
shell will lose contact with the supporting rollers during part of the rotation of the kiln.
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.
A mechanical crank is most often caused by partial superheating of the kiln shell, a so-
called hot spot. Arising due to loss of lining. Other causes of a mechanical crank are lack of
turning of the kiln during a shutdown (resulting in a permanent deformation of the kiln
shell) and welding together of misaligned kiln sections, for instance in case of
unprofessional repair.
A mechanical crank can be eliminated by cutting the kiln shell in two or more sections,
followed by suitable, mutual alignment and re-welding. This method necessitates a
shutdown of the kiln during the repair. Alternatively, a mechanical crank can under certain
circumstances be straightened by a heat method. This method allows the kiln to remain in
normal operation.
However, both methods require extensive preparations and great experience in order to be
accomplished successfully.
During operation of the kiln, the cross-sectional axis under the live rings is forced to
coincide with the axis of rotation. The existence of a kiln crank of considerable size will
show as a variation in the load on the individual support occurring periodically as the kiln
rotates.
Page No.1
Measurements Analysis
Section I From meter 0.20 To meter 7.65
The condition of the kiln shell in this part is good where most of all values of shell
deformation and kiln axis deviation is acceptable.
The maximum axis deviation is about 2.24 mm at the meter 0.2 of the kiln inlet while
the maximum shell run out is 8.9 mm at the same location.
Section II From meter 9.35 To 39.45
The condition of the kiln shell in this part is also good where most of all values of
shell deformation and kiln axis deviation is acceptable.
The maximum axis deviation is about 3.61 mm at meter 21.20 while the maximum
shell run out is 13.70 mm at meter 33.30.
Section III From meter 41.75 To 68.15
The maximum axis deviation is about 13.60 mm at meter 66.65 of the kiln while the
maximum shell run out is 35.30 mm at the same location.
Page No. 2
Section IV From meter 70.25 To 73.60
The maximum axis deviation is about 1.41 mm at the meter 70.25, 70.60, and 73.60
of the kiln while the maximum shell run out is 6.20 mm at meter 71.60.
Summary
All the kiln shell sections are in good condition.
Page No. 3
QENA CEMENT COMPANY
KILN NUMBER I
Shell Surface Deformation
Date 27/04/2009
0-10 10-20 20-30 30-40
I-1
I-2
I-3
I-4
I-5
I-6
10
11
12
13
II-
14
II-
15
II-
16
II-
17
II-
18
II-
II-
19
II-
20
II-
-1
-2
-3
-4
-5
-6
-7
-8
-9
3
II-
4
II-
5
II-
6
II-
7
II-
-1
II-
-2
-3
II-
-4
III
II-
III
III
II-
-1
III
II-
-1
III
II-
-1
III
-1
III
-1
III
-1
III
-1
-1
IV
IV
IV
IV
III
III
III
III
III
III
III
III
KILN AXIS DEVIATION
15.00
10.00
5.00
0.00
I-1 I-2 I-3 I-4 I-5 I-6 II-1 II-2 II-3 II-4 II-5 II-6 II-7 II-8 II-9 II-10 II-11 II-12 II-13 II-14 II-15 II-16 II-17 II-18 II-19 II-20 III-1 III-2 III-3 III-4 III-5 III-6 III-7 III-8 III-9 III-10 III-11 III-12 III-13 III-14 III-15 III-16 III-17 IV-1 IV-2 IV-3 IV-4
SHELL DEFORMATION CURVE
32 4.900 m
24
16
3
8
0
I-1
I-2
I-3
I-4
I-5
I-6
II-1
II-2
II-3
II-4
II-5
II-6
II-7
II-8
II-9
II-10
II-11
II-12
II-13
II-14
II-15
II-16
II-17
II-18
II-19
II-20
III-1
III-2
III-3
III-4
III-5
III-6
III-7
III-8
III-9
III-10
III-11
III-12
III-13
III-14
III-15
III-16
III-17
IV-1
IV-2
IV-3
IV-4
STATION I STATION II STATION III
10.500m 5.500m 26.200 m 26.000 m 5.800 m
Page No. 4
Shell profile
Date 27/04/2008 QENA No. 1 Time 11:00 am
mm
Inlet
26
24
22
20
Outlet 18
16
14
12
15 10
8
10 6
4
5 2
0
0 -2
10 20 30 40 50 60 70
Page No.5
QENA TEMPERATURE MEASUREMENTS
NATIONAL KILN IV
Date: 27/04/2009
ANGLE OF MAX. TEMPERATURE CURVE
350
320
290
260
230
200
170
I-
I-
I-
I-
I-
I-
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
IV
IV
IV
IV
140
1
-1
-2
-3
-4
-5
-6
-7
-8
-9
-1
-1
-1
-1
-1
-1
-1
-1
-1
-1
-2
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
I-
-1
-2
-3
-4
1
10
11
12
13
14
15
16
17
0
0
110
80
50
20
-10
MAXIMUM TEMPERATURE CURVE
500
400
300
3 4.900 m
200
M
100
0
I-1
I-2
I-3
I-4
I-5
I-6
II-1
II-2
II-3
II-4
II-5
II-6
II-7
II-8
II-9
II-10
II-11
II-12
II-13
II-14
II-15
II-16
II-17
II-18
II-19
II-20
III-1
III-2
III-3
III-4
III-5
III-6
III-7
III-8
III-9
III-10
III-11
III-12
III-13
III-14
III-15
III-16
III-17
IV-1
IV-2
IV-3
IV-4
10.500 m 5.500 m 26.200 m 26.000 m 5.800 m
Page No. 6
Temperature profile
Date 27/04/2008 QENA Kiln No. 1 Time 11:00 am
C
Inlet 400
380
360
340
320
300
280
Outlet 260
240
15 220
200
180
10 160
140
120
100
5 80
60
40
0 20
10 20 30 40 50 60 70
Page No. 7
Section I-1 mt: 0.20
Shell Profile Temperature Profile
Page No. 8
Section I-2 mt: 2.0
Page No. 9
Section I-3 mt: 4.0
Page No. 10
Page No. 11
Page No. 12
Page No. 13
Section II-1 mt: 9.35
Page No. 14
Page No. 15
Page No. 16
Page No. 17
Page No. 18
Page No. 19
Page No. 20
Page No. 21
Page No. 22
Page No. 23
Page No. 24
Page No. 25
Page No. 26
Page No. 27
Page No. 28
Page No. 29
Page No. 30
Page No. 31
Page No. 32
Page No. 33
Section III-1 mt: 41.75
Page No. 34
Page No. 35
Page No. 36
Page No. 37
Page No. 38
Page No. 39
Page No. 40
Page No. 41
Page No. 42
Page No. 43
Page No. 44
Page No. 45
Page No. 46
Page No. 47
Page No. 48
Page No. 49
Page No. 50
Section IV-1 mt: 70.25
Page No. 51
Page No. 52
Page No. 53
Page No. 54
VII- KILN HOT
ALIGNMENT
Rollers and Tyres Diameters Measurements
Station I (Inlet)
Diameter measured in 3 points for tyre &
rollers
INLET
C B A
Tyre
Left Roller Right Roller

Page No. 1
C B A A B C
C B A
A 1.60017 mt A 1.59897 mt
B 1.59788 mt A 5.76728 mt B 1.59962 mt
C 1.59961 mt B 5.76638 mt C 1.59943 mt
Average 1.59922 mt C 5.76519 mt Average 1.59934 mt
Average 5.766283 mt
Station II
rollers
INLET
C B A
Tyre

Page No. 2
C B A A B C
C B A
A 2.00074 mt A 1.99916 mt
B 2.00094 mt A 5.87948 mt B 2.00114 mt
C 2.00071 mt B 5.87904 mt C 1.99931 mt
Average 5.87937 mt
Station III( Outlet)

rollers
INLET
C B A
Tyre

Page No. 3
A B C
C B A
C B A
A 1.60053 mt A 1.60092 mt
B 1.60044 mt A 5.76832 mt B 1.60133 mt
C 1.60047 mt B 5.76788 mt C 1.60154 mt
Average 5.76821 mt
Theoretical Kiln Axis According to Rollers & Tyres Diameters
At= (Dt + dt )/4

A= racine (Dr/2+dr/2)-(Ht)
Station I AV = AT - A Station II Station III
Roller diameter 2.000 mm
Roller diameter 1.600 mm Left Roller diameter 2.001 mm Left Roller diameter 1.600 mm Left
Roller diameter 1.599 mm Roller diameter 1.600 mm
INLET OUTLET
Roller diameter 1.600 mt Roller diameter 2.000 mm Roller diameter 1.600 mm

Page No. 4
Roller diameter 1.599 mt Right Roller diameter 2.000 mm Right Roller diameter 1.601 mm Right
Tyre diameter 5.762 mt Tyre diameter 5.872 mm Tyre diameter 5.761 mm
Tyre diameter 5.766 mt Tyre diameter 5.879 mm Tyre diameter 5.768 mm
Theoretical values from the original drawing

Measured Values of rollers and Tyres after grindin
Rollers inclination
110.5207 110.4024 109.0609 108.9096 108.2399 108.1124
4.0% 4.0% 3.9%

Levels
INLET OUTLET Slope
110.519 110.4022 109.0642 108.914 108.2366 108.1097
4.0% 4.0% 3.9%

Base plate inclination
Page No. 5
Shims thickness under rollers(mm)

Conclusion
Station I Station II Station III It is not recommended to insert shims < 3 mm
Left Right Left Right Left Right All rolers slopes are acceptable
Bearing No. Inlet Outlet Inlet outlet Inlet outlet Inlet outlet Inlet outlet Inlet outlet
Shims to adjust slope 0.0 0.6 0.2 0.0 0.0 0.8 0.0 0.1 1.3 0.0 1.6 0.0
Actual kiln dimensions before adjustment
Distance measured by the total station

Left
31.829 26.117
INLET 1.844 mt 1.844 mt 2.008 mt 2.008 mt 1.879 mt 1.879 mt

Page No. 6
OUTLET
Actual horizontal
axis 1.844 mt 1.844 mt 2.007 mt 2.007 mt 1.880 mt 1.880 mt
Right
Kiln horizontal axis deviation before adjustment

Left
INLET OUTLET
OUTLET
3.30 mm
Right
Page No. 7
Kiln vertical axis deviation before adjustment
0.5 mm
INLET OUTLET
11.1
mm
Rollers movements to correct the kiln centre of rotation
2.5 mm 2.5 mm 18.5 mm 18.5 mm
INLET OUTLET
4.0 mm 4.0 mm 18.5 mm 18.5 mm

Page No. 8
Left Left
1.844 1.844 mt 2.009 2.009 mt 1.898 1.898 mt
1.844 1.844 mt 2.008 2.008 mt 1.899 1.899 mt
Right
Right
VERTIX ANGLES
STATION I ( INLET ) STATION II STATION III ( OUTLET )
30.05 30.06 30.64 30.63 30.67 30.68

30.05 30.06 30.65 30.64 31.01 31.01
Page No. 9
1844.4 1844.6 2008.1 2007.2 1879.3 1880.1

1844.4 1844.6 2008.7 2007.8 1897.8 1898.6
Burner Slope
measuring points
Page No. 10
Level diff. between two sections centers 0.089

Horizontal distance between two sections centers 2.915
Axis slope of the burner 3.05%

VIII-
FOUNDATION
SETTLEMENT
Kiln Piers
Pre -
Cooler
heater
No. 1 2 3 4 5 6 7 8 9 10 11 12
Date Level(mm) Level(mm) Level(mm) Level(mm) Level(mm) Level(mm) Level(mm) Level(mm) Level(mm) Level(mm) Level(mm) Level(mm)
03/04/2002 131024.7 131038.6 131033.0 131020.8 131044.9 131006.9 131008.0 131046.1 131003.4 131001.2 131001.4 131004.0
28/04/2002 131025.4 131039.6 131034.1 131021.8 131045.9 131007.2 131008.3 131047.0 131003.8 131000.0 131000.6 131004.2
29/05/2002 131026.2 131040.4 131035.1 131022.9 131046.7 131006.9 131008.5 131047.7 131003.8 131000.4 131000.9 131004.3
09/07/2002 131026.4 131041.3 131035.5 131022.8 131048.6 131006.6 131007.8 131049.4 131003.8 131000.0 131000.6 131004.3
29/07/2002 131026.9 131040.9 131035.5 131023.2 131048.6 131006.0 131006.7 131049.4 131003.3 130999.1 130999.7 131003.8
28/08/2002 131027.4 131041.6 131036.3 131022.5 131049.2 131006.1 131007.2 131050.2 131002.9 130999.5 131000.1 131003.4
29/09/2002 131028.6 131041.7 131023.6 131049.7 131006.0 131007.0 131050.9 131002.8 130998.6 130999.6 131003.2
30/10/2002 131028.8 131043.5 131023.6 131051.0 131006.2 131007.6 131052.2 131003.6 131001.1 131001.5 131003.6
27/11/2002 131029.7 131043.8 131037.6 131023.7 131051.6 131005.2 131006.6 131052.7 131002.6 130998.2 130999.1 131002.8
29/12/2002 131030.8 131045.1 131038.6 131024.4 131051.8 131005.3 131006.8 131052.6 131002.7 130998.8 130999.5 131003.2
26/02/2003 131032.2 131046.0 131039.3 131025.0 131052.6 131005.2 131006.8 131053.4 131003.0 130998.5 130999.5 131003.2
30/03/2003 131032.3 131046.9 131040.4 131025.8 131053.9 131005.1 131006.7 131054.4 131003.0 130999.7 131000.1 131004.0
29/04/2003 131032.3 131046.7 131040.0 131026.5 131054.1 131004.9 131006.6 131054.5 131003.4 130998.4 130999.3 131003.9
28/05/2003 131033.1 131046.7 131040.0 131026.8 131053.9 131004.9 131006.6 131054.5 131002.7 130998.5 130999.8 131003.5
06/07/2003 131033.1 131047.3 131040.6 131028.1 131053.9 131004.6 131006.3 131054.7 131003.0 130998.2 130999.4 131003.7
05/08/2003 131033.1 131047.0 131041.0 131027.2 131054.9 131004.8 131006.3 131055.4 131003.4 130998.8 130999.9 131004.1
15/10/2003 131033.1 131047.7 131040.8 131053.8 131004.0 131006.0 131054.5 131000.7 130997.3 130998.2 130998.2 131001.8
18/11/2003 131033.3 131048.1 131041.1 131027.2 131053.8 131003.9 131005.9 131054.5 131001.4 130997.3 130998.3 131001.9
16/12/2003 131033.4 131048.7 131041.8 131041.8 131053.8 131004.0 131006.0 131054.6 131000.9 130997.5 130998.7 131001.3
16/05/2004 131035.5 131049.7 131042.6 131029.0 131055.5 131004.1 131006.1 131056.4 131000.9 130997.4 130998.6 131001.7
13/10/2004 131035.0 131049.8 131042.6 131028.2 131055.5 131003.7 131005.1 131056.4 131000.0 130997.1 130998.4 131000.7
09/12/2004 131035.6 131050.5 131043.0 131028.6 131055.6 131003.6 131005.3 131056.7 130999.8 130996.8 130998.2 131000.4
28/03/2005 131036.4 131051.5 131043.9 131029.6 131055.6 131003.6 131005.3 131056.7 131000.6 130997.4 130998.8 131001.2
24/05/2005 131036.5 131051.0 131044.1 131030.8 131055.6 131003.5 131005.3 131056.7 131000.1 130996.5 130997.9 131001.1
30/07/2006 131034.8 131050.0 131043.5 131028.7 131055.2 131002.7 131003.7 131055.6 130999.8 130997.5 130998.6 131000.9
29/04/2009 131036.1 131049.2 131041.5 131028.8 ---------- 130997.5 130998.9 131052.0 130997.5 ---------- ---------- 130998.4
Page No. 1
Reference Points and Bench Marks
In order to perform the tracking job of foundations settlement we found that the used
Bench Mark was placed on the foundation base. Then we checked its level referring to
other known Bench Mark. We found that the old Bench Mark level is raised up by
4mm indicting false tracking job. So, we established new Bench Mark in suitable
place.
The local coordinates of the new Bench Mark which is defined by ASEC in a nearest
position to kiln no # 1 are (E: 142.1456, N: 231.5136)
This point has a level of 130.364 m above the Mean Sea Level.
In the future the study of the foundations settlement will be carried
out by referring the marks on the kiln no # 1 concrete foundations to
the new bench mark.
Old Bench Mark
New Bench Mark

Page No. 2
Levels Variation refered to old Bench Mark
Cooler Pre - heater

Page No. 3
1 2 3 4 5 6 7 8 9 10 11 12
30/07/2006 131034.8 131050 131043.5 131028.7 131055.2 131002.7 131003.7 131055.6 130999.8 130997.5 130998.6 131000.9
29/04/2009 131036.1 131049.2 131041.5 131028.8 ---------- 130997.5 130998.9 131052 130997.5 ---------- ---------- 130998.4
Rise Settlement Rise Settlement Settlement

Variation
1.3 0.8 2 0.1 5.2 4.8 3.6 2.3 2.5
(mm)
Outlet Station Middle Station Inlet Station
0.7 mm 4.5 mm 2.4 mm
Settlement Settlement Settlement
Levels Variation refered to new Bench Mark
Cooler Pre - heater

Page No. 4
B.M. 1 2 3 4 5 6 7 8 9 10 11 12
30/07/2006 130126 131034.8 131050 131043.5 131028.7 131055.2 131002.7 131003.7 131055.6 130999.8 130997.5 130998.6 131000.9
29/04/2009 130130 131040.1 131053.2 131045.5 131032.8 ---------- 131001.5 131002.9 131056 131001.5 ---------- ---------- 131002.4
Rise Rise Rise Rise Rise Settlement Rise Rise Rise

Variation
4 5.3 3.2 2 4.1 1.2 0.8 0.4 1.7 1.5
(mm)
IX-
RECOMMENDATIONS
Recommendations:
1. Repeat the foundation settlement measurements periodically at leats each

two months.
2. Perform the Hot alignment corrections as soon as possible.
3. Grind all inlet station surfaces ( two rollers, one tyre, thrust face,and thrust
roller ).
4. Insert 3mm shims under outlet tyre .
Page No. 1

Hot Alignment 2009

Uploaded by

Copyright:

Available Formats

Hot Alignment 2009

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hot Alignment 2009

Uploaded by

Copyright:

Available Formats

I- INTRODUCTION

I-1 ASEC Kiln Alignment System Overview

Kiln shell is physically carried by tyres, which are mechanically supported by

ASEC system measures rotary kilns quickly, precisely and without

ASEC alignment system is an extension of cold alignment techniques, as it

ASEC kiln alignment method depends on a new technology to determine the

Obtaining the shell profile is extremely useful when considering the

The CMD is an electronic device manufactured and developed by ASEC.

It is used to measure the

The device consists of a

Circumference Measuring Device (C.M.D.)

The total station, which

This type has a very high

The total station is used to

The total station Trimble 5601 DR

Kiln Shell Measuring Device

This device is specially

The ASEC Shell Measuring Device

The grinding machine mounted The grinding machine mounted

Other types of grinding

and rollers surfaces as these types are much faster

Station I (inlet) Left Roller

Surface Profile Before Grinding

Station I (inlet) right Roller

Surface Profile Before Grinding

Station I (inlet) Tyre

Surface Measured Average

Surface Profile Before Grinding

** Measured diameters are bigger than design diameters

Station II Left Roller

Surface Measured Average

Surface Profile Before Grinding

Station II right Roller

Surface Profile Before Grinding

Surface Measured Average

Surface Profile Before Grinding

** Measured diameters are bigger than design diameters

Station III (outlet) Leftt Roller

Surface Profile Before Grinding

Station III (outlet) right Roller

Surface Profile Before Grinding

Station I (outlet) Tyre

Surface Profile Before Grinding

Tyre I (Inlet) Tyre II Tyre III (Outlet)

Tyre III (Outlet)

Section I From meter 0.20 To meter 7.65

deformation and kiln axis deviation is acceptable.

the maximum shell run out is 8.9 mm at the same location.

Section II From meter 9.35 To 39.45

shell deformation and kiln axis deviation is acceptable.

shell run out is 13.70 mm at meter 33.30.

Section III From meter 41.75 To 68.15

deformation and kiln axis deviation is acceptable.

maximum shell run out is 35.30 mm at the same location.

deformation and kiln axis deviation is acceptable.

All the kiln shell sections are in good condition.

Shell Surface Deformation

SHELL DEFORMATION CURVE

ANGLE OF MAX. TEMPERATURE CURVE