Maintenance

Preventive maintenance is indispensable to ensure continuous production operation. It requires regular, accurate and reliable inspections and surveys of rotary kilns and ball mills - the core of any plant.

VDZ has these maintenance services at its disposal and utilises its proven independent expertise to provide them to technical-scientific state-of-the-art standards. The range of services especially comprises inspections and surveys of rotary equipment e.g. kiln, vessel, incinerator, dryer and cooler, as well as various services covering ball mill mechanics (crack test, accompanying assembly supervision and commissioning of new installation or after repair).

We are working for all kinds of industries using rotary equipment (for example cement / lime / gypsum, chemical, fertilizer, wood, paper, food, sugar, and refinery).

Drawing on its proven independent expertise, VDZ provides various maintenance services. For each installation, we offer a specific service portfolio from which we can select individual modules according to clients’ needs. Alternatively, we also provide a fully customised service.

MAINTENANCE – WHY AND WHEN?

During the lifetime and operation of rotary kilns and ball mills several failures and damage arise, endangering stable, continuous production and therefore require preventive maintenance:

Mechanical failure of refractory lining
Failure of tyre fixtures, axial, radial run-out
Uneven or varying contact pattern between tyre and roller
Cracks or material ruptures on tyres, rollers, girth gear, pinion, kiln or mill shell, mill head
Mechanical problems on main drive
High power consumption on main drive
“Knocking“ on main drive, girth gear/pinion
Unusual vibration around the main drive or pier
Uneven wear on tyres and rollers
Non “floating“ of the rotary kiln
Problems with the hydraulic thrust system
Hot bearings
Tyre is lifting from roller during operation
Kiln shell deformation (“banana”-effect)
High shell eccentricity on kiln in- and outlet section
Hydrostatic problems on slide shoe mills

Further occasions:

Routine equipment check (every two years)
Before and after major repair shutdown

MEASUREMENT AND SURVEY OF ROTARY EQUIPMENT E.G. KILN, VESSEL, INCINERATOR, DRYER AND COOLER

For each installation, we offer a specific service portfolio from which we can select individual modules according to clients’ needs. Alternatively, we also provide a fully customised service. VDZ’s surveys include the following partial services:

Geometry of tyre / roller station
Ovality (shell-test)
Shell deformation profile
Thermal profile of kiln shell / infrared-profile (photo/video-documentation)
Axial and radial run-out of tyres
“Relative movement” of loosened tyres
Radial run-out of rollers
Axial deflection on support roller shaft, to identify kiln crank (“banana”-effect)
Axial and radial run-out of girth gears
Thermal profile of girth gear and pinion
Root to tip and backlash measurement girth gear / pinion
Slope of base on support roller station frame
Slope of base frame, pier to pier
Cold gap measurement of loosened tyres
Vibrations- and thermal measurement (motor, gearbox, bearings)
Measurement of shell thickness (up to 350 °C)
Wall thickness measurement of other components up to 200 mm
Hardness measurement of components according to HB, HRB, HRC,HSD, HV
Roughness measurement according to Ra, Rz, Rq, and Rt ,  e.g. on bearing shafts

FURTHER SERVICES FOR MECHANICAL ROTARY EQUIPMENT

With the data obtained from measurement and inspection, immediate action might be necessary to prevent damage. Here VDZ’s individual, dependable service is well-proven:

Visual inspection of entire machinery
Survey and assessment of machinery mechanics
Detailed analysis, measurement report and inspection data, incl. assessment and recommendation for stable and smooth production
Adjustment of the axis of rotation
Control and adjustment of roller “skewing”
Control and adjustment of kiln balance/floating
Control and adjustment of girth gear and pinion contact pattern
Mechanical refurbishment of girth gear and pinion tooth flanks
Inspection of girth gear and pinion lubrication, function, lubrication amount, spray pattern
Crack penetration test red/white
Accompanying assembly supervision
Accompanying commissioning of new installation or after repair
Fabrication approval of components such as rollers, tyres, kiln shell, girth gear and pinion according to OEM or customers’ specification
Technical preparation of customised service check lists
Education and training courses

MEASUREMENT OF BALL MILLS

VDZ provides for its customers a system which also comprises complete inspection and symptom-based individual measurements. Depending on customers’ requirements we provide various testing services:

Geometry of support station
Thermal profile of mill shell / infrared-profile (photo/video-documentation)
Radial and axial run-out of tyres
Radial run-out of rollers
Radial axial run-out of trunnion
Radial axial run-out of journal bearing
Radial and axial run-out of mill flange
Axial and radial run-out of girth gears
Thermal profile of girth gear and pinion
Root to tip and backlash measurement girth gear/pinion
Slope of base frame
Slope of base frame, pier to pier
Cold gap measurement of loosened tyres
Vibrations- and Thermal measurement (Motor, Gearbox, Bearings)
Measurement mill body/mill head thickness
Wall thickness measurement of other components up to 200 mm
Hardness measurement of components according to HB, HRB, HRC, HSD, HV
Roughness measurement according to Ra, Rz, Rq, und Rt , e.g. on bearing shafts

FURTHER SERVICES COVERING BALL MILL MECHANICS

After the analysis of ball mill survey results, it can be crucial to act immediately. VDZ supports its customers with its well proven know-how and individual services:

Visual inspection of entire machinery
Survey and assessment of machinery mechanics
Detailed analysis, measurement report and inspection data
Assessment and recommendation for stable and smooth production
Control and adjustment of girth gear and pinion contact pattern
Mechanical refurbishment of girth gear and pinion tooth flanks
Inspection of girth gear and pinion lubrication, function, lubrication amount, spray pattern
Crack penetration test red/white
Accompanying assembly supervision
Accompanying commissioning of new installation or after repair
Fabrication approval of components such as rollers, tyres, kiln shell, girth gear and pinion according to OEM or customers’ specification
Technical preparation of customised service check lists
Education and training courses
Schulungen, Training

Contact

Frank Henning

Phone:
+49-211-45 78-369

Fax:
+49-211-45 78-400

Service Offer

Overview of all VDZ services in maintenance, inspection and measurement