It is impossible to create a complete check list that will cover all the various kiln systems. Even for two practically identical systems,i.e;PL1&PL2 kilns, there will be minor differences. Therefore each kiln system must have its own ,unique check list.
If a kiln check list exists it must, of course be followed up by kiln local operators but remember it is impossible in a written form to cover all eventualities and therefore a check list should include “ The use of your senses ״.In other words :
Look, Listen & Feel if there is anything that is not as it normally is on an inspection round .
Look out for unusually large amounts of dust in areas that are normally clear.
Is that belt drive loose?
Is that belt rubber skirt worn or unadjusted ?
Is that screen loose ?
Are there nuts or bolts loose or fallen out ?
Is that a hole due to steel wearing ? Check the floor around machinery.
Is there oil leaking from that machine ?
Listen to production noises from machinery and equipment. Get to know and recognize them and note when something does not sound as it did yesterday !
For example ;The grate cooler spillage chain conveyor, note the sound it makes when it is conveying too much dusty clinker during up-set kiln conditions.
Is the whine in the cyclone a sign of a large quantity of false air ?
Is there a compressor , motor or gearbox that is noisier than usual ?
Is there a screw conveyor , a fan ,drag chain or purging system that sounds different?
Feel motors, gearboxes and fan housings. Are there variations in the temperature or vibration levels ?
The following inspection descriptions are common for different kiln systems but for each system the individual machine specification / instruction must be consulted.
П : KILN STOP INSPECTION (OF A LONGER DURATION)
Inspection during kiln- shutdown has the advantage for the kiln operator (Burner) that he does not concentrate on production but the disadvantage that not all equipment can be tested ,for example the kiln main drive and main burner equipment .
Although it is most important that all machinery that it is possible to test is tested !
In particular the emergency electrical power generator .
Usually in the period up to a longer kiln stop ,a list of items requiring correction or repairing is prepared. The list could include items of equipment that require adjustment , calibration , rectification or replacement. Motors that need bearings changed ,belt conveyors that need replacing ,air slides that need textile replaced,etc..
It is imperative that this list is carried out in its entirety.
1: KILN MAIN BURNER
A) Burner Pipe
Check List: ▪ Is the refractory ( castable ) intact ?
▪ Is the oil lance fitted with the ignition nozzle ? Swirler element & orifice plate in position ?Check that they were not fitted wrongly or damaged during installation – they could have been over-tightened when screwed together or accidentally hit . during construction .
▪ Is the stand-by (replacement ) oil lance with production nozzle ready to be fitted if needs be ?
▪ Check that primary air exit-openings ;i.e.axial&radial,are in good condition ,clean undamaged & not worn . .
▪ Check the orifice plate diameter ; Ø ,if in doubt, check against drawings or previously taken measurements.
▪ check that the burner pipe is positioned in relation to the kiln cross section and outlet .
▪ Check the connections to primary air , crude oil analytical instruments & control
