Cement plant tyre shell replacement 5600mm
Proud to share a major milestone of our team! We have recently executed a complex kiln shell replacement job on a cement kiln, demonstrating our expertise in handling critical maintenance under challenging conditions.
This project involved replacing four shell sections across three positions: one each under the tyres at P1 and P2 with full floating chairpads, and two in the burning zone totalling 5,600 mm in length. Prior assessments revealed significant issues, including kiln shell runout exceeding 100 mm, shell run-out up to 325+ mm in the burning zone, and tyre migration over 100 mm. Despite these distortions making shell matching a tough task, our meticulous approach ensured precise alignment and installation.
Key challenges and solutions:- Site Constraints: Limited space and damp soil near a water tank complicated crane positioning—we addressed this through targeted soil conditioning for stability.
- Tyre and Roller Issues: The tyre side face was worn by ~50 mm at a 45° angle, while the outlet end support roller showed a 160 mm edge offset and 10 mm steps on raceways. We installed new retainer blocks and performed precise alignments.
- Girth Gear: Radial runout of 51 mm and axial of 15 mm (30 mm module) required careful handling to maintain gear-pinion contact without disrupting operations.
- Additional Repairs: Full floating chairpads with parallel shimming (achieving 12 mm migration per revolution initially), tyre alignment to ±1 mm, support roller skew corrections during operation, and replacement of both thrust rollers with a 5 mm offset toward the down-turning side.
The entire removal, installation, and alignment were completed in just 10 days. Post-repair, the kiln was successfully lit up and is now operating smoothly, a testament to our team's precision and problem-solving skills.
Check out the attached photos capturing the process—from cutting the old shell and welding new shell to final installations. We're committed to delivering reliable solutions that keep your operations running at peak efficiency.
If you're in the cement industry or facing similar rotary equipment challenges, let's connect! What's the toughest maintenance project you've tackled? #CementIndustry #KilnMaintenance #EngineeringExcellence #RotaryKiln #IndustrialRepair
