DEPARTMENT PROCESS IMPROVEMENT NO.

DOC REV 1

MAINTENANCE EFFICIENCY

REQUISITION 1 OF

REQUISITION
FOR
HOT KILN ALIGNMENT
& GIRTH GEAR INSPECTION

1 APPROVED 2018-05-15
0 ISSUED FOR APPROVAL SHF HD AWP 2018-04-13
REV DESCRIPTION PREPD CHKD APPRD DATE
 DEPARTMENT PROCESS IMPROVEMENT NO. DOC REV 1

MAINTENANCE EFFICIENCY

REQUISITION SHEET 2 OF 5

CONTENTS

Page No.

1. GENERAL..........................................................3

2. SCOPE OF SUPPLY..........................................3

3. EQUIPMENT SPECIFICATION....................5
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REQUISITION SHEET 3 OF 5

1. GENERAL
This requisition defines the requirements relating to hot kiln alignment and girth gear inspection
Baturaja I PT. SEMEN BATURAJA (PERSERO) TBK, INDONESIA.

2. SCOPE OF SUPPLY
2.1 This is the scope of work that must be fulfilled during hot kiln alignment:
a) KILN
 Basic inspection of working conditions.
 General mechanical inspection of drive mesh, bearings and shafts condition,
lubrication efficiency, inlet and outlet sealing, thrust unit, adjustment equipment,
covers and housing.
 Establishing the coordinate system.
 Determining the horizontal and vertical axis deviations.
b) PIERS
 Determining the rollers skews and axial movement.
 Measuring the rollers and tyres diameters.
 Determining the concave, convex or conical wear
 Measuring and calculating the rollers working angles.
 Determining the surface conditions of tyres and rollers
 Inspecting the rollers bed lubrication efficiency.
 Measuring the individual slope of rollers and tyres, including foundation frame
axial slope.
 Measuring the rollers’ shaft deflection in reference to the pier (indication of shell
crack formation)
 Measuring the tyres relative movement (tyre migrations).
 Measuring and calculating the tyres creep and under-tyre clearance.
 Measurement of tyres wobbling (run-out).
 Evaluating of thrust roller position in reference to the kiln axis
 Evaluating hydraulic trust device.

c) GEARS
 Girth and Pinion gears inspection.
 Inspection of tooth condition.
 6 points backlash measurement and root clearance.
 Lubrication efficiency.
 Individual slope measurement (girth gear and pinion).
 Girth gear wobbling measurement (axial and radial runout).
d) SHELL
 Measuring the shell deformation.
 Measuring and calculating shell run-out (circularity deviation) and eccentricity of
cross sections.
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REQUISITION SHEET 4 OF 5

 Measuring shell and roller bed temperatures.

 Design of the shell deformation map, shell polar diagrams and shell 3D animation
model.
 Analyse of measurements.

e) ENGINEERING
 Load on Bearing
 Bending stress in tyre
 Contact pressure between supporting roller and tyre
 Bending stress in kiln shell
 Tangential bending stress in kiln shell
 Kiln stiffness
 Preparing of the report.
 Presentation of report.

2.2 The contractor must be preparing recommendations for future preventive maintenance
actions, routines, necessary repairs and replacements.
2.3 Adjustment of rollers are supervised by the contractor
2.4 Control survey of final kiln axis position and rollers skewing after adjustment.

2.5 The contractor should monitor the operation of the rotary kiln after adjustment for 3 month
(maintenance period).
2.6 Personal Protective Equipment provided by the contractor.
2.7 The contractor must obey all company’s regulations.
2.8 Any risk in performing the work is the responsibility of the contractor.

3. KILN SPECIFICATION

II

II

Size: 72 X Φ 4.8m
Tyre (mm) Supporting Rollers
Tyre Liner
Inner Diameter Outer Diameter Width Diameter Width
1 4800 5880 1080 220 2000 700
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REQUISITION SHEET 5 OF 5

2 4800 5880 1080 220 2000 1000

3 4800 5880 1080 220 2000 1300