Reconstruction of the first foundation of the rotary kiln incl. drive

Complete reconstruction of the key parts of the drive and I. The base of the rotary kiln during a single shutdown. PME assumed the role of technical partner of the project — from solution design to production of key parts to supervising assembly and measurement. The result is reliable furnace drive, meeting strict quality criteria and coping with extreme time pressure.

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Customer: Buzzi Unicem Cement Hranice and s.
Scope of delivery of PME: Complete engineering, production and repair of key parts, technical support during assembly, supervision and complete documentation.

Assignment and goal of the project

The customer asked PME for technical cooperation in the design and implementation of the reconstruction of the first foundation of the rotary kiln ø4,328x64m including the new gear of the rotary kiln drive. The goal was to restore critical parts of the furnace drive, ensure long-term reliability of operation, and handle the entire event in an extremely short downtime.

Key deliveries and technical solutions

As part of the project, PME ensured the design, production and coordination of the following major components:

• new cast toothed wreath; z = 144; m = 42 mm (divided into two halves, connected by a system of Superbolts),
• new pinion; z= 25; m = 42 mm
• new Pinion Shaft
• new SKF Bearings,
• new toothed wreath pens incl. pins,
• new support part I of the foundation of the rotary kiln of thickness 60 mm length 2,2m including downstream side 2,1m
• new lub under the toothed wreath, thickness 36 mm length 5,1m
• new installation of the support ring on the I foundation
• new thrust pulley, including axial pulley shaft
• new Thrust Roller Bearings
• repair of the original forging of the bearing ring

The delivery also included complete engineering, design solution design and production documentation.

Main challenges of the project

The project was extremely demanding mainly in terms of time and coordination:

• critical delivery date Tooth Wreath Casting,
• production of a new pinion shaft based on actual measured dimensions of the original part,
• the need for professional dismantling Bearing ring rotary kiln, its immediate transfer to the PME, blasting, measuring, final design of the correctly selected removal during machining on the carousel,
• parallel repase pinion units including the pivot coupling part of the main drive of the rotary kiln,
• complete production, machining, pressing of new parts and final assembly during a single 7-day shutdown.
• Installation of new parts in their original positions with the help of 3D Scanning and accurate measurement

Everything was carried out under maximum time pressure while maintaining strict quality requirements.

Technical support and coordination

The PME provided:

• Technical support for Placing components in precise position
• coordination between the assembly and measurement company
• Supervision of the assembly and checking the correctness of the installation of the supplied products
• advice on setting up the pinion unit — including the need 3D scan of the entire drive for precise geometric adjustment

Quality control and documentation

Part of the final handover was the complete documentation according to PME Control and Test Schedule, containing:

• Material attestations — proof of origin and quality
• Production and Measurement Protocols — records of the production process, checks of dimensions, tolerances and functional parameters of individual parts and assemblies
• NDT checks — (VT, PT, MT, UT) including evaluation of proof of results
• Acceptance of individual parts — interim and final acquisitions of key units
• Compliance with customer standards and requirements — confirmation that the implementation complies with applicable technical standards, internal PME standards and strict customer criteria.

Outturn

The contract was implemented in full and within the required downtime. PME assumed the role of technical partner, coordinator and supplier of key components. The project was successfully completed to the satisfaction of the customer.

Collaboration:
The project was carried out in cooperation with companies MONTAŽE TRENČÍN a.s. and IKN CZECH s.r.o.

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