CEMENT KILN MAINTENANCe
Online Learning Experience
Imagine an online classroom that takes you to learn at your own pace, allowing more choices with your learning opportunities. The Cement Institute is dedicated to providing the most dynamic and engaging programs available, as our enhanced online experience demonstrates an interactive and hands-on knowledge applicable directly to your plant.
Start Date: May 10, 2021
This Course is scheduled to be available on the following date(s):
A 4-week modular course is designed to give the course attendee a solid understanding of the kiln maintenance system.
An emphasis on the understanding of the kiln maintenance technology: Kiln alignment, measurement, and consequences of the kiln shell temperature – optimization of kiln run factor– evaluation of kiln behavior based on kiln operation and process diagnostic – Impact of the burnability and kiln reliability – Evaluate, analyze and develop kiln maintenance activities based on failure mode equipment analysis.
Recognizing the importance of life-cycle and kiln reliability and establishing the right maintenance program represents a key element to achieving an optimal kiln run factor and performance.
This course covers the cement plant’s different challenges, an assessment of the plant situation focusing on equipment availability, reliability, and maintenance cost. Understand the equipment design and its limitations. Optimize and standardize preventive maintenance techniques, improve the overall equipment efficiency, and reduce the possibility of equipment failure – review and implement the best maintenance practices to achieve sustainable and stable run time.
This course aims to impart knowledge of maintenance procedures and maintenance instruction and predictive maintenance and condition monitoring techniques. The training will include case studies with actual plant data to improve skills and experience through group works, technical measuring, and individual evaluation and conclusions based on the kiln run-through inspection. The course consists of theoretical training, lectures, exercises, case study, and work sections.
Kiln Maintenance Learning Outcomes
This course gives the participants a more in-depth knowledge of a cement kiln’s components to learn the proper preventive maintenance, addressing essential cost-efficiency issues by focusing on the root cause and failure mode equipment analysis. The course program has been designed to outcome-based knowledge and skill covering real value parameters associated with cement kiln maintenance activities, such as:
- Understand the equipment design and its limitations.
- Optimize and standardize preventive maintenance techniques, improving the overall equipment efficiency and reducing the possible equipment failure.
- Review and implementation of the best maintenance practices to achieve sustainable and stable run time with the equipment.
- Eagerness and capacity to learn among the participants.
Who is this course for?
This course is primarily geared to all kiln maintenance staff personnel focusing on the preventive maintenance area. Future managerial persons, whether from maintenance or production, may also benefit significantly by participating.
Those with little or no prior experience with kiln maintenance will learn to understand, interpret, and use the core concepts of equipment design and their limitations. Gain valuable skills that can be used immediately to analyze and implement preventive maintenance.
Individual responsibility is vital for reaching usable technical conclusions and presenting their results to obtain a course certificate.
Topic 1: A refresher of general plant safety overview
Topic 2: An emphasis on special Hazards During the Cement Production Phases
Topic 1: Preheater tower
Topic 2: Kiln Process Introduction
Topic 2: Kiln Maintenance Introduction – RCA & FMEA
Topic 1: Kiln Shell Specification
Topic 2: Kiln Shell Deformation
Topic 3: Measuring Kiln Shell Deformation
Topic 4: Kiln Shell Mechanical Consideration
Topic 5: Cutting & Replacement of Kiln Shell Section
Topic 1: Kiln Alignment (Kiln Axis)
Topic 2: Horizontal & Vertical Axis Deviation
Topic 3: Kiln Loads, Pressures, Stresses
Topic 4: Kiln Alignment
Topic 5: Preventive Maintenance
Topic 1: Kiln Bearing Types
Topic 2: Bearing Liners
Topic 3: Bearing Lubrication
Topic 1: Kiln Support Piers
Topic 2: Kiln Support Rollers
Topic 3: Kiln Axial Balance
Topic 4: Kiln Roller Adjustment
Topic 5: Kiln Roller Calculation
Topic 1: Tire Clearances & Tangential Tire
Topic 2: Ovality
Topic 3: Tire Mounting and Filler Bar Design
Topic 4: Correcting Ovality
Topic 1: The Gear and Pinion (Gear Basics)
Topic 2: Horizontal & Vertical Axis Deviation
Topic 3: Gear Installation and Alignment
Topic 4: Lubrication
Topic 5: Maintenance and Troubleshooting
Topic 1: Kiln Inlet Seal and Outlet Seal
Topic 2: Thrust Roller
Topic 3: Solutions to Problems in Kiln Mechanical Performance
Topic 4: Kiln Preventive Maintenance Checklist
A unique combination of theoretical and practical skills throughout this course will be learned, which will help you develop and execute the concepts and technical knowledge acquired in the daily maintenance activities. The following downloadable materials are part of the course to enhance and facilitate the participants’ learning experiences.
Participant manual: Include the key concepts, definitions, and activities presented in this course.
Work section book: Provide learning activities and hands-on practice – case study and exercises. Solutions are included after each training is completed. Certification is achieved by completing a satisfactory level of exercises, quizzes, and final exams for each module.
The course is conducted online, allowing students flexibility (within four weeks) to complete all modules. Students should expect to spend more than 10 hours per week and some additional time for private reading/study. A computer with Internet access (broadband recommended) and email will be required.