Installation of K1 burner pipe deflection measurement system that will inform operators when the pipe High 6-9 months Maintenance team misalignment exceeds acceptable limits Implementation of a laser-based automatic burner axis management system that can easily eliminate K1 Maintenance and Medium 6-9 months burner alignment errors due to parallax after routine production teams A maintenance activities as well as enhance repeatability Installation of grease cups or extended grease pipes on each K1 induced draft fan damper arm bearing so that bearings lubrication can be done safely during normal High 6 months Maintenance team operations as opposed to the current bi-annual practice. Update K1 warm-up and cooling procedures to clearly Kiln coach, reflect the relationships between time, K1 speed, fuel production shift High 2-4 weeks injection and induced draft fan speed for individual managers and kiln stages of start-up and shutdown activities. operators Air balance measurements across K1 feed system should be conducted at least once every three months so that the efficiency of the feed transports systems B can be regularly determined. Air balance measurement is used to determine the ratio between air input and output of process systems, thereby making the High 3 months Process team identification of leakages or restrictions within the system possible. ASH cement plant reports show that the most recent of such measurements was performed more than three years prior to the investigated incident. Replacement of K1 feed weigh-belts tracking rollers, Quality and head drums and tail drums. This will significantly High 2-4 weeks maintenance reduce belts misalignment. teams Improvement of raw material sampling accuracy and C frequency by replacing the current manual system with Quality and an automatic online system that provides real-time High 9-12 months maintenance opportunities for correcting errors in feed teams compositions.
A Installation of K1 burner pipe deflection measurement system that will inform operators when the pipe misalignment exceeds acceptable limits High 6-9 months Maintenance team Implementation of a laser-based automatic burner axis management system that can easily eliminate K1 burner alignment errors due to parallax after routine maintenance activities as well as enhance repeatability Medium 6-9 months Maintenance and production teams Installation of grease cups or extended grease pipes on each K1 induced draft fan damper arm bearing so that bearings lubrication can be done safely during normal operations as opposed to the current bi-annual practice. High 6 months Maintenance team B Update K1 warm-up and cooling procedures to clearly reflect the relationships between time, K1 speed, fuel injection and induced draft fan speed for individual stages of start-up and shutdown activities. High 2-4 weeks Kiln coach, production shift managers and kiln operators Air balance measurements across K1 feed system should be conducted at least once every three months so that the efficiency of the feed transports systems can be regularly determined. Air balance measurement is used to determine the ratio between air input and output of process systems, thereby making the identification of leakages or restrictions within the system possible. ASH cement plant reports show that the most recent of such measurements was performed more than three years prior to the investigated incident. High 3 months Process team C Replacement of K1 feed weigh-belts tracking rollers, head drums and tail drums. This will significantly reduce belts misalignment. High 2-4 weeks Quality and maintenance teams Improvement of raw material sampling accuracy and frequency by replacing the current manual system with an automatic online system that provides real-time opportunities for correcting errors in feed compositions. High 9-12 months Quality and maintenance teams