ROTARY KILN AND STATICS PARTS REFRACTORY MANAGEMENT
INTRODUCTION :
Dear Readers.
The digital era in which we live allows us to do amazing things in computer science and automation and for the organisation of our offices. So today, with REFRAMANAGER , we turn to the technical departments of cement, proposing an and unique idea. It is unique because it does not exist on the market yet. We are the only ones who have created a management platform for maintenance, which is specifically for concrete production plants. We have worked in the industry for many years and experience has today enabled us to propose a particularly innovative idea that we will describe shortly.
The computer allows us to finally eliminate those immense and wasteful piles of paper enclosed in bulky files and folders. The goal, therefore, was to transform all of the data into software, i.e. all of the data of utmost importance that has to be collected and assessed during the planning of a maintenance service on kilns and static parts. All of your plant visuals will be a simple click of the mouse away. How many of you still are still buried under piles of paper, drawings, files and excel documents lying on your desk, which are also maybe not up to date?
We therefore think, that REFRAMANAGER , can be an innovative management software system with a single database which can also be centralized, and this allows the management of all historical data, organized by rotary kilns and static parts to be broken down into company group , factory , machine etc. We believe, therefore, that it will be an innovative idea which allows you to always have on hand all the technical details relating to each operation performed by sequential numbering and archiving of photographs, technical details , drawings , reports and data sheets, as well as all details of the materials used and the operating costs.
DESCRIPTION :
Let’s start with the creation of a tree structure to organize the plants that are part of the company. It will insert the name of the company, the business group, the factory and the machine.
A special table will allow you to view the list of companies divided into groups, and each group will correspond to a list of plants and hence to the data sheet of the kiln being analyzed.
You will be able to enter the identifying details of the machine by filling out an interactive table that schematically represents your kiln. You insert the diameter of the kiln (it is able to handle up to three different diameters), the length, the positioning of the rings and the girth gear, with a very simple and intuitive operation. Complete the datasheet insertion of the descriptions of the zones of the oven (for example: kiln outlet, lower transition zone, burning zone, high transition zone, the drying zone etc….).
Then a special archive will allow you to manage the complete list of suppliers and quality of refractory bricks used, according to format (ISO, VDZ , FORMLESS and OTHER DESIGNS ) and with a simple click you can view the data sheet for the product , size, the composition , the number of locks used , and the breakdown by category (ALLUMINA bricks and BASIC brick, etc. ) including costs expressed in local currency per kilogram , the specific weight, density, and so on. Each entry in the list will allow the possibility of inserting an attachment ( DRAWINGS , PHOTOGRAPHS AND TECHNICAL DETAILS ) .
With a step by step process which is simple and intuitive to follow, you can enter the number of the maintenance, commonly referred to in technical jargon as SHUTDOWN INSERT.
A click on the appropriate small table of shutdowns will allow you to choose which kind of maintenance you are doing. For example, the F-type is to shutdown the replacement of a refractory, or an S-type shutdown will allow you to identify issues not related to the refractory, but to other aspects of machine replacement external components, such as electric motors, fans and mechanical interventions in general. The P-type shutdown, however, will allow you to arrange a scheduled maintenance in the future so that all the little details will be under control.
Following the selection of the type of refractory brick that we employ, at that point in the sequence we will select the product type we need from the list, according to brand and quality, choosing the amount based on the refractory lining of meters required. All quantities will be calculated automatically in an absolutely precise and specific graphical representation, which will allow us to view the representative table of the oven, with the exact positioning of coating installed. Each product will be associated with a certain color and a certain texture, so that at a glance you can understand what the product is.
When completing the registration of the operation, the details of clinker production until the day of the shutdown will be inserted, and also the total number of operating hours of the kiln. The aforementioned data will then in the next step allow us to extract the data required for the calculation of specific consumption.
During the maintenance operation, you can either enter a single brick or a complete cladding, including traits possibly lined with simple mortar refractory.
You can even calculate the percentage of unused material or material which has been discarded for various reasons. What in technical jargon we call surplus or scrap
After recording the required maintenance on the rotary kiln, we can then pass onto the static parts of the plant. For example, the tower cyclones. Here, too, a tree chart can be customized to include all the technical details, separating them with a system of nodes and sub-nodes, that allows us to visualize the entire sequence of the components which make up the tower or pre-heater.
Let me give an example, we analyze the cyclone stage 1 of the tower. We subdivide the nodes, in particular highlighting the inlet pipe, the upper part that is also referred to as TOP, the cylindrical part, the conical part and then the drain.
We can then enter the details of the operation directly onto the part that we are interested in registering, with a serial number that will be part of a historical list and everything can be called up via a simple click on the system diagram.
Clicking on the node called the cylindrical part, we enter the details relating to the positioning of our work, by entering the size of the first layer of insulation that we will define LAYER 1, a coating of refractory bricks that are defined as the WORK LAYER. Then we also record all the accessories that have to be used, for example the number of anchors, and here we will have the opportunity to see the drawing, the measurements, the material with which it was made and the unit cost, the total weight and the total number of components used.
When the archive data is finally compiled, with a click of the right button of your mouse, all the details and documents recorded at the time you planned and executed your maintenance are made available, with an instant display, and the possibility of printing all the reports.
To complete our software we present a tabular and graphic customizable series that relates to specific well-defined criteria. We have named this section GLOBAL REPORTS.
Here you can analyze all the systems that are part of your company. You will be able to calculate the specific consumption, to assess the costs, consult the quality control archives, see where and how much you have installed, compare the data from a single plant or a group of plants, or perform a complete analysis for the entire company.
It will be possible to compare the last four years of operation and evaluate the moving average (moving average of the last four years).
You can, for example, even observe and recall the use of a single product quality, simply by asking the to see where you have installed a certain type of refractory brick. Then you can analyze the specific consumption of a single brick, or you can categorize them by dividing them into ALUMINA bricks, or BASIC bricks, or other types of material, and create graphs that highlight the percentages in cost and weight, both for QUALITY and for SUPPLIER.
Many types of data can be managed with the REFRAMANAGER. For this reason we are willing to let you try the program absolutely free. We will always be available to help you, and also to listen to suggestions that will allow us to further improve the quality of the REFRAMANAGER, by implementing those suggestions and by continuously adapting it, according to the experience gained by those who work in the cement industry everyday.
OPERATING NOTES :
The REFRAMANAGER platform can be both installed and used in 3 different ways:
1 ) Local Use or “LOCAL MACHINE “ . It can be installed on your personal computer for a single user, and is used only by a single client.
2 ) Corporate network Use “INTRANET Configuration” . Support will be installed through the use of a MICROSOFT SQL database, prepared on the central server, and each user will install an operating license onto their personal computers, thus being directly connected to the central server of the company. In this way all parameters and data will be centralized and all users can have access to it.
3 ) In “CLOUD” Use. We can offer the clients a dedicated space on a server owned by us, and all users will be able to use the REFRAMANAGER anywhere in the world, with just a simple click of a mouse on a specific link and an active Internet connection. We guarantee total security, privacy and data protection, through highly advanced software and hardware tools, for access control and data security.
The type of installation choice will dictate supply conditions and all three options are interchangeable. In fact, if the user chooses option 1 ), in the future they can move to options 2 ) or 3). Or the company that wants to start with option 3 ), can then move on to option 2 ) without any problems.
All MICROSOFT operating systems for home use are compatible with REFRAMANAGER .
TECHNICAL SUPPORT & OPERATIONAL TRAINING to train personnel who will use the system, or provide support in case of failure , will be ensured through constant “ON LINE” support, from one of our operators, who will be at your disposal and will be able to interact with you through a specific system, developed by us, which will allow the user to connect via chat with our
“CUSTOMER SERVICE “, and you will be able to work “TOGETHER “ directly on REFRAMANAGER. To complete the profile, a detailed operations interactive manual is activated by pressing the F1 function key on the keyboard of your PC.
We expect the crowning success of a complex and ambitious project that will allow your company to have a constant, comprehensive and highly detailed monitoring of your production facilities, which will be able to centralize and customize a database of vital importance. All this will be done with very low investment outlays that will permit enormous savings in time and costs.
Contact us using contact details found at the bottom of this article. It will be our pleasure to provide all the necessary details and, above all, to give you the opportunity to get to know the product by allowing you to use it, in order to assess the enormous potential of its contents.
We put the platform at your disposal completely FREE of charge, for extended periods of time, to allow you understand the potential of the REFRAMANAGER. And we will track your training and assessment, directly “on line” from all around the world.
FINAL THOUGHTS :
In the short space of an article it is difficult to describe in detail a program like the REFRAMANAGER . It is very structured and sequential to operate. We have done a lot to make it easy, fast and intuitive to use. Perhaps making it so easy and quick to operate was the most complicated part of the project.
In fact the sequence of operations in the registration of a maintenance intervention follows exactly the same logic that is used, in most cases, by technical experts in the factory. For this reason the presentation and the use of the REFRAMANAGER is having considerable success.
The REFRAMANAGER is a tool that can completely do away with all paper documents and is structured to become an extremely comprehensive database, which is available to everyone in the company. Above all, the technological innovation consists of, apart from the fact that it is a powerful computer tool, in having created a fundamental aid in the archiving and recording of documents which, notoriously, most of the time in the past, were left in the bottom of a drawer or were only to found in the minds of highly skilled engineers with many years of experience.
Today with the REFRAMANAGER everything will be stored in the digital memory of your corporate server, and archives will remain unlimited in time, and also available, to be consulted by everyone in seconds.
Roberto Ebrase
Sales and Administrative Manager by :
ELDIR SYSTEM
Via Francesco Petrarca , 85
10078 – VENARIA REALE
TURIN – ITALY
Vat Numb : IT 07577290013
Mobile : +39 335 7209385
Tel: +39 011 4509193
Website : www.reframanager.com
e-mail. : info@reframanager.com