DATscan 2.0 – Rotary Unit A · 2018. 9. 7. · SUBJECT: DATscan 2.0. TM for Rotary Unit A . Dear Mr. Smith: Thank you for the opportunity for Optimus Solutionsto perform this survey

DATscan 2.0TM – Rotary Unit A Company ABC Company Attention John Smith Optimus Job # O0 Equipment Rotary Unit A PRMS 98765 Make OEM Plant Code ABC123-45 Unit diameter 15’ Customer P.O. 987654321 Unit length 45’ Analyzed by Tom Zhang # of Piers 2

Reason for analysis: Customer would like Optimus Solutions to evaluate the dryers in terms of where the current system slope and orientation is located.

The Science behind the process

July 19, 2018

Mr. John Smith ABC Company 123 Rotary Drive Somewhere, KY 98765 Phone: (555) 555-5555 E Mail: [email protected] Optimus Plant Code: ABC123-45 Proposal #: 98765 SUBJECT: DATscan 2.0TM for Rotary Unit A Dear Mr. Smith:

Thank you for the opportunity for Optimus Solutions to perform this survey. The reason we are performing this survey is the plant has experienced excessive wear on the Rotary Unit s’ tires and rollers. The purpose of this survey is to determine where the unit is located in terms of slope and any misalignments.

Work Scope

• Perform DATscan 2.0TM (Cold Drum Survey) o Survey each tire to establish unit center point, horizontal misalignment, and unit

slope o Survey all support rollers to establish their relationship to each tire and support roller

slope o Survey all bases to establish slope and elevation o Survey one base horizontal center at each pier for center reference points

• Perform brief inspection on unit for any noticeable problems • Make recommendations on alignments that need to be made

Recommendations

• Rotary Unit A needs significant moves to bring back to OEM specifications. We recommend

making these adjustments with a grinding service immediately afterward. • Once adjustments are made with grinding, we recommend then adding 0.015” of uphill

thrust on each support roller. Note: this is a starting point. Add more uphill thrust until system is floating well between the uphill and downhill thrust rollers.

Page 2 ABC Company – DATscan 2.0™ – Somewhere, KY July 19, 2019

Executive Summary

Optimus Solutions performed a cold drum survey or DATscan 2.0TM on Rotary Unit A.The reason for this survey is due to the constant amount of grinding performed on Rotary Unit A, along with discovering some explanation of why the washboard patterns developed on both tires of Rotary Unit A

System Slope and Support Roller Slopes The design slope of the system is 1.25 in/ft. These are OEM 15’ x 45’ 2 pier units. The Rotary Unit A slope is 1.29 in/ft . The Rotary Unit A is significantly off and needs about a 1” overall elevation change to correct. The support roller slopes are quite bad on Rotary Unit A

Unit Skew/Thrust Rotary Unit A shows a noticeable pigeon toe pattern on the skews, which contributes to the washboard pattern on both tires.

Adjustments and Next Steps A detailed outline of the adjustments is shown for both Rotary Unit A. These adjustments are also broken down into their individual components for support roller skews, support roller slopes, and drum slopes. These adjustments include moving the rollers in and out along with recommended shims underneath each bearing housing.

We recommend making these adjustments if the system allows (conduits and hoods may be in the way). We recommend immediate grinding after adjustments are made so all slopes are correct with new grinded surface.

Thank you again for the opportunity to perform this survey. If you have any questions, please contact us at 844-880-5822, Ext. 1208.

Sincerely, Sarah Belew Tom Zhang, PhD, PE Key Accounts Specialist Lead Engineer – Technical Services Optimus Solutions Optimus Solutions SB/sd cc: M.G. A.B.F. M.W.


TABLE OF CONTENTS Page Work Scope 1 Recommendation 1 Executive Summary 2 Table of Contents 3 Overview 4 Orientation 4 Summary – Rotary Unit A 4 Total Adjustments – Rotary Unit A 5 Survey - Rotary Unit A 8 Isometric Graphical View 8 Discharge End Tire (Looking Uphill) 8 Feed End Tire (Looking Uphill) 9 Base Level Left to Right (Looking Uphill) 10 Base Slopes 11 System Slope 12 Support Roller Slopes 12 Center Line of Tires 13 Support roller Skew 13 Adjustment Breakdown – Rotary Unit A 14 Skew Adjustments 14 Support Roller Shims 14 Drum Adjustments 15 Drum Shim 15 Total Adjustments 16 Inspection – Rotary Unit A 17 Discharge End 17 Feed End 18


Overview

Orientation

Figure 1. Optimus orientation standard.

The system orientation is viewed from downhill of the discharge end looking uphill towards the feed end. From here, left and right are oriented accordingly. Figure 1 shows an illustrated view of the orientation. From this point forward all orientation will follow this schematic.

Summary – Rotary Unit A Rotary Unit A visually on the tires shows significant washboard patterns on Figure 2 to Figure 5 (can be viewed in inspection section page 17). Multiple grinding services have been performed on this unit and these wear patterns come back. This indicates that the system and support rollers may not have the same slope. This also means the system may not have good neutralization on support roller thrust. The system slope is 1.25 in/ft from OEM design. Rotary Unit A is current sitting at 1.29 in/ft, which shows the system is steeper than designed (page 12). The support roller slopes also show some significant differences with the two largest deviations on the left and right discharge support rollers at 1.17 in/ft and 1.32 in/ft respectively (page 12). The discharge support rollers are both already visually worn even though these were recently installed. The support roller skews also show issues via a pigeon toed pattern where the discharge end is pushing uphill and the feed end is pushing downhill (13). This contributes to the washboard pattern observed on both the feed and discharge end tires. In terms of adjustments, there is significant amount of moves that need to be made. However, we recommend making these adjustments when the next grinding service is performed. Making adjustments without grinding may cause other problems due to the worn nature of the tires.


Recommended Adjustments - Rotary Unit A

Total Moves

0.188" 0.212" 0.052" 0.148"Left

Center LineDischarge End of Base Feed End

Right

+ Y0.111" 0.289" 0.065" 0.135"

+ X+ Angle Plan View

Total Shims

Left Left0.660" 0.927" 0.167"

Level w/ Center of Discharge Base Point

Discharge End Feed End

Right Right0.883" 0.660" 0.100"


Discharge End Feed End+ Z

+ X Elevation View+ Angle


Survey - Rotary Unit A

Isometric Graphical View - Rotary Unit A

Discharge End Tire (Looking Uphill) - Rotary Unit A


Feed End Tire (Looking Uphill) - Rotary Unit A


Base Level Left to Right (Looking Uphill) - Rotary Unit A

Trunnion Base Level (Left to Right) General information as to the elevation of the bases.

Discharge Base Center of Tire Feed Base Center of Tire

Left Right Left Right-10.87 Origin -10.70 20.88 Origin 21.790.17 Lower -0.17 0.91 Lower -0.91

Uphill Base Uphill Base

Center of Tire Center of Tire

Left Right Left Right-16.63 Origin -16.47 15.26 Origin 16.18

+ Z 0.16 Lower -0.16 0.92 Lower -0.92

+ X

+ Angle Downhill Base Downhill Base

Note: Origin set at center of the Uphill side of the Discharge Base for 0,0,0

Discharge Base Feed Base

Left LeftEstimated locationof readings (TYP)

Downhill Uphill Downhill Uphill

Right Right

View Shown: Discharge Base, DownhillPlan View of Bases


Base Slopes - Rotary Unit A

Base Slopes:

Left Left

Right Right

Discharge End Feed EndElevation View of Bases

1.31 in/ft1.29 in/ft


Left Left

Estimated locationof readings (TYP)

Downhill Uphill Downhill Uphill

Right Right

View Shown: Discharge Base, Right Side

Elevation View of Bases


System Slope - Rotary Unit A

Support Roller Slopes - Rotary Unit A

System Slope:

304.54Distance between Tire Centers

Center Lineof Tires

delta Z = 32.69

+ Z

+ X Level w/ Center of Discharge Base Point

+ Angle 97.68 130.36Discharge End Elevation View Feed End

1.29 in/ft

Trunnion Slopes:

Left LeftZ = Z =

-10.12 22.07

X = -10.07 Level w/ Center of Discharge Base Point X = 269.01


Right RightZ = Z =

-10.17 22.25

X = -11.23 Level w/ Center of Discharge Base Point X = 269.43






Center Line of Tires w/ Respect to Center Line of Bases - Rotary Unit A

Support roller Skew - Rotary Unit A

Center Line of Tires (Drum) with Respect to Center Line of Bases:

304.54Distance between Tire Centers

Center Lineof Tires

+ Y Center Line-0.06 of Bases -0.17

+ X Discharge End Feed End+ Angle Plan View

0.00 in/ft-0.02 deg.

Trunnion Skew with Respect to Centerline of Tires

X =-35.04 X =

Y = 269.01 Y =63.19 62.49

LeftCenter Line

Discharge End of Tires Feed EndRight

Y = Y =-63.01 -62.77

X = X =

+ Y -35.12 269.43


0.07 in/ft -0.03 in/ft

-0.05 in/ft 0.02 in/ft

0.34 deg. -0.14 deg.

-0.26 deg. 0.10 deg.


Adjustment Breakdown – Rotary Unit A Skew Adjustments (to Neutralize Roller Skews) - Rotary Unit A

Support roller Shims (to Correct Support Roller Slopes) - Rotary Unit A

Skew Neutralization

0.12" 0.12" 0.048" 0.048"Left


Right

+ Y0.089" 0.089" 0.035" 0.035"


Trunnion Shims

Left Left0.267" 0.167"



Right Right0.233" 0.100"





Drum Adjustments (to Adjust Drum Slope) - Rotary Unit A

Drum Shim (to Adjust Drum Slope) - Rotary Unit A

Drum Moves

0.200" 0.200" 0.100" 0.100"Left


Right

+ Y0.200" 0.200" 0.100" 0.100"


Drum Shim

Left Left0.660" 0.660"



Right Right0.660" 0.660"





Total Adjustments (Combined Moves to Correct Thrust and Slopes) - Rotary Unit A

Total Moves

0.188" 0.212" 0.052" 0.148"Left


Right

+ Y0.111" 0.289" 0.065" 0.135"


Total Shims

Left Left0.660" 0.927" 0.167"



Right Right0.883" 0.660" 0.100"





Inspection - Rotary Unit A

Discharge End – Rotary Unit A

Figure 2. Significant washboard pattern on discharge end tire (viewed from right side).

Figure 3. Relatively new discharge support rollers (left support roller on left and right support roller

on right) with wear marks already developed.


Feed End – Rotary Unit A

Figure 4. Significant washboard pattern on feed end tire (viewed from right side).

Figure 5. Relatively new feed support rollers (left support roller on left and right support roller on

right).These support rollers look better than the discharge support rollers. Notice a small washboard pattern is starting to develop on the uphill side of the right support roller.

Documents

DATscan 2.0 – Rotary Unit A · 2018. 9. 7. · SUBJECT: DATscan 2.0. TM for Rotary Unit A . Dear Mr. Smith: Thank you for the opportunity for Optimus Solutionsto perform this survey