A rotary drum, be it a dryer, cooler, agglomerator, or otherwise, is a major investment and integral part of many industrial processing systems. From drying and cooling bulk solids before storage, to agglomerating ore fines in a heap leaching operation, the rotary drum often serves as the backbone of many industrial processes.
And while a significant amount of time and research is put in to finding the right rotary drum manufacturer and engineering a solution that blends seamlessly into your process, the work is far from done after the purchase.
The install of your new rotary drum requires just as much planning and attention to ensure proper installation, optimal performance, and equipment longevity.
Why Proper Drum Installation is Important
A properly installed rotary drum is the first step in prolonging equipment life and reducing potential downtime and maintenance. Problems that begin at install can quickly turn into serious damage and downtime. A poorly installed rotary drum or drum base can result in a variety of problems, including:
- Damage to wheels/tires from poor alignment
- Damage to the drum shell because it was handled improperly
- Re-work needed and/or voided warranties because critical hold points/inspections were not done
However, there are a few simple steps you can take that will help to achieve a smooth and successful installation, avoiding the problems mentioned above.
Key Steps for A Smooth Rotary Drum Installation
Have A Service Technician On-Site
Having a service technician from the manufacturer on-site for installation offers many benefits. The Service Technician is well trained in the exact specifications needed for efficient installment and operation of your equipment. They know what to look for and any potential places for error to occur. Service technicians can oversee installation, assuring that things are done right, and no warranties are voided in the process.
In addition, service technicians are a valuable source of knowledge for answering installation and operation questions on the spot. Furthermore, they can train maintenance personnel on the ins and outs associated with the equipment during their time on-site.
Plan Ahead
Contacting the equipment manufacturer well ahead of the installation date to begin planning is vital to carrying out a seamless rotary drum installation. Ideally, the equipment purchaser, manufacturer, and installation contractor should be in contact with one another prior to installation so that everyone knows what needs to happen before install day arrives. This will help to ensure that on-site service technicians and supporting manpower will have everything they need on-site, and won’t waste valuable time waiting on things that could have been prepared for.
The items listed below are all things that should be considered during the planning stages of installation:
- Appropriate equipment staging: In cases where the drum is a replacement and will need to be fit into place, ensuring all ancillary equipment, such as feed chutes and/or discharge chutes are in place and pre-positioned will prevent wasted time during install. This is less of a concern when putting together a new process where equipment will be fit around the drum, but can still be prepared for.
- Materials & Equipment: Having the right materials and equipment on hand can mean the difference between a smooth install and days wasted. Materials such as grout needed for pouring under bases, or shimming materials used in the alignment process should all be purchased and prepped for install. It’s worth mentioning also, that the proper tools and equipment should be on-site as well. While most install contractors will have the right tools and equipment at their disposal, the importance of having them on-site and ready for use cannot be emphasized enough. This too, will prevent wasted time waiting for the proper tools or equipment to arrive. An inadequate crane, for example, could mean that technicians have to wait for a new crane to arrive and be mobilized before work can begin.
- Pre-Alignment: The installing contractor should prepare for installation by installing and pre-aligning the drum bases prior to installation day. Having the drum bases installed and pre-aligned will allow technicians to begin their work right away on installation day, instead of waiting a day or two for the pre-alignment to be completed.
All of the items above can be planned for through a simple conference between the equipment purchaser, installing contractor, and original manufacturer. Planning for these items will help to ensure that no time is wasted on installation day and progress moves according to plan.
Use a Laser Tracking System for Optimal Alignment
Properly aligning the drum bases and shell is an important part of installation, and can set the tone for operational efficiency and equipment longevity. Rotary drum misalignment is one of the most common causes of drum damage and premature equipment failure, making proper alignment during install key to operational success. One way to ensure proper alignment is achieved, is through the use of a laser tracking system.
While traditional alignment techniques can offer a reliable alignment option, they leave much room for error. New laser tracking systems, however, provide an efficient, and accurate solution to alignment needs, offering fast, precise alignment. In a typical setting, laser alignment can get the bases to within +/- 0.005.
While traditional alignment methods rely on manual measurements and mathematical equations to determine and execute proper alignment, advanced laser tracking systems eliminate the opportunity for human error by utilizing a laser beam to measure 3D coordinates, and recording and analyzing data on a software program, resulting in faster alignment and extreme precision.
The proper installment of a rotary drum is key to process efficiency, prolonging equipment life, and avoiding unnecessary downtime and maintenance. Adequate planning for installation, such as having the appropriate materials, manpower, and equipment on hand, will go a long way in assuring a smooth rotary drum installation. Additionally, the use of a laser tracking system, as well as having a service technician on-site will aid in achieving the most accurate and efficient install possible.
For more information on rotary drum installations, contact us today!