Due to wear and tear and metal fatigue over time lance shroud protectors can break off and in turn damage/break the gas lances in a kiln. The kiln needs to be shutdown so it can cool before confined entry is required. This is a high-risk activity due to heat inside the kiln from the stone/lining surfaces, working on hot material (stone), cavities from uneven stone and exposure to gases.
The maintenance team designed a new shroud cover that could be completely fitted externally without the need for confined space working.
Please see additional pdf for details of the design process
Benefits
- Removed the need for confined space entry and the associated hazards of heat inside the kiln.
- Eliminated the need to degas the kiln.
- Quality of the product is not impeded by the new process.
- Three of the Fatal 6 risks mitigated (Contact with moving machinery; Struck by moving or falling object; Fall from height).
Time saving - the process previously took 3 days (average) to complete, but this can now be completed in one shift.