EXTERNAL ALIGNHENT PROCEDURE FoR ROTARY KILNS, COOLER, DRYERS, ‘AND SIMILAR ROTATING MACHINES FULLER COMPANY 124 BRIDGE STREET, CATASAUGUA, PA. 16032, USA. SERRA gud to anne Sale esa naan ae nuns SOUTH amc» CURB OEE 728-75~1-8801 Sheet I of 13TABLE OF CONTENTS INTRODUCTION. REFERENCE MEASUREMENTS SETUP FOR HORIZONTAL MEASUREMENTS Checking for Pler Shifting. 4. + «+ Horlzontal Allgnment Check os 1 4s Alternate Setup. + v- SETUP FOR VERTICAL MEASUREMENTS , 445 VERTICAL ALIGNMENT 4... 0 CORRECTING ALIGNHENT wae 3 sae 3 mg sae 8 sae 9 wae 12 728-75-1-8801 Sheet 2 of 13INTRODUCTION These procedures are Intended for use in checking shell alignnent.on a rotary kiln, cooler, dryer, or simblar type of rotating machine from the ‘outside when benchnarks are not avallable as reference points. A series of procedures are requl red to make a complete alignment check by this method, It is Important to perform them all, to make accurate setups, sightings, and measurements, and to recard data carefully. In many cases, making skatches to depfct the conditions will clarify the nature of an allgnnent problem and help determine the best course for correcting It. Refer to the machine's Installation, operation, and maintenance Instruc~ tions for additional pertinent alignment Information. REFERENCE MEASUREMENTS Prepare a sketch of the machine, showing and Identifying each riding ring and support roller. Hake the following measurements and calculations, recording them on the sketch: + Measure the circumference of each riding ring and calculate its radius. + Heasure the circunference of each support roller and calculate its radlus. + Measure the clearance between each riding ring and the pads on the shell at the top of the machine. Retain this Information for use In making calculations and in determining appropriate corrections in shell alignment. SETUP FOR HORIZONTAL MEASUREMENTS In the setup procedure which follows, the object Is to accurately locate a transit on a preselected horlzontal offset Ine which Is parallel to the centerline of the machine, Once the Instrunent 13 in the desired posi- tion, It {is left there unt!] all horizontal measurenents have been com pleted. The first and last plers are used as reference points under the assumption that nelther af them has shifted. Subsequent measurement may Indicate this assumption to be wrong and require the selection of other references. Two horizontal measurements will be made on each pier. As shown In Figure 1, meagurenents for pier shifting will be made from the centerlIne nark on each support frane and allgnment measurerents from the horizontal diameter of each riding ring. The location of the offset, therefore, mst be se- lected to permit a clear view of these points through the transit when it Is set up on the firing floor. The offset may be to either side of the 728-75~ +8801 Sheet 3 of 13g OFFSET MEASUREMENTS FOR SHELL ALIGNMENT MEASUREMENTS CENTERLINE FOR PIER MARK ON SHIFTING SUP PORT FIGURE 1 HORIZONTAL ' MEASUREMENTS machine. If any enclosures obstruct the line of sight, remove sections of wall siding as necessary. After selecting a suitable location for the offset, proceed as follows: a, Set the transit on the firing floor at a location which gives a clear view along the offset to each of the points where measurenents will be made. b, Select 9 straight rod or plece of wood approximately 2 inches by 2 inches and of sufficient length to reach from the center of a sup- port mechanism to 3 point at least 6 Inches beyond the offset. c. Measure the horizontal distance from the selected location of the offset to the centerline mark on the support frame of the reference pler at the discharge end, 728-75-1~8601 Sheet 4 of 13,From the squared end, measure an equal anount on the rod and make a pencil mark. fe. At the feed-end pler, carefully align the squared end of the rod with the centefline mark on the support Frané. f. Holding the rod horizontally hevel on the feed-end pler and par- allel to the edge of the support beam, sight on its premarked re~ ference point and lock the transit to’ prevent Its turning. Hold a pencl! point or small target at the reference point to facilitate sighting. g- Move the rod to the reference pier on the discharge end and" pos!~ tion It in the sane way. fh. Without disturbing the transit except for elevation, sight on the rod at the discharge~end pler and mark the polnt at which the line of sight crosses it. Heasure the distance between this point and the premarked reference point, i, Adjust the position of the transit as necessary until the vert!- cal hale falls on the reference mark when the rod is placed on both reference plers. Completion of this procedure locates the transit's line of sight to be equidistant from the machine's centerline at the reference plers and es- tablishes the offset from which the horizontal measurements can be made. CHECKING FOR PIER SHIFTING With the Instrument in the setup condition, perform the following at each support. mechani s1 ‘2. Hold the rod horizontally level and parallel to the edge of the support frane bean. Nove it as necessary to allgn the reference mark with the telescope's vertical halrline. b. Heasure and record the distance from the squared end of the rod to the centerline mark on the support frame. The measurement indicates the anount the pler has shifted horizontally. The Figures recorded will be used In determining the type and amount of corrective alignment to be taken after all measurements have been taken. Lf significant variations have been recorded, prepare a sketch showing the relative positions of all support mechanism centerline marks. Analysis Of the sketch may indicate that corrective alignnent can be minimized by selecting one or two different reference plers. The feed-end and discharge-end piers are used Initially because of thelr being at the ends of the shell and because, with housings and and other equipment attached to then, corrections are not as easily made at these 728-75~1-8801 Shest 5 of 13locations. If changing a reference point Is advisable, give special con= sideration to the thrust pier. Usually it is desirable to avoid changes In the mesh and alignnent of the drive and pinion gears or In the alignment of the other drive components. In addition, the relationship of the thrust roller centerline and the kt in canterline estab! shed'at Installation must be maintained, and there Is little lateral adjustment which can be made to a thrust roller. HORIZONTAL ALIGNMENT CHECK The object of the horizontal alignment check Is to determine the anount the Shell's actual centerline deviates from Its true centerline In the horizon= tal direction. Quarterpoint readings from the riding rings to the offset are taken on each pler and compared with a sinilar dimension derived from the preceding measurenents. The differences between then represent the horizontal deviation of the centerline. Proceed as follows: @ Square at least one end of a straight plece of 2 Inch, by 2 inch wood, long enough to extend from the horlzontal diameter of the shell to a point about 6 Inches beyond the offset. 5. Using a centerhead and level In the manner shown In Figure 2, deter- mine and mark the horizontal centerpoint on the face of each riding ring. Level carefully to obtatn an accurate mark. c. Hold the squared end of the rod against the centerpoint mark on the first riding cing, keeping It horizontally level and at right angles to the ring. dy With the transit still In its setup position, sight on the rod and mark the point where the line of sight Intersects Tt. Measure and record the distance from the squared end to the mark. ce. Repeat steps c. and ¢. at each riding ring. fF. Referring to Figure 3, determine for each riding ring the dimension Z, by subtracting the calculated riding ring radius R In the ref- erence measurenents fron the distance Cy, measured In the check for pier shifting. Compare the Z, distances measured In steps d, and e. with the Z, Figures calculated in step f, Differences between the two Figures at each pler represent the deviation of the actual centerline from the: rue’ one. fh. Rotate the shell 90, 180, and 270 degrees, making and recording Zy measurenents for each riding ring at each quarterpoint. I. Compare al! four quarterpoint measurenents at each riding ring to determine if an average deviation dimension should be calculated for any ring prior to using the figures In the realignment analysis. 728-75-1-8601 Sheet 6 of 13RIDING RING CENTERHEAD _e FIGURE 2 RIDING RING HORIZONTAL CENTERPOINT This completes the horizontal measurements. Proceed with the vertical setup and checks. 728-75~1-8801 Sheet 7 of 13RADIUS R g (Calculated) FFSET Zm (Measured) Ze (Calculated) Cm (Measured) CENTERLINE MARK. FIGURE 3 HORIZONTAL MEASUREMENTS & CALCULATIONS ALTERNATE SETUP At sone installations it Is Impossible to sight the transit from the firing roon Floor for horizontal measurements. In such cases, It is usually pos- sible to make the setup ona corner of the pler at the discharge end and gain a clear line of sight by renoving guards, rails, and other minor ob- structions. To use this method, proceed as follows: Select a polnt on the pler whlch will glve Hne of sight visibility to each pier and riding ring. Mark the point with a punch, Setup and align the transit with the punch mark, using the plumb bob. Measure the distance from the punch mark on the pler to the center line mark on the support frame beam, At the feed-end pier, establish a reference polnt on the pler the exact distance from the centerltne mark measured in step c. Sight the telescope on the feed-end reference mark and lock the transit. 728-751-8801 Sheat 8 of 13This completes the setup. Use the procedure detafled in the preceding paragraphs to make the horizontal measurenents, SETUP FOR VERTICAL MEASUREMENTS In the setup procedure for vertical measurements, the object 1s to eccur- ately position the transit on a line parallel to’ the centerline of the machine but offset above the shell. Once the Instrunent 1s at the de- sired helcht and the telescope locked at. the machine's angle of slope, it is left there until ail vertical meesuronents have been conpleted, — ThIs Procedure uses the discharge-end and feed-end riding rings as reference points, Proceed as follows: a, Set the transit on top of the firshood withthe, IIne of sight along the centerline of the machine and at the shell's angle of slope. Adjustments to this Initial setup wil! be made in Subsequent steps. As necessary, renove panels from enclosures to galn a clear view of each riding ring. Square at least one end of a stralght plece of 2 inch by 2 Inch wood, long enough for conventent use in making the measurements described below. ¢. Using a centerhead and level In the manner IIlustrated In Figure 4, locate and mark, the top end of each riding ring's vertical dianeter. 4. At the feed-end riding ring, use a, level to hold the wooden rod plunb with the back edge of the squared ond against the center- line mark in the manner shown in Figure 5. fe. Sight on’ the vertical rod and mark the’ point where the tele~ scope's horizontal halr crosses the réd. Use a pencil polnt or a small rectangular target to assist In sighting. f. Repeat steps d. and'e, at the discharge-end riding ring 9. Hake @ correction to account for any differences In riding ring radii which were calculated under the paragraph entitled REFER- ENCE MEASUREMENTS. If one ring Is smaller than the other, add the difference to the smaller and make 2 new mark on the rod for that ring. h, Adjust the position of the transit until the marks as corrected instep g. both fall on the hortzontal hair without changing the ingtrunent:: When alignment Is Sthieved, lock the transit. Mo further changes in height or elevation will be made until all vertical measurements have been conpleted. ‘This completes the vertical setup. The transit's Ine of sight Is now 728-751-880) Sheet 9 of 13,vertical from and parallel to the machine's true centerline. CENTERHEAD" RIDING RING FIGURE 4 RIDING RING VERTICAL CENTERPOINT 728-75~1-8801 Sheet 10 of 13LINE OF SIGHT LEVEL — CENTERLINE MARK RIDING RING FIGURE 5 TECHNIQUE FOR VERTICAL MEASUREMENTS VERTICAL ALIGNMENT The object of the vertical alignment check Is to determine the anount the shell's actual centerline deviates from the true centerline In the ver~ tical direction. Quarterpoint readings fron the riding rings to the off- 728-75~1~8801 Sheet M1 of 13When makIng adjustments, keep the axis of each roller parallel to the axis of the machine. Parallelism can usually be determined by using a tranme! to measure from the center of the roller shaft to the center! ine mark on the support frane. On floating klIns, reskew the rollers after the machine Is back in operation, 728-75-1~8801 Sheet 13 of 13INSTRUCTION MANUAL FOR ROTARY KILNS, COOLERS, DRYERS, AND SIMILAR ROTATING MACHINERY FULLER COMPANY A GATX COMPANY P.0. BOX 25, CATASAUGUA, PENNSYLVANIA 18032, U.S.A. otras 240 arcuRTES HPA FAIS» LONDON ENGLAND « SAN SRASTIN PA + SEURIN nan’. "FoRanvo suo Mawrnest’canaon = ate acu bs nse ssOuannebena dui aS HCk SoaaN OAS Meet CoM at 726-75-1-8800-1 Sheet ! of 46TABLE OF CONTENTS INTRODUCTION INSTALLATION Pre-installation Considerations Foundations Support Mechanisms | | Shelve ee Main Gear and Piaton " ) Drive Units ye ee Electrical tnstailation | | | Fre Hood vy eee ee Feed Hood 6 yt Nose Ring ve ee ay Burner ve ee Refractory Lining 21. Check-Out vee eee Drying Refractory 2 tft Post-Installation tdie Time OPERATING INSTRUCTIONS... Sefetyse rete Stopping vt Emergency Shut=Bown | 2. Power Failure eee see fuxiary Drives 2d Skewing Rollers 5 os ee Cold Weather Operation. MAINTENANCE ee ee Checklists and Records =. lubrication see... ce Kiln Allgnnent So0u00 fuxi tary Orive Unit 2 2 Refractory se we tte Haln Gear and Pinton |. Support=Roller Bearings. Thrust-Roller Sleeve Bearings Erratic KIIn Rotation... SPARE AND REPLACEMENT PARTS au 26 Dog 27 28 23 29 30 Hu on + 2B ead » 33 3 + 3h oH) 38 38 40 4) ay at 2 42 43 46 728-75~1~8800 Sheet 2 of 46INTRODUCTION These instructions cover the Installation, operation, and maintenance of Rotary Kilns, but because of the any similarities whlch exist, they are also generally applicable to Coolers, Dryers, and other rotating machines. Machines of this type do not operate in an independent environment, but are always part of a system which includes a nunber of other pieces of equipment, all of which must function together under close control. The systen can exist in many sizes and configurations depending on the appli- catlon. The same Is true for these machines. In addition, the nature of the fecd material and the results to be achieved determine the char- acteristics of the process and the detailed design of the machine, For these reasons, each machine varies as necessary to accommodate the appli- cation, Regardless of these considerations, all of these rotary machines are similar in basic design, function in the same ways, have the same baste relationships with other elenents In the system, “and require the same general considerations for installation, operation, and malntenance. It Is these factors with which these instructions deal. INSTALLATION Installation is to be made In accordance with the drawings provided. They define the physical arrangements, pertinent dimensions, nechani.cal and electrical Interconnections, ratings, capacities, loads, and other characteristics, data, and Information needed In the erection and instal le~ tion of all components supplied. The arrangement and assenbly drawings designate al] parts by Item numbers. The parts IIsts are arranged In acy cordance with these Iten nunbers and Identify each iten by Its proper name. While there is a general, over-all sequence of installation which will be followed, there are many’ details for which the sequence wil! be determined by conditions existing on site, some of whlch will be determined by the design and configuration of the machine itself, and others for which the sequence can be determined by local preference. Also, nany different methods and techniques can be used to achieve the desired results in a sat~ Isfactory manner. In those Instances where these instructions provide the cetalls of a technique, the purpose is to suggest one whlch has been used successfully rather than to indicate a mandatory course. 728-75-1~8600 Sheet 3 of 46This section of these instructions provides an overview of the Installa~ tlon and presents Important detal] on Individual assenblies, component: and various other facets of installation which will be helpful in deters mining and employing the sequences and techniques used at a speci fle site. PRE-INSTALLATION CONSIDERATIONS The Kiln Includes preciston bearings and a nunber of machined surfaces and’parts, all of which require protection from adverse anbient condi tlons.~ Although these conponents are adequately protected for shipment, the protective materlels have @ relat Ively Im ted life and should not be depended upon for extensive periods. At the tine that each of these con- ponents Is to be Incorporated into the assently or mated wlth other parts, Tt Is essential that It be cleaned and inspected thoroughly, .Bearings must be cleaned, flushed, and lubricated, Coat all Internal surfaces of bearings with bearing lubricating ol]. 0 not use grease. If the bearings wil! be Idle for an extended period after cleaning, it Is suggested that undiluted STP O71 Treatment or an equivalent product be used to form the coating. The Kiln 1s shipped In a disassembled state for erection on-site. The shell is shipped In sections which must be positioned, aligned, and welded together. Sefore Installing parts, renove the protective coatings applied for protection during shipment. MachIned surfaces, oll passages and pipes, water passages and pipes, and reservolrs must be free of all foreign matter. Inspect all machined surfaces and screw threads to be sure they are In proper condition for assenbly. Whenever practical, the Kiln should be enclosed in a suitable structure to protect It fromwind, rain, and snow, These elements tend to cool the shel! and put compress! ve forces on the refractory which can cause It to crack. Rotatlon of the Kiln cannot be. stopped In the presence of these elements because the uneven cooling can cause serious warping which may be both difficult and expensive to correct. FOUNDATIONS The Kiln and Its drive units are to be Installed upon foundations whi ch 728-75- 1-880 Sheet 4 of 46must be designed to support the waight of the equipment and the loads Occurring during operation. These toads and the general foundation out~ lines are identified on the drawings, but the detailed design Is depend- ent upon the nature of the geological substructure on which they rest at the specific site. Particular attention must be given to avoiding con- ditions which could result In settling. The ability of the Klin to retain Its alignnent depends primarily upon the foundations renalning Fixed. lt Is of particular Importance that the plers are properly located with respect to elevation, spacing, and alignnent. The alignment of the Kiln and center-to-center spacing Of various components depends on the precise location of the foundations and foundation bolts. Thelr positions should be checked and rechecked to ascertain that they renaln fixed. The top of the foundat Ions should be left rough to provide good anchorage for grout. To aid fiture Kiln alignment checks, permanent bench marks should be pro vided on each pier. The bench marks should be brass plugs located on the top of the plers on each centerline in the plan view. Bench marks for use in checking for movement of the foundations should be established away from the foundatlons. The location of foundation bolts with respect to both plan and elevation should be checked carefully agalnst certified drawings. Their location with respect to those on other piers must also be checked. Frequently, the longitudinal centerline through the piers Is obstructed, In such case, run an offset line on the side avay from the drive and measure all locations from it, Use diagonal measurements to verify that the bolts have been located squarely. Make certain that allowance Is made for shins, grout, equipment bases, and mountIng hardware. SUPPORT MECHANISMS After the foundations have been completed, the support mechanisms must be assenbled on the piers. The frame is the first component to be mounted, and it is positioned with particular care. The bearings and rollers are then placed on the frame, located with respect to the Frane's centerline, and aligned with respect to each other. FRAMES The Installation of the frames requires the use of shims. It Is recom= 728-75-1-8800 Sheet 5 of 46mended that the supply of steel shim stock for use on each pler consis! of one plece each of 1/16-inch, 1/4-Inch, 3/8-Inch, and 1/2-Inch thick. ness in 3-inch widths and 16-foot lengths; two pleces I-Inch thick by elther 3 or 2 Inches wide and 16 feet long; and standard rolls of 6-inch Wide stock In thicknesses of 1/32-Inch, .010 inch, .008 Inch, .006 Inch, +004 inch, and .002 inch, Cut the shims’ to 4~inch lengths. norice SETTING THE FRAMES FOR THE SUPPORT ROLLERS 1S THE NosT VHPORTANT AND TIME CONSUMING PART OF THE FNSTALLATION PROCESS. IT MUST BE DONE WITH PARTICULAR CARE AND EACH STEP CHECKED AND RECHECKED. THE FINAL CHECK I$ TO BE MADE IN THE EARLY MORNING BEFORE DIRECT RAYS FROM THE ‘SUN AFFECT THE SETTING. Each frame rests on stacks of shims which raise It to the speci ied ele- vation. The stacks of shims are located on both sides of each foundation bolt. The bottom shim in each stack Is usually of I-inch=thick stock, set in grout, and leveled In the transverse direction but parallel to the slope of the Kiln In the longitudinal direction. The bottom shim is set low enough to allow additional shinming. The shin should be centered with re- spect to the web of the support beams rather than the anchor bolts. The anchor bolts pass through the sides of the bean flanges and using then as a reference would result In the shins being Incorrectly located. The bot- tom shim In each stack Is°set by placing a snail azount of grout under it, then carefully positioning It. The grout should be allowed to set for one to two hours, then the levelness and slope rechecked. After the shim has been positioned accurately, wrap the grout in wet burlap and allow It to set for 24 hours, After this period, recheck the shin's position. Once the bottom shims have been properly positioned and verified, the frane can be placed on them. The top can be Identified because it and the Inner edges of the top Flanges have been machined. Sone franes are marked to Indicate the feed side. When this mark Is present, set the frane so that tt Is on the up-hIil side, Unless the KIIn Includes 9 hydraulle thrust system, only one thrust frane will be provided. This frane is used under. the riding ring closest to the girth gear. To assist In alignnent, both centerlines of the franes are marked by saw cuts in the flanges. Each frame must be set to the exact elevation, slope, and center-to-center distance between plers specified, Add shims to each stack to raise the frame to the specified elevation and set the centerlines of the frame to the centerlines of the pler. A block tapered to the correct slope is pro- vided for each installation. It should be used in conjunction with a 728-75-1~8800 Sheet 6 of 46nachinist's leve] to achleve the specified angle. The center-to-center distance from one pler to the next Is measured with a tape. It is manda= tory to use a spring scale to apply tension to the tape while the measu tment is belng made and a thermometer to Indicate the tenperature of the tape at the time of the measurement, The tape measurenent must be cor rected to a temperature of 70°F. hen the frame has been accurately positloned and bolted down, it is re~ checked. The center-to-center distance from one pier to the next should be within plus or minus 1/16-inch. The tolerance on the elevation Is plus or minus 1/16-Inch. The slope must be within 0,002 inch-per-foot, and In the transverse direction it must be within 0.002 Inch-per-foot of being level. The final check of the slope is made-on the rollers after thay have been assenbled to the frame. At that time It may be necessary to make minor adjustnents In the shimalng to keep the installation with in the specified tolerance. BEARINGS AND ROLLERS After the frane Is in place and secured, the bearings and the rollers they Support are assembled to it. The machined surfaces on the frame are lub~ ricated with @ graphited grease or sone other anti-seizing grease before placing the bearings on It. When anti-friction bearings are provided, they are assembled to the rollers at the factory. When sleeve bearings are supplied, they aust-be assembled to the rollers on-site. They may be assenbled In place or subassembled first then Iifted into piace. If the bearings and the roller are assembled In place, one bearing Is mounted on the frane, the end of the roller shaft slipped Into it, then the other bearing slipped onto the other end of the shaft. The shaft must be supported In position so that the second bearing can slide across the frane and onto the shaft. Rollers are stamped to identify the feed ond and must be positioned accordingly. It 1s also pernissable to subassenble the roller, shaft, and bearings on the ground and lift then into position as a unit. When: lifting a bearing-roller subassenbly, it 1s mandatory that a proper sling arrangement be used. Provide a sling for each bearing and use a spreader bar, Hake certain that the roller shaft will be In constant, full contact with the bearings and that the entlre subassembly will remain level while tt Is being lifted. CAUTION DO NOT LIFT THIS SUBASSEMBLY BY THE ROLLER 728-75~1-8800 Sheet 7 of 46Set the bearings from tranmel measurements made between the rollers and the centerline marks on the frame. If the Installation 1s being made from an offset line, the roller nearest the line should be set from the line, and the opposite roller set by a pin gauge batween the rollers. When the bearings are properly set, both rollers will be parallel to each other and to the longitudinal centertine. Check for parallelism by placing a stral ght- edge across the machined edges on the ends of both rollers. It {s not In= portant for the ends of the rollers to be In line with each other; only that they be parallel. Sleeve bearings are not secured to the frames, but provisions are made for each anti-frictton bearing to be held down by four bolts, After sleeve bearings and thelr rollers have been assembled arid positioned, they must be checked for shaft end-play, Total space for movement of the shaft must be not less than that shown below for the corresponding roller size. ROLLER DIAHETER MINIMUM END~PLAY 33 through 39-Inch 1/16-Inch 42 through 72-Inch 1/8 Inch 78 through 84~tnch 3/16 Inch 90 inch and up be inch, If additional clearance is required, efther renove stock from one of the thrust keys mounted between the bearing base and the support or Insert gaskets behind one of the end covers. ith the sieeve bearings and rollers set, the seals, oll elevators, and other ancillary Items can be Installed when It Is convenient to do so. A shaft seal Is installed on the side of the bearing nearest the roller and held in place with a cover plate. Of1-Fill pipes for the bearings are in two sizes. The longer up-right plpe belongs on the downhill bearing; the shorter one up-hill. The threads on the oll fIII pipes should be covered with pipe fitter's dope or teflon tape and screwed In tightly to avoid leaks. The bearing ené plate must be renoved to install the oll tray and the of] elevators. Care must be taken in Installing the tray to allow clearance for the elevator to rotate without striking It. In assembling the of] elevators, make certain that lock washers are placed on the bolts and that the bolts are secured tightly to the end of the shaft. It is possible to install the elevators backwards. Check them with respect to the direction of roller rotation and verify that they are Installed to fill with oll at the bottom of the sump, lift It, then pour It at the top of the shaft. Water must be piped to each bearing for cooling. A suggested piping arrangement 1s shown on Figure 1 which also tadulates the quantity of 728-75-1-8800 Sheet 8 of 46Water required at each pler according to the size of rollers employed. Drain lines should include an air-break and funnel to permit observation of the flow and to make temperature checks, Because the movenent of the bearing toward or away from the shell can range between four and five inches, the inlet lines must Incorporate flexible sections. The funnel for the drain Vines must bs of a design which will also accommodate such movenent, Install a valve in each inlet line to permit control of the Flow. Locate piping so that it doesn't Interfere with the use of the bearing positioning screws. The piping and funnels are not normally sup~ plied as part of the Kiln. After final assembly of @ bearing has been completed, fill its sump with oil. Refer to the lubrication Instructlons In the MAINTENANCE Section, THRUST ROLLERS Thrust rollers are Installed before the shell sections are positione Offset then 1/16 to 1/8 inch toward the donvard-turning side of the shell so that when they are in contact with the rotating riding ring there will be 2 small, downward thrust to keep then seated in thelr sup- port brackets, There is an ofl-fII1 standpipe for each thrust roller. The longer one goes on the down-hill roller; the shorter one up-hill. Shims placed between the back of the brackets and the lug on the top of the frame are used to achieve and maintain the specified spacing between the thrust rollers and the riding ring, Thetr final Installation cannot be completed until the shell Is Installed, welded, and the riding ring is in its final location. After this has been accomplished, and If they are included for this Installation, the bracket and block of graphite by which the face of each thrust roller Is lubricated can be mounted, On full thrust machines, only the dowo-hiT1 thrust rolfer has the full thrust capability. If this thrust roller contains a sleeve bearing, it will be water-cooled and it wlll be necessary to Install piping to and from it. If a hydraulle thrust mechanism Is provided, refer to the sep- arate Instructions for pertinent Installation information. GROUTING hen the mounting of the components of the support mechanism has been com- pleted, the frame can be grouted. The shins must remaln In place. If there is any grease or of! on the top of the pier, it must be renoved or neutralized; otherwise, It will prevent the grout from bonding. The rough top of the pler must be thoroughly saturated with water to 728-75-1+8800 Sheet 9 of 46 |s 2g 3g | aie 55 re thee | UL ie | se ae Pe 7 pee sbi ae Wg 3583 ei ist ES | g2a% Sez | z £ no & z eu: | ° 8 g of SIDE ELEVATION Lf UE tL 728-75-1-8800 Sheet 10 of 46 FIGURE 1 SUGGESTED WATER PIPINGprevent absorption of water from the grout and to insure 2 good bond be~ tween the grout and the concrete. Keep the pler wet for at least 12 hours before grouting If the foundation Ts less than 28 days old and for at least 24 hours ff it is more than 28 days old, The grout should be dry-packed If practical, otherwise, concrete of 2-to~ Jrinch slunp can be used, If destred,.a metallic non-shrinking grout can be used with standard cement. Use one part cement to one.part coarse, clean sand. If the grout thickness specified on the drawing 1s 2-1/2 _ Inches or more, add one part 3/8-Inch or 1/2sinch clean stone. Start from the outside of the beams and work from the Inside only when grout from the outside appears on the Inside, Grout must fill the space under the beams to Insure full bearing at all polnts. It is customary ela ecfonte eee coi least the top surface of the bottom ange. ‘The grout should set from 18 to 24 hours at tenperatures above 70°F be~ fore the forns are removed. If the temperature Is below 70°F, the follow Ing applies: at 60°F, 2-1/2 days; at 40CF, 4-1/2 days. The grout should be allowed to set for'at least 7 days before the equipment ts placed. in operation. If the grout manufacturer's Instructions are available, however, follow them. After the forms are renoved, the edges of the grout should be kept damp for several days, then a commercial curing compound app! ted. ‘SHELL The shell is shipped in sectlons, the lengths of which are determined by Himltations imposed by transportation and handling fecllities. Bracing is welded inside each section for shipnent to help prevent distortion while it Is belng handled. Depending on the dlaneter of the shell, the riding rings may or may not be factory~assembied to their shell sections. If they are not, they must be put on before the shell sections are posi- tioned on their support rollers, After the sections are holsted into position, they are aligned, then welded together. The alignment of the shell 1s a critical aspect of the Installation and must be accomp! ished with accuracy. MOUNTING RIDING RINGS All riding rings are not Identical, and there may be a difference between the up-hil] and the down-hil1 side. It is necessary to check the drawings 728-75-1-8800 Sheet I of 46and the parts themselves to determine which ring mounts on a given shell section and what Its orfentation should be, Before assenbling a ring to Its shell section, clean the bore of the ring and the mounting pads on the shell, then lubricate then with a heavy, graphite-treated grease, The ring Is then supported, usual ly by avshing threaded through the bore, and guided onto the shell. Position it between the lines scribed on the pads. A third line Is also present, but It Is offset for use in making measurements. in handling the rings, protect thelr machined surfaces, Because of variations which can occur at the Joints between sections, the final positioning of the riding rings should not be made until after the shell fs welded. Refer to the paragraph entitled SETTING THE RIDING RINGS. SHELL ERECTION AND ALIGNMENT Shell sections are usually 11fted onto the rollers by cranes, then suppor- ted by sultable temporary structures. If erlbbing Is used, It should be tullt carefully using only sound timbers. If A-frenes ‘are used, they must be sturdy and rigid. Handle the shell sections ins manner which will pro~ tect them from distortion. The shell section’ are to be positioned so that the longitudinal seams do not form continuous lines. “When there are to seans, position each sectlon so that ‘Its seams are about 90 degrees apart from those in the adjacent section. when there Is only one seam, position each sectlon so that its sean Is about 180 degrees apart from the one In the adjacent section. Sonetines It 1s necessary to rotate the shell with a winch or, some other source of power to secure this allgnment. If a cable is wrapped around the shell for this purpose, keep It as close as practical to the riding ring. Another technique 1s to sip a bar between the mounting pads under the riding ring and loop the cable around It. Provisions are normally made for the supporting structure to Incorporate Jacks to adjust the position of the shell sections. Construct cradles lihich will distribute the force from the Jacks over en area large enough to avold distorting the shell. 0 not place a Jack In direct contact with the shell. With the sections supported In position as close as practical to each other, remove the Internal bracing at the Jolnt ends. Do not disturb the bracing at the riding rings. Because of handling and shipping, 1t may be necessary to correct out-of-round conditions at the Joint ends to secure proper mating for welding, A nunber of alignment fixtures are then tem- porarily welded into position around the Inside of the shell at the joint to draw the two edges together and align then with each other. Sone 728-75~1~8800 Sheet 12 of 46alignnent fittings are supplied, but generally the dogs, wedges, and strongbacks must be fabricated in the field from plate suppifed for this purpose. A typical arrangement of fixtures at a Joint are shown in Figure 2. The dogs and wedges are used to secure alignment; the strongbacks are then welded in positton to retain it. Alignment fixtures renain In place until the outstde of the Joint has been welded. Refer to the paragraph entitled WELDING SHELL JOINTS for instructtons. CHECKING ALI GNNENT After all sections have been aligned through the use of the adjustment devices, the overall alignment of the shell must be checked. The usual procedure is to install a series of batter boards on the inside dianeter of the shell at key locations, determine the center of the shell at these locations, then use a transit to check the alignnent of this series of centerpoints, Adjustments In the alfgnment of the shell sections are then made as necessary. Several flxed lights are required in the KiTn, along with a portable light which can be taken to any location through out its length. Field telephones or two-way radios are Invaluable for communication during the checking process. CAUTION UNEQUAL TEMPERATURES, EVEN A FEW DEGREES, WILL CAUSE A KILN TO BOW. WHILE MAKING THE FINAL ALIGNMENT OF THE SHELL, ADJOINING KILNS OR OTHER SOURCES OF HEAT SHOULD BE SHUT DOWN, AND THE WORK SHOULD BE PERFORMED ON A CLOUDY DAY OR AT NIGHT SO THAT THE SHELL IS NOT HEATED UNEVENLY BY THE SUN, The internal metal bracing at riding ring locations should be renoved. Batter boards, usually 2 x 8's, are set across the dianeter of the Kiln 728-75-1-8800 Sheot 13 of 46728-75-1-8800 Sheet 14 of 46and wedged tightly to prevent any movement. As shown in Figure 3, boards should be located at both ends of each riding ring, near the Joint between each section, and near the feed end. Position the boards at the flelé Joints and feed end about 18inches to the down-hlll slide. Those at the riding rings should be located close to the gauge blocks. The cen ter of each board is located and a hole about two Inches In dianeter Is bored through it at that point. A file card is then tacked over the hole using two or three thunb tacks across the top edge and one to hold the bottom edge in place. At the feed end and at the field Joints, two sets of quarter points are used to locate the center of the KIln on, the cards In the manner shown In Figure 4. The first set of quarter points - four points on the Inside of the shell which are 90 degrees apart with respect to the center ~ are estabiIshed Immediately to the downhill side of each batter board, A tranmel fitted with a penct] and set to be about 3/4-inch longer or shorter than the in- side radius of the Kiln is then used to swing an arc fron each of the quarter points. These arcs will Inscribe a figure on the card which is essentially, a square. Drawing the diagonals to this square will estab: lish the center point of the Kiln as determined by this set of quarter points. Offset the second set.of quarter points 45 degrees from the first set and use them In the sane way to determine the center point of the Kiln again. If the two centerpoints do not colnclde, mark a point half-way between them and Identify It as the center. Refer to Figure 4. Only one set of quarter points 1s used at riding ring locations, and these are established on the lower step of the gauge blocks Inside the shell. Swing the arcs from them and draw the two diagonals to locate the center point. ‘At the batter board on the down-hiII side of the riding ring closest to the discharge end, drop a plunb-bob fron the center point on the card to the shell. ark the point on the shell with @ center punch, then set the length of the tranmel to be exactly equal to the vertical distance from the punch mark to the center point. Remove the batter board from this location, position a transit over the center nark, and set Its height to equal the length of the tranmel. Refer to Figure 5. Set and level the instrument carefully. Remove: the thumb tack from the bottom of all cards between the transit and the most distant riding ring, bend them upward, and secure then with the tack so that the holes are unobstructed. Sight on the center point of the second card at the last ring. This establishes the centerl Ine of the Kiln against which the center point on each of the other cards is to be checked. 728-75~1~8800 Sheet 15 of 46- FIRST SET OF QUARTER = POINIS IDENTIFIED BY ‘As: os “25° OFFSET = SECOND SET OF at GUARTER POINTS IDENTIFIED aY "8s - Ns, > “CARD ON BATTER BOARD | an ” M he ARCS AND DIAGONALS FOR FIRST POINTS ‘ARE SOUID; DASHED FOR THE SECOND SET CENTER POINTS 7 SHELL 5 DETAILS ON CARD: centersy | | oa x cand ae SELECTED CENTER | CENTER BY | FIRST SET ‘OF Quaerer Ponts — = FIGURE 4 LOCATING THE CENTER OF THE SHELL 728-75-1-8800 Sheet 17 of 46Without changing the instrunent, sight én each card In succession, in Cluding the one at the feed end, and make a penci] mark at the precise i S point where the line of sight through the Instrunent: Intersects It. : Sight on the tip of a sharp pencil being maved across the card until It is aligned with the crossed hairs. The objective of thls check 1s. to determine the anount of misalignnent at each location so that corrections can be nade to get the center point on each card as close to being co- incident with the potnt established by the Instrument as It Is practical fo achleve. Any adjustnent which can be made to inprove alignment should - 1e made. i At field Joints and at the feed end, the center point of each card must be within 3/32-Inch of the point established by the Instrument. At the riding rings the alignment Is particularly Important, and there are two factors to consider. The offset at both locattons on each ring must be reduced to a minimum, but they must also relate to each other in that es any discrepancies which renain after adjustment has boen completed must u fall within the same quadrant when viewed through the Instrument. If one centerpoint 1s on the opposite side of elther centerline from the other, there will be an undesirable notion in the ring sect lon when the machine Is placed in operation. Discrepancies at riding ring locations are corrected by adjusting the rollers. If the frames and rollers were Installed carefully, any adjust ment required should be minor. Misalignments at the other ldcatlons are corrected by adjusting the Jacks used to support and position the Kiln = sections, adjusting the alignment fixtures inside the Kiln at the joints, or both. If any adjustments are required, recheck the alignment of al! points after they have been made. hen the alignnent has been satIsfactorlly establ shed, leave the Instrument, batter boards, and alignment devices - ( in place. Alignment Is checked after the Jolnts have been partlal ly = welded and again after the welding has been completed. - 7 WELDING SHELL JOINTS When the alignment 13 satisfactory, the strongbacks are welded across the Seams and a serles of tack welds are made on the Inside to maintain the - alignment. The checking of alignnent, the welding of strongbacks, and the tacking of joints should be accomplished In one night. NOTICE ee 00 NOT ROTATE THE SHELL TO FACILITATE WELDING DURING ‘THE ALIGNMENT AND TACK-WELDING PERIOD - RELAY oP hefrior to welding, verify that the alignment fittings inside the Kiln are Eights then weld elght or more I=Inch x 4einch x 20-inch strongbacks edge~ ise Across the Joints in the manner shown In Figure 2. With the stronce backs In place, about § tack welds, each about 10 Inches long, should be spaced around the Joint. Tacking should be done with 5/32 or 3/16-Inch dlaneter Anertcan Welding Society (AWS) £ 6010 or 7OXX series electrodes. After the tack welds are completed, recheck the allgnment. When It Is satisfactory, the outside of the Joint canbe completely welded using elther a manual or en automatic procedure. The weld must be cleaned of Slag, loose deposits, and ail defects after each pass. In completing the outside of the Jolnt, welding should be done In the down-hand or flat position, preferably using AVS 7018 or 7028 series electrodes at least W/4-inch In dianeter. After most of the welding on the outside of the Joint is completed, the alignment fittings, excluding the strongbacks, can be removed, The strongbacks remain in place unt!1 all welding on the Joint 1s completed, Prepare the inside of the joint by chipping or arc-alring Into the root bead of the outside weld to Insure full penetration. Clear the joint of Slag, loose deposits, and defects before starting to weld. Again, weld In ‘the down-hand position and clean the Joint before starting each addi- tlonal pass. The reinforcement on the butt welds shall be not less than 1/32-inch and not graater than 1/16-Inch. Best results are achieved if the welding at each Joint is acconp! shed without interrupt ton. After all welding has been completed, remove all of the strongbacks, patch the scars, and grind the surfaces to be smooth and flush with’ the shell. Do not Weld when the surfaces of the Joint are wet, when rain or snow is falling on then, or Ice has formed on then. If the temperature of the base metal is lower than 32°F but higher than 50°F, an area extending 6 inches on each side of the seam should be heated to at least 60°F before welding Is started, If the temperature of the metal is 50°F or lover, Postpone the welding unt!! conditions Inprove. Welding Stainless Steel Sometimes the shells or certain other componants which must be welded are stalnless steel. Usually, the pertinent drawings in such cases will specify the electrode to be used. If they do not, the follouing tabula- tlon can be used to make the proper selection, The electrodes should not exceed 3/16-Inch diameter. Do not weave the bead or weld in excess of the size stipulated on the drawing. 728-75~ 18800 Sheet 20 of 46JOINT METALS WELD METAL Type 321 to Type 321 ESK7#E Or £309Cb Type 321 to Type 304L EBN7H« or £30906 Type 304L to Type 304L E3081 Type 309 to Type 309 £309 Type 321 to Carbon Steel E310Cb*R or £310 Type 304L to Carbon Stee! E310Cb*R or £310 Type 309 to Carbon Steel £309 or £310 Type 3098 to Type 3098 309Cb Type 3098 to Carbon Stee! E310Cb %% Preferred electrode, SETTING THE RIDING RINGS After the shell joints have been completed thé tires are to be set temporary, all except the thrust tire which Is set permanently. The riding rings are to be temporarily located as per Fig. 6 and foundation drawing. fillet weld For temporary setting, weld (4) gussets 6" x 6" x 1d!" wi on each side of the riding ring equally spaced between the pads. When locating the tires with respect to the thrust, use a tape. Use a spring scale to apply tension to the tape whlle the measurenent ts being made and a thermoneter to Indicate the temperature of the tape at tine of measurenent, correct measurement to 70°F. The setting of the tires toa final location Is done to eliminate the error Ta calculated expansions based on assumed temperatures. After the kiln has operated and It has been decided how much to move each riding ring Into a permanent position, locate and weld the retalners on the side In which the tire Is to be moved. Weld In accordance with. the shell assenbly drawing. After one side of the’ retalners have been welded, burn off the 6!" gussets on that side and adjust rolls to move the tire In direction desired, After the tire has moved, weld retainers on the other side with a 1/16" gap between tlre and retainer with tire against the retalners on the other side. Since the thrust ring Is permanently attached Initially, the shiamtng behind the thrust rollers then can be adjusted to attain the specifle spacing between them and thelr, riding ring. MAIN GEAR AND PINION In installing the main gear and pinion, the main gear Is sounted around the shell, then the pinion is mounted on a base adJacent to It and posi~ 728-75~1-8800-1 Sheet:21 of 6NOWV301 ONR ONTO 9 FuNOL HONL % 7 St ONR HOW3 JO NOUY2OI aNLL NO 3ONYERTOL aH “NIMH NOUWGNNOS 3HI NO G31IDRIS FRY GHIYDIONI SNOISNEWIO 3H —— 1 r | Sil Lt ana 728-75-1-8800 Sheet 22 of 46tloned to mesh with It. Separate instructions are provided which detall adjusting, aligning, meshing, and checking the gear and pinion instal la~ tlon. The main gear cones in two halves. The pinion shaft and tha two bearings which support it are factory-assenbled. Sone Installations in- clude two pinions Instead of one, but the sane techniques are used to Install both of then. MAIN GEAR The maln gear is a precision component requiring careful handling and precise Installation. At the tine of Installation, remove preservatives and all foreign matter, then inspect the gear carefully. The spring plates are attached to the halves of the gear while they are stIll on the Floor, They must be asserbled to the gear in the direct ion which will place them under tension while the KIIn is rotating during normal operation. After the spring plates are attachod, tle than In place, position the gear halves around the Kiln shell, and bolt them fogethor. The halves are match-narked to identify mating surfaces. The halves mist be dravn tightly together and closed properly before al ign- Ing thé gear.with respect to the shell. Feeler gauges should be used to verlfy that metal-to-netal contact has been secured, Improperly closed Jotnts could resutt in raptd wear. Separate instructions are provided to cover the assembly of the gear. The gear must be located at the pofnt along the centerline speci fled by the drawings, it must be perpendicular to the shell, and must be concen- tric with it. They are not normally supplied as part of the Klin, but many erectors fabricate Jacking frames of the type shown In Figure 7, Four or ore frames are set between the shell and the gear at opposing locations and are adjusted as necessary to position the gear. Final centering and checking for radial and rim-face run-out must be done with Indicators in accordance with the detailed procedures provided seperately. When the gear is properly set, weld the spring plates to the shell. Start welding at the tengent point of the plates and work toward, then across, the end. After all plates are welded, remove the jacking franes. PINION At Installation, it Is essential that both pinion bearings be opened, the grease removed, and the bearings cleaned thoroughly. The grease with which they are packed is for protection during shipment only and is not intended 728-75~1-8800 Sheet 23 of 46BWV¥d ONDIWT 2 2uNd! Gaisino} smava Na suNM sniava EIA Wv3D=@ vans. 00 TRHS 1 OL 1n>—, | Spee Hh aS ub / Ge NOt Via .z ¥Os LANGTEMA 390 NOH "via 72 Nana SHOWASSY OL SLAM LITINA 2% DIV ot/st-4 seazu GD —® a. sae | | 728-75-1-8800 Sheet 24 of 46 BV WOU aaV siassno TY NNVHD .9'91 81 S BWV vam rind .9%.2 $1 108 WoLIOs QvSYRL Ting “9 XK TeV SNOT IES a9T/L |eaS an operational lubricant. A light coating of lubricant should be applied to the bearings and to all machined surfaces. Depending on the installation, these bearings can be elther oll or grease lubricated. Mount the pre-assembled pinion assembly to the base with the fixed bear- ing at the location specified on-the drawing. Set the shaft to the sane slope as the Kiln, Shim es required, but shim over the: entire contact area - not intermittently. Refer to the separate instructions provided for details in securing proper allgnent, tooth contact, and the final positioning of the pinlon assenbly with respect to the gear. GEAR GUARD Once the main gear and pinion are In thelr final positions, the gear guard which encloses both of them can be installed. Before enclosing them, however, .gIve the gear and pInton teeth a thin coating of gear lubricant to prevent dry contact before the lubrication system has the ‘opportunity to cover them. The part of the seal which gets welded to the shell must be positioned first. The guard Is tn sections which heve been match-narked at the factory to sinplify the assenbly procedure. Shins are placed under the support legs of the guard to gain the proper concentricity of the mating sections of the seal. GEAR AND PINION LUBRICATION SYSTEM The girth gear and pinion are lubricated either by a spray system or by oi] Idlers, The Installation and adjustment of the gear spray system Is to be accomplished in accordance with the manufacturer's instructions. The spray panel is to be mounted on the gear guard in the manner shown on the drawings. The other components of the system are located for con~ venlence at the site. Wnen of} idlers are used, they are mounted on a bearing-supported shaft In the gear guard under either the pinion or the gear. The bottom of the gear guerd then serves as the ol! sump. A nunber of idler gears are pro~ vided. Place the first one near the end of the gear with which It meshes s0 that ofl will run along the teeth during normal rotation, then locate the others at about 10-inch intervals unless the drawings specify a diff erent spacing. The Idlers are secured in place with set screws. Once they are positioned, no further adjustment or alignnent 1s needed. In~ stall the of] fI11 standpipe to the gear guard, 728-75-1-8800 Sheet 25 of 46DRIVE UNITS Uartous combinations of notors, speed reducers, couplings, and auxiliary units are used to drive different Kilns. The manufacturer's Instructions which are to be used in installing: each of the units provided will be ube ited separately. The various units Included are identified on the rawings {n most installations, each unit has its own base which must be independ ently set, aligned, end grouted, The entire drive train should be aligned and bolted tenporarily unti{ final adjustments have been made on the gear and pinton. At that polat, each base Is rechecked and adjusted as neces sary to comply with final elfgnment tolerances. Anchor bolt sleeves may then be filled with grout, The frames should be grouted on the following day. Occasionally, al! drive units are mounted on a common adjustable base which, in turn, {s mounted on @ sub-base. This sub-base must be accur- ately positioned, grouted, and have all anchor bolts sledged tight before the base can be mounted to It, The base can be moved In or out to adjust for backlash between the gear and pinion, but It can be moved only a small anoint to improve tooth contact, so particular eare must be exercised in setting the sub-base and base. ‘It Is Inportant that sub-base elevation allows for additive shinning at drive components which are instal ted on the main base. ELECTRICAL INSTALLATION The Installation of power, control, and Instrumentation devices and cir= cultry are covered in separate Instructions which Include appropriate Interconnection inforsation, instructions, and schematics. In many cases, however, the detalled electrical Installation - conduit layouts, switch locations, wire sizes, etc. - has not been designed, and the associated safety switches, electrical wires, condult, and wiring devices are not supplied, Select and install electrical devices and materials which are compatible with the characteristics and ratings of the electrical equip~ nent which Is provided as part of the system. Electrical specifications - voltage, frequency, phase, and current or power requirements - for the equipment supplied are included on the drawings or in the literature fur- nished. Follow the Instructions of the manufacturers for wiring all 728-75-1-8800 Sheet 26 of 46electrical devices provided. Make certaln that the speci fled rated vol tage will be applied at the ternlnals of each plece of equipment under al] operating conditions. Design the electrical installation to conform to the requirements of the National Electric Code and any applicable state and local codes. Pay particular attention to the safety requirements and protective features of all devices used. Sone Installations include Instrumentation which Is mounted through the side of the shell. In such cases, trolley wires which encircle the shell and stand-off Insulators to support them are suppiled to pick-up signals from the sensors. Pantographs and their supporting base are supplied to transfer the signals from the rotating trolley wires to ex- ternal circuitry. Drawings are provided with the Kiln which show the Installation of the trolley wires, Insulators, pantographs, and base. information on the sensors, instrumentation, and Interconnect ing circuitry Js provided In separate electrical system Instructions It is Important to braze and grind Joints in the trolley wires carefully so that the transfer of signals is as effective as practical. FIRE HOOD The fire hood Is not put on until after the shell has been assembled and aligned There are many different kinds of fire hoods, but they are relatively simple enclosures to erect and assenble In accordance with the drawings provided. All fire hoods are refractory-lined. Most types are not bolted down and many are equipped with wheels. Particular care must be taken in assembling the seal between the fire hood and the shell. FEED HOOD The type and conf guration of the hood on the feed-end also varies a great deal and depends upon the equipment which will be located at 728-75- t-8800 Sheet 27 of 46fat end to feed material Into the Kiln and to handle the hot gases leaving it. ° While installation must be performed tn accordance with the drawings Provided for the specific hood supplied, refer also to the Instruce tlons for the interfacing equipment. They may include information which will clarify the installation of the hood itself, Special attention will be required in Installing the seal between the hood and the Kiin shell. The type used varies according to the appl i= cation. Some feed-end hoods require: a refractory lining. NOSE RING On the larger machines equipped with a nose ring for cooling, the cowl and support sections must be welded on-site. On smaller machines, these parts are assenbled to the shell section at the factory. In both cases, the segments which close the area between the cowl and the end of the shell are bolted into position on-site. All necessary holes and bolts are provided, If the cowl is welded on-site and 2 carbon seal is to be installed be- tween the nose ring and the fire hood, It will be necessary to grind the welds In the area where the seal plates will be in contact with the cowl. The fan is installed at a convenient location which will Init the length of ducting, Refer to the fan manufacturer's Instructions for In- Formation on providing a foundation for and installing the fan and its drive. The ducts are to be supported Independently so that their wel ght Is not carried by the fan housing. BURNER The burner and the equipment associated with it Is Installed in accord= ance with its manufacturer's Instruct ions. 728-75~1-8800 Sheet 26 of KéREFRACTORY LINING In most installations, the refractory lining required in the Kiln is rot Included with the equipment provided. Separate arrangements are usually made with other sources for procuring appropriate refractory material and having it installed, Brick-retalning rings which are to be welded inside the shell as the refractory is installed are provided. One ring should be Installed 18 to 2h inches from the discharge end. The Fost are usually equally spaced throughout the length of the Kiln. Consult the refractory supplier for his preferences on the number and location of rings with respect to the refractory being installed. Usually, refractory Is Installed along the length of ‘the Kiln to a ring location. The ring, which is In 4 or 6 segments, Is held tightly against the brick while it is welded to the shell, Installation of refractory then resunes. Welding the rings In position while the re~ fractory-is being Installed avoids the necessity of cutting refractory to fit between previcusly Installed rings. While the refractory is being installed, the Kiln Is rotated as neces Sary to permit the work to be performed in the most advantageous posi~ tlon. CHECK-OUT Because the Kiln will be placed In limited operation to dry the refrac tory lining, a thorough check of the instatlation should be made to verify that it Is ready to be started and operated, This inspection should in ¢lude the following points: All temporary forms and supports used during Installation of the refractory have been rerpved. Both the interior and the surrounding area have been cleaned; they are free of all foreign matter and refuse - particularly combustibles. Components of the Kiln requiring It - riding rings, thrust rotlers, bearings, reducers, motors, couplings, fans, etc. ~ have been properly lubricated, Lubrication systems are operable. 728-75-1-8800 Sheet’ 29 of 46Controls and Instruments are ready for operation. The rotation of al! motors Is In the required direction. After the Inspection has been completed, the Kiln is rotated and its con ponents checked to make certain they operate satisfactorily. The main Gcive lg started at its lowest speed and the following condi tfons ave veri fled: The girth gear and pinton, bearings, and similar devices are being lubricated, * Cooling water Is flowing through the bearing on the support rollers. All rollers are in contact with the riding rings. Drive units are properly adjusted, The seals are making proper contact. The speed is then increased [n steps up to the maximum, and all compon= ents are observed for proper operation at each step. The Klin 1s stopped after the check has been completed. DRYING REFRACTORY The refractory lining must be thoroughly dried before the Kiln Is placed In service, During this process the burner Is started and run on slow fire and the Kiln is rotated slowly, Drying normally takes about 48 hours, but instructtons will be avai lable from the manufacturer for the refractory used on the Installation. Initially, rotate the KIIn approximately one-half revolution every half hour. As drying progresses and a little sore heat Is used, change the rotation to be about one-third turn every 20 mfputes, then’ one-quarter turn every 15 minutes. As the tenperature is Increased, the Kiln should be run continuously at its lowest speed, The objectives are to heat evenly, to dry the refractory uniformly, and to avold heating one side of the Klln excessively so that a danger of warping exists. 728-75-1-8800 Sheet 30 of 46POST-INSTALLATION IDLE TIME If the Kiln will be idle after installation has been completed, it should be rotated for about 15 minutes each week to circulate ol! through bear Ings, speed reducers, and simi lar components. OPERATING INSTRUCTIONS The satisfactory operation of a Kiin Is primarily dependent upon the ex- perience and capability of the operator, {t requires a thorough know~ ledge of the process, of the material being processed, and of the equlpnent itself. It also requlres skill at accurately Interpreting the state of the material and influences of the many variable, Interacting conditions which exist during operation and in achieving precise responses from the equip- ment when adjustments are necessary. The less sophisticated installations depend heavily on the operator exer~ cising direct manual control. As the complexity of the installation In Greases and wore operations becone autonated, the emphasis Is shifted to the operator establishing the control points to which the circuitry must Fespond, monitoring the operation of the system, and being prepared to Intervene in the event of @ malfunction, The capabl lities offered end functions performed by the Instrumentation and control system are covered in separate Instructions prepared for each installation. The paragraphs which follow present general Instructions and procedures concerned with the mechanical operation of the Kiln. SAFETY Because of the high temperatures, both Internal and external, the entire Kiln must be treated as a dangerous area, Skin temperatures generally range from a tou of about 300°F up to about 600°F, 1728-75-1-8800 Sheet 31 of 46WARNING SAFETY PROCEDURES MUST BE OBSERVED AT ALL TIMES Personnel working on the plers or other Jocatlons where they can cone into contact with the shell must be safety conscious to avold Inadver- nt contact. Care must be taken in opening Inspection ports In the fire hood. Be~ cause the Kiln Is under suction, hot gases should not escape from an open port when the KiIn Is operating under normal condi tions. There should be an Inward flow of alr. However, hat dust from any kind of puffing in the fire hood can be blown In the operator's face. Pro tection for the face and eyes must be worn at these tines. STOPPING The primary concern In stopping the Kiln Is protecting the refractory from the effects of sudden temperature changes, Rotation of the Kiln Is continued at progressively lower speeds as the temperature drops. When low temperatures are reached, the rotation can be reduced to a fraction of a turn each hour, It should be stopped com pletely only when the danger of creating local hot spots and warping of the shetl no longer exist. ENERGENCY SHUT-DOHN The shut-down action to be taken In an emergency situation Is-dependent upon the nature of the emergency and its anticipated duration and can be determined only at the tine and on the basis of an evaluation of the situatton by experlenced personnel. 728-75~1-6800 Sheet 32 of 46Host such situations arise because of a malfunction in another plece of equipment in the system, and matertal cannot be processed through the kiln until a repalr ts effected, in many Instances, a complete shutdown Is not required. In all cases the priority of consideration must be first to the safety of personnel, then to the protection of equipment, and Finally to the Product or materfal In process. In considering equipment, the kiln is glven a high priority because of the time and expense required to effect repairs as well as its original cost. POWER FAILURE In the event of @ power fallure, It Is vital to the shell that the aux- Mary drive be started Inuediately so that rotation can continue. Refer to the separate Instructions provided for the auxillery drive to become familiar with the starting sequence and control procedures. fallure to keep a hot shell rotating results In dasage to the refractory and warping of the shell. Any warping is sertous, but It can becone 50 severe that corrective measures becone both difficult and expensive. Most power failures occur during storms when there Is rain, wind, snow, or various combinations of these elements, each of which has a signifI~ cant cooling effect on the shell. In addition to causing a rapid heat transfer fron the lining, thts cooling of the shell tends to cause it to contract and exert a compressive force on the refractory, causing it to crack and loosen. Should a situation arise where neither primary power nor the aux! lary drive is avallable to rotate a hot shell, an improvised means of rotation must be devised. A tractor to pull a cable wrapped around the shell or hydraul 1c Jacks pushing agalnst bars placed between the pads under the riding rings could be used, A warped shel! wilt alter proper gear and Pinion mesh and could result In gearing fallure. ‘THE AUKILIARY DRIVE Aside from emergency use to rotate the kIIn during a power fallure, some operators use the auxillary drive to rotate the kiln slowly or Intermit~ tently during the early stages of heatIng or the later stages of cool ing. If this procedure is followed, it Is inportant to make certain that the lubrication system for the main gear remains in operation when the other poner untts are stopped. The auxiliary drive Is an energency system only and should not be used for continuous operation. 728-75-1-8800-1 Sheet 33 of 46WARNING DO NOT USE THE MAIN DRIVE AND THE AUXILIARY DRIVE TOGETHER Attempting to use both drives to start a Kiln can exert much more torque than the drive components can withstand. Personal injury and serious danage to the installation can result. SKEWING ROLLERS Rollers are skewed on floating KiIns only. They remain parallel to the centerline on full thrust Kilns and those equipped with a hydraulic thrust mechanism. The purpose of skewing Is to cause the shell to operate In 3 position where It, is floating between the thrust rollers rather than rest- ing agalnst either of them. By setting the rollers at slight angles to the shell they exert a thrust on it which is adjusted to counteract Its tendency to move down-hill. Figure 8 shows the direction that rollers are to ba skewed for both directions of rotation. At the time of installation, all rollers were set with their centerlines parallel to the centerline of the Kiln so that when the KiIn {s first Placed In operation, no roller wilt be exerting a thrust in either the up- AEM or down-hil! direction, While the rollers are in this neutral posi- tion, the adjusting bolts should be marked so that the amount each one Is subsequently turned to skew a roller can be seen. It 1s necessary to skew all rollers slightly and in the same amount so that although each roller Is at an angle to the Kiln, each set of rollers Is parallel with the other sets of rollers. NOTICE ONE PERSON SHOULD MAKE ALL ADJUSTHENTS TO ALL ROLLERS ON THE KILN. Adjustments are made In small Increments, ali réllers must be adjusted the 728-75-1-8800 Sheet 34 of 46ana cag ona oaas ——_{—__, —_— orive FIGURE 8 SKEWING ROLLERS LOWER THRUST ROLLER 728-75-1-8800 Sheet 35 of 4¢ ONS 39KVHOSIC Na 39WVHOSIaSame amount, and they must share the load equally. In addition, one per- Son becomes familiar with the Kiln and knows the change an adjustment wi 11 effect. For these reasons, one ind! vidual should be assigned to make all roller checks and adjustments on the Kiln, He should maintain records of adjustments and alignment checks to ald in future adjustments and alignment corrections. Skewing and making adjustments to the skew are performed while the KiIn Is In operation and at its normal operating tenperature. Hoving the rollers Inward with the Kiln stopped would be extremely difficult mechanically. Also, the adjustment should be made after the KIIn has completed its ther= mal expansion. WARNING BECAUSE ROLLERS ARE ADJUSTED WHILE THE MECHANISM 18 IN MOTION, PERSONNEL NUST EXERCISE CAUTION TO AVOID INJURY Although the parts are rotating at relatively low speeds, danger does ex- Ist. Personnel must exercise particular caution In keeping'-thenselves and their clothing well clear of the moving parts. In addition, the exter- for surface of the shell will be hot enough to cause burns. If the guards are renoved to make the adjustment, make certaln they are re-installed pro~ perly afterward. Rollers are skewed through the use of the adjusting screws mounted in the support Frame and pressing aginst the base of each bearing. Turning @ sérew moves the assoclated bearing, and the angle at which the rol ler addresses the riding ring is changed a corresponding enount. On Kilns equip~ ped.with the larger sizes of rollers, hydraulic cylinders operated by a hand ung are mounted on the frame to move the bearing. The screw Is then used to retain the bearing in its new position. The hiold-down bolts on anti- Friction bearings must be loosened while their roller 1s being skewed. When It Is desired to move the KIIn up-hill, the bearing on the up-hill side of the roller on the upward-turning side of the Kiln is moved toward the riding ring as Illustrated In Figure 8. The down-hiTl bearing on the down- ward-turning side of the Kiln would then be moved toward the ring the sane azount. Moving the other pair of bearings would result in the Kiln moving down-hill, but this is rarely desirable, A small amount of up-hill thrust is usually needed, 728-75~1-8800 Sheet 36 of 46The direction e roller ts thrusting can be determined quickly by striking the end plates of the bearings with a small hamer, When a roller Is skewed to hold the Kiln up-hill, the bearing plate on the doun-hill bear- Ing wil] have-a solld sound when it is struck, and the up-hil! bearing wil] Sound Hollow. The opposite Is also true. If the roller Is set to move the Kiln down-hill, the up-hill bearing will have @ solid sound and the one down-ht}] WITT’ sound hol low. Adjustments are made in snall Increments which are rarely larger than one- Sixteenth of a turn of the screw. They should be made to all rollers in the sane anount so that the thrust Is divided equally between all piers and between both rollers on each pler. One roller is never set to thrust In the opposite direction from its mate, nor is any pair set to thrust In the opposite direction from the others. When the rollers are first skewed from the neutral position, a period of at least 6 to 8 hours should elapse before the riding ring contacts the upper thrust roller. If the shell moves uphill In less tine, the rollers have been skewed too-much and must be adjusted to avoid unnecessary wear. Depend- Ing on the’ size and speed of the KIIn, a pertod of from 2 to 8 hours may be required for the Kiln to adjust itself to a change made in the skew angle. Once the skew of the rollers has been set and the load balanced anong them, additional adjustment should not be required for 9 long time. Some move~ ment of the Kiln may occur from time to time, but the change should be ob= served for @ while to see If the condition corrects Itself, if the change is too small to warrant an adjustment, or if an adjustment Is desirable. COLD WEATHER OPERATION For Kilns located In areas subject to freezing weather, precautions must be taken to prevent cooling water from freezing In the bearings or piping. During shut-down periods, drain the water fron the bearings. MAINTENANCE Maintenance of many components of the Kiln, such as anti-Friction bearings, 728-75-1-8800 Sheet 37 of 46drive units, and the gear spray system, Is to be performed In accordance with the instructions of their Individual manufacturers. In those Ine stances, the Information available from the manufacturers 1s provided Separately. The Instructions contalned in this section pertain to con Ponents not otherwise covered or are supplenental to the separate mater~ jal CHECKLISTS AND RECORDS Check! ists should be prepared which fnclude a routine for examining, Jub ricating, adjusting, and otherwise servicing the various elements of the Installation so that nothing is Inadvertently overlooked, Complete and continuous records should be maintained for the repair and replacement of the refractory IIning. The record should Indicate the date, make, and exact location of refractory material installed. This record can assist in deternining when to replace sections of the lining and to identify the type of material which has proven to be the most de- sirable for the application. Records should also be kept of shel! alignment measurements, roller adjust ments ,-ané gear chacks, The burner daily report should Include the current or power being drawn by the Kiln motor. An Increase In power consumption may Indicate misalign- ment of the rollers. LUBRICATION Table | is a lubrication schedule which Identifies the types of lubsicants to be used with the bearings and gears on the Kiln. The 11 In all bearings on the Kiln = support, thrust, and pinion = should be changed after the first month of operation, then every 6 ronths unless the anount of contamination to which it is subjected requires that it be changed more frequently. The same applies when oil idlers are used to lubricate the girth gear and pinion. Although the gear spray system does not retain or re-use its lubricant, it does produce a sludge which accum~ lates in the bottom of the gear guard. Periodically, the door near the 728-75-1-8800 Sheet 38 of 46TABLE [ KILN, COOLER, AND DRYER LUBRICATION’ SCHEDULE cone: 110 - Engine O11 120 - Turbine or Circulating O11 220° ~ Extreme Pressure O1T (Lead-Naphthenate) 235 - Gear Lubricant (Residual Compound ~ With Di lutent) 370 - High Tenperature E,P, Grease Tex cove SPECIFICATIONS APPROX. No. SAE, NO, Roller Support Bearings: (1) O11 lubricated + 120 1650 $.5.U,/100°F, (2) Grease lubricated > 370 NUGE #2 (3) Anti-friction ofl type 120 800 $.$.U./100°F Thrust Roller Bearings: (1) Sleeve, ol! lubricated = 120 1650 $.8.U./1009F. 50 (2) Anti-friction, olf type - 120 1850 S.S.U./1009F. 60 Pinion Shaft Bearings: (1) anti-friction, grease type - 370 NLGI #2 ~ (2) anti-Friction, of] type - 120 800 $.5.U./100°F, 40 (3) Sleeve, grease type = 370 NLGL #2 = (4) Sleeve, of type = 120 1850 $.S.u./100°F, 60 Girth Gear and Pinion: (- 235 3000/8000 s.3.U./210°F, (1) Intermittent spray system (+ 220* 500/800 S.S.U,/2100F. (2) Oil Ing Idler = 220 400/500 $.S.U./210°F. Speed reducer) coup! ings) ~ See Manufacturer's Instructions Gasoline Engine) Extreme pressure lubricants are not necessary in Kiln sleeve bearings. If the user prefers £.P. lubricants they should be chosen to be stable at temperatures over 200°F, Some of the more recently prepared lubricants do have this stabl lity. #Preferred 728-75~1~8800 Sheet 39 of 46bottom of the guard should be opened and a hoe-type tool used to scrape the sludge out. A graph ted grease of the sams type used at Installation should be used to lubricate between the riding rings and thelr mounting pads. A hand gun with an extended nozzle can be used. ‘The faces of the riding rings and rollers are lubricated only by the solid graphite plate mounted on one of the rollers in each support mech” anism. The graphite, held against the roller by Its own weight, provides ade- quate lubrication, 00 not use ofl, water, or other lubricants. The face OF each thrust roller and the side faces of Its riding ring are also lub- ricated by a graphite plate held against the thrust roller, No other type of lubricant should be used on these surfaces. If the bearings on the support rollers are of the sleeve type, the caps should be opened periodically while the Kiln is in operation to Inspect the Interior and to deternine if the bearing is being lubricated ade- quately. Keep the of1-f111 pipes on both the support and thrust bearings clean. Under some conditions, dirt can accumulate In these pipes and, if not cleaned out, can give a false indication of the of! level. Inadequate lubrication leading to bearing fallure can result. Check the of! level regularly, adding of! as necessary. ‘The contact Faces of labyrinth and rubbing-type alr seals should be lub- ricated with a graphited ol! mixture. Seals which are effected through the use of graphite blocks will require perfodic replacement of the blocks but no lubrication. KILN ALIGNMENT Kiln alignment should be checked periodically and corrected as necessary to avoid excessive wear on rings, rollers, gears, bearings, and seals and to restrict cracking of the lining, The preferred method of check~ ing allgnment Is performed inside the Kiin along the centerline. The pro- cedure Is much the same as that used during Installation except that checks are made only at ring locations, Refer to the paragraph In the INSTALLATION Section enti tTed CHECKING ALIGNHENT. There are instances where this technique canrot be employed and It is necessary to check the alignment from measurements made on the outside, Outside alignment is quicker, but not as accurate. A procedure which can be used Is available from the factory. 728-75-1-8800 Sheet 40 of 46Sench marks established while the Kiln was belng’ Installed should be used to check the piers for shifting or settling which could cause misalign- ment. AUXILIARY DRIVE UNIT The components of the auxlIlary drive mst be checked regularly to maln~ taln them in a condition where they wlll start inediately when needed. Most are engine driven, and the engine should be started and run dally. The oil level and fuel level should be kept at the full mark. Haintaln 2 full charge on the starting battery, keep the terminals clean and tight, and add water as necessary to keep the cells full. The discharge-charse cycie'of starting and running the unit regularly is advantageous to good battery life. Refer to the manufacturer's instructions for these units. REFRACTORY The refractory lining should be inspected whenever an opportunity arises and: any damage repaired. Unusual operating conditions sometimes cause the refractory to crack and to break loose from the interior while the Kiln Is in operation, resulting In hot spots on the shell which can glow and warp. In such cases it Is necessary to shut down as quickly as pos- sible to repatr the IIning and patch the distorted shell. Whenever the Kiln Is relIned or repairs are made to the lining, time must be allowed to permit thorough drying before the Kiln is returned to ser~ vice. Refer to the paragraph entitled DRYING REFRACTORY in the INSTALLA- TION Sectlon. MAIN GEAR AND PINION The main gear and pinion should be Inspected periodical ly to ascertain that they are receiving adequate lubrication and that good contact end proper clearance exists between them, An annual check of backlash con~ ditions should be made and the results recorded, Refer to the gear in~ stallation and alignment Instructions provided separstely. Wear on the riding rings and support rollers will change the mesh of the gears. Even- 72-75-1880 Sheet 41 of 46tually, adjustments In the location of the support rollers may be neces~ sary to maintain proper clearance. The roller-to-race clearance on the pinion shaft bearings should also be easured once each year. An appreciable increase in the clearance will Indicate the necessity for changing these bearings. 8 sure to record the measurements for future reference. SUPPORT-ROLLER BEARINGS Periodically, roller end-play should be checked to determine the amount the thrust washer has worn, Heasure and record the change’ in. end-play from when the thrust washer was new. Replace It when the measurement in- dicates that the oll grooves are worn away. Refer to the paragraph en~ titled INSTALLING BEARINGS AND ROLLERS, If sleeve bearings are used, check for excessive wear of the bronze half- sleeve. Replace as necessary, Wear of the coverplate on the roller side of the bearing would Indicate excessive wear of the sleeve, The seal on the roller side will also wear and should be replaced when it begins to leak. To replace a sleeve, take the load of the Klin off of the roller by sup- porting the shell in a cradle watch can be Jacked up the amount necessary to unload the roller. Support the roller tn a sinflar manner. Remove the end cover fron the bearing, unbolt the sleeve, and slide it out the end. Lubricate the new sleeve so that there can be no Initial dry con- tact, slide It Into position, and bolt it, Regardiess of the type of bearing, this sane technique of supporting the shell and roller is used If an entire bearing aust be renoved and replaced. On Kilns equipped with anti-Friction bearings, measure the roller-to-race clearance once each year. An appreciable Increase In the clearance will Indicate the necessity for changing these bearings. Be sure to record the measurements for future reference. THRUST-ROLLER SLEEVE BEARINGS Wear of the sleeve bearing on a thrust roller and the thrust 1728-75-1-8800 Sheet 42 of 46the roller should be checked pertodically.’ Wedr of the bearing can be de- termined by measuring the amount of lateral-movement of the roller, The amount. of thrust ring wear will be evident From successive neasurenents made from the frane to the. top of the thrust roller. The bearing sleeve Is press-fit Into the bracket with only enough inter ference to hold it in place. One screw through the side of the bracket and Into @ hole in the wall of the bearing prevents rotation. To replace the sleeve, remove the bracket fron the frame, lift the roller from it, remove the screw, then draw or press the old sleeve out. In pressing ‘the new sleeve in, allgn-it with respect to the screw'In the side. Once the roller has been removed, the thrust cing can be removed and replaced without disassembling any other parts. ERRATIC KILN ROTATION Properly Installed, operated, and maintained Kilns rotate smoothly and steadily. Erratic rotation - bumping, jerking, or bouncing ~ can be caused by a number of conditions, The: following paragraphs discuss causes of irregular motion. WARPED KILN SHELL Warping unbalances the weight distribution of the Kiln such that the con~ vex zone is heavier. As this zone moves upward, rotation can stop momen- tartly es each pinion tooth moves away from the meshing girth gear tooth causing the next pinion tooth to bump against the next girth. gear tooth. Warpage can also cause the shell to rub Inside the fire hood, feed end housing, or at any point where rigid structures are set close to the shell. This added pressure can Increase the gear bunp mentioned above, overload the drive motor to cause speed fluctuations, and force the shell to flex with each bump of the gear. In combination, these conditfons can cause the shell to bounce with enough force to be seen and felt, SEAL RING PRESSURE Air seals may bind or choke. When this happens, a chattering form of vibration can be started which will be transmitted throughout the Kiln, 728-75~1-8800 Sheet 43 of 46The condition will be aggravated If it begins before the Klin has ex- panded fully, Continuing expansion will place severe pressuré on the rubbing surfaces. IMPROPER LUBRICANT VISCOSITY When the lubricant is not of the proper wal ght or classification or is dirty and sludge-filled, it can cause drag which will overload the motor and, in severe cases, damage-the roller shaft. WORN THRUST WASHERS OR BEARING LINERS After these parts have worn to the polnt that the effectlveness of the O11 grooves has been serlously diminished, the resulting Inadequate lub- rication can cause a chatter or vibration and an overload condition for the drive. INADEQUATE COOLING ‘An inadequate flow of water to the bearings or blocked water passages within the Jackets or piping can result in over-heating, affect the tubri~ cation, and cause the shaft and bearing to seize and result in drag and chatter. EXCESSIVE BACKLASH Excessive backlash will cause the Kiln to jerk as It rotates. GEARS MESHING TOO DEEPLY Improper gear alignment or KIIn alignment may place the gears too deeply in mesh causing the teeth to bottom and resulting in a sever bunp as each tooth passes. With a warped shell, the mesh can alternate between belng too deep and too shallow on each révolution, WORN RIDING RING PADS Full-Floating rings require small amounts of clearance which pe! them 728-75~1~8800 Sheet 44 of 46to slip. Eventually, this space may becone excessive, the center Ine Wi} Toner, and the girth gear will mesh too deeply with the pinion. IMPROPER ROLLER ALIGNMENT Aside from encouraging rapid wear, Improper roller alignment can result in several forms’ of irregular movement including flexing of the shell and too deep gear meshing accompanied by reactions which range from light vibration to severe bumping. If, in a floating Kiln, .the rollers..are not properly skewed, excessive pressure on either thrust roller can cause a chatter-type vibration. Minor shifting, settling, or tilting of the plers will appear as Improper roller alignment. UNDERSIZE DRIVE MOTOR At times and under certain conditions, the Kiln Is operable under feed and load conditions greater than those of ‘the original design. If a propor- tlonatly larger notor and drive Is not installed, the small motor will, at least, tend to have a Fluctuating speed which Is’ transmitted to the Kitn as erratic rotation. LOOSE FITTINGS AND UNITS Loose fittings or components can result in 2 vartety of vibrations and erratic motions. UNUSUAL MATERIAL CONDITIONS Certain materials will shift in an erratic manner rather than sliding or tumbling In the usual way. Such motion will affect Kiln rotation, At tlmes, material accumulates to form slabs on the refractory lining and have the same results as a warped shell, LoW VOLTAGE Low voltage at the drive motor can cause the speed to fluctuate and result in erratic rotation. IMPROPERLY POSITIONED THRUST ROLLERS Thrust rollers are set 1/16- to 1/8-inch off the centerline of the Kiln toward the invard-running side of the Kiln to permit the riding ring to contact the roller rim on the down-sweep and keep the thrust roller seated 728-75*1-8800 Sheet 45 of 46in its housing, If the thrust roller Is set to the up-sweep side It can be IIfted to rub against the ring retaining band and, In combination with the up-sweep pressure, cause vibration. SPARE & REPLACEMENT PARTS Parts lsts and l!sts of recommehded spare parts are provided separately. In ordering parts from the factory, be certain to specify the quantity, description, and part nunber for each one, include the serial nusber of the machine'on ail orders and related correspondence. 728+75- 18800 Sheet 46 of 46