Mechanical OK.

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Mechanical kiln inspection

Improves and ensures kiln
availability by optimisation of:
■ Kiln axis
■ Kiln shell ovality
■ Axial balance
■ Kiln crank
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Introduction
INSPECTION

MAIN FEATURES Kiln inspections F.L.Smidth

Regular kiln inspection is required to ensure
• Ensures high kiln optimum availability of the kiln installation
availability and to verify that the kiln operates within
the load and stress parameters laid down by
• Reduces maintenance the kiln designer.
costs Today’s state of the art methods of inspection
performed during normal operation of the
• Short payback time kiln are based on advanced measuring
techniques and evaluated by highly
• Performed during experienced kiln specialists.
normal kiln Although the vast majority of cement plants
operation employ a very experienced maintenance
KILN
F.L.Smidth is the world's largest supplier of
rotary kilns, spare parts and services to the
cement industry. With more that 120 years
of experience as kiln designers, F.L.Smidth
possesses a huge technical know-how on
rotary kilns and employs a group of highly
experienced field engineers, who work daily
as kiln specialists at cement plants all over
the world backed up by the entire
F.L.Smidth organisation.
The Hot Kiln Alignment method was
introduced into the cement industry in

staff, it is not economically and technically 1981 allowing a full inspection of the kiln
• Extended lifetime viable for the individual plant to invest in to be performed during normal operation.
of refractory lining the measuring instruments and develop the Since then, F.L.Smidth has continuously
and other key kiln computer software required, acquire and updated and improved the method,
components maintain the skills necessary to perform measuring instruments and computer
MECHANICAL

these advanced inspections, process the software to provide our clients with the
• Backed up by data and evaluate the results. best possible tools to evaluate the
F.L.Smidth´s Therefore it is an accepted practice in the consequences of the kiln’s present
in-house engineering cement industry worldwide to call on an operating condition in respect of the
departments outside company to carry out these availability.
comprehensive kiln inspections at regular
• Based on more intervals.
than 120 years of
experience in kiln
design

• Performed by
highly experienced
F.L.Smidth kiln
specialists
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Symptoms and root causes

Symptoms
Hot bearings Cracks Wear Lining loss
In On suppt. Between
On bearing On thrust In kiln supporting roller tyre and Between Under
journal collar shell roller shaft and tyre kiln shell the tyres the tyres

Kiln axis Kiln axis Kiln axis Kiln axis Kiln axis

Kiln shell Kiln shell Kiln shell

ovality ovality ovality
Root
Kiln crank Kiln crank Kiln crank Kiln crank
causes Axial Axial
balance balance
Lubri- Corrosion Operation
cation
Lining
qualities

The F.L.Smidth concept F.L.Smidth to tailor an inspection to meet his

The inspection concept innovated by F.L.Smidth focuses on the specific needs.
following four elements: The results of the F.L.Smidth inspection are
• Kiln axis presented in a written report and/or on a
• Kiln shell ovality CD-Rom, with recommendations of measures
• Axial balance to be taken.
• Kiln crank Additionally, any adjustments to the kiln
The root causes of the vast majority of the failures of kiln installa- recommended by F.L.Smidth can, at the
tions originate from one or more of these elements, thus posing a client’s request, be supervised and verified by
serious threat to the availability of the kiln. an F.L.Smidth field engineer in continuation
In addition, the F.L.Smidth concept includes a thorough inspection of of the inspection.
the drive station, kiln shell profile analysis, and a general inspection of
the mechanical condition of the other key kiln components. Very often Benefits
the load condition of a kiln changes over the years due to e.g. increased The comprehensive kiln inspection performed
capacity, change of fuel and/or changes of refractory lining quality. on a regular basis in co-operation with
To compensate for such changes, F.L.Smidth recommends that the F.L.Smidth provides the client with the
kiln be recalculated based on the present load conditions and that knowledge necessary to prolong the lifetime
the optimum kiln axis be determined taking the load distribution of the refractory lining and expensive kiln
between the individual supports and the stress levels in kiln shell, components and reduces the risk of
tyres and rollers, as well as the bearing loads into consideration. unscheduled stoppages, thus ensuring high
kiln availability.
F.L.Smidth inspection types Empirically, the payback time of a
F.L.Smidth markets the following three standard inspections covering comprehensive kiln inspection is very
all types of rotary kilns: short as the expenditure on this inspection
• Comprehensive kiln inspection is very marginal as compared with the
• Two-support kiln inspection cost of refractory lining and components
• Hot kiln alignment check to be replaced as a result of avoidable
The F.L.Smidth standard inspections consist of individual modules, mechanical failures as well as the cost of
most of which are optional, enabling the client in co-operation with the consequential production losses incurred.
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Elements
Kiln axis
The kiln axis is defined by the position of the supporting rollers.
It determines the distribution of the kiln weight load between the
supports and thus the distribution of the longitudinal bending
stresses in the kiln shell.
Misalignment of the kiln axis may result in overloading of supports,
excessive stresses in kiln shell, tyres and supporting rollers as well as
bearing overload.
The kiln axis is measured during normal kiln operation using two
electronic theodolites, connected to a computer calculating the
horizontal and vertical kiln axis by specially developed software.
Additionally, the “Comprehensive kiln inspection” includes a complete
recalculation of the kiln, based on the axis measured and the present
load conditions, to determine the optimum kiln axis, taking both
load distribution on the supports, the stress levels in kiln shell and
tyres, and the kiln axis into consideration.

Kiln shell ovality

The dynamic ovality is defined by the degree of
deformation of the kiln shell and determines
the distribution of the cyclic, circumferential
bending stresses in the kiln shell.
Excessive ovality can result in circumferential
bending fatigue in the kiln shell and refractory
lining failures.
The ovality is either calculated on the basis of
the tyre migration or measured via the Shell
Test method.

Axial balance
Although a rotary kiln is always in axial balance, the axial balance
can be established either between large forces or preferably, in
order to ensure the availability, between small forces.
The state of axial balance is defined by the degree of parallelism
between the kiln axis and the axes of the individual supporting
rollers determining the magnitude and directions of the axial
frictional forces between the tyres and supporting rollers and
on the thrust roller(s).
Large axial forces may result in hot supporting roller bearings,
failure of the thrust device(s) or damaged end seals.
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Elements
Kiln crank
A kiln crank, whether mechanical or thermal, can cause
excessive, extra, cyclic loads between supporting rollers
and tyres and stresses in the kiln shell.
A mechanical crank is caused by a permanent deformation
in the kiln shell, whereas a thermal crank is caused by tem-
perature variations along the circumference of the kiln shell,
and so it is present only during operation of the hot kiln.
Excessive crank formation can lead to failure of contact sur-
faces, supporting roller shafts, tyres, kiln shell and lining.
The kiln shell is checked for crank formation by measuring
the variations in the deflection of the supporting roller
shafts, which has to stay within certain limits.

Kiln drive
An examination of the kiln drive constitutes another
important element of a kiln inspection. The condition of
the kiln drive is determined by measurering of the axial
and radial wobbling of the girth gear as well as evaluation
of the mesh and root clearance between the girth gear
and pinion(s).
Further, the condition of the tooth profiles, the lubrication
of the gears, as well as the stud bolt connections between
the girth gear and the spring plates and the welds between
the spring plates and the kiln shell are examined. To complete
the examination of the kiln drive, the operating temperature
and vibration levels of the main gear unit are checked.

Kiln shell profile analysis

A kiln shell profile analysis is made to investigate the
degree of deformation of the kiln shell. Such deformation
may have no influence on the loads on the supporting
rollers but can contribute to refractory lining and kiln shell
failures.The kiln shell profile analysis is based on an evalua-
tion of the kiln cross-section geometry measured at regular
intervals along the length of the kiln. The analysis is pre-
sented graphically.

General inspection
The general inspection of the kiln comprises a visual exami-
nation of the condition of other key kiln components not
included in any of the above activities, but the possible
poor condition of these components can also pose a threat
to the availability of the kiln.
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Standard kiln inspections

General mechanical condition

stress distribution in kiln shell

Inspection
Verification of axial balance

Calculation of current loads

Check of supporting rollers

Calculation of longitudinal
Check for kiln shell ovality

Surface condition of tyres

Check of girth gear / kiln
drive and main gear unit

modules
Kiln shell profile analysis
Check of thrust device(s)
Check for tyre wobbling

supporting roller shafts

Verification of kiln axis

and supporting rollers

Ultrasonic testing of
Check for kiln crank

and bearings

on supports
Inspection
types
Comprehensive kiln
inspection
Inspection of
two-support kiln

Hot kiln alignment check

) Included in the standard inspection
*) Optional
Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice.
12-04-258 Bazement Grafisk Design ApS

DENMARK USA INDIA

F.L.Smidth A/S F.L.Smidth Inc. F.L.Smidth Ltd.
Vigerslev Allé 77 2040 Avenue C Capital Towers
www.flsmidth.com DK-2500 Valby Bethlehem, PA 18017-2188 180, Kodambakkam High Road
Copenhagen Tel: +1 610-264-6011 Nungambakkam
Up-to-date addresses of worldwide Tel: +45 36 18 10 00 Tel: +1 800-523-9482 Chennai 600 034
subsidiaries and sales offices are Fax: +45 36 30 18 20 Fax: +1 610-264-6170 Tel: +91 – 44-52 191234
available from our website
E-mail: info@flsmidth.com E-mail: info-us@flsmidth.com Fax: +91 – 44-2827 9393
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