Professional Documents
Culture Documents
Rotary Kiln Erection PDF
Rotary Kiln Erection PDF
SM
Frame CL
D D
Elevation C Elevation E
Elevation F
(Approx.)
Elevation A B G
1
2”
3 2
Frame CL
Pier CL
4
L
Bolt C
Bolt CL
A E
Use a precision spirit NOTE:
level for test work. A Roller assemblies are to be
stainless steel v-block set before grouting frames.
is supplied for test work, Final test for slope is made
or use an inclinometer. on top of each roller.
SM
Support Frame
Kiln
Kiln
Support
Support
Base Dimension Pier
Pier
(Shown on Foundation Drawing)
NOTE: “Support Roller Assembly” drawing numbers for each pier are shown on the “Foundation”
drawing. Refer to the correct drawings for piers being checked. These drawings show the dimension from frame CL
to beam CL for each assembly (frame & roller dimensions may vary from pier to pier).
Add half-frame dimensions for piers being checked and subtract total from slope dimensions shown on foundation
drawing to obtain test dimension (as shown above in sketch).
Use spring scale to apply 20 to 25 lb’s or 9 - 12 kg. tension to tape line (depending upon wind conditions).
Check tape line temperature and make allowances for possible variation for dimension being checked.
SM
Diameter A
Diameter A
C
ter
ia me
D
Diameter B *
NOTE - Frame dimensions shown on “roller assembly” drawings. Align frames on CL’s, adjust for elevation, slope and
cross-level.
Dimension A - Nominal dimension from frame CL, measured and marked equally at all test points (in field at time of installation).
Dimension B - Test dimension from frame spacing and parallelism. (Tolerance 1/16” or 1.50 mm).
* Use spring scale at 20 to 25 lb’s or 9 - 12 kg. tension on tape line. Check tape line temperature and allow for expansion or
contraction of line.
SM
Plumb bobs C
in oil
Measuring to plumb
lines is not completely
Adjust shims accurate (rollers may be
as needed for final tapered).
true-up of frame.
(Slope & transverse-level
tolerance @0.002” per foot or
Install boards at inner
0.15 mm / 1000 mm).
edges of beams for ramming
Fill anchor bolt sleeves high strength non shrink
with high strength grout. grout from outside edges
of beams.
A - Establish offset reference lines at both edges of frame. Offsets must be parallel to, and symmetrical about the verified true kiln CL.
B - Use adjustment screws to set roller assemblies parallel to the kiln CL .
C - Measure from plumb lines to offset lines.
SM
B
D
AR NT
I NWSTME R
JU LE
AD ROL LY
OF SEMB
AS
E
D NOTE -
Keep lines clear of end plates
to allow for bearing inspection
C and maintenance work.
SM
A
B C
B
A - Longer timbers for clean and soft
A - Timbers in place between rolling surface.
ground and tire.
B - Belt wrapped around tire and tied “Plumb” position of tire
B - Rubber belting for protection with wire.
of tire surfaces. after pick-up.
C - 3 wraps of 1” wire rope hitched to A
Pads
A B crane hook.
C B
A - Kiln tire section on elevated saddles. A - Circumferential sling for moving tire into position
Set level as possible. on pads. Place wire rope inside rubber hose split
lengthwise and tied with baling wire.
B - Tire in position for resting on shell section.
B - Use 4 spacer bars with centering gussets and end
C - Set tire on 4” by 4” timbers for removal of set-screws.
wire rope and belt material.
SM
Preferred arrangement, using a spreader beam and Acceptable hitch arrangement, but anti-creep
two cradle slings. Two cranes should be used for gussets should be installed to prevent wire ropes
longer shell sections with two heavy padded from crawling toward each other when the crane
sections for riding rings. starts to pick up the load. Calculate the sling
tension for the included angle & use an adequate
capacity slings.
SM
Diameter
1000 lbs. 1000 lbs.
.
lbs
115
60°
Kiln Shell Kiln Shell s. 1
lb 90° 415
5
115
lbs
15 l
14 45° 45° bs.
.
60°
2000 lbs. 2000 lbs.
Diameter Diameter
“Choker” no good for Go with “Cradle” for
handling kiln shells. Handling Kiln Shells
SM
l
ud ina
t
ngi
Lo ld
We
SM
Adjusting lug
Strong-back
Edges of adjacent
shell sections
“Push” - “Pull”
Adjust Bolts
SM
Feed End
Field Joints
Gauge
Blocks
Discharge
End
Transit Replacing
Batter Board
Instrument cross-hairs or center of a laser beam must be within 3/32” or 2.5 mm of target center at all
test positions.
SM
Steel Spider
(1 of Several Types)
2” X 6”
Board
1/4” X 4” X 4”
2” or 50 mm Diameter Hole
Steel Plates
Drilled at CL’s
A - 4” X 6” index card held in place by thump tacks (or staples) and push pin.
B - Shows card turned and pinned to clear 2” or 50 mm diameter hole for through sight to next targets. Card
can be returned precisely on starting position for target re-check.
SM
Card on
batter board
A4 A2
Center by
first set
of quarter
points
SM
3 4 5 6 7 8 9 10 11
1 2
After aligning and tack-welding span “A”, as for 2-section 2-support kiln (figure kiln overhead 014.cdr) or when this length
has been factory built, alignment of following spans can usually be achieved by adjusting support rollers.
Usually completion of joint in span “A” will eliminate need for support at joints in following spans. Actual support
requirements will depend on section design for shipping.
Actual sequence of installation and alignment must be determined on-site to suit actual number of shipping sections.
Lock transit on target 8. Back-check on 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of site within 3/32” or
2.50 mm of target centers.
Lock transit on target 11. Back-check on 10, 9, 8, 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of sight within
3/32” or 2.50 mm of target centers.
Minor errors on short fore-sight will “grow” on each following target. Avoid errors, save time and avoid confusion by
working from most-distant far-sight.
SM
Edges of adjacent
shell sections
Prewelded end
Tack weld in bevels, at least 6” or 150 mm long, at fixtures used for alignment of adjacent plates.
Discharge
end
Thrust
Chair in position to
support and adjust
the gear for correction
of axial and radial runout.
Typical gear chair
( 1 of a set ) for
temporary duty.
2” X 6” (or to suit) bolt
for gear radial adjustments.
SM
Feed End B
A - Gear guard section
A B - Flange joint for removable panel
C - Splash band sections
D - Spring plate for gear
E - Kiln shell plate
F - Spacer guides
NOTE:
If conduit must pass through bands to reach a thermocouple, install before guard assembly work.
SM
Low end
of kiln
In (discharge) In
Rollers move Support Rollers move
toward discharge end Roller toward discharge end
SM
With a two thrust roller system (as here) the kiln should be floating between the thrust rollers.
With a one thrust roller system there should always be contact between thrust roller and tire pressure
200-800 psi or 15 to 60 bar.
SM
Kiln may be
Beam Support on slow rotation
top roller Plumb if plumb bob
A
lines is suspended
in oil *
Bearing
Base
A
B
B Offset reference line
(may be a tight wire
High temperature metal surfaces or a straightedge at
can cause severe burns. established reference
Plumb
Moving (rotating) machinery can bobs in marks).
cause hands and arms to become caught. oil
Avoid personal injury.
A - Scribe beam surface at edge of bearing base to establish reference points for measuring bearing movement during
the roller relocation work period.
B - If it is possible to work simultaneously at both bearing positions, use 2 plumb lines for measuring movement.
* - This procedure is not valid if the roller is cone shaped or distorted on the rolling contact surface.
SM
Rotation B
Rotation A
Roller Shaft
180° B
bearing
bushing A Shaft Rotation Shaft
Recessed Zone
(Both Edges) B Rotation
SM
36°
72°
Variable
All pieces
from 1 1/4”
plate
Saddle for Kiln/Shells
Chord Length
Kiln Saddle Dimensions
72° = 5 spaces @ 0.587785 X outside diameter = Chord Length
Rule of thumb:
“Chord Length” does not apply when designing a saddle for under a riding ring. A saddle for a riding ring must
straddle a tie beam between support frame beams and must be designed to fit between rollers on that frame.
Saddle width should be same as width of nearest tire but not less than 12”.
SM
Drive wedges and/or filler plates between tire and pads to eliminate top
clearance for early pick-up of the tire when jacking against the saddle.
Clearance
Tire
Clearance
Tire
Shell Brace
Refer to the foundation drawing for the kiln for the pier loading figure at the tire to be raised;
jacking capacity for that area will be indicated by the vertical load shown for that pier.
SM
B
A
Slope Line
Pier Surface
A - No oil leaks at downhill shaft seal except when overfilled, dirt and rainwater enter housing when seal is bad, as
when a liner is badly damaged.
B - Shaft seals are not dams. Oil level must not reach seals at uphill bearing assemblies.
SM
Oil Trough
Felt
Oil Cup
Seal Oil
Heat Shield
Scraper
Thrust Ring
Liner
Oil Gauge
SM
SM
Support
Roller
In
Rotation
Low end
of kiln
(discharge)
In
Rollers move
toward discharge end
Counterclockwise Rotation
SM
In
Rotation
Low end
of kiln
(discharge)
In
Rollers move
Support toward discharge end
Roller
Clockwise Rotation
SM
In
In
Kiln
Bearing
Kiln Bearing
Support Support
Roller Roller
Kiln Bearing Rotation Bearing
Kiln
In
In
Moving (rotating) machinery.
High End
In
In
Kiln
Bearing Bearing Kiln
Support Support
Roller Roller
Bearing Rotation Kiln
Bearing
Kiln
In
In
Moving (rotating) machinery.
Rotation
Idle
Down Correct
Down Down
1/16” to 1/8”
Roller Kiln
Centerline Centerline
SM
Rotation
Up
Idle
Wrong
Up Up
Any amount
Kiln Roller
Centerline Centerline
Bearing Housing
Oil Bucket Wheel
Thrust Washer
Feed End
CL Roller
Detail
Oil Level and
Oil Fill Pipe
Bearing
Roller Shaft
Adjustment Plate
SM
Thrust
Roller
Housing
Shims
Thrust Rod
Oil Spherical
Seal Roller Bearings
Detail
SM
C-C
C
SM
To Hydraulic
Power Unit
Stroke
Adjuster
Lower Thrust
Thrust Housing Spherical Housing Support
Thrust Support Rod Roller
Roller Bearings
Frame Upper Thrust
Housing Support Drain Plug Oil
Seal
Feed End
Detail
NOTE: Oil Pipe & Graphite Lubricator Included but Not Shown
SM
C
Limit Switch
Assembly
CL
D C B A E F G
Bumper + + + + + + +
Assembly Riding
CL Kiln
Ring
Pier 3 Pier 2
Hydraulic
Power Unit Hydraulic
Cylinders
Hydraulic Thrust Orientation
(Single Hydraulic Cylinder May be Used)
A-A
SM
SM
Shell Overheated
and Choked
Inside Tire
Expansion
Shell overheated and choked inside tire. Shell expands proportional to internal heat, but must bend at sides of tire.
Tire retainers on bend pads bite into the tire, tire and retainers become worn. When shell temperature returns to
normal, shell pad to tire clearance is excessive.
No shell migration may eventually be followed by permanent kiln shell choke-down deformation.
SM
Pre-Welded
End @ 90°
Brace No. 1 Sag From Start
Brace No. 2
When the pre-welded end of Brace No. 1 is at the top of the shell after 90° of rotation, shell sag moves the loose
end against the bottom of the shell and in position for welding.
Brace No. 2, and possibly No.’s 3 and 4, will be needed for pad replacement work requiring frequent rotation
of the shell.
Spider bracing is for holding the shell as round as possible for pad replacement work. Before welding bracing
to the shell, verify roundness by using trammel layout work for marking the shell axis on Brace No. 1 to establish
a reference point for radius measurements.
SM
Almost zero
clearance.
Shell continues
View at to migrate within
Top Position the tire.
SM
Clearance
When normal coating builds up on refractory, the main shell returns to normal diameter but the permanently
deformed tire section shell is small in relation to the tire bore diameter.
With the tire in a normal alignment position the kiln shell is misaligned at the low-riding deformation zone.
Excessive down tire follows choke-down deformation.
SM
2
1 1
4
SM
Clearance Clearance
0.6125” 0.6125”
New measurement problems must be considered when/if internal bracing holds the shell in a perfectly round condition.
If the riding ring rests on support rollers, ovality will not have changed; now measurements will be between a round
shell and an oval riding ring.
When the riding ring is on the support rollers, and the kiln shell is round (after bracing), measure clearances at both
sides at the horizontal centerline, and at top-dead-center between shell pads and the riding ring bore surface. Add
dimensions recorded for these three check points, then divide the total by two to determine the actual diameter for
shell pads and riding ring bore.
SM
Clearance
Tire
Shell Brace
Clearance between the tire and pads at the top of the shell is usually overlooked when all other details have been
considered in arrangements for jacking up the kiln shell to take a tire off the support rollers for maintenance work
on the roller assemblies in position on the support frame, or for lifting out one or both assemblies for work at ground
level or in the maintenance shop.
SM
By the time the upper pads touch the tire jacks are fighting all shell weight to adjacent tire sections.
Two to four times the jacking capacity anticipated for lifting the shell will be required if tire to pad clearance is
not considered (especially when excessive).
SM
NOTE:
NOTE: The tire will not rise until top area clearance is eliminated by the rising shell.
SM
Clearance
Tire
SM
3 3
2
1 - Spider bracing (installed before locking out the kiln drive system, including the auxiliary drive arrangement).
2 - Timber cribbing stack with hydraulic jacks in place under steel saddle. Saddle and jack arrangement must raise
the kiln shell just enough ( 1/32”, 1 mm, or less ) to be fully loaded for removal of both roller assemblies. *
3 - Install steel or hardwood columns for security of the temporary support arrangement during the pad removal and
replacement work period.
* - If the tire is rising with the shell. If clearance between the tire and shell pads was not accounted for, excessive
jacking will be required to lift the tire away from the support rollers.
SM
Pier Slope
Top Line
Level Line
Pier Reference
Work Point
“Cutaway” view of roller assembly bearing bases shows internal arrangement of components with critical clearances.
Whenever roller and bearings are to be lifted as a complete assembly, hitching arrangements must hold bearings in
full-line contact with shafts, and with no contact at shaft seal zones.
A - Remove shaft seals. Insert wood or rubber wedges between shaft and seal inset in housing. Secure these wedges
with at least one wrap of duct tape (or similar material).
B - Edges of frame beams have machined insets for control of shaft clearance between bearing end plates. Key bars
at bottom positions on housings hold bearing housings in position against machined edges for operation of the
assembly. One or both keybars must be removed to avoid interference when the complete roller assembly is
moved toward the outside end of the support frame.
SM
Prepare hitching material similar to the arrangement shown in these sketch sheets. Distance between connecting
points must place the crane hook, spreader bar and shackles far enough above the kiln horizontal centerline for
flexibility in the lines for lift-out maneuvering.
Remove all cooling water input and drain pipes from bearing bases. Remove bearing adjustment lug and screw
combinations from frame beams. Prepare beam surfaces for outward travel of the roller assembly.
Jack or pull the assembly outward on the frame until motion is stopped by roller contact against the tie-beam at the
end of the frame.
SM
Place timbers at the ground level work area for support of the assembly with the roller off the ground The low-end
bearing housing will touch down, and hitching will become loose, before the other bearing housing rests on its own
support timbers.
SM
FEED
E
ND
OUT / OFF
IN / ON
SM
Move the roller into its realignment position and into a load carrying condition. Reassemble all pipe fittings, guards
and other items which may have been removed for crane handling maneuvers. If internal fittings had not been
reinstalled at ground level, remove end plates for final fit-up work. Re-fill bearing lubricant reservoirs. Remove
pedestals, jacks, saddle and cribbing.
SM
Level Tire CL
Slope Shell CL
True Kiln Axis
Align the kiln shell before shutting down for repair work. Cold-condition external alignment procedures are not
acceptable unless excess clearance and other deviations are accounted for. Kiln shell section alignment is critical
at all tire positions, alignment of tires is not necessarily kiln shell section alignment.
SM
Level 1 1
Slope
Preparation:
1 - Install spider bracing. (See bracing installation procedure on other sheets). Bracing must be installed before the
kiln auxiliary drive system is secured, along with the main drive motor, to prevent accidental rotation during the
repair work period.
2 - Remove retainers at the side of the tire toward the direction of movement away from pads. Grind off weld scraps.
Level
Slope
2
Preparation: 1
1 - Install steel saddle and two (or more) hydraulic jacks in a convenient location that will not interfere with work.
2 - Back support rollers away from the frame center line to let the tire move downward.
3 - As rollers move outward, check tire to shell clearance all around. Stop roller adjustment work when the tire is
in balanced position around the shell.
4 - Install skid bars at the top of the shell. Use shims for adjusting bar height for smooth movement of the tire.
Level
Slope
1
Preparation:
1 - Install a tight arrangement of steel or hardwood pedestals between the support surface and saddle.
2 - Start to jack or tug the tire off pads and onto skid bars.
SM
Level
Slope
Preparation:
1 - Move the tire far enough onto skid bars to allow for installation of new extra long pad plates.
2 - The bottom of the tire will swing toward a “plumbed” position if not restrained. Install gusset plates at the
bottom of the shell to hold the tire away from the pad zone.
STRAIGHTEDGE
Level
Slope
Preparation:
1 - Finish pad removal work. Grind down weld scraps. Remove caked dirt, rust and oil from the shell at the pad zone.
2 - Use a straightedge or a tight line for measurement from undamaged shell surfaces to the top of the depressed shell.
Measure at several points around the shell for a realistic approach for planning and preparing filler material.
The depressed zone must be filled for support of new pads. Any unfilled space, however small it may be, will allow
new pads to bend to fill the spaces as soon as rotation starts after the kiln is returned to the production department.
SM
STRAIGHTEDGE
Level
Slope
A “typical”, but unsatisfactory shim stack arrangement for filling spaces between shell and pads is shown at the
bottom of the shell. Since “all-position” fit-up work is necessary, shim stack installation is tedious (and frustrating)
work. Shim stacks are rarely, if ever, tight enough to prevent pad distortion when the work is called “finished”.
A more acceptable filler arrangement is shown at top of the shell, a rolled plate, at a thickness determined by prior
measurement, is used with appropriate thickness-adjustment shims for a more secure packing arrangement. In this
arrangement filler plates are welded to pad plates, not to the shell.
SM
Slope
Lubricate
When new pad plates, with fillers, are secure around the shell, lubricate surfaces to facilitate movement of the
entire to the predetermined operating position for that particular tire.
SM
3 - Return support rollers to positions on the frame. Adjust for recalculated set points which consider new
conditions at the tire.
CL Tire
Do Not Weld
Gusset to Pad 3/8 to 3/4 TYP
3/8 to 3/4
Pad Pad Pad Pad
Loose End Welded End Loose End Welded End
A
A-A
SM
5
6 7
Tire
1 - Be sure that rollers are carrying the load of tire and shell.
SM
1” Chamfer
Wear
8” Pad Length 8” Ring Height of
Pad 1” Anti-Rotation
Min. Min. Wear Ring Plate
Min. Thickness
5” Riding Ring Pad
Taper Shell
Thickness
TYP
Pad Heavy Shell Plate Fillet Weld Size
Thickness 1/16” or 2 mm Downhill Side Only
A-A
In this arrangement pads are not welded to the shell at all.
The shop installed cost for this arrangement is high, but the future field replacement of pads is simpler and less
expensive.
The continuous wear rings installed between the riding ring end faces and wear ring retainers reduces bearing pressure
and gouging in the riding ring end faces and also increase wear life of the components.
It is very easy to reduce tire creep: Install shims between shell and pads and tack weld new shims to pads.
SM
Lube
ote
Molyk
Cold Kiln
Weld Wedge to Tire
Weld Wedge to Pad
SM
24”
Ignore triangle
in chain
Chain 2”
hook-up
3/8”
Maintenance problem:
Tire
SM
Right triangle re-calculation to suit creep @3/4”/rev. X number of revolutions: 24” chain constant hypothenuse.
Approximately 13 revolutions to move tire 2”. No allowance for elongation of chain under load. Calculate
for actual creep and length of chain(s).
SM
Count kiln revolutions after placing matchmarks. Measure distance between matchmarks after “X” number
of kiln revolutions, then divide that dimension by kiln revolutions during the test period to determine shell
migration (creep) for each revolution of the kiln.
SM
NOTE: Kilns with floating shell pads --- DO NOT PLACE MAGNETIC BASE ON A LOOSE PAD.
SM
1 1/2”
Drill & Tap
10-24 X 1” Deep
6”
10-24 Slotted
Capscrew X 3/4 Long
Permanent Horseshoe Magnet
(10 Lb. Pull)
Description Material
Magnet General - #351-6 Pencil must move freely in tube (no slop).
Ret/G Block 1/2” Hex Bar X 2” LG
Ret/G post & block (tackweld). Drill, ream, tap.
Ret/G Post 1/2” Hex Bar X 1” LG
Cap Screw (Slotted) 10-24 X 3/4” LG
Spring to be retained at end shown.
Holder Chromed Tubing (Plumbing)
Spring 5 /16” Diameter X 1 1/2” LG (Medium Ten.)
Tire clearance & creep tracing-pencil holder.
Pencil Standard HB (No Eraser)
(Berol Black Warrior #372)
SM
2 1/2”
1” TYP.
8 1/2”
Drill & Countersink
To Suit 10-24 Csk Screw
(TYP) 2 places 1/8” Tempered
Bolt & Nut to Magnet Hardboard
Cut strips of manila file folder sheets to fit on hardboard surface. Hold strip in place with spring clips.
Principle of
Distortion Measurement
d b
d
a
h
A 1m
L=
D Shelltest Diagram
== h
C 15
Recorder System
“Holderbank”
h
15. h
B E G
Ovality: = 2 (a - b)
= 4 .d 2 .
h
3 F H
SM
2 3
1, 2, 3, Shell Lines
A, B, C, D Measuring Planes 1
Diagram of One 2 3
Measuring Plane
1
3 2 3
12
SM
%
0.8
0.6
% Ovality
0.4
0.2
0
3 4 5 6 m
Kiln Diameter
SM
SM
End
Start B
SM
Shell Overheated
and Choked
Inside Tire
Expansion
Clearance
SM
= G† :
D
Distorted Shell
Crush Zones
for
Brick Lining
Tire
CL
CL
Shell
Note Note
Note: Deflection also occurs at contact points where the tire rides on support rollers.
SM
Roller CL
As seen
from Frame
Long’l CL 180° Liner
180° Liner Matched Liners
Frame Slope True
Planned Slope
Level Line
SM
Rough Outside
Minor Axis
Rough Inside
Major Axis
ce
ete ren
am fe
Is Bore Worn
Di um
r
and Grooved?
nd irc
Fi e C
To sur
ea
M
Anticipate refractory problems starting at about 0.5% shell ovality. Some older tires started (new) thin
and at critical ovality. Ovality increases when tire is cut too thin for roller supported operation.
SM
Sag
When a tire is too thin
the combination of sag, crimping and
excessive clearance can account for
shell ovality approaching 0.9%.
Check out shell ovality factors before
arranging for tire true-up.
(May need replacement parts).
Crimping
Rollers
SM
Excess
Clearance Thin Tire
Shell
Sag
Crimping
Rollers
Thin tires and excess clearance contribute to shell ovality and fracture at pad welds or in shell plate
at toes of welds.
SM
Load
Concentration
Narrow
Tire
Longitudinal Fracture
Lines Form in Shell
SM
Excessive
Clearance
Sag
Bending Zones
Crush Points for Bricks
Fatigue Points for Shell
Flex
Welds
Pad Pad
Shell
Shell
Shell ovality and pads with full length longitudinal welds, may also include pads with intermittent stitch welds.
SM
Tire
Pad
Shell
Refractory
Remove Refractory
to Expose Shell for Use Rotary Wire
Tracing and Repair Brush to Prepare
of Fractures Clean Surfaces for
Gouging & Welding
0.7 t
T
Shell
Fracture
Inside
Surface
SM
Trace
to
Ends
Shell Outside Surface
Finish
Gouge Weld
Outside
Inside
Bore Zone
w
w
Old Style
llo
llo
Ho
Ho
Hollow Tire
Ta Tr
Real Thickness Varies
Apparent Thickness
Apparent Thickness
Ta Tr
w
llo Old Style
llo
Ho
Hollow Roller
Ho
Excessive cutting & grinding on faces of cored tire and rollers has been known to put holes in surfaces
above hollows. Do not reduce original diameters of hollow tires & rollers more than 3”.
SM
Ridges must be removed. Sided of tire and rollers must be scraped clean for test with a try square. High ridges
must be removed. Tool must be indexed for surface grinding parallel to shaft CL a nd true axis of tire.
SM
1 A B C
Hot Shell
Slope Line
Concave Up
2 A B C
Hot Shell Heavy Load
Slope Line
SM
Assume tire wobble (measured total) @ 3/8”. Tire outside diameter 16’. Tire face 28” (2.333’).
0.357” : 16’ = 0.0234” per ft. X 2.333’ = 0.055” : 2 = 0.0275” v-gaps 180° apart in cross-over cycles.
Grinding will form a “parallelogram” tire profile, pads will become deformed.
This condition is not a valid reason for grinding a tire for improved contact across roller faces.
Do not arrange for cutting or grinding when axial wobble exceeds 0.125”.
SM
Tire wobble not eliminated. Tire face becomes convex, roller faces become concave. Surface true-up is
needed but wobble should be eliminated before any cutting/grinding work is scheduled.
Roller faces will wear into concave contour. Tire face will wear into convex contour. With expansion/
contraction of the shell, large zone of tire moves onto a larger zone of the roller(s). Bearings are overloaded,
shell suffers from reaction to vertical misalignment.
SM
Parallelogram
Tire Profile
After
A A Grinding B B B A
B B A A A B
Important Note:
Shell migrates inside tire. Starting with matchmarks AA and BB, first180° of rotation does not show
significant change of tire contact on rollers. In a regular cyclic sequence with migration of the shell,
when original matchmarks are 180° out of phase (BA & AB) original contact crossover v-gap will have
been doubled.
Two (2) full contact zones will be seen at crossover points 180° apart on the rotating tire.
SM
Tires & rollers need true-up grinding plus realignment, but ripples on shaft & bearing surfaces may
interfere with adjustments when high points meet and generate heat.
Obvious need for surface true-up, but feasibility of metal removal should be verified by ovality analysis.
SM
A B
A - Assume tire not centered on rollers because of wrinkles or other shell problems. Repair work will
move the tire to normal operating position on rollers.
B - Typical wear pattern after long-term operation with tire in offset position.
Tire & rollers must be trued up before shell repair work is started, or to eliminate overload &
misalignment in case of over-expansion or changing position of the thrust tire.
Roller set points must be recalculated to suit tire & roller dimensions after finishing the grinding
process.
SM
Unacceptable
Acceptable
SM
CL Neutral
90° Tire CL
Surface is Surface is not
parallel to bore parallel to bore
Tire Tire
For control of surface concentricity, test with extra large square and
measure circumference at 3 control points across the face.
Control
Control
Control
CL Tire
Neutral CL
SM
Shell
Wrapper
Shell Not
Repair Recommended
Section Temporary
First-Aid only
Longitudinal
Butt Weld
SM
Fillet Welds
Kiln Shell
Reinforcing Band
t
u p por
S
Sup
p
ort
Kiln Shell
Supp
ort
t
uppor
S
Typical Field Cut
SM
Product Description
SM
Weld Shrinkage
Weld Shrinkage
Cumulative effect of weld
Longitudinal
Longitudinal
shrinkages will warp
patch-plate and surrounding
shell plate inward.
Circumferential
Weld Shrinkage
When a patch plate is installed between a riding ring and the end of the shell, anticipate warp-related
runout at the end of the shell and in the seal arrangement.
When a patch-plate is installed in shell between riding rings, anticipate riding ring wobble at the nearest
ring (or both) and also at the seal in most situations.
Start planning for shell replacement when two or more patch plates have been or must be installed.
SM
Weld Shrinkage
Weld Shrinkage
Longitudinal
patch plate double-vee butt
Longitudinal
welds. Radius instead of 90° Transverse weld shrinkage for plate thickness
corners minimizes, but does not is shown in chart. Yield point of adjacent
eliminate stress concentration plate surfaces would be exceeded if the shell
points.
would not be free to move in any direction in
reaction to weld shrinkage stress forces.
t 0.10
60° Double V
0.05
0
1/4 1/2 3/4 1 1 1/4 1 1/2
t = Plate Thickness (in.)
SM
A B
Equations For Calculating Shrinkage-
Transverse Weld Shrinkage (shrinkage perpendicular to the axis of a weld) is particularly important when the
shrinkage of individual welds is cumulative as, for example, in the shell-to-shell connections between rotary kiln
(and similar machines) riding ring positions (support points). Unless allowances are made for transverse weld
shrinkage - usually by spreading the joint open by the amount it will contract after welding - the cumulative
shrinkage of several shell-to-shell connections could be great enough to significantly shorten the span between
preset riding ring retainer locations or scribed reference lines.
For a given weld thickness, transverse shrinkage increases directly with the cross-sectional area of the weld. The
large included angles in (A) are for illustrative purposes only.
Source - Adapted from text in “The Procedure Handbook of Arc Welding” published by the Lincoln Electric
Company.
SM
Prepare rods (cold rolled steel) for installation as shown, nuts are shown in position for safety stops, but
washers or short bars may be welded at end of rods for equally good results. Rods should not be more
than 24” long.
SM
Use trailing end of retainer block for placing a soapstone mark (line) on the side of the tire.
SM
5-6 mm Clearance
Zero Clearance
Discharge End
SM
If original “feed” stencil marks have been eliminated by rubbing or by shop cleanup procedures, look for the
1/8” X 45° chamfer at one end of the roller bore zone. This chamfer will indicate the larger diameter of the
2-diameter bore for the roller.
The step-diameter lockup of roller and shaft requires the chamfer, indicating the larger shaft and bore diameter,
to be aimed toward the low, or discharge, end of the kiln.
FIGURE:
“Last resort” checkout of support rollers for correct installation on support rollers.
SM
SM
Fig. 1
Fig. 4
Fig. 2
Fig. 3
T
3 5-8 mm
0 mm 0 mm
SM
SM
M a
M FV X a
FH
RL FV / 3 + FH
FV
30° RR FV / 3 - FH
RL RR
SM
P
L1 L2
R1 R2
R1 = (L2/L) P R2 = (L1/L) P
SM
SM
A
Since the kiln shell will advance inside the tire during rotation Start
the marker must be placed on the tracing surface at the end of
the sheet trailing the direction of rotation. The sketch shows an
approximate pattern after four revolutions of the kiln.
Finish
High temperature metal surfaces can cause severe burns. Moving (rotating) machinery can cause hands and arms to
become caught. Avoid personal contact.
SM
SM
1”
1/4” 1/4”
SM
Difference
Reading
11 1
Station
1 215 9 10 2
2 213 7
3 211 5
4 211 5
5 209 3 9 3
Approximate
6 206 0 Shell Center
7 207 1
8 209 3
9 208 2 8 4
10 212 6
11 214 8
12 216 10 5
7
1 215 1
6
Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset
also 3 and 9 : 5 and 2 = 1.5 mm offset
Low reading - close to fixed reference circle
High reading - away from fixed reference circle
SM
12
Difference
Reading
Station 11 1
6 mm
1 417 6 21 mm
10 2
2 432 21
3 427 16
4 418 7 16 mm
5 420 9 9 3
6 425 14
7 435 24
7 mm
8 438 27
9 427 16
8 4
10 421 10
11 420 9
12 411 0
7 5
1 416 5
This is very bad. 6
12
Difference
Reading
Station
11 1
1 10 2
2
3
4
5 9 3
6
7
8
9 8 4
10
11
12 7 5
1
6
SM
SM
VII
II I
.6
.5
.4
.3
.2
Laser .1
X1
X2
SM
Step 1
Tire
Offset Line
Measuring Points
Step 2
Tire
At
Slave
Laser
SM
Ar1
Ar2
Laser
Step 4
Pmax
P1
P2
Laser
SM
Laserstråle C
R
90°
ZA
ZV
ZH H
ZV ZH
VR
VV
LR VH
R Y
HR
X1
X2
Y1
OSV.
SM
Maintenance Seminar
Enter Kiln Length and Dimensions Between Tire Centerlines
6 - Support Kiln
5 - Support Kiln
Feed End
4 - Support Kiln
Feed End
Discharge End
3 - Support Kiln
Feed End
2 - Support Kiln
Feed End
Feed End
Tire 1 Tire 2 Tire 3 Tire 4 Tire 5 Tire 6
L1 L2 L3 L4 L5 L6 L7
Feed End
Feed End
Feed End
Feed End
Feed End
Discharge End
1A 1B 2A 2B 3A 3B 4A 4B 5A 5B 6A 6B
Dim =
2S 3S 4S 5S Dim =
L1-1A
OHFE OHFE OHFE OHFE L7-6B
Feed
Disch Dim = Dim = Dim = Dim = Dim = End
End L2-(1B+2A) L3-(2B+3A) L4-(3B+4A) L5-(4B+5A) L6-(5B+6A) Over-
Over- hang
hang Basic Basic Basic Basic Basic 6S
OHDE Plate Plate Plate Plate Plate OHFE
Span 1 Span 2 Span 3 Span 4 Span 5
Zone Shell I Dia. Linear Feet Thickness Cone(s) (Yes or No)
OHDE
Span 1
Span 2
Span 3
Span 4
Span 5
OHFE
Transition Cone Diameters Length Thickness
&
SM
With or without original reference information, actual lengths, widths circumferences and
thicknesses must be verified per accurate measurement procedures. Use an appropriately calibrated
ultrasonic thickness gauge for measurement of shell plate thickness, especially at zones affected
by erosion caused by abrasive or chemical reactions(s).
Kiln at (Company):
Plant Location:
Plant Telephone: ( ) -
Fax Number: ( ) -
Data From: Title / Department: Telephone Extension:
Checkout Date(s):
SM
SM
Level Line
Difference
Reading
11 1
Station
1 215 9 10 2
2 213 7
3 211 5
4 211 5
5 209 3 9 3
Approximate
6 206 0 Shell Center
7 207 1
8 209 3
9 208 2 8 4
10 212 6
11 214 8
12 216 10 5
7
1 215 9
6
Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset
also 3 and 9 : 5 and 2 = 1.5 mm offset
Low reading - close to fixed reference circle
High reading - away from fixed reference circle
SM