S-03-H11180-630-AV Group Nackawic Alignment and Diagnostics Report

Lime Kiln Alignment and Diagnostic
Report
AV Group
Nackawic, NB
Canada
Measurement Date: June 18-23, 2021 Date issued: September 9, 2021
Customer: AV Group
Nackawic, NB
Canada
Attention: Dapeng Fan
Phone: (506) 575-5208
E-mail: Dapeng.Fan@adityabirla.com
Contact: ANDRITZ, Inc.

Project Manager: Josh Brant
Phone: 470-701-9314
E-mail: Josh.Brant@andritz.com
www.andritz.com
Confidential document. All rights reserved. No duplication or disclosure to third partiers permitted without the written consent of ANDRITZ AG.
Table of Contents
Table of Contents .......................................................................................................................... 2

1. Introduction ............................................................................................................................. 3
2. General Comments and Discussion of Findings .................................................................. 4
2.1 Pier 1 (Feed) ................................................................................................................... 4
2.2 Pier 2 (Drive) ................................................................................................................... 4
2.3 Pier 3 (Discharge) ........................................................................................................... 5
3. Summary of Recommendations............................................................................................. 6
3.1 Major Repair Recommendations in Order of Priority ....................................................... 6
3.2 Recommendations ASAP ................................................................................................ 6
3.3 Recommendations for next Kiln Outage .......................................................................... 6
4. Lime Kiln Measurements ........................................................................................................ 7
4.1 Overview ......................................................................................................................... 7
4.2 Deflection of Support Roller Shaft ................................................................................... 7
4.3 Support Roller and Tire measurements ......................................................................... 13
4.4 Trunnion Bearings ........................................................................................................ 16
4.5 Axial Balance of Support Rollers ................................................................................... 20
4.6 Support Rings (Tires, Riding Rings) .............................................................................. 21
5. Lubrication ............................................................................................................................ 56
5.1 Lubrication of support rollers and bearings.................................................................... 56
5.2 Lubrication of Support Tires .......................................................................................... 56
6. Appendix A ........................................................................................................................... 58
Confidential document. All rights reserved. No duplication or disclosure to third partiers permitted without the written consent of ANDRITZ AG. Page 2 of 58
1. Introduction
Lime kilns are some of the largest machines ever built. Because they are very heavy, large loads
are transferred to the kiln supports. This transfer of load is accomplished through the support rings,
support rollers, support bases and piers. Therefore, the highest concentration of stress in a lime kiln
is near these support areas. Knowing this fact, it becomes clear that special attention to these areas
is warranted.
The total weight of the kiln is made up of the weight of the steel shell plus the weight of the brick and
refractory lining, any internal components such as chain, and any suspended loads such as coolers.
The kiln shell is designed to accomodate these loads and to provide a more or less equal load
distribution to each of the support piers.
A kiln shell is subject to many stresses, including thermal stresses and mechanical stresses. Often
these stresses can work to create a bend in the shell commonly referred to as a “crank” or a “dog-
leg”. In this case, the rotational center of the shell is different than the geometric center of the shell,
which creates additional forces on the kiln supports. Any deformation which changes the geometry
of the kiln shell is likely to change the load distribution to the kiln supports. In the simplest terms,
any load which is removed from one kiln support must then be taken up by another support since
the total weight of the kiln must be borne by the kiln supports.
In some circumstances, certain deformations in the kiln shell can result in cyclical loads which are
imposed and then removed at the frequency corresponding to the speed of kiln shell rotation. This
type cyclical load can be particularly damaging due to the effects of metal fatigue. Cyclical loads,
when not properly addressed, can lead to premature failure of components. Once cracks begin in
the support areas of a kiln, they can propagate rapidly if the underlying condition causing the cracking
is not corrected.
In order to avoid this situation, along with the accompanying unplanned kiln downtime and
emergency maintenance costs, it is advisable to have a regular measurement and inspection
program on the lime kiln. The cost of even one component failure will be many times greater than
the cost of recommended inspections to prevent this occurrence in the first place. Regular
measurement checks can identify potential problem areas and allow corrective action to be
performed long before those small problems can advance to a point where they negatively affect kiln
availability and uptime.
2. General Comments and Discussion of Findings
2.1 Pier 1 (Feed)

2.1.1 There is an excessive amount of lime dust on the pier top. There is a leak on the discharge
side of the ID fan which is causing the excessive amount of dusting in the area. Having an
excessive amount of dust in the area has potential to promote issues with the supporting
components. Allowing dust/debris to get between the roller and tire can lead to pitting of the
surfaces. Also, the dust has a high potential of getting inside the bearing housings whenever
performing an inspection and/or when checking the axial position of the shaft. All of these
issues can lead to premature failure of the equipment.
2.1.2 There is an excessive clearance between the tire and the retaining ring on the uphill side of
the tire. There is a fair amount of wear on the downhill retaining ring that contributes to the
clearance. Refer to section 4.6.1 for more details.
2.1.3 The tire has a convex profile which has translated a concave profile to the rollers. Having
these type of profiles on the supporting components make it extremely difficult to manage
the axial forces (thrust). These profiles have led to poor contact between the rollers and tire.
The tire and rollers need to be ground back to a true profile to optimize the axial balance at
this Pier. Refer to section 4.3 for more details.
2.1.4 The right (upturning) uphill bearing oil seal is leaking. This oil seal should be replaced during
the next Kiln outage. Insufficient lubrication can lead to accelerated wear and cause
premature failure of the equipment. Furthermore, allowing oil to get on the surfaces of the
supporting components and lead to pitting of the surfaces and cause accelerated wear.
Refer to section 4.4 for more details.
2.1.5 The ovality is slightly elevated at this support but nothing to be of concern currently. The
creep is approximately 11/16” (18mm) per revolution, which is within our allowable
tolerance. To ensure prolonged life of the equipment it would be advised to properly
lubricate between the tire and shell since the tire is directly mounted to the Kiln shell. Refer
to section 4.6.6 for more details.
2.2 Pier 2 (Drive)

2.2.1 The spring plate welds were inspected and no issues were noted. Also, the spring plate
pins were inspected and no issues were noted. The current inspection window that is on
the gear guard doesn’t allow enough space to take axial and radial runout readings.
Therefore, only a visual inspection was performed on the gear and pinion. The driven face
of the pinion is in good shape, there are no indications of pitting across the tooth face and
there is adequate lubrication in the system. There are no signs of clashing between the girth
gear and pinion. Refer to section 4.6.7 for more details.
2.2.2 The right side cooling water lines are ran onto the walking surface and pose a tripping
hazard. They should be rerouted such that they do not pose a hazard. There is also a lot of
clutter at this Pier such as pieces of plywood and random tools. This area needs to be
cleaned up to eliminate hazards.
2.2.3 Good contact between the rollers and tires. There were some minor ridges noted on the
edges of the left roller. They are not of concern currently but the condition needs to
continued to be monitored to identify when roller grinding will be required. Refer to section
4.6.1 for more details.
2.2.4 The right (upturning) uphill bearing oil seal is leaking. This oil seal should be replaced during
the next Kiln outage. Insufficient lubrication can lead to accelerated wear and cause
premature failure of the equipment. Furthermore, allowing oil to get on the surfaces of the
supporting components and lead to pitting of the surfaces and cause accelerated wear.
Refer to section 4.4 for more details.
2.3 Pier 3 (Discharge)

2.3.1 The cooling water lines were found to be pinched back such that they were practically closed
and not allowing a sufficient flow to cool the bearings. The valves were opened up to ensure
proper cooling water flow to achieve the proper heat transfer.
2.3.2 Skew adjustments were attempted to optimize the axial forces but the support roller base
bolts were found to be tightened down. Having the base bolts tightened down prevent any
kind of adjustments being made. If adjustments are attempted, there is a chance to incur
damage to the adjustment bolts and post which will hinder future adjustment capabilities. It
is recommended that during the next Kiln outage to loosen each base bolt such that they
can be turned by hand.
2.3.3 There is an excessive amount of creep, 1 ½” (38mm) per revolution, which far exceeds our
allowable tolerance. There are two rows of stiffener plates welded to the Kiln shell to help
support this area. By doing so, this helps maintain an acceptable amount of ovality.
However, at location “B” there is elevated ovality. This is due to the fact that there is cracking
occuring at the stiffener plates. It was observed that there has been previous crack repairs
performed. There are currently several cracks on both the uphill and downhill side of the
tire starting at the edges of the stiffener plates. The cracks have begun to propagate into
the Kiln shell. It was also noted that there has been a lack of lubrication between the tire
and shell at this support location which accelerates wear. It is recommended to replace this
section of Kiln shell and implement a full floating filler bar system. The shell section should
include the thick section beneath the tire and extend through the flank plates on both uphill
and downhill side. Refer to section 4.6.1 and 4.6.6 for more details.
2.3.4 There is an excessive amount of lime dust accumulated on the Pier top. This area needs to
be cleaned regularly to avoid from getting dust/debris onto the supporting component
surfaces. Allowing dust/debris to get on the surfaces could lead to pitting and premature
failure of the equipment.
3. Summary of Recommendations
3.1 Major Repair Recommendations in Order of Priority

3.1.1 Approximately 8 feet of Kiln shell needs to be replaced located at the discharge Pier, which
includes the thick section beneath the tire and extends through both the adjacent flank
plates. There are currently two rows of stiffener plates to help stiffen the Kiln shell at this
Pier. There has been previous crack repairs performed on some of the stiffener plates and
there are currently several cracks present at the stiffener plates which have propagated into
the Kiln shell. The current design has a tire that is directly mounted to the shell. It is highly
recommended to implement a full floating filler bar system when replacing this shell section.
By implementing a full floating filler bar system this will result in a larger outside diameter of
the tire. In order to compensate for the change in diameter there are two options which will
need to be explored in greater detail before project execution. Option 1 is to examine how
much space is available in the baseframe slots and see if increasing the slot length will
suffice. Option 2 would require a complete modification of the baseframe assembly which
would include, but not limited to, lowering the baseframe assembly elevation. It is also
recommended to perform a HKA post installation.
3.2 Recommendations ASAP

3.2.1 Perform a Load Study to help aid the design of the shell and tire replacement to be
performed at the discharge Pier. By implementing a full floating filler bar system this will
require a change in the pressure angle due to the change in outside diameter of the tire.
3.2.2 Ensure that lubrication is being applied between the tire and shell at a minimum of once per
month. Proper lubrication will help prolong the life of the equipment. Refer to section 5
3.2.3 House keeping needs to be performed at every Pier as well as at the ground level. Having
an excessive amount of dust/debris on the Pier tops poses potential risk to the integrity of
the supporting components. This can lead to pitting of the supporting components and
ultimately premature failure of the equipment. Furthermore, having a cluttered area
increases safety hazards for anyone working in the area.
3.2.4 Perform roller and tire grinding at Pier 1 (feed). The rollers and tire have concave and
convex profiles, respectively. The surfaces of the supporting components need to be set
back true to optimize the axial loading.
3.3 Recommendations for next Kiln Outage

3.3.1 Measure the root gap between the girth gear and pinion to identify if any excessive amount
of radial runout is in the system. If an excessive amount of radial runout is identified, the
root gap should be adjusted to the high spot so that the girth gear and pinion do not clash
during operation and prolong the life of the gear system.
3.3.2 Install a new inspection window on the gear guard such that gear runout data can be
collected with the Kiln in operation as well as to perform visual inspections.
3.3.3 Repair the expansion joint on the discharge of the ID fan. This leak is one of the main
contributing factors to the dusting issue in the Kiln area which is causing build up on the
Pier tops.
3.3.4 Remove the bearing housing covers and inspect the bearing internals to identify any signs
of wear of the components. The clearances between the shaft and bearing sleeve should
be measured as well as a thorough inspection of the shaft for any deep scoring. This should
be carried out for each bearing at every support location.
3.3.5 Loosen the support roller base bolts such that they can be turned by hand. The base bolts
of the support roller should remain loose so that adjustments can be made while the Kiln is
in operation. This should be done at each Pier
3.3.6 Replace the right (upturning) uphill bearing oil seal on Pier 1 (feed). Inadequate lubrication
in the bearing could lead to premature failure of the equipment. Furthermore, if oil is allowed
to get on the supporting component surfaces it could cause pitting of the surfaces and
accelerate wear.
3.3.7 Replace the right (upturning) uphill bearing oil seal on Pier 2 (drive). Inadequate lubrication
in the bearing could lead to premature failure of the equipment. Furthermore, if oil is allowed
to get on the supporting component surfaces it could cause pitting of the surfaces and
accelerate wear.
3.3.8 Perform a thorough inspection of the refractory inside the Kiln especially around the support
locations to identify any onset of crushing the brick.
3.3.9 Once items 3.2.4 and 3.3.5 are completed, the axial balance of the Kiln should be
optimized once the Kiln is back in operation and operating near steady state. Optimizing
the axial balance of the Kiln will help prolong the life of the equipment.
4. Lime Kiln Measurements
4.1 Overview
Andritz state-of-the-art kiln alignment methods utilize unique precision measurement tools to gather
and process the kiln data. These tools are specifically designed for lime kiln measurement, therefore
they are especially well adapted to the required service. With these tools, the Andritz alignment
specialist can measure all points of interest to gather a complete picture of the mechanical condition
of the lime kiln. Thousands of individual measurements are gathered during the inspection process
and then displayed graphically so that the results are very easy and fast to interpret, even by those
without specialized knowledge of lime kilns.
4.2 Deflection of Support Roller Shaft
4.2.1 Tool Description and Measurement Principle
An inductive measuring tool is used to measure deflection in each support roller shaft. This tool
utilizes an electric field to measure the distance between the instrument and metal surfaces with
high accuracy while gathering up to 1000 measurements per second. The versatility of the inductive
measurement device also allows its use for other measurements such as tire wobble and gear run-
out. This device may be compared to a traditional dial indicator but the advantage of the inductive
tool is that no contact is required between the moving parts and the instrument. Since the tool is
only affected by metal, the presence of normal amounts of grease and oil on the part to be measured
does not negatively affect the measurement accuracy.
The presence of support roller shaft deflection indicates cyclical loading on the roller. This is normally
caused by the presence of a bend in the kiln shell commonly referred to as a “dog-leg”. This bend
creates a cranking motion of the shell which results in a higher load being applied to each support
roller as the point of maximum bend in the shell passes the roller position. Once the bend passes
by, the applied load is then reduced. This cyclic loading can accelerate fatigue of the material and
result in the development of cracks in the roller shaft, the roller, or even the tire.
A dog-leg in a kiln shell will normally be the result of one of two possible causes:
Mechanical bending – This is a permanent deformation in the kiln shell which can be caused
by improper kiln shutdown allowing the kiln shell to sag between supports or occasionally by
an improper kiln shell installation.
Thermal Crank – This is caused by an uneven temperature distribution around the kiln shell
which can be removed with even shell heating and time. Common causes of thermal cranks
are uneven build-up of product inside the kiln or a loss of brick or refractory in one area
allowing that area to receive more heating than other areas of the shell. This can be detected
by a careful temperature scan of the kiln shell. The following images illustrate the effects of
a shell crank on the support rollers.
Guidelines for the acceptable limits for shaft deflection are shown in the chart below. These values
are relevant regardless of kiln diameter.
Additionally, the inductive measuring tool provides information about the circularity of the roller. It
will indicate any out-of-round condition. If rollers are found to be out-of-round by more than 2 mm
then the Andritz alignment specialist may recommend that alignment measurements not proceed
until the support rollers can be machined to restore the circularity.
4.2.2 Roller shaft Deflection Data
The total shaft deflection readings are shown in the graphic along with the angular position of the
peak deflection. Each graph is made of three lines. The dark green line contains the raw
measurements. The lime green line is a “best fit” curve through the data points which indicates the
presence of roller shaft deflection, if any. The blue line indicates the circularity (roundness) of the
roller. Shaft deflection is observed at the rotational frequency of the kiln shell. Roller circularity is
observed at the rotational frequency of the roller which is typically three to four times that of the kiln
shell.
Pier 1
Comments: No issues noted for Pier 1.
Pier 2
Pier 3
4.3 Support Roller and Tire measurements
Measurement Principle - Andritz uses a measuring wheel to measure the diameter of the support
rollers and support tires. This allows these measurements to be collected without stopping the kiln.
By gathering circumferential measurements at multiple locations along the surface of one roller, the
presence of taper will be detected. Due to the forces applied to these surfaces, some amount of
wear is expected over time. Once this wear reaches a certain point, it is necessary to machine the
surface of the component to restore roundness and remove taper.
The normal procedure is to measure several locations along the surface of each roller and tire, as
illustrated in the figure below. In addition to detecting diameter and taper of rollers, a proper
measurement technique will also reveal
concave or convex surfaces. The presence of
convexity or concavity can prevent proper
movement between the kiln tire and support
roller. Most often when this condition is
discovered, the support tire is convex and the
roller has a corresponding concave shape. The
two parts may seem to fit together very well,
however, the parts will try to maintain their
relative positions. If an attempt is made to
adjust this roller it can be very difficult to move
since the parts seek to return to the previous
positions. In some cases, if adjustment is pursued further, partial contact of the surfaces can result
which can cause bearing temperatures to rise.
Pier 1
Comments: The tire and rollers have a convex and concave profile, respectively. These types of
profiles create issues with trying to optimize the axial balance. Having such profiles creates a
tendency to “lock” the tire into position. They could also induce unfavorable thrust conditions. There
is also potential of creating a high point load on the roller due to the ridges formed from the convex
profile. This could lead to damage of the mating surfaces due to extremely high Hertzian pressures
and/or could potentially lead to cracking of the shaft.
Recommendation: It is recommended to perform grinding on both rollers and tire to true up the
profiles to optimize the axial balance and prolong the life of the equipment.
Pier 2
4.4 Trunnion Bearings
Pier 1
Figure 1: Right uphill bearing oil seal leak
Pier 2
Pier 3
4.5 Axial Balance of Support Rollers
4.5.1 Measurement principle
The axial balance of the support rollers is necessary to distribute the thrust load of the kiln. Since
lime kilns are designed with a slight angle of inclination, the weight load of the kiln is resolved into
two force vectors. One is the downward force and the second is a horizontal force (thrust). It is very
important to distribute this thrust load properly between the rollers to avoid excessive wear in any
one area. The ideal roller adjustment is to divide the thrust force by the number of rollers and equally
distribute the thrust among all the rollers. However, in practice this is not always a satisfactory
solution. In this case, a percentage of the load is distributed equally between the support rollers with
the remainder of the thrust load supported by the thrust roller.
In cases when some rollers are assuming too much thrust load, overheating of the axial bearing in
the bearing housing can occur. When this happens, it is advisable to adjust the support rollers to
achieve a more equal load distribution among the rollers. Andritz recommends regularly monitoring
these axial loads in the bearings and making adjustments as necessary to maintain the correct load
distribution between the support rollers and the thrust roller.
4.5.2 Axial equilibrium – Consequences of Excessive force
In a kiln where the support rollers and thrust bearing are sharing the thrust load, each of the support
tires also carries a similar thrust load. When this is achieved, the forces transmitted from the rollers
to the tire and subsequently to the stop blocks adjacent to the tire are also balanced. This is the
best condition which allows the stop blocks for each tire to share the thrust load and wear similarly
at each pier. However, it is not unusual for this balanced condition to be lost for various reasons. In
that case, unbalanced axial loads are applied to the support tires and subsequently to the stop
blocks. This condition can be detected by noticing accelerated wear on the stop blocks at one pier
when compared to other piers. When one area is more heavily loaded problems can occur. Typical
problems noticed in this situation are cracks in the welds of the stop blocks or even loss of stop
blocks. If left unattended, these cracks can sometimes propagate into the base shell material. While
repairing these cracks is necessary, crack repair is not the final solution. The uneven thrust loading
must be corrected to alleviate the underling condition causing the cracks to occur in the first place.
For this reason, it is recommended to periodically inspect the riding rings and stop blocks to detect
the first signs of any uneven thrust loading.
Comments: Skew adjustments were attempted to optimize the axial balance of the Kiln. However,
the base bolts were found to be tightened down on all of the support roller bearings. These bolts
should be loose enough to be turned by hand. This allows adjustments to be made while the Kiln is
in operation. If adjustments are attempted with the base bolts being tightened down there is the risk
of incurring damage to the adjustment bolts and post which will hinder any future adjustments.
Recommendation: It is recommended to loosen all of the support roller bearing base bolts such
that they can be turned by hand. This should be done during the next Kiln outage.
4.6 Support Rings (Tires, Riding Rings)
4.6.1 Stop Blocks
The purpose of the stop blocks is to restrain the support ring in the proper location on the kiln shell
and to transfer the axial force between the kiln shell and the tire. All the axial load of the kiln shell is
transferred to the tire through the stop blocks. The tire subsequently transfers this force to the
support rollers. For this reason, an uneven distribution of the thrust load of the kiln will cause some
stop blocks to be overloaded as described previously. Kilns are designed with a small clearance
between the support tire and shell. This clearance is necessary to allow for differential growth of the
kiln shell and tire during conditions of uneven heating such as experienced during a kiln startup. Due
to this necessary clearance, the inner diameter of the support tire and the outer diameter of the kiln
shell are different. These different diameters of the two adjacent parts yield two different
circumferences of the parts. Since the kiln shell and tire rotate together at the same rate, there is a
differential movement between the kiln shell and support tire. i.e. the tire has to travel further in one
revolution than the kiln shell travels, so since they travel at the same speed, the kiln shell “arrives”
at the end of one revolution before the tire. This differential movement is called “Creep”.
Since there is a relative movement between the tire and shell (Creep), there is also a relative
movement between the tire and the adjacent stop blocks. For Andritz kilns, the total clearance
between the tire side faces and stop blocks is 5 mm. Under normal operating conditions, the tire will
be in contact with the stop blocks on one side only, so this clearance between the tire and stop
blocks can be easily measured.
Pier 1
Pier 1 Right Side
Pier 1 Left Side
Pier 2
Pier 2 Right Side
Pier 2 Left side
Pier 3
Pier 3 Right Side
Pier 3 Left side
Crack at Stiffener Plate
Comments: There is an excessive amount of clearance between the tire and the retatining ring on
the uphill side of the tire on Pier 1 (feed). Having an excessive clearance can have some negative
effects. One of which could be an increase in tire wobble. Fortunately, there is a minimum amount
of tire wobble occuring at this support. Refer to section 4.6.4 for more details. Another effect that can
be seen is having a “negative” roller clearance. This simply means that the tire is overhanging the
support roller which can lead to spalling of the roller surfaces and ultimately premature failure. Again,
fortunately for this system it is not experiencing a negative roller clearance. However, the rollers
have a concave profile and the tire has a convex profile. Having such a profile tends to “lock” the tire
in position and makes managing the axial balance challenging. Refer to section 4.3 for more details.
There is an excessive amount of creep at the discharge Pier. Furthermore, there are several cracks
located at the edges of several stiffener plates that have propagated into the Kiln shell. There was a
loud popping noise observed at the time of inspection. Refer to section 4.6.6 for more details.
4.6.2 Thrust Rollers and girth gear position
Downhill thrust roller
Gear System
4.6.3 Support Tire Wobbling (Axial)
Tire wobble (Axial run-out) is movement of the support tire face relative to a plane perpendicular to
the kiln axis. This measurement indicates the degree that the support tire is not perpendicular to
the axis or rotation, i.e. the kiln shell axis. Andritz also measures the “flatness” of the tire face and
records any deviations in the flatness. The deviation of the face flatness summed together with the
tire wobble equals the total axial run-out of the tire.
The figure below illustrates these different components that make up the axial tire run-out.
Wobbling + Straightness Deviation = Total Tire Run-out
4.6.4 Measurement Results
Tire Tire Wobble Straightness Deviation Total Tire Run-out

1 ± 0.1 mm / Peak: 122° ± 0.3 mm ± 0.3 mm
2 ± 0.5 mm / Peak: 20° ± 0.2 mm ± 0.6 mm
3 ± 0.6 mm / Peak: 110° ± 0.3 mm ± 0.7 mm
Comments: No issues noted.
Support Tire 1:
Support Tire 2:
Support Tire 3:
4.6.5 Creep and Ovality
As discussed previously, kiln support rings are designed with clearance which causes the tire to
“creep” with respect to the kiln shell. While this creep is desirable for proper kiln mechanical
performance, it must be maintained within certain limits. The clearance between the kiln shell and
support tire has a direct correlation with creep. As the clearance between the components increases,
the creep increases.
Although it is not immediately noticeable to the eye, a kiln shell will flex downward (sag) at the top
due to its own weight. When the shell is constrained within a support ring, the shell can only move
until it contacts the inner surface of the tire. In a properly designed support tire and kiln shell
interface, the tire provides support to the shell and limits this sag of the shell. This shell flexing is
described as “Ovality”, which is normally expressed in terms of “% Ovality”. % Ovality is a measure
of the shell flexing at the support tire in relation to the inner diameter of the kiln shell. Just as shell
to tire clearance and creep are related, creep and ovality also correlate. When the creep increases,
this means the clearance between the shell and tire increased. A larger clearance between the shell
and tire allows the kiln shell to sag more, resulting in more ovality. For this reason, it is recommended
to monitor tire creep on a regular basis. When increased creep is observed, this provides an
indication of increasing clearance and ovality.
Ovality is important for a few reasons. Ovality greater than recommended limits increases the
possibility that the brick lining inside the kiln shell will also flex, thereby crushing the brick. This
causes premature failure of the brick lining near the support tires and allows all the associated
problems that accompany the loss of the kiln lining. In severe cases of ovality left untended, the kiln
shell can also crack from metal fatigue. Ovality is a flexing of the kiln shell that is cyclical so it occurs
during each revolution of the kiln shell.
A simple tool similar to the illustration on the right can be used to easily measure creep. This device
has the benefit of simultaneously measuring both the creep per revolution and the total clearance.
The length between the end points of the curve represents the creep and may be directly measured
from the chart. The amplitude of the curve represents the total clearance, which includes both the
clearance of a round shell and tire and the shell sag. The calculated clearance may be subtracted
from this total clearance and this is a direct indicator of ovality.
For a new lime kiln, creep should be approximately 15mm

(~19/32”). If creep is greater than 40mm (~1-19/32”) this is an
indicator that ovality will be higher than recommended limits.
Anytime brick loss is experienced that starts near a support ring,
or is isolated to the support ring area then ovality should be
investigated.
Andritz directly measures Ovality with an instrument that magnetically mounts on the kiln shell near
the tire and collects hundreds of measurements as the kiln rotates. Ovality measurements are
recorded at 120 degree intervals around the shell on both sides of each support ring. These positions
are normally referred to as the “A”, “B”, and “C” positions, with the “A” position aligned with the kiln
manhole.
Comments: The ovality at Pier 1 (feed) is slightly elevated but not to the point of concern. The creep
is 11/16” (18mm) per revolution which is within our allowable tolerance range. However, this area
needs to continued to be monitored to identify when the condition worsens to the degree that action
is required. The refractory at this location should be inspected during the next Kiln outage to see if
there are any signs of crushing.
The creep at Pier 3 (discharge) is extremely high, 1 ½” (38mm) per revolution which exceeds our
allowable tolerance of 1” (25mm) per revolution. The clearance between the Kiln shell and tire is
proportional to creep, therefore, an excessive amount of creep correlates to an excessive amount of
clearance. Having an excessive amount of clearance between the Kiln shell and tire allow the Kiln
shell to undergo more flexing which promotes an increased fatigue loading on the Kiln shell. This
increase in fatigue loading can lead to fatigue cracking of the tire hardware and/or the Kiln shell itself.
To help stiffen the shell at this support there has been two rows of stiffener plates welded to the Kiln
shell. As can be seen in the ovality data, the stiffener plates do indeed help. However, at location
“B”, the ovality is much greater than the allowable limits for this Kiln. This is due to the fact that there
are cracks located around this location. The cracks begin at the edges of the stiffener plates and
have propagated into the Kiln shell. It was observed that there have been several crack repairs that
were previously done in other locations. The stiffener plates have sharp corners which promote a
high stress concentration area, therefore being more prone to cracking. While onsite, conversations
were had about possibly installing a third row of stiffeners. It was not recommended to do so because
that is not addressing the root cause, it simple delays the inevitable. Also note that the effects of
ovality tend to dimenish approximately 1-1.5 times the Kiln diameter away from the tire centerline,
therefore continuing to put stiffener plates is not an adequate nor economical solution. It is strongly
recommended to replace this Kiln shell section and implement a full floating filler bar system.
Recommendation: It is recommended to ensure that proper lubrication is being applied between

the tire and Kiln shell to prolong the life of the components. Lubrication should be applied at all
support locations at a minimum of once per month. It is also advised to inspect the refractory at each
support location to identify any signs of crushing. The Kiln shell at the discharge support needs to
be replaced. The shell section should include the thick section beneath the tire and extend through
both the adjacent flank plates which will eliminate the stiffener plates. Furthermore, a full floating
filler bar system should be implemented in the new design.
The figure below illustrates Ovality as discussed above and shows the measurement locations
around the shell.
Since Ovality normally affects the brick lining of the kiln before other negative effects are observed,
Andritz does not provide firm recommendations on ovality limits. However, brick lining
manufacturers do offer guidance. The chart below can provide some general guidelines for
interpreting acceptable ovality limits. Andritz recommends that customers consult with the
manufacturer of the brick lining products in use in their kiln for firm recommendations on acceptable
ovality limits.
The graphical data below shows the ovality readings for each measurement position along the kiln.
The three colored lines represent the readings collected at each measurement location “A”,
B”, and “C”.
Pier 1
Pier 2
Pier 3
4.6.7 Girth Gear - Wobbling and Eccentricity
Radial deviations in the drive gear (eccentricity) is especially significant, therefore measurement of
this on a regular basis should a priority. Improper alignment of the girth gear and pinion will cause
premature wear on these components and in extreme cases can lead to gear failure. It is important
to align the pinion parallel with the girth gear and adjust the backlash at the point of maximum
eccentricity of the girth gear to avoid damage to the gears.
Total Run-out – This corresponds with actual, measured values. It is the combination of eccentricity
and deformation. Total Run-out is indicated as a +/- value (Color Red) in the graphs.
Eccentricity – This indicates the degree to which the center of the component is not aligned with
the center of rotation. (Color Blue)
Deformation – Roundness deviation shows the deviation from an ideal circle and is indicated in the
graphs as a +/- value as referenced from the ideal circle. (Color Green)
Peak At – Indicates the location of the point of maximum eccentricity in degrees as referenced from
the kiln manhole.
Reference - The reference point of 0° / 360° is aligned with the kiln manhole for all measurements.
Eccentricity + Deformation = Total Radial Runout
Girth Gear Wobble (Axial run-out) is movement of the gear face relative to a plane parallel to the
face perpendicular to the kiln shell axis. This measurement indicates the degree that the girth gear
is not perpendicular to the axis of rotation, i.e. the kiln shell axis. Andritz also measures the “flatness”
of the gear edge and records any deviations in the flatness. The deviation of the edge flatness
summed together with the gear wobble equals the total axial run-out of the gear.
The figure below illustrates these different components that make up the axial run-out.
Gear Wobbling + Straightness Deviation = Total Gear Run-out
If a girth gear is discovered to exhibit eccentricity outside the tolerances provided by the gear
manufacturer, there are only two possible ways to correct this problem. The shell may be cut at the
point of maximum eccentricity and then re-welded to straighten the kiln shell, thereby reducing the
gear eccentricity. The second option is to remove the gear and reattach it to the kiln shell with new
connection hardware. Each of these options involves significant effort and kiln downtime, so this
should be performed as part of a normally sheduled mill shutdown.
Comments: Due to the arrangement of the gear guard there was no sufficient space to place the
equipment to record measurements. Only a visual inspection was able to be performed. From the
inpsection window that is currently in place, only the pinion could be seen. The pinion driven and
non-driven face were in good condition. No issues with pitting across the face of the tooth and
adequate lubrication for the application. Spray lube system was observed to operate without any
issues. All of the spring plate welds were inspected and were found to be in good condition. The
spring plate pins were inspected as well and no issues were noted.
Recommendation: During the next Kiln outage the root gap needs to be measured to identify if
there is any significant radial runout of the gear system. If excessive radial runout is identified, then
the root gap needs to be set to the high spot so that clashing of the gear and pinion is avoided during
operation. It is also recommended to install an inspection window on the gear guard during the next
Kiln outage
Kiln Shell Profile
The lime kiln shell is exposed to high temperatures. Although the kiln shell is designed to withstand
the normal operating temperatures, there are times when the shell can be vulnerable to damage
from the high heat. For example, a loss of the kiln lining in a certain area will expose the kiln shell
to very high temperature in a localized area, or an unexpected kiln shutdown without executing the
proper cooldown procedures can allow the kiln shell to deform.
Andritz measures both the shell roundness and the eccentricity of the kiln shell at specified intervals
to create a digital model of the kiln shell shape. A graph of the kiln cross section shape is generated
at each measurement location. Many measurements along the length of the lime kiln shell can be
combined to create the 3-D shell model.
The 3-D model uses various colors to provide a visual representation of problem areas that require
closer examination of the graphical data. The figure below illustrates the measurement concept and
the instrument setup.
Total Run-out – This corresponds with actual, measured values. It is the combination of eccentricity
and deformation. Total Run-out is indicated as a +/- value (Color Red) in the graphs and should
not be confused with the similar term “Total Indicated Run-out (TIR)” which has a slightly different
meaning.
Eccentricity – This indicates the degree to which the center of the component is not aligned with
the center of rotation. (Color Blue)
Deformation – Roundness deviation shows the deviation from an ideal circle and is indicated in the
graphs as a +/- value as referenced from the ideal circle. (Color Green)
Note: The color references above refer ONLY to the illustration below, and may not match colors
shown in measured data graphs.
Eccentricity + Deformation = Total Shell Run-out
Peak At – Indicates the location of

the point of maximum eccentricity in
degrees as referenced from the kiln
manhole.
Reference - The reference point of

0° / 360° is aligned with the manhole 0° / 360°
on the Kiln.
Each measurement location yields a

graphical cross-section of the kiln.
When more cross sections are
measured, the resolution of the re-
sulting kiln shell model is greater.
In most cases, only certain areas of the kiln profile are of particular interest. Some examples of
these areas are:
• In areas with a history of refractory failures to determine if the root cause of refractory failure
if kiln shell deformation.
• Lime kiln inlet and outlet so that the impact on the kiln seals can be determined.
• In areas of kiln tires to determine the impact, if any, of shell deformations on tire wobbling.
• In an area where shell section must be replaced to locate an area with low run-out so that
new shell sections may be correctly fitted.
• In the area of the girth gear when the gear requires replacement to determine if the kiln shell
also needs to be replaced due to deformation or runout.
In most cases the kiln is measured every 1 to 2 m. If a localized problem is encountered, it may be
prudent to measure the affected area in smaller intervals to provide a higher resolution image of the
deformation.
4.6.8 Polar Diagrams/Radar Charts of measurements

The values measured from each kiln cross section may be displayed in a radar chart, which appears
as the measured cross section. It is these radar charts that are combined to create the shell models
displayed below. The individual radar charts of each measured shell cross section are available for
review in Appendix A of this report. In these graphs, the dark green points are the measured values.
The light green is an ideal circle formed from analysis of the measured data and the blue X is the
geometrical center of the cross section. In areas where the kiln shell models below indicate prob-
lems, it is often helpful to review the individual cross section charts for a better understanding of the
issue.
Note: The two charts below are for illustration purposes only and do not reflect the condition of this
kiln. For the charts specific to this kiln refer to Appendix A.
Example 1 below illustrates a situation in which a kiln shell has significant shell deformation but very
little eccentricity. In this case, the center of rotation is very close to the center of gravity of the section
even though a traditional “run-out check” using a pointer and tape (or dial indicator) at 12 places
around the shell may suggest a “dog-leg” or “crank”. Note how the blue line (Roundness) and dark
green (actual measured values) track together in this example, while the light green line (Eccentricity)
remains flat. The blue “X” in the radar chart indicates the Center of Gravity of the section.
Example 1
Example 2 below illustrates a situation in which a kiln shell has eccentricity but very little shell defor-
mation. In this case, the center of gravity is 10 mm from the center of the section and there is very
little shell deformation. Note that in this case the blue line (Roundness) departs from the dark green
line (actual measured values) as the light green line (Eccentricity) tracks with the dark green line. In
this case, a traditional “run-out check” using a pointer and tape (or dial indicator) at 12 places around
the shell would also suggest a “dog-leg” or “crank”, which would be the correct assessment.
Example 2
The two examples above illustrate the two ends of the data spectrum that may be encountered when
reviewing kiln shell profile data. Typically, the data will fall along a continuum somewhere between
these two extreme conditions. However, the review of these two examples highlights the importance
of understanding the data and distinguishing between Eccentricity and Shell Roundness when con-
sidering whether a kiln shell section should be replaced.
Amplitude of deviation – This shows the height of deformations in different colors. Blue and red
represent the low and high values with green representing the nominal position.
Comments: Due to regulations of shipping equipment across the US/Canada border, the Kiln shell
laser was unable to be shipped across.
5. Lubrication
5.1 Lubrication of support rollers and bearings
5.2 Lubrication of Support Tires
It is very important to properly lubricate the tire. There are two points to consider:
1. Lubricate the space between the riding ring and the shell. If any lubricant collects on the tire
and roller contact surfaces it must be removed to avoid damage to the contact faces.
2. Lubricate the tire side face in contact with the stop blocks
The following lubricants are recommended by Andritz for this application:

1- Easy Bar
2- Molybdenum Sulfide Paste or Copper Paste
Andritz recommends to periodically inspect the riding ring rotation and creep. If the simple
instrument previously described is not available, simply mark the shell and tire simultaneously with
a easily visible marker such as a paint marker or soap stone. Count the rotations of the tire, and
once 10 full revolutions are completed, measure the distance between the marks. Divide the total
distance by 10 to calculate the creep. Creep always increases over time (at the same shell and tire
temperatures). If the creep decreases, add lubricant and perform the procedure above. The creep
should return to previous values. If additional lubrication does not re-establish previously recorded
levels of creep, Andritz should be contacted for further assistance.
Procedure:
1- Insert “Easy Bar” Lubrication as recommended into the space between the kiln shell and tire
at least once each week of operation.
2- Apply copper paste or Moly sulfide paste to the support ring side faces in contact with the
stop blocks. The best way is to use a brush applicator. Using a brush to apply this compound
helps prevent excess lubrication which can migrate onto the roller face.
Note: Excessive oil or grease on the support roller can

cause the roller to stop rotating. This can result in a
flat spot on the roller. The liquid can also migrate into
microscopic voids in the metal surface and cause
hydraulic pressure between the roller and the tire.
This hydraulic action caused pitting on the roller
surface.
Keep support rollers and and support rings free of oil

and grease to avoid damage to the components.
6. Appendix A

S-03-H11180-630-AV Group Nackawic Alignment and Diagnostics Report

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S-03-H11180-630-AV Group Nackawic Alignment and Diagnostics Report

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Lime Kiln Alignment and Diagnostic

Contact: ANDRITZ, Inc.

Table of Contents .......................................................................................................................... 2

2.1 Pier 1 (Feed)

2.2 Pier 2 (Drive)

2.3 Pier 3 (Discharge)

3.1 Major Repair Recommendations in Order of Priority

3.2 Recommendations ASAP

3.3 Recommendations for next Kiln Outage

4. Lime Kiln Measurements

4.2 Deflection of Support Roller Shaft

4.2.1 Tool Description and Measurement Principle

4.2.2 Roller shaft Deflection Data

Comments: No issues noted for Pier 1.

Comments: No issues noted for Pier 2.

Comments: No issues noted for Pier 3.

4.5.1 Measurement principle

4.5.2 Axial equilibrium – Consequences of Excessive force

4.6.1 Stop Blocks

Wobbling + Straightness Deviation = Total Tire Run-out

4.6.4 Measurement Results

Tire Tire Wobble Straightness Deviation Total Tire Run-out

Comments: No issues noted.

For a new lime kiln, creep should be approximately 15mm

Recommendation: It is recommended to ensure that proper lubrication is being applied between

Eccentricity + Deformation = Total Radial Runout

Eccentricity + Deformation = Total Shell Run-out

Peak At – Indicates the location of

Reference - The reference point of

Each measurement location yields a

4.6.8 Polar Diagrams/Radar Charts of measurements

5.1 Lubrication of support rollers and bearings

5.2 Lubrication of Support Tires

The following lubricants are recommended by Andritz for this application:

Note: Excessive oil or grease on the support roller can

Keep support rollers and and support rings free of oil

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