Professional Documents
Culture Documents
GAP MEASUREMENT (Clearance) AND DISPLACEMENT (Control of Clearance) BETWEEN THE KILN SHELL AND
TIRE (Kiln Tires).
1.1 OBJECTIVE AND SCOPE
The objective of this measurement is to count with the necessary information to control displacement and clearance between the kiln
tube and tires due that it is fundamental for the refractory life as well as for mechanical conditions.
This is a control requiring a lot of caution, and the recommendation is to check at least once per shift.
The kiln tube and the rolling rings are dimensioned so that D internal diameter, of kiln tire, is a little bit bigger than the d kiln tube
external diameter, measured in support blocks (or in the kiln tube). The diameter difference is necessary considering that the thermal
expansion is a little bit bigger than the kiln tube.
The absolute diameter difference, i.e., the diameter difference between a circular kiln tire and a circular kiln shell, is named 2s. See
Figure number 1.1.
The diameter difference provokes, during the kiln rotation, a relative movement between the kiln tire and the kiln shell due to the
different expanded lengths of both supporting faces.
The kiln tire movement, regarding the kiln shell, is named kiln tire displacement.
1.2.1 Importance of Clearance
It is important that the clearance between the kiln tube and the kiln tire is maintained within certain values obtained by
experimentation.
If the kiln tube temperature is suddenly increased, so that the temperature difference between the kiln tube and the kiln tire is
substantial, perhaps the clearance between these becomes null or negative. This way represents a possible choking between the kiln
and the kiln tire. In case the choking is very pronounced, a permanent deformation called “constriction” (or trumpet) will be
produced in the reinforced kiln shell of the kiln tube.
The risk of this situation is higher in the kiln tires, above and below the calcinations zone. Consequently, it is important that the
relative displacement between the kiln and the kiln tires is controlled.
In case of producing permanent deformations on the kiln tube, this can result in, that a diameter extended difference involves
difficulties in coating, with the consequent need to reduce the clearance between the kiln tires and the support blocks for the ring
due to supplements placed below the blocks.
In order to protect the rotary kiln against deformations and / or damages in coating, produced by overheating during service, it is
necessary to control strictly and perform, if possible, service corrections to maintain the diameter difference, between the kiln and the
kiln tire, within an acceptable level, so that the ovality can be maintained within the admissible maximum and minimum limits.
A control of the current diameter difference, during the kiln service, is made in the simplest and most accurate mode in order to
measure the kiln tire displacement, the kiln tube relative movement regarding the kiln tires.
The diameter difference, the clearance between the kiln shell and the kiln tire, provokes, as indicated, a relative movement between
these two components.
It is not possible measuring the diameter difference in a hot kiln, but, considering that the kiln tire displacement is a function of the
diameter difference, this can be indirectly controlled by the kiln tire displacement confirmation.
1.2.3 Causes of kiln tire clearance reduction
A kiln tire in cold status is never fixed seated over the kiln. The technical reasons related to mounting explain the need to have
certain clearance, so that the kiln tire can move along the kiln.
With the purpose to consider the variable thermal expansions of the kiln shell and kiln tire during the heating period; the kilns
suppliers calculate both diameters so that the clearance between the kiln tire and kiln, at service temperature, adopts a minimum
value. It would be ideal that the kiln, in hot status, would exert certain pressure over the kiln tire, without being subject to a
contraction. This would naturally demand that the temperatures used for calculation would be really reached during the service. It is
confirmed, based on experience, that it is practically impossible to anticipate the calculation of the temperatures profile related to a
rotary kiln shell.
There is always a danger for the kiln when the kiln shell expands with a higher speed than that of the kiln tire. It is easy to understand
that this happens when a coating damage occurs under the kiln tire. But it is not clear, on the other hand, a too quick heating
condition, i.e. a start within a record time, can also have serious consequences. In this case, the kiln tire is relatively cold and the kiln
shell is quickly heated, so that permanent deformations can occur due to the kiln shell contraction. In such cases, the kiln tire internal
heating can lead to an inadmissible increase in the kiln tire clearance.
Figure 1.2 shows the temperature development of the kiln tire and kiln shell during a kiln facility-heating period. t máx. is the
maximum temperature difference, which can occur between the kiln tire and the kiln shell.
Temperature curve of kiln tire and kiln shell during a kiln-heating phase
A kiln shell permanent contraction will be produced below the kiln tire when the thermal stress T for a kiln shell impaired expansion
exceeds the elasticity limit F.
sT = E . t . t max < F
This can be the case when the required clearance in cold status sth is little or zero.
In the same way, whenever the maximum temperature difference t max is too high due to an excessively fast heating situation.
1.3 METHOD DEVELOPMENT
1.3.1 Equipment and tools to be used
F.L. Smidth supplies automatic equipment for kiln tire displacement surveillance and control. In case that such equipment is not
available, it is possible to measure the kiln tire displacement manually.
One of the most utilized methods in Cemex is the use of Displacement and Gap Meter (Figure 1.3). This measurement appliance is
composed by a bracket (02) that, through a magnetic base, is placed on one of the support blocks. The bracket supports a recording
needle (03), under a spring and in horizontal position, pressed against a piece of paper that is, through the usage of adhesive tape,
fixed to a plate (04), that in turn, is fastened to the kiln tire by magnetic blocks.
Additionally the measuring can be made by a manual method, which is described in the procedures section.
1.3.2 Periodicity
The measuring operation of the kiln tire (tire) displacement and gap is a control requiring the most caution, and the recommendation
is to check it at least once by shift.
When dealing with kiln starts, the measuring operation must be more intensive, i.e. measuring two or more times per shift.
= ————-
1.5 a 2
The curves shown are equivalent to 5 kiln turns or rotations illustrated in Figure 1.4, the values V and S can be directly measured in
the curve.
As previously mentioned, it is important that the clearance between the kiln shell and the kiln tire is maintained within determined
values.
If the recording needle, during the kiln starting process, begins to draw smaller and smaller curves, means that V and S tend to null
value, and it can be necessary to participate in order to prevent “constriction”.
1.3.4 Interpretation of results.
Gap Adjustment
As previously mentioned, the big deformations are observed in the zone of the kiln tires having an important clearance.
In order to reduce deformations, it is necessary to reduce the kiln tire clearance by lower shimming of kiln tires wear pads, provided
that it is constructively possible (kiln tire wear pads are screwed).
– Daily determination of a relative movement U and / or during a period sufficiently long (3 months).
– The minimum value U and / or V occurring within this period must serve to determine the mean clearance of the kiln tire.
– The supplementary plates thickness is obtained from the mean clearance of the kiln tire s th and / or .
U
sth = ——–
– As a safety factor regarding the big thermal expansions, the supplementary plates thickness will be dimensioned so that the
clearance in service status is within the order of 3 mm.
1.6 REFERENCES
– Control of clearance between the kiln tube and the kiln tires,
– Deformations of kiln tires in the rollers zone, coming from both reaction forces Q/2.
– Deformations of kiln shell, or crushing in the highest point, caused by the clearance between the kiln shell and the kiln tire.
These deformations are transferred to the kiln coating and therefore influence essentially its duration. Due to the constant variation
of kiln shell curvature radius, the so-called crushing process is produced during a spin.
For this reason the kiln coating bricks are strongly requested in the side areas, with the potential consequence of an elevated wear or
bricks falling down. In order to prevent these difficulties, it is essential to know these deformations magnitude, by measuring them
regularly to take the necessary steps on time. See Figure number 2.1.
2.2.2 The rotary kiln ovality
The term ovality is applied to the dimension or deformation degree. If is considered that the kiln circular shell adopts the elliptical
form when deforming, the ovality can be defined as twice the difference between both semi-shafts (axis). See Figure number 2.2.
Previous Condition:
Periphery of ellipse UE = Periphery of circle UK
UE = (a + b) UK = d .
Definition:
W = 2a – 2b = 2(a – b)
In order to compare among themselves the ovality values for different sizes, the ovality is shown in % of kiln internal diameter (kiln
shell plate).
2.3 METHOD DEVELOPMENT
2.3.1 Equipment and tools to be used
The radial deformations of a kiln shell in service can be recorded through any measuring appliance for deformations of kilns in usage:
A bridge (A), where a magnet series (B) has been provided on every end, is attached to the rotary kiln in vertical position to the
central shaft. The bridge covers a circle segment with a basis length 1 = 1 m. and an arch height h. The recorder (C) is placed in the
beam center.
During the measuring , its feeler’s point (D) must rest over the kiln shell, in order to obtain the height h change transmission (caused
by the curvature radius r change) to the pencil (E9. The pencil is moved within a pantograph guide transmitting the deviations h in
a 1:15 rate.
The polar diagram disk (F) is screwed to the pendulum disk (G) in the recorder shaft. This is permanently maintained in the same
perpendicular position due to the weight (H). In this way a relative movement is produced between the pencil and disk of diagram.
This movement remains synchronized with the rotation angle variance.
After a revolution in the diagram a closed line appears. This line is the polar representation of the height h change in function of the
rotation angle , meaning a graphic geometrically similar to the deformed section of the kiln (Shell test diagram).
The appreciation results very easy due to the polar representation, as the curve constitutes an image geometrically similar to the kiln
transversal section deformed.
It is possible to recognize quickly, for example, if a big deformation exists in the kiln tires (rollers) zone (this is the case when the kiln
tire is not sufficiently rigid), or when the kiln shell deformation is on the highest point, in this case there is a too big clearance of the
kiln tire.
The utilization of this method does not allow a real measuring in the sense of absolute values. What is recorded is the variation of
arch height h according to the polar system, being only interesting the maximum deviation or maximum difference between both
semi-axis of the ellipse contained in the diagram. For the diagram evaluation the following concepts are important:
– Deformation degree = ovality w, defined as twice the difference between both semi-axis of the kiln transversal section, deformed in
ellipse form.
a = big semi-axis
W = 2 (a-b)
– Deformation Dimension , the biggest difference between both semi-axis of the ellipse contained in the diagram.
The mathematical relationship between the ovality W and deformation dimension is obtained based upon the following formula
deducted by G. Rosenblad.
W = 2 (a – b) = 4/3 * d2 * (mm)
where: W = Kiln ovality
d = External diameter of kiln shell (m)
The appliance is quite similar in construction to the Shell test, but the main difference consists in the handling of measuring, instead
of plotting it directly into a diagram, it is recorded in an electronic recorder, as illustrated in Figure 2.4.
The recorder stores the entire bar positions. And the maximum and minimum values are utilized to determine .
This value can be mathematically related to the maximum change in kiln radius. This is shown as R in Figure 2.4, and is equal to
R2 – R1, where R2 is the highest radius of the deformed kiln during its revolution, and R1 is the lowest radius of the kiln deformed in
the same revolution, from this the following deduction is obtained: W = kiln ovality
W = 2 (a-b) a = big semi-axis = 2 R2
b = small semi-axis = 2 R1
The mathematical relation between ovality W and deformation dimension is obtained based on the following formula deducted by
F. G. Rosenblad.
W = 2 (a – b) = 4/3 * d2 * (mm)
where : W = Kiln ovality
– Mark with chalk lines all along the measuring points, precisely on those points where is the measuring appliance feeler’s tip.
– Every time it is necessary, clean the support points of the magnet with a wire brush.
The small hole in the middle, is used for disk fastening, points out to it, over the diagram, the highest point (kiln shell highest point)
of the measured transversal section.
The appliance will be prepared now for measuring in the following way, or it will be adapted to the kiln diameter.
Drop the sleeves in form of a star and displace the magnet carrier so that the inscribing pen is located in horizontal position when the
appliance is placed. The inscribing pen must be fixed in the first notch (disconnected position).
– At the same time of kill spinning, place the measuring appliance in a marked position (point 1) and confirm if the appliance
adhesion force is sufficient. The diagram image side (coordinates network) must indicate always in the same kiln entrance direction.
– Place the inscribing pen, through the precision adjustment screw, so that the three curves of a measuring plan (points 1, 2 and 3)
have enough space in the same diagram. For the first measuring, place the inscribing pen slightly upwards, for the second measuring
in the middle and for the third measuring slightly downwards.
– In the disconnected position of the recorder, the appliance must remain disconnected during two or three kiln turns, in order that
the feeler’s tip can extend because of the kiln shell temperature, which does not influence the diagram.
– Through a slight pressure, carry the inscribing pen till the second notch, so that the inscribing pen is supported over the diagram.
– After one turn (measuring time), remove the inscribing pen to the disconnected position, by pulling at the pulsating button.
– Remove the Shell test appliance, fix it in the next measuring point and proceed in the same way as before.
– Once all the measuring operations are finished, place the protection plates over the magnets.
The readings of every kiln base are used (the appliance can store data for maximum 8 bases). These readings are stored separately
from the kiln running parameters.
The detailed operation is not explained here because it is too long; therefore it will be necessary to refer directly to the appliance
manual.
Figure 2.5
2.3.4 Interpretation of results
2.3.4.1 Results evaluation
The evaluation through calculation, this means that the ovality calculation from the Shell test diagram or the Ovality Beam graphic, is
performed based on the following relations:
4 * d 2
Absolute Ovality = wa = ———– * mm
4 * d 2
Relative Ovality = wr = ———– * * 100 %
3 * dN
= ’ / 15 (mm) measured in the Shell test diagram.
Data legend:
= dN + 2 . t
t = Plate thickness.
The position 1 of the curve represents the reference point #1. The position 1 coincides when crossing through the first roller. The
depression in the curve is caused by the support roller reaction over the tire. The ovality W is a tire ovality transfer over the kiln shell.
The tire is deflected by the roller and this to the tire, and this in turn to the kiln shell, causing a reduction in the kiln shell curvature.
Immediately after the first roller, the bar passes to position 2, which is the kiln lower central part. Between the rollers, the shell
curvature is appreciated as normal.
In position 3, the bar reaches the second roller. And the kiln reaction is similar to the position 1. Again the kiln shell is crushed, and
the curvature is reduced.
From position 3, the ovality appliance passes to the kiln ascending lateral upper part. The kiln curvature is increased at its maximum,
just in the vertical tangent point.
The position 5 is the kiln top. The kiln shell is crushed in this position, and the curve indicates a curvature reduction.
The position 6 is a mirror of position 4, excepting that it corresponds when the kiln goes downwards.
The maximum and minimum points are used to calculate the ovality.
Make sure that the measuring bar whether is Shell test or ovality beam or that everything is free around the shell. The upper half
must be inspected to prevent obstructions. It is possible that there is no view from the base upper part, and the remarks must be
made from an other point of view.
The shell area where the bar magnets are located, must be polished with a wire brush in order to assure their correct fastening.
Avoid the magnets placement over the kiln shell welding cords as it can lead to incorrect readings.
When the ovality limit value does not exceed the corresponding kiln diameter, the coating request will be insignificant as
consequence of the kiln shell deformation.
2.4 COMMENTS AND OBSERVATIONS
The ovality measurement is an extremely important factor that must never be overseen for the good preservation of a rotary kiln.
Thanks to experience, there are data available that help preventing from major damages, as the ovality graphics can determine the
following:
– Kiln cracks
Chapter 3 TIRES AND ROLLERS DIAMETERS MEASUREMENTS (In cold and hot environment).
3.1 OBJECTIVE AND SCOPE
This procedure indicate us the form of higher precision measuring and count with the exact diameter of rollers and tires (kiln tires), in
order to determine their wear based upon their original dimensions, and in turn to utilize such measures for other calculations such
as alignment, etc.
3.2 METHOD BASIS OR FOUNDATION
3.2.1 Support rollers and tires tracks (kiln tires) wear.
The wear and deterioration of the rollers and tires surfaces can be produced due to:
– Misalignments.
Due to these causes, the tracks of rollers and tires lose their cylindrical form, that is the condition of a correct support and load on the
bearings and axial device. Therefore it could be eventually necessary to rectify the tire tracks in order to establish the cylindrical
surfaces.
For this purpose, currently exist devices for tire tracks rectification, with the kiln running.
F.L. Smidth, has developed this circumferential measuring special equipment, which offers the advantage to perform such measuring,
without kiln shutdown, it means that in full production process the existing diameters as well as their “conicity” can be determined.
3.3.2 Periodicity
The measuring must be made on annual frequency, or every time when the rollers measuring will be utilized as precise data, for
example in the kiln alignment, etc.
In this support the follower element (01) is defined, which send the movement signal to us, this element will make contact with the
roller, at the moment when this element (01) has made the contact, the spinning begins. Care must be observed to assure the
follower wheel is in correct position, at 90° regarding an imaginary horizontal line, this can be made, by adjusting the 3 setscrews
placed at every 120° regarding the follower wheel (01) diameter, another important point is to adjust the 3 mm. Setscrew, fixing the
feeler wheel coupling and shaft in order to assure an uniform movement between both components.
It is convenient, to note that the feeler element, must be placed in three different positions along the contacting surface width, in
order to get an idea about the roller conicity.
The next step is to place the element (03), magnet, with its fitting, (in the left roller, right roller and in the tire), depending on which
one is being analyzed, this element is placed in the lateral face of the bodies to be analyzed, and it must be made during the first turn
passing free, in order to prevent reading mistakes.
Once the above is done, place the electronic eye (02), by support with the dial indicator magnetic base; the appropriate position is
when the element (03) placed in the roller and / or tire, crosses freely the magnetic eye and this one detects it as from this point the
signal will begin to count the number of turns, according to the selection made in the electronic counter.
Once the previous points are confirmed, proceed to connect the electronic counter, which has a digital screen where the analyzed
wheel perimeter measuring will be read, whose units are shown in mm.
This counter has a selector to elect the number of turns wanted to be analyzed, normally one turn is considered to obtain the roller or
tire perimeter.
After every measuring, control must be reestablished in order to pass again the fitting (03), through the magnetic eye, the count
down is restarted, repeat this operation 2 – 3 times and get an average.
Note that the circumference-measuring appliance allows obtaining the perimeter, for roller as well as for tire, thereby the following
formula is utilized to obtain the diameter:
D = ——
– The bearing is exposed to irregular axial or radial loads at abnormally high temperatures.
– Change in the geometrical forms of the shaft trunnion shaft and the bearing gland (bronze).
– The oil type utilized does not have the prescribed viscosity.
From the cited problems, the most frequent is the bearing heating due to excessive axial loads.
The axial reaction is originated when the kiln tires are not in parallel position regarding the kiln shaft or they have a divergent
inclination, i.e. when parallelism does not exist between the kiln tires and the tread ring shaft. In case the axial loads exceed the
allowed limits, an adjustment will be made during the running operation displacing the supporting bearings in horizontal sense.
The cited adjustment guarantees also a correct load in the retaining system and a good tread of the detention kiln tires with the ring.
The wear is reduced at the minimum, as 100 % contact exists between the surfaces of ring and kiln tires.
4.3.1.1 Equipment description.
(See the figure 4.1)
The equipment for axial measuring is composed by a pressure tip screw (04), a pressure cylinder (13) and fastening pieces. The
pressure tip screw is placed on the fastening pieces, which are suspended on hinges (02) of the supporting bearings box. The tip
screw is activated by the pressure cylinder (13) when the latest is placed under pressure.
It is also composed by a hand pump (12), provided with a manometer (11) and connected by a hose (19) and a coupling piece to the
pressure cylinder (13).
The hand pump is additionally provided with a pressure-limiting valve, which prevents, that the cylinder pressure can exceed 580
bars, which is equivalent to a force of approximately 8 tons.
4.3.1.2 Measuring principle.
The measuring has, in principle, by effect that the pressure cylinder presses the tip screw against the kiln tires shaft end, with a force
opposed to the kiln tires reaction and sufficiently big to exceed the latest, so that a permanent space is produced among the pressure
ring and the pressure neck in both sides of the kiln tires.
Once this condition is satisfied, these both forces are compensated between each other, and the axial reaction can be calculated
through the cylinder pressure and the piston area.
4.3.2 Periodicity
The rollers pressures revision, must be made once a year minimum or every time observing an excessive heating (or tendency to it)
on the bearings.
Mount the shot sections (03) and the console (07) through the four 20 mm pigs (01).
Mount the distance tube (06) and the fastener (05) for the pressure tip screw (04).
Place the pressure cylinder (13) in the fastener, place the centering pig (08) in the hole for the tip screw, in the kiln tire shaft, and
stretch the cylinder.
Mark and drill and appropriate hole exactly in the kiln tires center, if it is not provided in advance of a hole to introduce the tip screw.
Connect the cylinder with the hand pump through the hose (10) and the coupling piece.
4.3.3.2 Dismounting
Remove the pressure to the equipment, by opening the return valve of the hand pump.
Dismount the hand pump and hose.
Dismount the shot sections and four pigs (01), so that only the hinges remain in the bearing box.
4.3.3.3 Procedure
In general, the rotary kiln tires must be parallel to the kiln shaft, when it is equipped with hydraulic guiding device, so that a normal
tread is produced, without axial reaction between the kiln tires washer and the tread ring.
This is impossible in practice, it is necessary to orient the kiln tires so that all of them have a little tendency to press the kiln upwards.
The axial reaction to be produced as consequence of this, must be within determined maximum and minimum values, for the
different types and sizes of bearings, as indicated in the table number 4.1.
The axial force is transmitted to the supporting bearings through a pressure ring in the kiln tires shaft and a corresponding pressure
neck in the gland. It is possible to control the sense of the axial force when verifying in which bearing there is a clearance between
the pressure ring and the pressure neck of the bushing. See the Figures number 4.2 to 4.5.
The measuring of the axial forces and the kiln tires adjustment must only be made when the kiln is under normal running conditions.
The pressure sense of kiln tires pressing the kiln downwards changes its direction and the measuring is performed.
This procedure is performed through a determined method, so that the guiding kiln tires are not reloaded in any moment. Read,
therefore, the hydraulic pressure on the guiding kiln tires manometers before and after every adjustment.
Place the measuring equipment in the bearings box hinges, as described in point 4.3.3.1 (see Figure number 4.1).
Begin the measuring operation by pumping the cylinder up to the maximum pressure for the corresponding bearing size. See the
table number 4.1.
In a time term of approximately 10 minutes the pressure in the cylinder will be adjusted to a value mediating among the maximum
and minimum pressure, if the supporting washer is correctly adjusted. At the same time, a permanent clearance will be produced on
both pressure necks of the bearings.
The pressure could vary a little bit during the kiln rotation due to the tread ring warping, etc., thereby a mean value of the read
pressure must be available. If the marked pressure does not decrease below the maximum pressure, or if it decreases below the
minimum, the kiln tires position must be modified according to the indications contained in Figures number 4.2 and 4.3.
This is High-pressure hydraulic equipment ,care must be observed to never bend the hoses; additionally special caution must be
taken for their conditions, as the usage of defective hoses implies a serious risk of personal injury.
– The spherical axial bearing, in the pressure tip screw, is of perpetual greasing and does not require any lubrication.
– The equipment must be mounted after utilizing it, as well as plug all the hydraulic couplings and place the equipment in an
appropriate transportation case.
– The fastening pieces must be well painted with anticorrosive paint.
4.5 ATTACHMENTS AND FORMS USED
Table number 4.1, indicates the maximum and minimum values of the axial load in the kiln tires as well as an adjustment value, which
is an intermediate value between the maximum and minimum values.
The tables also indicate the hydraulic pressure, corresponding to the axial loads, when a cylinder with a piston area of 16.6 cm 2
is
utilized.
The Figures 4.2 to 4.5, instruct how to control the kiln tires position through the placement of a clearance and the hydraulic pressure
value, in addition to how to obtain the desired position for the kiln tires.
Chapter 5 MEASUREMENT AND ADJUSTMENT OF THE ROLLS INCLINATION (or support sheaves)
5.1OBJECTIVE AND REACH
The objective of this procedure is to have a good contact between rolls (support sheaves), and the tread hoops (rims),
5.2 BASIS OR SUSTENTATION OF THE METHOD
A deficient contact can be due to an incorrect inclination of the sheaves in relation to the tread hoops, the correct inclinations in
theory may be calculated using an inclinations meter, the inclination can be controlled and the proper adjustment performed.
5.3 DEVELOPMENT OF THE METHOD
5.3.1 Equipment and tools to be used
The inclinometer (see figure 5.1) is used to measure the inclination of a plane, that means, the absolute deviation of the vertical or
horizontal plane.
The inclinometer is made up of a magnet holder (09), mounted to a bubble level holder (02), using a spike (08). Both carriers are
manufactured in an aluminum body.
The Magnet holder supports two cylindrical magnets (10) and an adjustable top screw (13) with spherical tip.
The Bubble Level holder has a micrometric screw (05) and four bubble levels. A spring (11) supports the micrometric screw against
the top screw’s spherical tip.
Figure 5.1
The bigger bubble levels (03) and (04) are used to measure deviations of the vertical and horizontal plane inclination, respectively.
The bubble levels are mounted in such a way that they can be regulated using the adjustment screws (06).
The small bubble levels (01) and (07) are directional levels used to control the position of the inclinometer in the plane.
When the inclinometer has to be used in rounded surfaces for example, trunnions of rollers, the Magnet Holder can be provided
with a support bridge that can be attached to the magnet holder using a milano tail (12).
The distance between the micrometric screw (05) and the spike (08) is exactly 100 mm. Therefore, the millimeter graduation of the
micrometric screw will correspond to the inclination percentage, so, 1 mm is equivalent to 1% of inclination.
In the micrometric screw 0.002 mm, its equivalent to an inclination of 0.002%, or 0.02 mm, by 1000 mm
The reach of measurement of the micrometric screw is 0 – 25 mm, nevertheless, the hinge, between the Magnet Holder (09) and
the bubble level holder (08), limits the clinometer’s reach of measurement to 0 – 20 mm, that is about + / – 10 mm
The inclinometer is provided by the supplier already fixed, however, the adjustment must be controlled before using the
inclinometer. The adjustment must be verified always if the device has been used previously.
The adjustment can be considered as correct when the inclinometer is in horizontal plane, the bubble is centered and the micrometric
screw is placed in 10.000 mm The adjustment demands a high degree of exactitude and can be difficult if a precise angular plane is
missing, for example from a machine tool or a mark end.
When it is only necessary to measure in vertical plane, for example in ends of support sheaves axis definitively mounted, that is our
case, it will be more advisable to perform an adjustment in the top screw with sphere (13) until assure that the bubble level (03) is in
perpendicular position to the magnets support face, when the micrometric screw is adjusted to 10.000 mm
5.3.2 Frequency
The measurement of the rollers inclination must be made annually.
Control with the directional levels to have the inclinometer parallel to the inclination direction. In measurements due in trunnions,
the inclinometer must be on vertical position upon the axis line in the same axis.
Turn now the micrometric screw until the bubble of the chosen level is centered. Read the value h in the micrometric screw and
calculate the inclination percentage V as following:
V = 10 – h %
The sign depends on the inclination sense and the inclinometer position, nevertheless, the sign has not any meaning considering that
the inclination is indicated in percents and the inclination sense has been established.
-Measure in both trunnions. In unloaded support sheaves the measurements must be identical, that is to say that the deviation
degree of 10,000 must be the same one if the measurement has been performed correctly. In support sheave under load a difference
of a few thousandths of percentage between the two measurements may appear.
Control, at the same time, if the axis ends are perpendicular to the trunnions. This can be important during later measurements that
only can be made in the axis ends When measuring the inclination of definitively mounted support sheaves, normally the
inclinometer is placed over the turned axis ends of the support sheaves and it is measured, at the exit end of axis as in the entrance
end, an average value is then calculated.
It is necessary to be assured against inaccuracies as a result of irregularities in the mechanized of the axis ends measuring in both
sides of the axis center and use the average value of the two measurements. See the figure number. 5.2.
The inclinometer must be placed in such a way that the line in the magnet holder flank (09) is located exactly upon the horizontal line
of axis of the same axis, as shown in figure. 5.3.
If the inclination in a support sheave under load is measured, according to the described method, an insignificant divergence
between the measurements of both axis ends can be appraised (as previously mentioned), as a consequence of the bent in one of the
support sheaves. This is not an anomaly symptom and applying the average measurements when performing the inclination estimate
is compensated by this divergence.
5.3.3.2 Operation Procedure.
Carefully clean the axis ends before perform the measurements.Measure firstly the superior axis end, next to the entrance of the
furnace. Measure both sides of the axis center and compute the average value R i . See figure 5.3. Next, measure next in the end of
inferior axis, nearest to the output, and compute the average value R 0 based on the measurements conducted here.
The numerical value of the two measurements will be in the proximities of the value for the horizontal plane, as shown in figure 5.3
and the inclination of the support sheave could consequently be established as:
R i – R o
R m = ———— %
2
Once the two measures R i and R 0 have been taken, it will be necessary to establish their deviation of 10,000, that means the
inclination percentage for both axis ends Being an unloaded sheave of support, both percentages must be identical, and in a support
sheave under load the reciprocal difference does not have to surpass 0,02%. In case of having a superior divergence it means that
the measurements have not been taken correctly and, therefore, will have to be repeated.
5.3.4 Interpretation of results
The difference between the inclination percentage in the entrance and exit extremes of the support sheave must surpass the 0.02%.
As well as the maximum deviation of parallelism between support sheaves (rollers) and the tread hoops (rims) must be 0.02%. In all
cases the indications of maximum inclinations the mentioned in the position plane corresponding to furnace must be followed.
In the case that this operation does not offer a sufficiently reliable result either, it will be precise to disassemble the superior part of
the rowlock, in order to be able to perform a control measurement on the trunnions.
Different types of kiln design exist, which have different needs to maintain the kiln in flotation.
6.2.1. Floating kilns
In these kilns the requirement is fundamental in the adjustment of support rollers by inclinating them, to carry the axial gravitational
pushing and by this way maintaining the kiln in a floating position. In this position, the tire (kiln tire) does not have contact with any
axial pushing rollers (candlesticks), when the kiln has load and when the temperature conditions are considered as normal as long as
the material is being processed. From this floating position, the kiln is displaced upwards or downwards until getting contact with the
axial pushing rollers (candlesticks).
6.3.2 Periodicity
The axial pushing revision must be made every 6 months as minimum, although a daily inspection per shift will provide a clear idea
about the need to make adjustments in the rollers inclination in order to prevent overloads in the axial pushing rollers.
6.3.3 Procedure, calculation methods and results
6.3.3.1 Floating kilns
In these kilns the axial pushing rollers must not be forced to perform pushing operation, only check that it does not have overload.
The bearings movement must be monitored by watch (dial) indicators in order to prevent an over adjustment of any assembly, and
having all the support rollers with an approximate equal load. See Figure number 6.1
The adjustment begins with a known neutral position, by positioning the rollers longitudinally parallel to the kiln shaft, the rollers
start inclination, as required by the kiln rotation direction, to move the tires upwards or downwards, beginning to displace the kiln
shell, reacting to the rollers movements. See Figures 6.2 and 6.3. The variances in material quantity inside the kiln, affect the rollers
and the kiln axial movement. With rollers inclined for a long period in typical conditions, the heaviest production loads will increase
reloads in the axial pushing roller (candlestick) in the direction(s) determined by the inclination angle. Heavy loads cause severe
reactions, light loads cause light loads.
6.3.3.2 Kilns with complete gravitational axial pushing
As the axial pushing assemblies are capable to carry gravitational axial loads, it is required that the support rollers are in a neutral
position and parallel to the kiln shaft.
In order to make corrections, the best practice is to make small movements regarding the rollers neutral position, by deliberately
inclining the rollers to make their pushing plates push downwards. In many cases, this can be done by inclining them 0.125 mm –
0.250 mm in the parallel position correct direction.
6.3.3.3 Kilns with hydraulically operated axial pushing
Due that the movement is made here with the hydraulic system the support rollers must be parallel to the kiln shaft, to make the kiln
traveling freely.
To make adjustments, the procedure is equal to the previous case, moving the screws to their neutral position. This can be made by a
slight inclination to lighten part of load in the axial pushing hydraulic system to move the kiln to its upper position.
It is extremely important that the inclination adjustments in the support rollers do not cancel totally the kiln gravitational pushing; in
this manner it is possible to move the kiln upwards without the help of the hydraulic system.
1.- Place a hand as though you were holding (grasping) the roller in favor of its spinning sense.
3.- The index finger indicates the bearing pushing, and the thumb indicates the adjustment or movement caused in the kiln.
4.- As the thumb indicates the direction towards the movement will be made, from here can be seen what hand is used, left or right,
and corresponding to the left bearing and right bearing respectively (if the roller is seen from the front position).
Chapter 7 CONTROL AND EVALUATION OF ALIGNMENT IN HOT (RUNNING) AND COLD ENVIRONMENT (KILN SHUTDOWN).
7.1 OBJECTIVE AND SCOPE
The objective of the present procedure consists in presenting the most useful methods to perform the kiln alignment control
increasing its service life.
With in a well aligned kiln, advantage exists that it will not be submitted during the running operation to hazardous flexion stresses,
nor will it gravitate in some kiln tires (tires), a bigger part than the provided in the kiln load, producing disturbances as for example
the facets (marks) and punctures (or pitting) formation on the bearing (tires) support faces and the kiln tires. A kiln without correct
alignment, will have a force consumption exceeding the normal consumption. Therefore, the kiln must be timely realigned, in order
to locate the centers again on a straight line.
7.2 METHOD BASIS OR FOUNDATION
Within the methods utilized for rotary kiln alignment control and evaluation, are the following:
In both cases the kiln is examined based on vertical and lateral leveling.
After determining the required alignment correction as the case may be, there are factors to be considered: The clearance between
kiln tires and the kiln tube, the tube ovality and gearing set from the teeth gearing. These procedures are seen separately.
In the measuring system development, the technicians have been struggling in complying with this new technique utilization with
respect to the following demands:
– Precision level.
– Magnetic tips
7.3.2 Periodicity
The kiln shaft alignment verification must be contemplated in the preventive maintenance activities, corresponding to the median
repairs, otherwise annually.
In case of any eventuality or doubt in the operation due to excess of current intake in the kiln main motor, overload in rollers, checks
must be made to know if the cause is due to kiln misalignment.
7.3.3 Procedure, calculation methods and results
In order to determine the kiln alignment conditions, the kiln position (mounting) drawing must be available, where the support rollers
(tire) diameters are indicated, as well as the distance between the kiln base or foundation.
The temperatures of the kiln shell and tires are also involved, which are obtained with a pyrometer, as well as the tires diameters.
The above involves taking away the bearings by the lateral parts, in order to place the magnetic tips on the shaft, once they are
placed, the level rod or rule is placed, where a level must be placed, to check if it is well leveled.
See Figure number 7.1, which illustrates the form to place instruments.
The height elevations form a horizontal plane, from where are determined, through horizontal straight rules, the measures “a” and “b”
to be used in determining the height H measures.
Once this data is known and taken as sighting line, both magnetic tips of the same side (entrance and exit) are placed, and a
verification of separation between rollers trunnion shafts centers is made.
In the position plane appear marked corresponding height measures series, which have likely been calculated from another
horizontal plane. Therefore, the differences between the height measures of the different kiln supports shall be the same, as long as
the kiln was correctly aligned, while the differences between them directly indicate how much the deviation is of the kiln shaft from
the straight line
Examinations also can be made for the height differences H-H 1 = “a”. They will be corrected in the same way that is in the oblique
sighting (Figure 7.2), and the deviations will be alignment mistakes.
For the determination of the corrected shaft kiln exist the following relations:
a4 = A4 – A1 a3 = a4 (L1 + L2) / L
a2 = a4 L1/L a1 = 0
The correction distances “a” can also be determined by means of drawings.Afterwards the theodolite is placed aside the kiln close to
the lower support, and the distance between the optic sighting line and a vertical level rod (or plank) is measured. The “n” measure is
directly measured, after this procedure the lateral measures “b” will be determined.
The measures V can also be determined, by measuring the distance between an optic sighting line and the kiln shaft determined with
basis on supports positions measuring. If both support rollers have the same diameter, then the result will be it and C2. If little
difference exists between both support rollers (or supports) diameters, the calculation can be made approximately just with the
condition that the lowest is closer to the kiln shaft than the other as much as the difference between both diameters.
Two forms types (7.1 and 7.2) exist. The format to be utilized, depends on how sighting line was traced, i.e. it depends on the
discrepancy of the line traced by theodolite regarding a kiln shaft parallel line.
Once this data is checked, they are transferred to the form 7.1 or 7.2 depending on the place where the sighting line was traced, and
by triangles difference a1, a2, etc.. are determined, as previously mentioned.
Knowing this data (from shaft line to sighting line), the kiln normal axis was plotted by taking a kiln ideal axis as reference.
The recommendation is to place the appliance over a firm place, without any vibration, as well as to protect the appliance from kiln
heat radiations to prevent reverberation, with this we can assure to have real data, in order to obtain this, it is necessary to be well
coordinated with the person who stops the level rod in the indicated place, which must be two levels, one of them to control the
lateral position and the other to control the frontal position. It must be perfectly leveled.
In Figure number 7.1, is illustrated the form in which the appliances must be placed in order to measure, whereas in Form number
7.3, is schematically illustrated the procedure, and are noted down the values checked as well as the drawing data related to how it
remained originally (in the mounting operation).
Once the calculations of form 7.3 are made, we will calculate the data required in Form 7.4, where the temperatures are involved, for
the kiln shell as well as the tires, which are obtained with a pyrometer, as well as the tires diameters and the displacement,
determined through the appropriate procedure, as well as position drawing (mounting operation) data.
Once the final data (A = Y – F) is determined from Form number 7.4, we transfer the data to Form number 7.5, where the data of the
form number 7.3 is also written, in the section of Form number 7.6, that asks us to make a foundation “0”, preferably base III is
considered, in order to prevent as much as possible to have movements influencing the axial device as well as in the gear ring, we can
finally obtain the values indicating the vertical position of the kiln, and with these values, we proceed to plot it in the lower part of
the form. See Form 7.5.
The equipment utilized in this method is very similar to the ones used for the method in hot environment conditions, additionally to
the same recommendations that must be followed in order to prevent mistakes.
The information obtained in this process, is stated in Form number 7.1 and 7.2 (depending on the place where the sighting line is
traced), corresponding to the format for horizontal alignment under in cold environment conditions, in this figure, a clear and
detailed sight can be obtained, as well as in the method in hot environment conditions, this calculation is also made through similar
triangles.
H-001 Measuring the gap (clearance) and displacement (clearance control), between the Kiln shell and the tire (bearing tires).
H-003 Measuring the rollers and tires diameters (in cold and hot environment conditions).
The alignment correction, is very linked to the previous procedures, thereby its observation must have extreme care to perform any
adjustment in the alignment.
When performing corrections, the transmission must be observed in order to make the necessary adjustments.
Two format types exist for horizontal alignment, depending on the manner how the sighting line was traced, i.e. the discrepancy of
the line traced by theodolite with a line parallel to the kiln shaft.
For vertical alignment, there are three format types and they are utilized in combination.
The high-pressure jacks are utilized for tire bearings displacement in the connection kiln transversal sense with the position
adjustment for the kiln tire or the kiln shaft alignment.
The jacks can be also used when performing a change of kiln tire or a tire bearing.
These high-pressure jacks are mostly utilized in the F.L. Smidth bearings types 58, 74 and 80.
8.3 METHOD DEVELOPMENT
8.3.1 Equipment and tools to be used
The equipment is composed by a manual pump (01) with an oil tank, 2 high pressure cylinders (02) (high pressure jacks), a high
pressure manometer (07), a distribution piece (11), and also three high pressure hoses (06), and three quick couplings (03) and (04).
See Figure number 8.1.
The equipment also includes an angular meter (15). See Figure number 8.2.
Both cylinders are interconnected and are placed on each side of the adjustment screw (14), of tire bearing, between the bearing base
and the fastening piece (16). See Figure number 8.2.
The cylinders are connected to the distribution piece and the manual pump through the hoses.
The adjustment screw (14) is the component, which determines the tire bearing position in the kiln transversal sense, so that, a
bearing position modification, is performed when spinning the adjustment screw. As a consequence of the enormous load coming
from the kiln tire, the kiln tube, the coating and filling operation, the bearings are pressed towards their adjustment screws, with so
much force, that they can hardly spin. See Figure number 8.3.
Both jacks help to relieve the pressure acting over the adjustment screws, whenever a spin on the screws is wanted.
8.3.2 Periodicity
This procedure is utilized provided that the kiln shaft position correction is desired as result of its alignment review.
The trajectory of piston, high-pressure jacks, is 10 mm., for this reason it can be necessary to place supplements (shims or wedges)
between the jacks and the fastening piece (or tightening).
It is very important that the faces, where the jack’s pressure is exercised, are completely parallel, as otherwise the jacks could be
damaged.
Before
starting the operation must be determined, how much and in what sense must the corresponding bearing be displaced and
calculating, according to that, the equivalent spin to apply to the adjustment screw.
L X 360
G = ————
Where G is the number of degrees to spin the adjustment screw, L is the wanted distance to displace the bearing measured in
millimeters, and S is the screw thread passage, also measured in millimeters.
For example if the desire is, to displace a bearing 0.2 mm towards the kiln theoretical shaft and the adjustment screw thread passage
is 4 mm., the screw must be spinned:
0,2 X 360
1. c) As soon as the adjustment screw can be spun, place the angular meter over the screw head, by spinning the screw as many
degrees as necessary in the correct direction.
2. d) Open the manual pump unload valve (13) The bearing will quickly slide outwards until the moment when it has contact
again with the adjustment screw.
1. e) Tighten again the bearing fastening screws.
It is important that the operation must be realized as quickly as possible in order to prevent bearing heating condition. The
adjustment result must be controlled with axial measuring equipment, as mentioned in the pertinent directions.
The supporting bearing movement, during the operation, can be eventually controlled through a micrometer with quadrant placed in
the bearing base.
8.3.4 Interpretation of results
After every roller movement or adjustment wait for some time to let the kiln stabilize itself in order to observe its behavior, by doing
this the kiln shaft will move to its correct position.
8.3.5 Safety aspects
Care must be given to observe that the hoses are absolutely intact, as the usage of defective hoses implies serious risk to personal
damages.
It is very dangerous to work close to a rotary kiln. As when performing the lead trials it is required to work very close to it,
appropriate clothing, safety goggles, safety shoes, gloves and safety shield must be utilized.
– Cutting operation for support rollers with pine shape are not allowed.
– The cutting operations must be executed in one or two rollers group at a time.
Whenever the support roller diameters difference is 20 mm or higher, its surface must be rectified.
Chapter 9 CONTROL OF CONTACT BETWEEN ROLLERS (support rollers) AND TIRES (kiln tires), THROUGH LEAD WIRE
9.1 OBJECTIVE AND SCOPE
Confirm and control the kiln supports positions during the kiln running or normal operation, through trials with wire lead.
The compressed wire form will serve as illustration for the pressure conditions existing between the kiln tire and the support roller
along the surface where the crushing will take place.
A trial isolated with lead wire is extremely difficult to be evaluated as are there are many factors contributing to provide the lead wire
with its crushed form, as mentioned subsequently.
The trial results are easier to be evaluated when intending to perform a comparison between two trials, for example, performed
before and after a supports position correction. The difference between these both trials will provide an authentic image of the
correction effects.
Also, trials performed systematically and methodically when compared against other periodic measuring, will clearly show eventual
modifications in the kiln alignment.
The trial with wire lead alone must only be considered as a relatively simple remedy for the kiln mechanical preventive maintenance,
and there are series of factors influencing the result, for example:
The very hot kiln roller (tires), can cause higher crushing than the own pressure.
The supporting faces poured (cast) and deformed in the kiln tires and the support rollers will give a false image of the pressure
conditions.
The wire leads quality and diameter.
The running conditions of the same kiln, i.e. rings formations, load distribution, formation of crusts and other adhesions, refractory
status and nature, special internal installations to improve the kiln economy, etc..
9.3.2 Periodicity
Under normal conditions it will be sufficient to perform the trial with wire lead every 3 months period.
Nevertheless, during the first period of a new kiln running, the recommendation is to perform trials with shorter intervals in order to
discover timely eventual settlements of kiln foundations or bases.
As a wire lead trial also discloses, if the kiln tube is warped, it must be always made jointly with a normal alignment of the kiln
supports and, depending upon the case, consideration must be made for the kiln tube straightening.
These trials set will form the comparison basis for all the subsequent trials.
A complete set encompasses six crushed wires coming from each support, three of them for each kiln tire. The trial with these three
wires is made in front to three generatrixes, marked in the kiln tube with a space of 120 degrees between each of the, such as
illustrated in the Figure number 9.2.
When the three generatrixes are marked in the kiln tube, it is more convenient to leave the generatrix A in the diametric plane,
crossing through the man entrances center, and the other generatrixes displaced at a distance of 120° from there. Observe the letters
sequence regarding the rotation sense.
Introduce the wire lead between the support roller and the kiln tire just in the moment when one of the generatrixes crosses through
the kiln tire.
Provide, carefully, the crushed wire with date, support number, specify if it is right or left tire (seen from the kiln operator) and also
write the corresponding generatrix number.
Place the tag on those wire lead end closest to the kiln exit end, see Figure number 9.3.
The result of wire lead trials can be preserved fixing it with adhesive tape to a carton piece, or simply limiting to transfer, carefully, the
wire leads contour to a paper and maintain it as illustrated in Figure number 9.4.
With support on Figure 9.4, which we section in 10 equal parts, to be identified as variables t, from t1 to t5, which is the exit side and
we identify them as tU and from t6 to t10, which is the entrance side identified as tJ, see Figure number 9.5, the only recommendation
is that the marking must be correct.
Subsequently, with the obtained measures the results are introduced in Form 9.1.
The mean values for every wire lead half are calculated, and the result is written in Form 9.1.
Immediately proceed to calculate the values tu – tj for each generatrix and its mean term is calculated, which is the value utilized to
make comparisons.
The mean term results of tu and tj are written on the upper part and in the lower left table, the next step is to make the addition and
the average is again obtained for every tire (right and left), subsequently the tire difference is calculated and the average t L is
obtained.
The value of tL found, is compared with the value tL of the supports rest, specially with the mean terms previously confirmed for the
corresponding support.
9.3.4 Interpretation of results
9.3.4.1 Supporting washers intersection
The kiln tire intersection i.e. how correct is the kiln tire and the support roller orientation regarding the kiln spinning or rotation.
In order to make comparisons the mean term tu-tj is used, if the kiln shaft is rectilinear (without warping), and the different
supporting faces are in good conditions, the three differences tu-tj , one for each generatrix result almost equal.
Both kiln tire for a same support must be always of opposed intersection, when the kiln tires are located at parallel positions.
As rule can be specified, that the intersection must not exceed the following values:
A too big intersection results in a very big surface pressure, in a material overload, and the wanted effect to retain the kiln in the axial
sense through an uniform axial pressure of the kiln tire is not obtained.
Additionally with the lead wires trial detection of irregularities as the following can be made:
A wire trial of lead wire performed in the generatrix D kiln, located at Vº from generatrix A in direction towards B, will mark the
maximum crushing, i.e. equal to OD distance, measured in the diagram.
If the major mean width tD, divided by the minor one, generates as result a major value of 1.3 , then the kiln tube must be
straightened.
If the lead wires crushing in a tire is higher in one roller than in another one, the reason is because the rollers have been laterally
displaced. The pressure coming from the sprocket and the kiln load can generate an unequal crushing and therefore, the rollers
position in the lateral sense must not be corrected until the moment when confirming, through a control optic leveling, the kiln shaft.
The maximum surface pressure between the washer and the kiln tire can result as big as with risk of “pitting” or “punctures”
generation, if the kiln tube is not straightened.
The mean values tH and tV are divided, the highest by the lowest, and in this surfaces pressures ratio the following values can be
expected:
In the support where the transmission is: 1.05 – 1.2
If a higher ratio is checked, a support control leveling must be verified (i.e. the kiln alignment) and make a correction.
But the trial by itself evidences, if the optic control is immediately required:
It is not possible to determine in advance an admissible variance of the mean superficial pressure from one support to another, but it
is valid as a general rule that if the mean surface pressure of a support apparently is extraordinarily big – or small – regarding the
superficial pressures on the other supports, the kiln must be submitted to a control leveling operation.
Chapter 10 CONTROL OF GEARING BETWEEN GEAR RING AND PINION IN KILN THROUGH LEADEN HEELS
10.1 OBJECTIVE AND SCOPE
The main objective of this procedure is to maintain a good contact between the gearings teeth (pinion / gear ring), in order to
increase the transmission service life.
10.2METHOD BASIS OR FOUNDATION
The transmission objective is to transmit the motor spinning momentum from the kiln reducer to the kiln tube.
One or two pinions and a sprocket, composed by two or four parts, compose the transmission. The sprocket is subject to the kiln
tube through the sprocket springs.
The faults previously mentioned, are normally consequences of a permanent or thermal deformation in the kiln tube, causing an
overload of gear ring teeth generating as result the contact (support) reduction in teeth width as well as in teeth height.
In order to monitor the clearance between pinion and gear ring, the lateral caps above the pinion must be removed. In case of
having two pinions, this measuring operation must be repeated for the other pinion.
The gear rings springs, or their fastening pins, are marked with the consecutive numbers from 1 to 12.
The heels are inserted at the pinion back, crossing through the gear ring every time a pin fastens the supports to the gear ring.
During this operation, the kiln in hot and / or cold environment, must be spun with the slow spin.
The heels are measured and the measures are recorded in a scheme (polar diagram), see Form number 10.1
If the confirmed set is not in accordance with these values, an adjustment must be made, duly considering the teeth wear, with
arrangement to the clearance indicated above, i.e. that it must be considered when the new kiln shaft is determined. Given the case
an incorrect gearing can be corrected by displacing the pinion through command supports intermediate sheets (or shims) thickness
modification.
If the contact between the teeth is not correct, this means that the teeth are not in uniform contact along the entire surface, one of
the pinion supports could be displaced in horizontal sense. The original position of the support is indicated by chisel strikes in the
support basement, and in the seat plate. The supports position can be adjusted through the adjustment screws.
A pinion and a sprocket, in two or four parts, compose the transmission. The sprocket is fastened to the kiln tube through the
sprocket springs.
The problems occurring with the pinions and gear rings of the kiln are generally originated by the following:
– Sprocket axial warping.
– Lubrication.
The faults previously mentioned, are normally due to a permanent or thermal deviation in the kiln tube, causing an overload of the
gear rings teeth as a consequence of the support reduction in the teeth width and teeth height.
11.3.2 Periodicity
The recommendation is to perform this measuring operation once a year, or every time the kiln alignment is performed.
Three people perform the measuring operations at the same time, in a same kiln revolution.
Continue the slow spinning during a whole additional revolution, and control that the measuring operations results provide the same
deviations level.
11.3.1 Radial eccentricity measuring.
For radial eccentricity measuring a stopwatch or depth measuring device is utilized, as illustrated in the Figure 11.1. During both
methods of execution it is important that the measuring operation is performed from a persistent bracket, firmly fastened to the base
plate, in order to prevent vibration-reading mistakes. First is measured the distance to the turned measuring face of the sprocket.
Spin the kiln tube one turn and read the stopwatch / depth meter in front of every mark in the kiln shell. Write the values, by utilizing
Form 11.1.
Trace a polar diagram based on the measuring operations. The radial eccentricity sense and size will be detached from the diagram;
this will also show if the big deviations are caused by ovality or eccentricity.
When adjusting the sprocket a distortion by tightening it must not be provoked. I.e., when tightening one side the other side must
be equally loosened.
Two stopwatches must be utilized for the axial warping measuring operation. They are placed on each kiln side, displaced 180° one
from each other, but on the same side of the sprocket (both stopwatches will be placed in the entrance or exit side). See Figure 11.2.
Both brackets, where the stopwatches are placed, must have good stability, in order to have a good measuring result. Both persons
necessary to read the stopwatches must be standing up in a bracket or platform, independently from the bracket where the
stopwatches will be located, so that the persons movements do not influence the measuring operations.
The reason why two stopwatches are utilize, is in order to compensate for failures generated as consequence likely to the kiln tube
axial misalignment, during the slow spinning. Which can be better appreciated by seeing the Figure 11.3.
The Figure 11.3 shows that the sprocket counts with a total eccentricity W, meaning that if the kiln is spun 180°, “A” will generate a
positive deviation (+W) and “B” a negative deviation (-W), i.e. if the kiln has not been displaced in axial sense during the slow
spinning.
Now suppose that the kiln, during a slow 180° spinning has been displaced (F) mm in the sense indicated by the arrow in Figure 11.4.
The stopwatch A indicates F+W and the stopwatch B indicates F-W.
In order to find the W value, the value we are interested in, the following method is utilized:
The deviation of stopwatch B (F-W) indicates a negative symbol, it means -(F-W) = -F+W and it is added to the deviation (F+W) in
the stopwatch A.
Adding 2W
W is obtained by dividing by two.
The method is also valid when the kiln is spun any number of degrees instead of 180°, and as it is compensated mathematically by
the axial displacement; the displacement “sense” does not have any sense.
If the sprocket is flat, the curve will always have a sinusoidal form.
In the Form 11.2, the measuring operations results are written. The axial warping must not exceed +/- 0.75 mm.; despite in recent
dates (new kilns) a higher demand exists (to increase even more the transmission life), as this value must not be higher than +/- 0.5
mm.
Whenever it is necessary to align the gear ring, this must be made immediately, and the gearing of gear ring with pinion must be
revised by following Procedure H-010.
The axial warping (run out) must not exceed +/- 0.75 mm.; despite in recent dates a higher demand exists, as this value must not be
higher than +/- 0.5 mm.
In case of exceeding the previous values, a correction must be immediately made.
Chapter 12 KILN SECTIONS (KILN SHELL) REPLACEMENT, IN WHICH DISTORTION CAUSES PROBLEMS.
12.1 OBJECTIVE AND SCOPE
This procedure, intends to cover whatever is needed when a kiln tube section or kiln shell must be replaced.
The fault shown by the kiln section or kiln shell requiring its replacement, is normally due to a permanent or thermal deformation in
the kiln tube, causing additionally damages in the bricks as mentioned, showing irregular overloads in the support rollers.
– Mounting angles or angular consoles with their adjustment screws (see Figure 12.1)
– Punch.
12.3.1.2. Support equipment
– Ultrasound equipment.
– Support beams, to support the kiln shell, they could be railroad mudsills, etc.
12.3.1.3 Work materials
– Welding application
12.3.1.4.Supporting materials
– Kiln position plan or drawing
12.3.2 Periodicity
The eventuality in the kiln shells or kiln sections replacement, is made whenever so required, due to problems caused by it when
being distorted or deformed.
2.- With the kiln shell or kiln section dimensions, the new kiln shell can be ordered to Manufacturing.
It must be inspected when being received, by measuring the diameter at the ends through a rule assuring it is perfectly circular, and
provided with a reinforcement cross, in order to prevent its damage during the transportation and handling. If the kiln shell is thick
(higher than 2.85 m.), it must have an extra cross placed in the middle point.
It is recommended to leave the reinforcement cross on its place in the kiln shell, until the moment when it is joined by angles and
pins (or alignment pins) with the adjacent kiln shell. As soon as the pins (or jacks) for kiln shells union, and once the joint is centered
through the adjustment irons, the reinforcement crosses can be cut, or can be left until after the first bottom cord¡.
If the circular form of the new kiln shell has been deformed previous to the mounting operation, the shoring crosses joists are cut
before proceeding to the kiln shells union. Jacks or tensioning pins must be utilized to make the kiln shell return to its circular form.
If this work is made during the mounting operation, exclusively tensioning pins are utilized.
The shoring crosses situated in the middle point of a thick kiln shell, must not be removed until finishing its total mounting and
welding operations.
When the kiln shell is to be utilized, the chamfers provided for the welding joints must be perfectly clean. All the paint, when burned
produces gases and reduces the welding application quality must be removed.
12.3.3.2 Preparation steps
Previous to proceed with the kiln shell removal, and the new kiln shell placement, it is necessary to examine:
1. a) The possibilities to transport the pieces, before and during the kiln shell removal, and the new kiln shell mounting.
2. b) The elevation devices available, such as cranes, hydraulic jacks, etc.
3. c) The possibilities to spin the kiln during the alignment and welding operations. It is recommended to perform spins with the
slow spinning device, and in case of utilizing tackles or hoisting machines, observe that the traction is upwards in order to
reduce the supports friction.
12.3.3.3 Damaged kiln shell removal, and surfaces preparation
1.- In a convenient extension around the repair place the material, the refractory and the internal installations are removed.
2.- Spinning the kiln, supporting against just one of the guide roller (or candlestick), lines are traced on the kiln shell corresponding
exactly to the new kiln length. 100 mm away from each side of these lines, two reference lines are traced, see Figure 12.2. The
reference lines are provided with punch marks. Identify at the same time, if a kiln shell warping correction is needed.
3.- The kiln tube is supported as illustrated in the beginning in Figure 12.2, and the kiln shell is cut with the automatic oxyacetylene
cutting equipment, and the kiln shell is dismounted.
4.- The kiln tube cut edges are chamfered such as indicated in Figure 12.3.
5.- In case the kiln shell being changed, contains a kiln tire (or tire), this is the time to perform its change, from the old or damaged
kiln shell to the new one.
Normally the adjustment irons are welded in the kiln shells internal wall, with limitation to the number of irons absolutely necessary,
see Figure 12.1.
2.- The kiln shell is aligned regarding the kiln lower part (the part towards exit), considering the eventual warping mentioned in
Paragraph 2 of the previous point 12.3.3.2. According to the indicated in Figure 12.4, the measure includes the reference line traced,
and is internally confirmed through a rectilinear rule.
3.- Internally and externally in the bottom (or lower part) and above (or upper part) of the kiln shell, respectively, a welding cord of
800 – 1 000 length is welded. Internally the complete joint is welded and externally a cord with the same dimensions must be
applied, so that, both cords have the same section, in attention to a uniform contraction.
4.- The kiln spins carefully approximately 800-1000 mm, and it is again supported, then a new welding cord with appropriate length
can be applied.
5.- Once the joint half is externally and internally finished, the kiln shell alignment must be controlled. In case the alignment is
incorrect, it must be corrected by cutting, beveling and welding part of the circular joint welded. If in the previous work the reference
line measuring has been confirmed and if the welding application has been executed with equal sections of the internal and external
cords, the kiln shell must be centered.
6.- The bottom cord is chiseled, and the joints are finished.
7.- The upper part (towards the entrance) of kiln is mounted and welded in form analogous to the explained in the above:
Chapter 13 MEASURING THE BEARINGS SET FOR KILN TIRES (or support Rollers)
13.1 OBJECTIVE AND SCOPE
The objective of this procedure is to develop a control of sets to have in the kiln tires (support rollers) bearings, in order to prevent
premature damages.
13.2 METHOD BASIS OR FOUNDATION
The rotary kiln kiln tires bearings, are of self-adjustable type (spherical base), or without adjustment (straight base).
The lubrication principle normally, is of a hydrodynamic type, i.e. that during the rotation a support oil layer is formed between the
bearing and the trunnion shaft.
That is the reason why it is very important – due to the kiln low rotation speed – that the difference between the diameter of the
trunnion shaft and bearing is exactly of the same size making possible the wedge effect, necessary to form the support oil layer under
the trunnion shaft.
Consequently, the oil viscosity has decisive influence on the bearing running and, therefore, it is very important to note down
carefully the lubrication directions.
If the correct oil is used at the correct bearing temperature, the perfect liquid friction can be obtained between the trunnion shafts
and the bearings, this prevents wear of bearings. There are examples of kilns, which have been running during fifteen years, without
any possible detection of a remarkable bearings wear.
By general rule, the bearings are provided with a machining application corresponding to the original diameter of kiln tire trunnion
shaft (or support roller), and with an appropriate sized clearance between the trunnion shaft and the bearing.
The nominal clearance between the kiln tires shaft and the bearing is obtained from Table 13.1 and it is conformed according to the
hydrodynamic lubrication principle of bearing.
The trunnion shaft (or trunnion) of the kiln tire rests, theoretically, in a generatrix at the back of the bearing. At a sufficient shaft
rotation speed, the oil will be introduced in the space between the shaft and bearing, with wedge effect, so that a thin film will
support the shaft. Depending on the speed and temperature, the thickness of such oil film can be approximately 0.01- 0.02 mm.
The evolution (or course) of pressure in the oil film is illustrated in Figure 13.l
13.2.1 Self adjustment bearings
In the self adjustable bearings, the spherical seat of the bearings guarantees that there is always a perfect support for the trunnion
shaft (or trunnion), despite one of the bearings is displaced regarding the other, whether in vertical or horizontal sense.
– Crane or frame
– Shims gauge
– Tools such as wrenches, etc. to remove and put the bearing cap and lock.
– Ink to mark metals (it can be oil paint, Prussia blue or red colored)
14.3.2 Periodicity
The eventuality of the kiln roller bearings replacement is made when required, because it is damaged whether by Babbitt or bronze
worn, or the need exists to change the roller (or kiln tire), by trunnion shaft measure change, or by any other reason.
The trunnion shaft (or trunnion) of the kiln tire rests, theoretically, on a generatrix at the back of the bearing or lining. At a sufficient
shaft rotation speed, the oil will be introduced in the space between the shaft and bearing, with wedge effect, so that a thin film will
support the shaft. Depending on the speed and temperature, the thickness of such oil film can be approximately 0.01- 0.02 mm.
First of all, the roller bearing or support cover is removed, and the bearing is dismounted, then, the placement of a new one can be
performed in the following manner:
1. Clean and dry the new bearing, eliminating paint, dirt and anticorrosive oil as well as control that it has not been damaged
during transportation. Eventual damages produced by strikes or a slight polishing or reaming removes scratches.
Control that the bearing contains a smooth transition since the oil pocket (or deposit) to the supporting face, on the radial and axial
surface, i.e. steps with cutting edge do not exist.
Dismount the support cover and mount the bearing in the bucket so that the pressure neck chamfered faces the pressure ring.
Control that the bearing, through the fastening pieces (in case of having them), be carefully fastened to the bucket, at level with it,
and no clearance exists between the bearing and the bucket.
Remove traces left by reaming of the kiln tire (or supporting roller) shaft trunnion.
Place eye screws in the bucket corners, so that, it, with bearing, could be suspended with the bearing facing downwards. See Figure
14.1.
1. Dry the kiln tire shaft carefully and apply a very thin layer of marking ink (it can be oil paint Prussia blue colored) along all the
trunnion shaft length and with a width covering approximately 120°.
2. Dry the bearing – fastened in the bucket – and place it carefully in the kiln tire, at the same time that, the pressure ring is
utilized as guide when performing the lowering (or placement).
3. Push the bearing forward and backward with short axial movements (10-12 mm) as long as it rests over the trunnion shaft.
Control the clearance between the bearing and the trunnion shaft, as illustrated in Figure 14.2.
4. Elevate the bearing and bucket by removing them from the trunnion shaft and control the foundation between the trunnion
and the bearing to inspect blackening or spot of marking ink in the bearing.
14. If the contact is shown as a narrow strip interrupted or partially interrupted at the back of the bearing, it means that the
foundation is satisfactory. See Figure 14.3.
If the contact is only shown as sporadic spots, the projecting parts regarding the bearing must be removed through slight scrapping
and repeating the process until a satisfactory result is obtained.
1. Subsequently, control that the transitions between the oil channels and the support faces of the bearings are leveled. When
everything has been controlled and approved, the same type of oil as the one utilized for support is poured. The tire is placed
in the correct position, and the support mounting operation is finished. Apply joint paste in all the union faces in order to get
the bearing watertight.
14.3.4 Interpretation of results
The results under this procedure must be positive and when the new bearing is correctly installed, the kiln will be working
satisfactorily.
Considering the kiln size and its running form (spinning in few supports), the multiple welding applications are subject to long and
varied stresses.
When there is a normal operation, such as a kiln shaft replacement, etc., excessive loads can result on certain welding applications.
Whenever these abnormal conditions continue for a long period of time, the cracks risk increases, especially in terms of cracks under
fatigue inside the welding applications, and around the most critical welding applications in terms of stress loads.
Therefore, it is fundamental to check the welding applications periodically, visually and with penetrating liquids, magnetic particles,
and / or ultrasound.
All the kilns but especially those with planetary or satellite cooling system, containing more welding applications subject to stresses
loads, the following are considered as the most critical in terms of stress:
1. All the unions in transition between the heavy section (or kiln shell) and the adjacent unions. Especially in the supports around
the burning zone and in the cooling tube suspension arrangements.
2. The welding applications at the kiln exit (reinforcement frames).
3. The satellite cooling tubes arms welding applications.
4. The reinforcement welding applications around the man entrance frames.
5. The welding application of tires saddles or supports of the kiln tires.
15.3 METHOD DEVELOPMENT
15.3.1 Equipment and tools to be used
15.3.1.1 Inspection
– Wire brush
– Polisher – Hammer
15.3.1.2 Repairmen
– Punch
15.3.2 Periodicity
The union welding applications can only be examined with the kiln out of operation or shutdown during a determined period of time,
thereby try to perform these activities in a time of shutdown scheduled by production or maintenance area.
The welding applications inspection frequency will depend upon the kiln operation. It must be made every two years under normal
operation conditions.
When the operation conditions are abnormal, the load stresses are increased on the union welding applications; therefore the
welding applications most exposed to these additional stresses must be inspected.
Every welding application repaired, must be reviewed subsequently every 6 months of kiln operation.
After this initial inspection, the welded union surfaces are carefully cleaned, by using a hammer and a wire brush, and in sometimes a
polisher can be required.
Caution must be observed to never confuse the irregularities of a crack welding application.
It is recommended that the unions welded are inspected with penetrating liquids, or with methods related to magnetic particles,
ultrasound, or with another more advanced. method and / or equipment
1. Wait until the surface is dry, and then apply a thin layer of developer, this is a high absorption dust, suspended in a volatile
solvent.
2. After the solvent is evaporated, the possible cracks will appear with a strong appearance in form of red lines contrasting on a
white base.
Important is that when the cracks are full of grease, oil, etc., this method cannot be utilized.
There where the cracks are extremely deep, the penetrating liquid will penetrate so deep, that the developer will not function. Assure
that sufficient penetrating liquid is applied and provide a reasonable time period for penetration.
At temperatures below 0°C the plate requires to be preheated with a gas burner or a blowtorch or with hot air and this before the
penetrating liquid application.
A magnetic field is generated in the area, at least in two directions with the highest degree of perpendicularity between them.
The indicating material will not be accumulated in the cracks, and this incompatibility will show the surface region defects, the defects
extend up to 3 mm below the surface.
In order to make the cracks identification easier, before examining, all the area must be painted with a light of contrasting color.
The inspection with magnetic particles must be performed in a way that the magnetic field efforts in the area to be examined are
within the 2,400 to 4,000 A/m (30-50 Oersted) range. The simplest method is the usage of an electromagnet with 90° change of
phase.
The ultrasound inspections must be made after the welding application is repaired.
Normally an ultrasound inspection can be performed with angular testers of 4 MHz at 45° and 70° and with normal testers of 2 Mhz.
15.3.3.5 Repairmen
Whenever a crack is discovered, the most appropriate method of repair must be determined.
The cracks with a length lower than 10 mm rarely have a depth exceeding 3 mm. Such “minor cracks” can normally be eliminated with
a polisher.
This form of repairmen is sufficient if it is possible to remove the crack by polishing or rabbeting the material, not reducing the
thickness more than 3 – 4 mm or higher than 10 % of the plate thickness, as long as it is polished, at the same time, the surface must
be clean, without splits and with a minimum radius of 15 mm.
It must be inspected later with magnetic particles, as higher grinding application can be required.
Welding application must repair the major cracks, cracks supposed to have a depth deeper than 3 mm.
Along with the welding application repairmen, these directions must be strictly followed:
1. Welding Application
Arch – air must be applied on the welded union, from the cracks ends to its center. The carbon electrode thickness must be 8 mm,
and the welding machine, must have as minimum 400 A power.
The welded union must be undermined as deep as the crack is totally eliminated. For passing cracks, the depth of the welded union
must correspond to 75 % of the plate thickness.
On the base, the width of the welded union must be so that there is enough space left to deposit a good mooring, or base welding
application.
The area to be welded must be perfectly polished, because a not proper polishing application will generate new cracks. A minimum 1
mm grinding application must be made, in order to eliminate every trace of carbon. The union must be totally clean from metal.
The union to be welded must be subject to inspection with penetrating liquids or magnetic particles. Not forgetting the sides of the
welded union. In case of existing traces of cracks formation, they must be eliminated again and the repairmen process must be
reinitiated.
The welding application is not ended, until eliminating every trace of defect or imperfection.
Subsequently a preheating of 150° minimum is performed. This temperature can be obtained through the welding process.
After the welding application is finished, it must be covered with mineral wool, or something similar, in order to minimize the cooling
speed, which could cause generation of new cracks.
As the electrodes are highly sensitive to the humidity, they must be maintained in a dry kiln at temperatures between 200 – 250°C at
least 3 hours previous to be utilized. In the welding application place, the welding application must be maintained at 70 – 150 °C.
In case of having a passing crack, the previous procedure, is repeated, but now the other side regarding where just has made the
welding application.
In order to minimize the appearance of new cracks, the welding application must be grinded, eliminating its convex face, leaving a
smooth surface.
The repaired area must be finally inspected, in order to assure absence of cracks or defects.