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UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
Vienna International Centre, P.O. Box 300, 1400 Vienna, Austria
Tel: (+43-1) 26026-0 · www.unido.org · unido@unido.org
I

I
I rsl Fo!,2 ~~~'\Yr~~P~IsE
Cllal-•binski~go I td~fon .10-05-22
·(._--·~··"'

I SfRvl Cf 00-611 Warszawa


J>o/and
tlx 811519 upo/ pl
td~fax 27-81-02

I 20//~
I
I
I Hot l<iln alignment
I BY
Gx,., GEosERVEx svoGoszcz POLAND
I Go,.,. ENGINEERING MEAsunEMENTs ENTEnPmse LTD

I F I NAL RE P 0 RT

I REPORT ON HOT KILN ALIGtlMEtH OF THE ROTARY

I KILNS OF HAWARI ANO BENGHAZI CEMENT PLANTS

IN BENGHAZI - LIBYA
I
I
I TIME Of EXECUTION :
~ O V E M a E R 1992
I
I

I

I
I
I F I NAL RE P OR T
----------------------
I I. FORMAL DATA

I 1. Order issued by Uni~ed Nations Industrial


Development Organization
I Vienna Austria
2. Executor
I POLSERVICE - Foreign Trade Enterprise
Warsaw Poland

I J. "o. of contract : 92 I 212


4. Subject of contract: Measurements of axial deformations
I and adjustments of the rotary
Kilns no 1 and 2 at " HAWARI"
I Cement Plant in Benghazi

I L I BYA

I 5. Contract was carried out by: Engineering Measurements


Enterprise " GEOSERVEX "
I Oydgoszcz POLAND

I 6. Responsible person: Enon. Wieslaw PAUSZEK CM.Sc)


7. Time of execution : NOVEMBER l ? ~ 2 •

I O. Additional arrangements By request of "Hawari"

I Cement Plants Representatives


an additional measurement of kiln

I no J was taken.(short programme )

I
I
I
I
II. DUCUMEHTATION
I Documentation on all measurements and adjustments
I was prepared separately for each Kiln and is enclosed
in appendixes which are the integral part of this report.
I Appendix no 1 - regarding the kiln no 1 of l~awari

I Cement Plant contains 14 pages


of conclusions and drawings.

I Appendix no 2 - regarding the kiln no 2 of Hawari

I Cement Plant contains 14 pages


of conclusions and drawings.

I Appendix no 3 - regarding the kiln no 3 of Benghazi

I Cement Plant contains 9 pages


of conclusions and drawings.
I
III. COHCLUSIO~S
I
1. Conclusions were presented and prepared separately
I for each kiln and are included in appendixes nol and2

I of the above mentioned documentation.

2. Hawari Cement Plant Representatives were fully


I informed about all measurements and adjustments

I which were carried out and received the whole


documentation. Two copies of this documentation

I ~ere passed on to Hawari Cement Plant Representatives


on 26th of Nov.1992.
I
I
I
I

I
I 3. Final R E P 0 ~ T uas si~ncd on 26t!l llov, 1992

On behalf of llat-1;ni Cencnt Plant it uas signcc by:


I Mr El - ZADIN

I On behalf of POL5ERVICE it was sinned by:

I ~r Ryszard Szelagowski ( ~.Sc. Engg.)

IV. AODITIO~AL REMARKS


I
Appendix Ila 4 contains sone explanation~ about our technique
I of r.ieasurencnt and adjustr.1cnt called "ilOT l<Illl ALIGIJi.;EtlT".

I All materials included in this appendix arc to be used


as training r.iaterials and informations.
I
I T ll E F I fl AL R E P O R T

I \las elaborated b~ieslaw Pauszek ( M.Sc)

I
I " G E 0 S E H V [ ~\ " - 13YOGOSZCZ - P U L A II 0

I 3rd of Dec. 1992

I
I
I
I
I
I

I
I rsl Fo!12 ~R~~l\Yr~~P~ISE
Cltt1f•bl1blrlego I t~te/on 10-05-22

I SERVI GE 11 00-6/J JYarszawa


Po/ant!
tlx 113519 upo/ pl
telefax 27-81-02

I
Ap P E NDI X No 1
I
I
I Hot kiln alignment
I BY
CXN-r GEOSERVEX BVDGOSZCZ POLAND
I GQnnrr ENGINEERING MEASUHEMENTS ENTERPRISE LTD

I
I
I kiln no 1 HAWARI
I
I
I
I
I
~ Lil&!flt#J.OG. C•awcoa.a- Coa;p•oa.pp "'~1u.-.~
I ~ /JutriM CoryWc,
for c'""'"' •u '""""w !l{AuriJW
flllblllltcf.on IM.S • • • •

I
I

1·-
1

1
REPORT ON HOT KILN ALIGNMENT OF 2.500 TPD, DRY PROCESS,
I 3 SUPPORT KILN OF H/S THE LIBYAN CEMENT COMPANY,
BENGHAZI-HAVARI , LIBYA.
I
I Hot Kiln Alignment of the above kiln was carried out

with the aid of Optico-Hechanical method, based on Patent


I
.
authorised to Mr B. Krystowczyk (Ph.O.En9g) •

I 1.0 SCOPE OF WORK

I The scope of work includes following:

I 1.1 Measurement of kiln axis in horizontal and vertical

I planes during the kiln operation.

1.2 Measurement of support rollers axis in horizontal


I and vertical planes.

I 1.3 Measurement of undertyre clearance by means

I of differential method during the kiln operation.

I 1.4 Calculation of the deviation of the actual kiln axis


from optimal axis in horizontal and vertical planes
by a computer programme.
I
1.5 Calculation of rollers torsion and the adjustment
I required.

I 1.6 Working out the schedule for rollers adjustment


with the participation of LCC's representatives.
I
1.7 Checking measurements after the adjustment.
I
I
1·. 2

I 2.0 Measurements were carried out by representatives

of audexpol-Polservice from 2nd Nov. 1992


I to 21st Nov. 1992.

I 3.0 The results of above meesurements are as below:

3.1 The deviations of Kiln axis are as below (refer page No4)
I Support No in vertical in horizontal

I (from inlet end)


1
plane (mm)
0.0
plane (nun)
o.o
I 2
3
1.0
o.o
1. 0
o.o
I 3.2 The support roller axes torsion in vertical and horizontal
planes were found within the tolerance (refer page No5)
I
3.3 The rollers working angles are found within
I the tolerance which for this type of Kiln should be

60• +I- le 30 I (refer page No 4)


I Support No Angle

59•55•
I 1
2 59• 45'
3 59• 50 I
I 3.4 The Kiln's inclination is accurately at 3.50%.

I 3.5 The undertyre clearance was measured by means


of differential method on each tyre and the results
I are as below (refer page No 4,10 )

Tyre No
I 1 6.0
17.0
I 2

3 10.0

I
I
I
I 3

I 3.5 The undertyre clearances on supports 2 and 3

I are incorrect and require some regulations.

The proper value of such a clearance •in hot conditions•

I various from 3 to 6 mm.

I 3.6 We have noticed that the clearance between girth gear

and pinion was little (1/4 of the gear close to PNil•

I It requires an adjustment by lifting the Kiln axis up.

3.7 As we were informed about frequent lining failure


I problems near the 2nd support tyre,
A measurement of Kiln's shell deformations was taken (pagel3)
I and during this measurement we have stated a big •crank•

in sections 4 and 6 on both sides of the tyre.


I It also requires some adjustment.

3.8 The Kiln axes in horizontal and vertical planes


I are correct and do not require any adjustment.
Rollers' torsions in horizontal plane require adjustment
I { page 7 shows the details ).
Rollers' torsions adjustment should be taken into

I consideration after reducing ur.dertyre clearances


on 2nd and 3rd supports.

I 4.0 CONCLUSIONS

I To improve the Kiln's operation,it is necessary


to undertake following:

I 4.1 Reducing big undertyre clearances by inserting


undertyre shims,

I - tyre No 2 - thickness of shims 6mm

- tyre No 3 - thickness of shims 3mm


I We recommend to remove old shims and sum up the thickness
Yith new ones.
I
I
I

I 3a

I 4.2 It is also necessary to lift the 1st tyre axis up

for 5 mm , which is going to increase the clearance


I between girth gear and pinion. (page 6)

I 4.3 Our proposals of above mentioned regulations are shown

on pages 6,7 and 8 .

I The adjustment shown on page 8 is to be done


after inserting undertyre shims on 2nd and 3rd tyre.

I - First of all , the rollers on 1st support


ha"'lto be shifted for 8 mm ( inside direction ).

I - Second step considering shifting rollers on 2nd support.


- Final step is to shift the rollers on 3rd support.

I 4.4 After the whole adjustment the Kiln axis and the rollers'

I torsions will be corrected( pages 11 and 12 ).

I 4.5 The "crank" could be wind up (liquidated)

by cutting the Kiln's shell off in sections 4 and 6.

I Later on it is necessary to adjust the Kiln axis

and weld the Kiln's shell again.

I 4.6 If the whole adjustment was carried out according to

I our suggestions it would certainly have a significant

influence on decreasing lining failure and would reduce

I the numbnr of unexpected stoppages.

I
I
For BUDEXPOL - POLSERVICE
I
I
I
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DJAGRAM OF AXIAL DEFORMATIONS - FDR EEGULRT/0. .


r~- ------------ C(·
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(j..
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I
I KILN SHELL TOP CLEARANCE

I
I
I
I
I TYRE

I
I
I 1.
L
THE VALUE OF THE KILN SHELL SHIFT AGAINST THE TYRE

AFTER ONE ROUND

I 2. THE VALUE OF A CLEARANCE BETWEEN TYRE ANO THE KILN

I SHELL AS HAS BEEN HEASUlfED FR0/1 THE SCHEDULE

I
I
J.
s THC REAL CINOERTIRING CL CARANCE

I '· GJ
A KILN Sl'IELL BENO f OVALIZATION J

I
I
I
I
1· KILN No 1
I UNDERTIRING CLEARANCE
I
I TYRE ] Date of measurement
I NOV. ~
11,
1'J'l2
I NOV. 12 14 ,,,2

I No V. 11'" 1992

I
I ·-TYRE -II
----
I
© l• 5.3 mm clearance S• f? mm
I
I _,(_.
I l

I
I TYRE
- - - lff
--
I
L• 30 mm clearance '5• f0 mm
I
I
I 120 ,,,,,,
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for c..,t.ic. ~
....... w9•lUlv
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Es•atllllled• 1965. 4 .•
.,.,

DEFORMATIONS
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JN VERTICAL PLANE AFTER 1Nse:RT1N§ u...ioegJyRE" SH1ns ~

If B ~~mm
~
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I KILN No 1
I -; O/J.
g_05 M

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I
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- 20 [mm]
I - f5 tnOJf 30

I - 10

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I
I rsl Fo!12 ~R~~l\YJE~P~ISE
Cltt1f11bl1bkl~10 I td~/011 10-05-12

I SERVI GE 00-611 Jl'arszaw11


Poland
tlx 111519 upo/ pl
td~/•x 27-81-02

I
A P P E N D I X No 2
I
I
I Hot kiln alignment
I BY
Chr GEOSERVEX BVDGOSZCZ

I Go-- ENGINEERING MEASUHEMENTS ENTERl,RISE LTD


POLAND

I
I
I kiln no 2 HAWARI
I
I
I
I
I
~ LiJS!IGffl c--..~~ cofl(J(J.JP<#J.1KJ.!fl ~1~1 U~1'o~
I '1ll 1J111frVI c..,tuc.
/or'"""" t1M '"""'¥ !lf.14,W:,
ftl~.on 1"5. c • c

I
I
I 1

I REPORT ON HOT KILN ALIGNMENT OF 2.500 TPD, DRY PROCESS,

I 3 SUPPORT KILN OF M/S


BENGHAZI-HAVl\RI ,
THE LIBYAN CEMENT COMPANY,
LIBYA.

I
I Hot Kiln Alignment of the above kiln was carried out

with the aid of Optico-Mechanical method, based on Patent

I .
authorised to Mr B. Krystowczyk (Ph.D.Engg) •

I 1.0 SCOPE OF WORK

I The scope of work includes following:

I 1.1 Measurement of kiln axis in horizontal and vertical

planes during the kiln operation.

I 1.2 Measurement of support rollers axis in horizontal


and vertical planes.
I
I 1.3 Measurement of undertyre clearance by means

of differential method during the kiln operation.

I 1.4 Calculation of the deviation of the actual kiln axis

I from optimal axis in horizontal and vertical planes


by a computer programme.

I 1.5 Calculation of rollers torsion and the adjustment

I required.

Working out the schedul~ for rollers adjustment


I 1.6
with the participation ot LCC'e representativeP.

I 1.7 Checking measurements after the adjustment.

I
I
2

I
2.0 Measurements were carried out by representatives
I of Budexpol-Polservice from 2nd Nov.1992
to 21st Nov.1992.
I 3.0 The results of above measurements were presented before
the LCC's representatives on 14th Nov.1992,which are as below:
I 3.1 The deviations of Kiln axis are as below (refer page No 4)

I Support No
(from inlet end)
in vertical
plane (mm)
in horizontal
plane (mm)
1 0.0 0.0
I 2 2.5 1. 0
3 0.0 0.0
I 3.2 The support roller axes torsion in vertical and horizontal
planes were found within the tolerance (refe~ page No 6)
I 3.3 The rollers working angles are found within the tolerance
which for this type of kiln should be 6rf+/- i• 30'
I (refer page No 4 )
Support No Angle
I 1 60· 02'
2 59• 56'
I 3 59• 56'

3.4 The Kiln's inclination is accurately at 3.51%.


I 3.5 The undertyre clearance was measured by means
of differential method on each tyre and the results
I are as below (refer page No 4,9,10)
Tyre No
I 1 2.0

I 2
3
7.5
12.0

I The undertyre clearance of the tyre No 2 has been measured


for six times and the real value of this clearance is 7.5 mm.

I However.during the measurement taken on the 6th of Nov.1992


a considerable difference was noticed when the clearance

I reached 12 mm. we can only presume that the reason of such


differences was caused by a mome11tary change of the Kiln's shell

I temperature near the above mentioned tyre.


I
I 3

I 3.5 The undertyre clearances on supports 2 and 3


are incorrect and require further adjustment

I which should take place during the replacement of the Kiln's

shell under tyre 2 and 3. The proper value of undertyre


I ~learance • in hot conditions • is 3 to 6 mm.

I 3.6 During our measurements a considerable whipping of the tyre


No 2 was noticed ( upto Smm ) as well as a slight movement
of supports 2 and 3 ( upto 2mm). which is caused by an improper
I shape of the tyre No 2 and a • crank • movement of the Kiln.

I 3.7 The ovality of the 2nd tyre was measured in B different


places around this tyre ( page 11,12 )
Differences in diameters are exeeding 3 mm.
I Improper ovality of this tyre was probably caused by
"overheating • the Kiln's shell under above mentioned tyre.
I 3.8 In addition a measurement of the Kiln's shell deformations
was taken ( page 13 shows the details
I and a considerable deformations under the 2nd tyre were found.
It is recommended to change this part in the nearest future.

I 3.9 Although, the Kiln's axes deviations were found


within the tolerance , we decided to carry out a slight
I adjustment on the support No2 to reduce the friction
on the 2nd tyre and to smooth the Kiln operation.

I The adjustment was taken on 16th and 17th of Nov. 1992.

The checking measurement after aforesaid adjustment


I was taken on 18th of Nov. 1992.

4.0 CONCLUSIONS
I
I The Kiln's shell condition
is poor and some parts of
und~~

th~
2nd and 3rd tyres
shell r~quire to be changed.
( the sooner the better ). The Kiln's shell deformations
I cause a frequent lining failure.

4.1 Except a poor condition of the shell near the :yre NoJ
I we have also noticed a great number of cracks.

4.2 Page 13 shows all the parts of the shell that should be
I chang~d ( orange coloured parts
I
I Ja

I 4.3 After a proper replacement of recommended parts


there should be a significant improvement in Kiln's

I operation , lining failures and the whole regulatior.


should also improve production by decreasing other

I failure problems.

I
I fur BUDEXPOL - ~OLSERVICE

I
I Engg. (M.Sc.)

I
I
I
I
I
I
I
I
I
I
I
...
- --- - • ~lf!N
'JU tJ,utnlll C-.i*t.
for C....,., .US11"4Qiw ~
'!!'s1dlla:"!.o•)tlllJ - . . . • I , , . .•.J*"' -
E1lablll\ed4111 1965 • 4 • 4 - -I

DIAGRAM OF AXIAL DEFORMATIONS


G: .. 6Ql1 •
I ~ - --- - 02. _- - 0( • _ .5_9~ _5 6 ~;.=s · Ci•- 5 9--~Y--
~~"Z"--.
:ii._-..:...:.J

~
IN VERTIC Al PLANE CLEA

'
1
f:·1~1111n
'
rt- --:~:t._
i , ~,__,.r--_____
--- . --·
·+
,---. -=-------- . - RE~t... A)(15
3.51,% z:s ;;;;; T7;,,:,-. --- - .: : :. .: .- + ·' -.-- ..
~ Qfmm
rt- . '

. ..... ~<,,Id
~·l"z 'I/'/ ·1 ·'/I~~~~
·'1.·zz.Zl
1

~1
~I
f%%·l%·Z·7,.'J///l1
. ...., I
Cl
IN HORIZONTAL PLANE c::
~
1"?1
'"1

LF.:FT SIDE' r·~


42~P
I

Q !om
- - -~ ··- --- - t J
I
?: ~ mrn ;-·_-._.-
l-1rnm__ ! .__ --·-_--- -- - . - - I -~_lm'!J_ .
Axis
RERL. t •
I -
---------- --·-----;g·- -+i :r-;---------·
I --- - _, ·-
ttffi 1
. E.:. -~~~}-~--
-.~
_B_)~HT_51DE~-- IL- -
-L· ··-r· .... 1--
1
~
~
~
----- _l,.._~_,~

~ 1""1.strill/ C.,,t&.t
for CMUlll Mil~ Naurillls
w 3 5!"565 5 .. ~~~
- -·- - -
~JllblilhedAlll I t65 • 4 • 4 -·
~- --- . _
DIAGRAM FOR iRDLLERSAXls-TOFiSifitvl
O(•
--
--------·
.. v·------
N ------1
~
<...).
[-' ------- IN VERTICAL PLANE ,_ -- -· ;

I « \

1[ ~ 3s1:t '· lI ;;;

, · • 111 I: I I !
0
1
mrn
mfll
I.... -- _j
l 4 rl'11'1
-r·-

t / TT7'T!T1"r.1 () rnn1
. / ,' ; .' I , I , i • ///I / / ,"1
I
- 1'
I._ F777i~')1_1.1,1
I -. I
'I '/::I'I
I. ' I I , ' I . I

'1~:
-.. IN HORIZONTAL PLANE

LJ 2~m
- , -4= .
! .
T +

-r l
m111 f n1rn ~
<II
1'11GEG
I
I OUTLET I
I...... /E
rE
~t
E.
I

Ii Ii
I
I
I

'b•
11
I
t I
t•
r• E
E
lo E
E
I,•
cN 0

'
.1
~n
~ •

~ ~~
l; ~I
I~ i
t~~
I
I • •

I
I -'-Q- =~ .1 - .=--.LJ./~ '+
,.._II

I ~
I
. '
I FRGE t
I [ Oi.:'Tl ET

I 0
-di{
-dy
-dl
dH-
-----4Jv -
tit - 0
'~ -di! dff-

~i 0 -d'{r--
-di
--Id'/ -
di- 0
I
t ':I

·~·
.~
~
as
t ~
~
~ C3
~
5mm 1--dl/
4--drt--
I dlf-• 3mm
d"-"
~
I
--t !!:
0-dt dt-o

I;
-~ f ~d11 I dll~f
--*
•• 1 5mm Q:
*~rt--
~-<Ii
; LJ---; dy
I dt-r1 •
l'H
C>
I.&...

~
5
4 mm

ta
~l~
iI
t5
V)

"""o
r~~

I
-dll di/-
I 0 -drt--
-~t
; ---i dt-
di- 0
I -chi
. - -~

I
I

~· di/-

I 0 -d-11-- '
-dt ...
----i d·t -
di- 0
I :~-Nf.ET
I_
- . Lif~11a Ccacat Coap~
. . t.WUllilll ~
I forc-.t . .,..,. . ~

I
KILN SHELL TOP CLEARANCE
I
I
I
I
I
TYRE
I
I
I
1. THE VALUE Of THE KILN SHELL SHIFT AGAINST THE TYRE

I I
l AFTER ONE ROUND

I 2. THE VALUE OF A CLEARANCE BETWEEN TYRE ANO THE KILN

SHELL AS HAS Bf£N HEASURED FROH THE SCHEDULE


I
I J.
s THE REAL UNDERTIRING CLEARANCE

I
4. w A KILN SHELL BEND f OVALIZATION J

I
I
I
I
I PRGE'j

I KILN No 2
I UNDERTIRIN6 CLEARANCE
I
I -I
I
TYRE --- Measurement date

l- 6.6 mm c.·~w-rance s- 2 ,,.,m


I .Nov s Iii 4992

I
I
I
I
-
___ -
_TYRE Ill
_.;;;...._ --

I
L=- 41.~ mm

·® clearance· S = 13 mm

G
lh
I NOV. 1992 _

I
I
I @ {• 38.6 mm clearance. .s- 12 mm

I~
I NOV '3
aae
f 'J'12

I k. l ----t
I ff6mm
PAGE 10
I -
I TYRE II- - - - -
- Heasurement o'ate:

I l• 38 mm dearonce .S ... 12mm


I ll.
--=- NOV ~ /992
I
L
I "4mrn

I
I [ • 2f. 7mm cltZaronce .S • f m'71

I
I ~·le-- - !7 ,,,.,..., --->I

I
I le 22.s mm clearance .s-= 7s mm

I - NOV. fOH, f'J'J2


ti() v. 11"' 1'192

I 90 mm·_ _ _ ____,_,
NOV.
/fOV.
14 '"
16 ,,,
'1'72
4'192

I
I
I 1s mm

I
I
I
I PAGE 11

I MEA5UREMENT OF THt T'<RE No Z OVAUT'<


I
Kl LN No Z
I
I
I
I
I
I
I
I
I
I
I
I
POSITION Dlff~r~nce
Diameter
I No
1
10
averoq11 dlamJe.
+ 1.1
.I 5 363.E mm

I 2
3
s 363.l
5 360.4'
+
-
1.B
{. [j
VIEW FR0/1 INLET
I 4 ./ s 36C. 0 - 1. g
s .5 .363.G + f.;

I 6
7
5 3G3.1
5 360.4
t
-
1. 8
1. s
I B s 360.0 - 1. 9

I
- - - - - - - - - - - - - - - - - - -·-
Diagram of the tyre§ bottom hei9ht
.

varLatLon accordio9 to the Kiln P-oslti.oo.

OUUET 1 1/ + 900 -C• +1so 0


L, + Z'lo
~
POSITION .
.. ,....
A
-.._A
;--......
:t
1 ..__,, i3 "---" 14 it
INtT
VI E\.J ~
I

~
I
,,,
~

_____ 2.Smm
1. 1 mrn ~3 mm
1::::1
;s;-..-..::".' •
• , (DLO

~
~
~
'.
iU ~ ~ . '-'-" """""
......
1 Ff 2
-1 +1

8~
;:s 9¥81 m
~ .
'·"fi$ ____ - - -
-" •3 -t5 -2-

('j
t-
"".,,CD
w *"68 0 2 -z 0
-

t
-t

~ EB

!,lf 53 !,l,57 I I \I .-- +2 +3 -2 -2

~' ~~
~I l ~·- 12.10
41tGf LP
w
t,t,,;2
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\' :z: +4- +2 -2 -3

~~ ~
w

"m( F:J t,.1fa2 +2 +1 -2 -f

tLJi
535rn\
535B
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0 +f 0
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41, 11'L!'\ I ) -2 +1 3 - 1
'1J of

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- -
~

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~

ii Lour£ Er]
.
'1r'
VIEW FROH INLET
~
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+
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fl I II . II
.. d1'ameter.s
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i
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lflfB1 --1-
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IJl,~S .. - ·- - - - -- -~ •3 +5 -~

---- l .
PRGE4J/

I I
I OUTLET I
\D'
\():
I .. ~-
f I

1H ~
--Oi-- ....

l
Ii

nl •

I I

If· I
• •

It
.~ I

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•;I~
•~ I


1rlf I
~ }l
~~!

I

~~~ I•
I
I I
• '
E
I I
I
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t
~
I .,, £

I ~,•
,
.-Q - - -
N
I
I
I
I
I
rsl Fo!12 ~~~l\Y)E~P~IsE
Cllaf•binski~go I td~fon 10-05-22
SERVI GE 00-611 JYarnawa
Poland
tlx 111519 upol pl
tdr/ax 27-81-02
I
I AP P E N0 I X Ho J

I
I
I Hot kiln alignment
I Cx.-r GEOSERVEX
BY
BYDGOSZCZ POLAND
(j,.~ ENGINEERING MEASUREMENTS ENTERPRISE LTD
I
I
I
I kiln BENGHAZI

I
I
I
I
I "'$1 y1.1£;,~
~ .£ii6J~C11fl C•tJOtUe11fJ.t COflUflJP~!!I
I ~ 1.wulrllll c,,,,.,,tuc.

'"' c''""' '114 'IJJUJ°iw Miiurillli


Es1atilsll.-.on IMS· 4 • 4

I ..
I.
I 1

I
REPORT ON HOT KILN ALIGNMENT OF 2.500 TPD, DRY PROCESS,

I 3 SUPPORT Y.ILN OF M/S THE LIBYAN CEMENT COMPANY,


BENGHAZI-HAVl\RI , LIBYA.
I
I Hot Kiln Alignment of the above kiln was carried out

with the aid of Optico-Mechanical method, based on Patent


I authorised to Mr B. Krystowczyk (Ph.D.Engg).

I 1.0 SCOPE OF WORK

I The scope of work includes following:

I 1.1 Measurem~nt of kiln axis in horizontal and vertical

planes during the kiln operation.


I
1.2 Measurement of support rollers axis in horizontal
I and vertical planes.

I 1.3 Measurement of undertyre clearance by means

of differential method during the kiln operation.


I
1.4 Calculation of the deviation ot the actual kiln axis
I from optimal axis in horizontal and vertical planes
by a computer programme.
I
1.5 Calculation of rollers torsion and the adjustment
I required.

I 1.6 Working out the schedule for rollers adjustment


~ith the participation ot LCC'a representatives.

I 1.7 Checking measurements after the adjustment.

I
I
2

3.0 Measurements were carried out by representatives

I of BUDEXPOL-POLSERVICE from 21st to 25th oi Nov. 1992

I 3.1 The results of our measurements are as below:

I J.2 The deviations of Kiln axes are as balow:(refer page No 4)

I Support No
\from inlet end)
in vertical
plane (mm)
in horizontal
plane (mm}

I l 0.0 o.o
2 6.0 2.0
I 3 0.0 o.o
I The Kiln axes in vertical and horizontal planes
require adjustment which is shown on page No 6.
I 3.3 The support roller axis torsions in vertical plane

I were found within. the tolerance ( refer page No 5


However, torsions in horizontal plane require

I some regulations which are shown on page No 7.

3.4 The rollers working angles are within the tolerance


I which for this type of Kiln should be 60°+/- 1 30'
( refer page No 4 )
I Support No Angle

I l 59° 4 7 I

59• 4 5 I
2

I 3 59 °so •

I 3.5 The Kiln's inclination is accurately at 3.00%

I
I
I 3

I 3.6 The results of undertyre clearance are as below:

I (refer page No 4)

I 1 5 mm

I 2 10 mm

J 15 mm
I We recommend to reduce the undertyre clearances
on 2nd and 3rd supports by inserting undertyre shims.

I ( thickness of shims shows page No 6 ).

I However, this regulation is not as important


as Kiln axes adjustment which is recommended to be
carried out as soon as possible.
I In this particular case inserting undertyre shims
will not change a vertical Kiln axis and can be done
I at a later time.(During a long Kiln stoppage)

I 3.7 Improper rollers torsions in horizontal plane keep

I the Kiln in its upper position.

Besides, these torsions make the Kiln's floating

I impossible to achieve, because of improper thrust rollers


performance.(Roll~rs torsions regulation is shown on page7)

I 3.8 We would also like to point out that considerable

I Kiln axis deformations are slowly breaking off the Kiln's


shell on 2nd support and have a big influence
on all lining problems.
I All steps of above mentioned adjustment shows page No 9.

I For BUDEXPOL - POLSERVICE

I
Engg. Wi
I
I
-- - - - - - -
•••lf41iv
..-
4JM '""'""" c...,&.t ~
forc...,
------~----~-~-..,
-Ea&~···· .'
DIAGRAM OF AXIAL DEFORMATIONS_
r~- .. !f_i__
::.~'-.°..
6
<J..• - _5_~ _4_s_' - _-1'_? ()'.. __ :?J_.._!'?!.' _ - - ]

~ ~~l
S• 5
.--,.....
mm
c::ii
~
IN VERTICAL PLANE
S• 10 mm._ f!E.fll. l/f'(QEll.T'l8E Cl.ER~lll'ICI!
'
'5· f5 mm
~
u
'« '
--
J,.
,,r---....J '
,_ _,
__. I Fl • • • _1...... ~ .1
. t
-===-- -- .
'1~m~fm,.,- - -~ - J '

mm

~
,_
..,
f' 7l!.z ·Z·Z·'/. ·1 ·'/,,.~
7
1///,/·' I I I 1 I I

0
"-1 I lf:I HORIZONTAL PLANE c::
~
I
I ""
""1

·-r. Ll!FT SIDE'

I ·-----------------------J -,- 1--------------------------------~


.4 .• , =±.J
0 mm
• __ .:__ I
l2'.-~~;~~-~ -~=-~ ~E"l nx~s__
5 mm
-------
- I-
JjlGlf.T_ ___ .f!?'?..: ____ _
------
,
- -. .-.,- --
__J}JAGRAM FOR IROLLERS -Axls··--rofisiON_·;
fol· ---·-------- O(• __________ _
Ci·------ ------1
- . IN VERTICAL PLANE ~
! f &- r-±1 ,~,
~ e>/ '' r--- ,_ -- _, .

~I I .J_ ~.oo/... ~ - -jf,....._-

h i==I - l

0
rnrn
mrn 2 m1n
---------;
r .. ,.,.,,,, /l.>n'/,.'/7/1

:~I
.
, ·.:. :·1./.; , , , .• , , ,
,
?
•· 011r1

r
'~fTTi rr;-rr;n-,-;-
1. / / , · , . '., 1, ,.,j
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I - • 0
IN HORIZONTAL PL:.~l\'E c:

-----r- . .FJ . rm fl~


,....
""1
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r---, .r---a-·---------·--·-·-··--··------·1
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C!LL·--·-· -
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---- r·-·
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1~- -H-- ·- -- - -· · ·
---4 -, -l ~ :-- ·· - --· ·- - - - - -- --- ·1-· :---··-
---l :J----t-..=..~---------------·-···- . -----..-· ·····-~·
·--·- ; t----·--.. · .... -·-·- . ··-·-.--------·-----·-·--··- --· ---· ~:
t~ ! t-l I '. I '

<I .... ·-
r :~1--
·-
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r·~l -· -~~
'--1::_ __,_
S ···-·
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- ... _ --4-- -__ _]-
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=t=.:.: . -..--
~I ?dl
,. tJ • (; .•
_§!(>ft_.
. ---
-[_ .
-J
•-
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(

2. s mrn 2s rnrn 0 rr1rn


'
(
PFIGE 6

I
I [ OUTLET'
I
- I
01
,\f): 41 ,._
--°''
~i .,;
E
--- .--- -l-0
b

I

I


I

INLfT -1
PRGE f
r-;.;·r;"---,
~
0 -I £ 0 mm

·~ ~
- . <:)
~

~·-~
~
=-
- ll
J; I 0 t-- ---; 0 mm
~ -
w

lq

I -~

I I
t -
~
V)

~
.._
"
.....
~

I ~ 1«mm 1-t -I t
t JI
1 mm
I ~
g ~
tit
>-

I
; 4\\ ...
I

(\i \Qs

I
G
~ ~
1
~
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Cl

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I
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1 mm

I ~-· .. ,.c.\4• \~s-

I 0 --f
"'
Ill!
1 "''"
I l~cr-]
·--·-·-·- .............

I
I fRGE8
Oi.!Ti ET
I
I 0
o-dN
o-Jy
o-ol~
I
dH-0
----tdV -0
tit - 0 0 mm

I :If~;i
o-dll dH-0
I;.'
1;, I
0 o-d"t-- ;
0-dl:
I
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d-t-0 0 mm
. ';;
1&I

I
'~
II
~
~

~
t V)

I~
I st ~
:::'.:)

C3
~

~
b z_,1,,
,fO~Yt--
,f ~dt
.
I

'.
cll(-.2
----1 d" _,,.,to
dt~1
13 mm
i:::
I; ~
~
~ ~ 2--will dH~2
10 4F:--r:/rt-- . --tdr--10

II I Q::
<:::>
~
1 mm
1~t dt.-1
11 mm

lfjf lu
5
eiS
I '4 l] V)

I ~iil!~

I
O-dll dl{-0 1m.
I 0 o-dvt--
o-dt
--I dt-0
etc-">1

I -..... ,, --

. ·f
I I
I I
- --
I
--
I
I

dll-o mi
---trh-o
I 0 dt.~1

I INlfT

I
PllGE 9
I Oi:T! El

0 IM;
I ! 0
..
~~

Ix'
Q
~
- -:
:


I

-- - : 1:
:

I
,r 1
... Ii

,; I... 0 .
:
I
I 0
~

; ~~;v
: ~\ --*"
'0 .-----5 ,,..,.,

--l-- ·-- ·.- :


L.:_-~---.-c:: i s ,,., i : I

@'

0 __.._.f mm

@_.....,.. f mm
0
r,
I INLET
I
GEOSERVEX
I ENGINEERING MEASUREMENTS

I ENTERPRISE LTD

ERV/CE
I &. SEROCXA STREET
IS-552 IYOGOSZCZ
PHONE: <•-52) 271-Ul
211-'21
TUfX: 05l27l7 Pl
PO LANO FAX: 271-191
I
I
AP P E NDI X No 4
I
I
'
I
I Hot kiln alignment
I
I
I
I
I
I
I Author :
Oolcslaw Krystowczyk PH.D.Eng.

I 1991.10.04

I
I
I
I
I CONTENTS
page
I 1. Introduction l - 2

I 2. Problems and peculiar characteristics of rotary


kiln deformation measurments 2 - 7
J. Description of rotary kiln deformation measure-
I ments and corrections calcula~ion
J.l. Survey results presentati~n 7 - 9
I J.2. Corrections calculation
J.J. Adjustment of horizontal torsions ~f rollers
9 - 11

I axis
4. Adjustment rules - rolles shifting
11 - 13
13 - 14
5. Kiln operation while adjusting
I 6. Adjustment disturbances
14 - 15

6.1. Bearings temperature rise 15 - 18


I 6.2. Axial shift 18
6.3. Change in adjustment variant 19
I 6.4. Increase in motor power consumption
7. Final comments
19
19 - 20

I 8. Bibliography 21

I
I
I
I
I
I
I
I
I
I
I 1

I
Introduction
I One or basic conditions or reliable operation Of t~e
I rotary kiln is to maintain the ideal. geometry duri:1g
the kiln rotation, namely:
a/ the rectilinearity of the kiln axis in horizontal
I and vertical plane
b/ proper horizontal and vertical torsions of roller
I axis
ci rolle 's working angles /./, =60° I
I d/ kiln drive t.eeth contact
e/ kiln axis slope

I f / under-tyre clearances

The hot kiln alignment is the process of measurement


I and adjustment ai.!lling at meeting the above said
geometrical conditions imposed by the kiln manufacturer
I or the kiln operation conditions as the sum of expe-
rience of the mS1.,ufacturer and the rotary kilns users.

I The alignment is ~o result in optimum setting of the


kiln geometry and rollers to attain the best produc-

I tivity of the kiln.


After a certain time of operation the kiln undergoes
deformations due to the temperatures c~anges /axial
I and tyre elongat.ion/ in result of foundations settlement
and the rotary motion impact /vibrations, cyclic dis-
I placement of supports/ as well as usual wear and tear
and all ';hese factors cause the necessity of alignment
I process.
Apart from the above said reasons of the kiln deforma-

I tions, which are beyond the human control, there are


deformations caused by. the assembly defects,
.
post-
overhaul assembly defects as well as servicing mistakes.
I Experiences gained Juring the alignment process of
various rotary kilns operating in many countries lead
I to the opinion that the kiln alignment should take
place ~eriodically during the operation;

I
I
I
2

The first alignment should be carried out immediately


after th~ new kiln start-up and when the production
paramete~s are fully attained and then the further
alignment process should be repeated each time after
:c~ overhaul, when rollers or other kiln parts were

replaced, but not less than once a year.


As a rule, the alignment process consists of two
necessary e.nd L~tegral stages:
a/ measurements of kiln geometry defonnation and cal-
culation of corrections
b/ introduction of corrections through the rollers
shifting

L~ this paper, problems concerning measurements


of deformation shall be touched within the small
I range considering the fact that the measurements are
complicated and require special equipment and specia-
I lized personnel.
Assuming that each kiln is measured once a year on an
I average, there is not necessar1 the cement-plant
staff training but the users should be instructed

I how to take advantage of the results of measurements.


This paper is to ?resent gained.experience concerning
the methods of alignment, evaluation of kiln operat~on
I during the alignment process, presentation of correc-
t ions calculation for various types of alignment
I as well as the assistance in case necessary precautions
have to be taken during the process /roller pivot over-
I heating, axial shift etc./
Acquaired knowledge shall allow to ta~e advantage

I of.the measurements results and to solve some problems


between seguent alignment processes.

I 2. Problems and oeculiar characteristics of rotary kiln


deformation measurements

I The correctness of alignment depende,to a large extend,


on the method of measurements carrying out.

I At present the "hot kiln alignment" becomes the world

I
J

standard method /1/ /2/ /)/.


So far, the alignment process took place on the basis
of survey made with geodesy methods at cold kiln
or the SHELLTEST device information on deformation~.
The SHELLTEST results inform about the kiln shell ova-
lization but data necessary for particular rollers
adjustment are not obtainable.
The SHELLTEST results concerning the kiln axiality
are approximate and ineffective ones, and ~oreover,
no information necessary for adjustment of roller
axis torsion, roller working angle , kiln axis and
rollers inclination, adjustment of axialshift has been
received from shelltest.
This method has been criticised in the published
pa.per /J/.
The second widely applied method of alignment based
on results of cold kiln geodesy survey deserves more
details.
There is asaUllled that the survey was made d .tring
the kiln standstill, rollers had been shifted and the
ideal cold kiln alignment was reached.
It is generally known that dimensions of the kiln
have changed during the operation and particular
constructional elements have been dis.placed due to the
temperature influance and the kiln operation conditions.
I In order to illustrate the character and the range
of changes there are presented results of survey of
I w
rotary kiln with dimensions ~5.6 x 160m.

I ~
-·- - -· ·-

I
I
.
I
Fig. 1
I
I 4

I Figure No. l presents the map of temperatures and the


~rofile of teoperature ranges of the examined kiln

I shell /the exa::!ination was carried out with thermo-


Yision camera AGA-680/ on which the temperatures

I distribution on the kiln shell is 1ifferent and does not


~tick to the theoreti.cal distribution and to that

of newly-assembled kiln.
I In table No.1, on the basis of fig. No. 1 are presented
elongations of particular segm~nts of drum in relation
I to the same secti~n of drum during the kiln standstill.
There are also figures defining changes of tires positior.

I in relation to the kiln center point.


,,...,.,.....
I
!
GnNiliee
1~111

i .....,,
~ c-1
""" •••lion
..,,. ,.....,.
..,, ~-"'
C.•I
Ill

r...,
,_
.,,.,. r....,.,..,, ...............
,....
AL

- Table No. 1
I -• I
,,m
-• ''"'"
JIOlO
.106'4> 1010] "
..___ :SflO " _,,'
71'77 f7
I
-m..-
l'9

- N
:SS"1
., 7111.1 17

I - "'
v
- ;""° _.,
7&.SJ7
-10!'

If the roller axis is parallel to the kiln axis


I and if it is truly cylindrical in shape I fig. 2.. 1 I
the deformations of kiln axis ~z would not occur
I due to the change of 6L tire position on the roller
/this situatior. occurs in new kilns which are correc~ly

I assembled/

I I 4t

I ·:-:__
. ·-.
1Cilltt11ii'Wflil#
1
'°"'11fiU
-
~ 4I ..J.
I.
-
I
J-i ".I.
I
r-+
I
Kitt ·
-...!'!' -!::!f..1# ,,_.,,_
. - ----y
I I I .

I I . I
I I I .
L
I

I Fig. 2.1 · Fig. 2.2 Fig. 2.3

I After a certain period of operation the running surfaces


of rollers are as shown on figure 2.2 •. ana a few
or a dozen milimeters of the central part is worn.
I Under these circumstances the deformation· Az vertical
axis of kiln after ita start-up shall be a dozen mili-
I metres according to the rollera wear-out degree
as it is presented on fig. 2.2

I
5

Also the roller axis L"lclination out-of-parallel


to the kiln axis shall cause the deformation 6z
of the kiln axis I fig. 2.3 I
In most cases, both reasons of vertical axis defor-
mation due to axial elongation appear together
and cause n~n-alignme.nt of kiln during its operation;
this non-alignment exceeds the maximum permissible
tolerances /J + 5 mm/
In result of variable temperature the tire and drum
diameters c~ange accordingly I fig. J I
a,._. ...,,. ,,._,.,. ..,.,.,.
I

i
...... in .,........ orr....nc.
r-1
·- ,. ..,
f l«lf.0
7 Stflf """·'
6000..
•7..
•.J.J
?
I
6001.. 1007.1 •U
4

s '°°'°
19U
IOOlf
ltflf
·•.J
• .1,4

' llX11.0
,,.,..,,,__
IOt0,1 •cf

I _,,... ,,...
Table No. 2 Fig. J
I Considering the fact that the temperat~re rise is not
the same or proportional for all, tires I fig. 1 I
I this is another reason of deformation 4z
In table No.2 are specified diameters of tires of
I examined rotary kiln measured during the kiln stand-·
still and during the operation.
I One can see that the diameters growth is different
and out-of-;Jroportion to temperatures distribution /fig. l;
I but differences in diameters are very important for
correct alignment of the kiln.

I Some of conditions of the kiln operation can cause


consid~rable distortion of meas~rements results at the
same time destroying the efficiency of the alignment
I process.
The rotary motion ot non-aligned kiln causes vibrations
I and cyclic deflections ot the upper parts ot piers
and the kiln axis as well.

I
' .
I 6

I
The amp_litude of deflections in ·acme cases attained
I 10-30 mm.
This concerns especially )-pier kilns. with long

I diameters of drum where relatively small deflections


caused resonance and devastation of kiln refractory linin~
more frequent than in normal conditions and consider-
I able economic losses are unavoidable.
Basing on the carried out measurements there was
I stated that geometrical axis of drum has various
position in given situations and this results from
I local str~sses as per the presented fig. 4.

I {mmJ
II Ill IV y

I 2

I
~~~~~Q

I kiln p:is. o~
90
ieo 0
7 H 270°

I Fig. 4
axis of rotation

I '
So, if the measurement is made in defined static
I condition of kiln, even though the kiln should ·be
turned by 90°, the indicated geometrical axis can be
I different from the axis of the kiln rotation known
from measurements taken du~ing the kiln o~eration.

I ·rhe aLove specified dynamic conditions of the kiln


operation have their impact in common and .cause
deformation of the kiln axis after the start-up.
I Figure No. :5 shows results of 2 measurmentsof the same
kiln, one taken before and another·one taken after
I the start-up and ·,yhen the normal operation 9arameters
have been attained.

I
I
I
I
7
I
I The differences that were found exceed several times
admissible limits of kiln axis rectilinearity deviation.
I l.JrAllKAM) U,. HUIAK1 K/Lf'I A.US Of.FOH":fAltON

I ti horizontal plane in r•rfical plan•

I
• Ill

I
I _,,_..... ,..... ...... I ,.,,"'
.. ..... ...... ,,,
-t·"
I l•fflld:
io 0.,1 ... .,
I

- - - - A/In Pb ...,,. 111Jtd11ff .


Un w wNI• tllllditf f.ig. 5

I As results from the above said-the kiln alignment


·during the standstill does not provide its rectilinearity
I during the operation, because eyen the most accurate
measurement taken during the standstill defines different
I position of the kiln parts in relation to these parts
position during the operation.

I 3. Description of rotary kiln deformation measurements


and corrections calculation
I J.1. The survey results presentation

I Figure 6 shows the results of measurements of rotary


kiln of Messrs UBE /Japan/ installed in

I obtained through.hot kiln alignment method.


OIAGRAH OF AXIAL Q[FORHATIONS

f«· 59"60" I
I c( • S9"SO' tr,· Cl(. 6o·v·
IN V(Rr!(AL PLAN( A7

I .-·
--·-·...L
. -·'3.99Z

I
I 1,-,_1.,1,,)
LU[,t/Jg

I
I Fig. 6

8

I
I The kiln axis deformations at-e shown in both planes:
horizontal fly and the vertical d~.
I Deformations are presented in relation to stright
line connecting axial points of the kiln shell and

I placed in planes going through the center of width of


the first and the last tire.
Horizontal deformations " fly" of the shell axis and
I the axis of tires set are the sam~, ho~ever vertical
deformations" Az" of the shell axis in the places
I of supporting and vertical deformations of tires set
axis are different because of under-tyre clearances
I Fig. 7
under tyre dearance

I
I
I
I
I Fig. 7
If the under-tyre clearances "S" .measured during the

I kiln operation are of the optimum value J+ 6 mm,


the kiln alignment can be ide~tified with tires set
alignment.
I The values of under-tyre clearances are presented
as the measured parameters of kiln geometry.
I Figure 6 presents roller axis torsions:
horizontal projection of horizontal torsion& of roller
I axis /at horizontal deformation fly I and. vertic:;il torsions
on vertical section.

I Roller axis torsions are shown in relation to the kiln


axis.

I
I
I
-
I
axis of kiln ---------
I I

I ptra.11~1 to

I the axis of kiln


--
I
I Fig. 8

I Roller !=Xis torsions are not in angular measure


but in linear measure /in milimetres/

I Horizontal torsions stand for the distance dl


shown on fig. 8

I out-of-parallel roller axis in relation to the kiln


axis along the length of axis between adjnst ing

I screws.
Vertical torsions, in most cases, are shown as the
out-of-parallel roller axis in relation to the ~:ln
I axis m:asured along the whole length of th~ roller
9ivot /between centre holes/
I J.2. Corrections calculation

I On the basis cf measurements results /fig. 6/ we can


calculate corrections of rollers shifting.
·Horizontal deformations f:sy are removable by shifting
I both rollers to the same direction and by the value
dy= Ay, but the vertical deformations Az are removable
I owing to a?proaching or moving away to different
dire ct ions both rollers by the value of dz = '{J= 6z
I In case of the decision that the kilns axis after the
I

adjustment /adjustment axis/ should go through the


I a.xis points of tire at the kiln inlet and outlet
the left roller on the central a~ppor~ e~ould be pushed

I outside /outside ot kiln/ by 16 mm and right roller


should be pushed outside of the kiln by 13 mm.

I
I
I 10

I
In most cases the alignment process is carried out
I at the additional geometric conditions concerning:
- changing or leavin~- in the same position the toothed

I wheel rim and pinions •


- leaving in the same position or shifting inlet
and outlet points of the kiln shell in relation
I to the kiln heads
leaving the same position of a.xis on selected
I support as "constans"
The straight lin.e connecting two points that meet
I additional requirements of cooperating parts is called
the adjustment a.~is.

I If there is more conditions than two the adjustment


a.xis should be centered or the one of conditions
should be abandoned /solved with another method/.
I
I
..._. c.r.v
I IN V!.~r:(,:t ?f,ANf
1

I --·
I
IN HCllrlO.'trAL Pf.-'Nf

I 11'1"""1/t?/n)
(EFT pp£

I
P1r.~1r .St,,,E

I 2-
(~tr)

Fig. 9

I The alignment/adjustm~nt of kiln presented on fig. 6


has been carried out at the condition of unchanged
I contact with pinions
The plan o~ a~ju•tmen- •hown on ~ig. 9 ___ _
~.

Oef~rmations Oy and Oz has been replaced by movement


I vectors 4~ and 6: in relation to the adjustment axis.
I
I
I l. l.

I Figure Ho .10 presents the method of calculation

I of support roller due to vertical and horizontal


"dy" and "dz" shifting and due to rol~er axis torsions
in horizontal .olane ."dl" /the .oroblem of torsions
I adjustment shall be the subject of next chapter/

I
I
I a:!J'
t+k i-44·
-~
~.,.,~

f/'1_,,/a,n)
LF.FL_s1o_~
.
~ ~~

H>r
-~-
r
.e.:et
i-+-1-
S!

I -----=11-
t'•t. _,-
-- ·-p-
-- -- -.

rliJ~
[Tf---1.) "''"'~
_,__ -~- ~
~

"'
I ~
_!1f..:.·?L;Ll!L
• Ecr_J=-
1-l:r
f:..'r.:)
...
.....
I-~ t I -~H· ·•·•""'
~.,~

r
~.'!-l' ~~"'!:. ~!:.,t.

1~ l~
I I
.
f' 1·:'\
l Fig. 10
~
~
l
i~~ 3 !" ti-"
)
~
3
-----
I J.J. Adjustment of horizontal torsions of roller s axis
The rotary kilns with hydraulic adjustment of axial
I shift shoulj be equipped with rollers parallel to the
kiln axis.
The majority of kilns has no hydraulic adjustment
I and the axial shift is controlled by rollers torsions
/axial force starting/
I Axial force depends on direction of kiln rotation
and on the direction of roller torsion - those depen-
I dences are shown on scheme /fig. 11/
IJS(ffAR(j[ SIDE

I I/;· 1~ !/-
/

1. :0:s
kiln's rotation

I/"
I -·Gf:J- ~
/l • .'l
-
- 4ifi1 t -- c:::::e:t.
- ...
'6
r::-h
-
ii
ti _.!+- ii'· ~j
. e
~

ii
kiln's rolafion

I
/din'• rofo!J!!i

I \I

.-:-b..- t
&
~
\1·,.
--~~ -eB-
I I' e
i\ ~
!\
I\
Fig. 11 FEED SIOt kiln's rofalion

I '
• 12

I
I There are various theories concerning rollera'torsion
adjustment two of them, the most recognized ones are
worth presenting:
I - minimal torsions of all rollers pulling the kiln to the
inlet side and equilibrating gravitational axial
I slide down
positioning roller torsions in burning zone as in
I the neutral position remaining rollers as per the
first .method.

I Figure No.12 shows rollers'torsions of Messrs "ALLIS


CHALMERS" kiln.

I Rollers'torsions on the right side of kiln are


corretly oriented /kiln is pullad up/ but the half
~f rollers on the righ~ side pushes down.
I VERTICAL PLAN£

I
I
H<RIZ<WTAL FtANC

I
I
I 31mm

Fig. 12
I
Of course, the axial force coming from rollers
I pulling kiln in unproper direction has to be equilibrate:
by pulling up rollers'torsions bigger than needed ones.

I The torsions of half of rollers on the right side,


through correct in orientation are incorrect by star-
ting various axial forces /roller on the second
I '
support "pulls" 4 times more than rollers on supports
),4,5.
I
I
I
• ll

I
I This causes considerable wear of the roller and tire
surfaces, overheated pivots, increased power consump-
I tion of motors, broken thrust blocks at the tires,
worn-out plates between tires and the kiln shell etc.
I Rollers'torsions corrections have been sho~n on fig. 12.
Optimum torsions of rollers of the kiln agreed during the
I adjustment: 2 mm
The correct plan of adjustment of torsions could be
I made out basing exclusively on the measurements,
but the decision is made according to the results. of:

I - visual inspection of tires parts cooperating


with rollers
visual inspection of rollers pivots position
I coperating with thrust bearings
The rollers'wear-out degree should be additionally
I taken into consideration /shape of roller/ as well as the
influance of rolle:r;-s axis torsions
I 4. Adjustment rules - rollers shifting

I Figure lJ shows the pro gra.:une of adjustment 9rocess


with specified sequent actions.

I ;J 1 gf ~f ~1 ~1 ~1 °'t
0.1

I
e
:.:: r. %
~ 1; 3
••• ••
-=
3 3
~

e
'I
~
: .
Ill it
3 3


:
it it
3 g
Ill •

®@
It It
a
••
3

Jt :0.
3

®©
~
'II

I I
.. It
''
0 0 0
.§. 0
Sl ~

~ -
"' ~

I I.... "'
~
"'~
I -ee ~=-,~~~ ~=i~ ;~ .,I I
a ~
0
"'
I o
"'f
'~
I fl I
- 0 0
.. """':..,.
.cr.i:r. ,.. .cr.n e
I
~
f 0 0
®
.
I
~ ~

I
33~333
••ia•12• •••a11 433
"lit
3~
op
•II :• fr:-."o
It
~
• •
-!
It
~

It
a
11

~t ~t ~t J ~ ~t
I «> ,,.,,,,~,.,_.

Fig. 13
I
I
• l.\

I
Rules of adjustment are as follows:
I a/ one shift of roller should not be longer than 5 mm
/next shift after·12 ~ 24 hrs/
I b/ both ends of the roller /e.g •. action "1" and "2"

I ")" and "4" etc./ should be shifted in parallel


position, if possible
c/ If the equipment possibilities makes the above
I condition i~possible there is necessary
- to shift the roller's ends in minimum intervals
I - to start shifting from the roller's end '.'Vhich'
provoke axis force pulling the kiln "down"

I d/ at first, rollers which need the most adjustment


corrections /including subsection "a"/ should be

I shifted
el the adjustment causing ahangea.~::t.n rollars 'torsions
should be carried out after the rough alignment
I of kiln /50 + 60l. of corrections/
f / torsions which pull "down" the kiln should be
I removed
g/ the sum of kiln axial forces should be zero after
I the rollers adjustment.
h/ big torsions should be decreased and small torsions
I. should be increased

5. Kiln ooeration while adjusting


I Nhile adjusting the kiln, both the cooperating parts
and the kiln itself should undergo the.observation
I The following ~tages are to be observed:
a/ axial shift, toothed whee 1 rim and points of the
I kiln contact with heads at the inlet and outlet
b/ motor power consum9tion
I /increase in power consumption in the first 9eriod
of adjustment u~ to 15~ is considered as normal
I phenomenon which retreats after J+S days/
cl temperature of rollers'pivots /momentary inoreaee
I in•pivote temperature is normal/

I
I l
I
15

I
d/ axial changes of tires position and chan:ges in rollers
I pivots position in relation to slide bearings
e/ vibrations on parti~ular piers of roller
I f / technical condition of rollers, rings, kiln shell,
under-tyre washers/pillows/
I Keen observation of techni~al condition of kiln
and rollers before the adjustment wo~ld be much-desired
I because any crack or deformation etc. which was cot
found or notified before adjustment should burden
I the alignment.
6. Adjustment disturbances
I 6.1. Bearings temperature rise
The most important problem during the adjustment
I is the slide bearings temperatures increase.
This phenomena which is not corrected in time could
I lead to the bearing seizing. This problem causes
the mechanicians forbearing from any adjugtment
I in fear of problems with temperatures of bearings.
Good knowledge of adjustment rules allows for safe

I shifting the rollers and remove the increase of


bearings temperature thro11gh the appropriate co!Tectic
shifting.
I As it· is known from practice and experience bearings
are overheated due to axial forces impact.
I In order to understand some phenomena it is indispen-
sable to make acquaintance with bearings structure,
I axis force
bearing's body
axis force

I ;--=:o:.:.r"T'"""1..----.
,..------..\
I
I
I
I A TYPE ROLLER B TYPE ROLLER
Fig. 14
I E
16

Figure tJo.1~ . presents two methods /mostly ap9lied


type "A" and type "B"/ of limitation of roller !>iVOt

I axialshift. The roller position is defined regarding


clearances /fig. 14/ - where the clearance is "zero"

I there is a friction causing the bearing temperature


rise. If the axial forces generated by roller axis
torsions are excessive ones, the immediate temperature
I rise is registered in the pivot shift limitation place
and then are coming down: reduced oil viscosity,
I rise in temperature of further parts of pivot,
rise in temperature of bearing bush and the bea-
I ring seizing.
There are situations that occur during the kiln

I operation /not necessary during the adjustment/,


therefore the detailed examination and evaluation
of behaviour of mechanicians facing this problem
I would be ad vi sable.

I
CXSCHARUE SIDE
bearing gets hat

/
I
I
I
I
I FEED SIDE
Fig. 15

I Figure No.15 presents the roller of type "A" with


one of overheated bearing. In most cases mechanicians
I push away the "overheated"· end from kiln, but without
changing the situation at all, then both enda ot roller

I are carried away from the kiln until the temperature

I
I
17
I
I becomes normal due to the load /kiln weight/ reduction.
The described operation results in kiln axis maladj~st­
I ment, increased load influance on neighbouring rollers
and then problems characteristic for non-aligned kiln.
I The correct operation should be the invert one, namely
the overheated pivot should be immediately shoved to

I the kiln by 1 or 2 mm or the another end of roller should


be shoved away from kiln and then cooled the oil and
should be changed it, if posible
I The described situation concerns the roller type "A" ,
for roller type "B" the operation is quite invert.
I Moreover, the procedure is different for rollers on the
right side of kiln and for rollers on the left side,
I and another one method should be applied for kiln with
the opposite direction of kiln rotations.

I DISCHARGE SIDE

I <!=i

I
I
I
I
I FEED SIDE

Fig. 16
I Figure 16 shows the scheme of the procedure proper
for rollers "A" according to the kiln rotations direction,
I the "overheated" bearings /pivot-besring bush/ marked
with lines and proper directions"o! correction shifting
I have been marked as well.

I
I
I 18

I
I The another reason of rise in temperature of bearings
is the axial change of the roller pivJt situation
towards bearing bushes after the change of the roller
I axis torsions 1irec~ion.
Of course, the pivot surface is not perfectly smooth
I and its convexities and micro-grooves /fig. 17/ fit
microgrooves of bearing bush.
I
I
I
I
I
I Fig. 17

I After the roller torsion is changed the pivot is shi~ted


and the bearing bush should fit the pivot. This causes
I the rise in tem~erature; the more cooperating·parts
are ·r1orn-out the higher is the rise in temparature.
I In this ca~e the roller housing should be cooled,
oil should be cooled and special oils or 9astes should

I be applied. I manganese bisulphide I


After a certain time the temperature usually is back to
normal.
I 6 .2. Axial shift
I ·rhe axial shift should be corrected after the adjustme'lt
or, if necessary, through the rollers torsions.
I The axial force direction has been described with full ·
particular• in prev1oua chapters anJ to make the proper

I decision the information of chapters J.J. and 4 could be


very useful.

I
I
• 19

I 6.J. Change in adjustment variant

I During the adjuatment it may occur that shifti~g


of one of selected rollers cannot be carried out
I or the range of shifting- is limited.
In that ces~ the adjustment axis situation should

I be changed so as the corrections of roller ~ere zerc


Of course, the roller shifting carried out uo to the
limit r.iust be also taken into consideration.
I The calculation of corrections has been described
in chapter J .2.
I 6.4. Increase in motor oower consumotion

I There was found that directly during tne adjust~ent


the motor po·11er conswnption increased ty ca 10%.
This is caused by kiln "setting", axial forces
I changes, fitting slide bearings etc.
During not very long time /J-5 days/ the power
I consumption is back to normal and falls by ca 10~.
1. Final comments
I The rotary kiln alignment is a complicated process
and should be carried out. by firm specialized in
I this process.
Small corrections of rollers situation /axial
I shift changes, corrections of roller overheated
t:>ivots etc. I could be ~arried out by kiln operation

I servicing staff.
This paper is to make the servicing staff acquainted
with the adjustment rules and to make the deforma-
I ti~n survey results more useful.

The results of the recent survey should constitute


I the basic material used for any correction.
For example, in order to change the excessive kiln
I axial. shift it is enough to turn any of rollers
but this would not be the best solution.
'

I The best solution is the analysis of results


of recent survey and correction of rcllers with
biggest torsions through their reduction and the
I correction of rollers with smallest torsions by
extending thE.m.
I
'

I'
-I 20

Thia procedure gives the additional effect-


the possible slightest wear-out of cooperating
I kiln part~. The same procedure is obligatory in case
of kiln position changing at the kiln heads.
I Shifting the roller placed near the head of kiln is
not sufficient - t~e calculation of all rollers
I corrections shou1:1 be taken into consideration ·.·1hile
designing new adjustment/alignment axis.

I Cf course, the procedure should be observed in r~spect


of results of recent survey, which have to be
up-to-date ones.
I The results of deformation measurements are considered
as U?-to-date in the course of 1 year under condition
I that ·juring that ti.me no roller, tire, bearing bush
or pivot, roller basis etc. are replaced.
I The cost of measurements and adjustment is insigni-
ficantly low in relation to the effec·."' among which

I the most important are:


- increased productivity of kiln owing to reduced
number of standstills
I - saving materials and labour necessary for overhauls
- prolongation of lifetime of kiln parts and rollers
I - reduct ion of power consamption necessary for kiln
rotation
I Special note for those users who never carried out
the kiln alignment during the kiln ope~ation and who are

I convinced that the kiln operates correctly:


those users do not know whether the kiln can operate
even better.
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21

I
I 8 I 8 L I 0 GRAP HY

I ( 1 ) Gebhardt w0 - nLB ALIGNMENT l A PERSPECTIVE


" ROCK PRODUCTS " - ootober 1989 - USA
I ( 2) Krystowczyk B; - AUSRICHTEN VON DREHOFEN UlID KORREKTUR
DER TRAGROLLEN - VERDREHUIGEN WAHREND
I DES BETRIEBES
• ZEMENT, KALK, GIPS " nr 5/1983 - BRD
I ( 3) Krystowczyk B • - Osiowanie piec6w obrotowych w swietle

I do,wiadcEen krajowych 1 zagranicznych


" C»tENT t WAPNO, Gl1:'S " nr 7/1986

I Poland

( 4) Krystowczyk B. - VERMESSUNGEN AH IN DAUERBETRIEB ARBEITERDEH


I MASCBIBEH UND EINRICHTUR}Eli - GEZEIGT
AM BEISPIEL EINES DREHOFEH
I "VERMESSUlnS~WESSEN UND RAUMORDHUln 11

Heft 7 I Oktober 1986


I ( 5) Robertson J • - IDEAS ARD TRENDS - KILN ALIGNMENT ALLOWS

I CORRECTIONS WHILE OPERATIIG


" ROCK PRODUCTS n - juuary 1987

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