Kiln System Maintenance

Module 3: Maintenance Procedures for Kiln Supports

TEXTBOOK

Course name : Kiln System Maintenance

Module number : 3
Module title : Maintenance procedures for kiln supports
Module objectives : The participants will be able to:

 Describe and perform maintenance proce-

dures for kiln supports

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Kiln System Maintenance
Module 3: Maintenance Procedures for Kiln Supports

TABLE OF CONTENTS

MAINTENANCE PROCEDURES FOR KILN SUPPORTS AND THRUST DEVICES

.......................................................................................................................................... 6
3.1 Introduction. ............................................................................................................... 6
3.2 Safety Precautions in relation to kiln supports and thrust devices. ............................ 6
3.3 General about Maintenance activities......................................................................... 7
3.4 Corrective maintenance .............................................................................................. 8
3.4.1 Emergency intervention on a hot kiln bearing..................................................... 9
3.5 Preventive maintenance. Procedures for kiln supports including live rings and live
ring supports ................................................................................................................... 10
3.5.1 Systematic preventive maintenance. PM. 1st level inspections. ........................ 10
3.5.1.1 Inspections during operation. ............................................................................. 11
3.5.1.1.1 Live ring support blocks and side guides. ....................................................... 11
3.5.1.1.2 Contact surface condition. ............................................................................... 13
3.5.1.1.3 Kiln position i.e. live ring axial position on rollers. ........................................ 14
3.5.1.1.4 Live ring migration .......................................................................................... 15
3.5.1.1.5 Temperature monitoring of bearings. .............................................................. 16
3.5.1.1.6 Lubrication ...................................................................................................... 18
3.5.1.1.7 Internal examination of kiln bearings. ............................................................. 21
3.5.1.1.8 Measurements .................................................................................................. 23
3.5.1.2. Inspections during kiln stop............................................................................... 25
3.5.1.2.1 Measurement of wear on live ring support blocks and side guides. ................ 25
3.5.1.2.2 Measurement of linearity of rollers/live ring faces ......................................... 26
3.5.1.2.3 Lead wire test................................................................................................... 26
3.5.1.2.4 Internal examination of kiln bearings. ............................................................. 28
3.5.1.2.5 Ultrasonic examination of live rings. .............................................................. 31
3.5.1.2.6 Ultrasonic examination of roller shafts. .......................................................... 31
3.5.2 Work generated by the preventive maintenance.................................................... 33
3.5.2.1 Correction of live ring clearance/shell ovality. .................................................. 33
3.5.2.2 Machining of contact faces between live rings and rollers. ............................... 40
3.5.2.3 Other maintenance work carried out on support components. Tools and
procedures. ...................................................................................................................... 44
3.5.2.4 Replacement of bearing liner. ............................................................................. 46
3.5.2.5 Rectification of roller journal ............................................................................. 51

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3.5.2.6 Correction of alignment. ..................................................................................... 52

3.6 Thrust devices. .......................................................................................................... 52
3.6.1 Systematic preventive maintenance. PM. 1st level inspections ......................... 53
3.6.1.1 Inspections during operation. ............................................................................. 53
3.6.1.1.1 Kiln position. ................................................................................................... 53
3.6.1.1.2 Operating oil pressure...................................................................................... 54
3.6.1.1.3 Bearing house oil level. ................................................................................... 55
3.6.1.1.4 Graphite block lubrication. .............................................................................. 55
3.6.1.1.5 Pump station. ................................................................................................... 56
3.6.1.1.6 Condition of contact. ....................................................................................... 56
3.6.1.2 Inspections during kiln stop................................................................................ 59
3.6.1.2.1 Measurement of linearity of rollers/live ring faces ......................................... 59
3.6.1.2.2 Lead wire test................................................................................................... 59
3.6.1.2.3 Internal examination of thrust device bearings................................................ 59
3.6.1.2.4 Ultrasonic examination of roller shafts. .......................................................... 60
3.6.1.2.5 Replacement of bearings ................................................................................. 60

TABLE OF FIGURES
Fig 3. 1 Typical oil cooling arrangement ......................................................................... 9
Fig 3. 2 Typical kiln support .......................................................................................... 11
Fig 3. 3 Chips from live rings/Support pads ................................................................. 12
Fig 3. 4 Wear on side guides .......................................................................................... 12
Fig 3. 5 Spline steel cast live ring design with spline plates ......................................... 12
Fig 3. 6 Tangential suspension steel cast live ring design with steel cast brackets ....... 13
Fig 3. 7 Surface in good condition ................................................................................ 13
Fig 3. 9 Surface with spalling ......................................................................................... 14
Fig 3. 8 Surface with heavy wear spalling and “pitting” .............................................. 14
Fig 3. 10 Live ring migration and ovality....................................................................... 15
Fig 3. 11 Ovality as a function of kiln diameter ............................................................ 15
Fig 3. 12 Temperature monitoring.................................................................................. 16
Fig 3. 13 Temperature monitoring.................................................................................. 16
Fig 3. 14 Oil film thickness relationship with temperature and oil viscosity ................. 17
Fig 3. 15 Typical kiln lubrication gear oils from Mobil Oil ........................................... 17
Fig 3. 16 Typical kiln lubrication synthetic oils from Mobil Oil ................................... 17
Fig 3.18Cooling water system with temperature indication. .......................................... 18
Fig 3. 17 Simple cooling water system. ......................................................................... 18
Fig 3.19 Recommended live ring lubricants. .................................................................. 19
Fig 3.20 Hand pump for live ring lubrication. ................................................................ 19
Fig 3.21 Graphite block lubricator. ................................................................................ 20
Fig 3.22 Graphite block lubricator. ................................................................................ 20
Fig 3.23 Water cooling of roller. .................................................................................... 20

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Fig 3.24 Oil lubrication of roller surface with indications of facet building .................. 20
Fig 3.25 Oil level glass with level marking .................................................................... 21
Fig 3.26 Journal in good condition ................................................................................. 22
Fig 3.27Damaged journal ............................................................................................... 22
Fig 3.28 Scraper and seal................................................................................................ 22
Fig 3.29 Lip seal. ............................................................................................................ 22
Fig 3.30 Position of thrust collar and ring ...................................................................... 23
Fig 3.31 Live ring migration measurement .................................................................... 24
Fig 3.32 Live ring migration measurement and top clearance. ...................................... 24
Fig 3.33 Measuring of Wobbling of Live Ring. ............................................................. 25
Fig 3.34 Measuring of Wobbling of Live Ring .............................................................. 25
Fig 3.35 Lead wire test. .................................................................................................. 26
Fig 3.36 Lead wire test ................................................................................................... 28
Fig 3.37 Lead wire test. Examples ................................................................................. 28
Fig 3.38 Closed bearing housing. End cover .................................................................. 29
Fig 3.39 Split bearing housing........................................................................................ 29
Fig 3.40 Bearing liner clearances. .................................................................................. 29
Fig 3.41 Detail of measuring faces. ................................................................................ 30
Fig 3.42 Bearing lubrication. .......................................................................................... 30
Fig 3.43 Bearing Tolerances. .......................................................................................... 30
Fig 3.44 Ultrasonic inspection of live ring. .................................................................... 31
Fig 3.45 Sensitive areas .................................................................................................. 32
Fig 3.46 Sensitive areas .................................................................................................. 32
Fig 3.47 Deflector positions .......................................................................................... 32
Fig 3.48 Signal peaks and crack indication .................................................................... 32
Fig 3.49 Residual area ................................................................................................... 33
Fig 3.51Replacement of side guides ............................................................................... 34
Fig 3.50 Installation of shims ......................................................................................... 34
Fig 3.52 Measurement of existing supporting blocks. ................................................... 36
Fig 3.53 Support blocks, clearance measurement. ......................................................... 36
Fig 3.54 Support blocks, clearance measurement. ......................................................... 36
Fig 3.55 Table of values. ................................................................................................ 37
Fig 3.56 Table of values. ................................................................................................ 38
Fig 3.57 Table of values. ................................................................................................ 39
Fig 3.58 Measurement of roller profile .......................................................................... 40
Fig 3.59 Remaining thickness ........................................................................................ 41
Fig 3.60 Lathe. ................................................................................................................ 41
Fig 3.61 Lathe, machining of roller. ............................................................................... 42
Fig 3.62 Lathe, machining of live ring. .......................................................................... 42
Fig 3.63 Belt grinder. ...................................................................................................... 43
Fig 3.64 Disc grinder ...................................................................................................... 43
Fig 3.65 Lifting tools ...................................................................................................... 44
Fig 3.66 Lifting tools. ..................................................................................................... 45
Fig 3.68 Transversal detachable beam ........................................................................... 45
Fig 3.67 Adjusting screw ................................................................................................ 45
Fig 3.69 Bearing liner clearances. .................................................................................. 46
Fig 3.70 Detail of measuring faces ................................................................................. 46
Fig 3.71 Oil film pressure ............................................................................................... 47
Fig 3.72 Typical liner design. ......................................................................................... 48
Fig 3.74 Testing of liner ................................................................................................. 49

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Fig 3.73 Testing of liner ................................................................................................. 49

Fig 3.75 Testing of liner. ................................................................................................ 49
Fig 3.76 Testing of liner ................................................................................................. 49
Fig 3.78 Final result. ...................................................................................................... 49
Fig 3.77 Scraping of liner. ............................................................................................. 49
Fig 3.80 Testing of liner ................................................................................................. 49
Fig 3.79 Ball/Liner deformation. .................................................................................... 49
Fig 3.81 Scraping of liner .............................................................................................. 50
Fig 3.83 Shaft honing machine ....................................................................................... 51
Fig 3.82 Shaft honing machine ....................................................................................... 51
Fig 3.85 Mechanical single thrust device ...................................................................... 52
Fig 3.84 Mechanical double thrust device ...................................................................... 52
Fig 3.86 Hydraulic thrust device .................................................................................... 52
Fig 3.87 Mechanical single thrust device with position indicator .................................. 53
Fig 3.89 Single hydraulic thrust device for stationary axial kiln position...................... 54
Fig 3.88 Double hydraulic thrust device for axial kiln displacement. ............................ 54
Fig 3.91 Graphite lubricator for thrust device ................................................................ 55
Fig 3.90 Lubrication of thrust device ............................................................................. 55
Fig 3.92 Pump station for thrust device .......................................................................... 55
Fig 3.93 Thrust device alignment ................................................................................... 56
Fig 3.94 Thrust device alignment ................................................................................... 57
Fig 3.95 Thrust device alignment. Geometrical relations .............................................. 58
Fig 3.96 Thrust device .”Facets” building due to alignment fault. ................................. 58
Fig 3.98 Thrust device. “Facets” building due to “stick-slip” friction forces
(Alignment). ................................................................................................................... 58
Fig 3.99 Thrust device alignment ................................................................................... 59
Fig 3.100 Thrust device alignment ................................................................................. 60
Fig 3.101 Thrust device with sleeve bearing .................................................................. 61
Fig 3.102 Thrust device with antifriction bearings......................................................... 62

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Module 3: Maintenance Procedures for Kiln Supports

MAINTENANCE PROCEDURES FOR KILN SUPPORTS

AND THRUST DEVICES

3.1 Introduction.
The rotary kiln is the central machine of the cement plant. A high availability is essen-
tial for the overall economy of the plant.
Unscheduled stops of the kiln will not only give rise to expenditures in terms of spare
parts and repair costs but will also cause loss of production which can be difficult to re-
trieve.
The run factor is particularly dependent on the condition of the lining. The lifetime of
the lining is related to the mechanical condition of the kiln supports. In order to deter-
mine the mechanical condition, it is necessary to carry out regular preventive mainte-
nance of the individual components of the kiln supports. One must be able to discover,
monitor, and rectify any fault or development of wear, which would eventually lead to
any unforeseen, unscheduled stops of the kiln.

3.2 Safety precautions in relation to kiln supports and thrust

devices.

 Personal Safety. Your actions affect the safety of yourself and those about you.
 Group Safety. Safety is a group effort and involves concern for your fellow
workmates.
 Local Safety Program. Know and follow the safety program of your factory.
All safety programs must comply with regulations.
 Unique Safety Issues. Working around the rotary kiln equipment has many in-
herent dangers. Be sure that you understand this equipment and area about it.
 Crane Usage. Kiln support maintenance involves lifting and moving heavy
components. Make sure that you are fully trained in safe rigging practices for
the use of overhead and mobile cranes.
 Safety Audits. Conduct a safety walk-through before any maintenance or opera-
tion of equipment is started.
 Installation and Assembly Procedures. Be sure to read and understand the in-
struction manuals provided by the kiln manufacturer.
 Electrical. The vast majority of all kilns and ancillary equipment such as the lu-
brication system and hydraulic power units are electrically operated. Be sure that
proper lockout techniques used when working on such equipment.
 Pressure Systems. Thrust devices utilizing hydraulic systems must have the
pressure released prior to working on the systems.

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Module 3: Maintenance Procedures for Kiln Supports

 Lifting Heavy Components. The manufacturer’s instruction manuals and parts

manuals list the weights for various support parts and assemblies. Make sure that
the crane capacity and rigging is adequate. Make sure that this equipment is in
good condition.
 Welding and Torch Cutting. Make sure that such activities can be carried out
safely and without the possibility to light flammable materials or materials under
pressure.
• Tools and Equipment. Make sure that all tools and equipment are in good con-
dition and working order. Use the right tool for the job. Do not use cheater bars
or altered tools that could fail and cause personal injury. Do not use damaged
tools and equipment.
• Housekeeping. Good housekeeping is essential for a safe working environment.
Spillage about a kiln support should be cleaned up as soon as possible. Spillage
can result in slips, trips and falls.
• Report Safety Concerns. If necessary, tag out all equipment presenting a safety
issue or needing repairs, this can help prevent costly downtime.
• Plan Your Work. The process of planning a maintenance job also includes
conducting a safety review. Never let a time deadline get in the way of working
safely.

3.3 General about maintenance activities.

The maintenance terms and definitions used in this training package are as follows:
Maintenance activities:

1. Corrective maintenance.

• Corrective curative maintenance.

• Corrective palliative maintenance.

2. Preventive maintenance

• Systematic preventive maintenance. PM.

i. 1st level inspections.

ii. Specific inspections with measurements

• Work generated by the preventive maintenance. PG.

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• Work generated by predictive maintenance. PD.

3. Condition based maintenance.

4. Maintenance for improvement.

3.4 Corrective maintenance.

This type of maintenance is valid for the maintenance activities following the break-
down or degradation of some part of the kiln support. This activity deals mostly with
uncertain events at front.

In a well maintained plant this type of maintenance should be seldom seen.

In fact, this kind of maintenance requires immediate stoppage of the kiln and the in-
volvement of more personnel and spare parts than other activities.

Typical activities could be:

1 Fast increasing bearing temperature.

2 Sudden axial displacement of the kiln due to skewing of one or more kiln
support rollers.

The resulting activity could be:

 Corrective curative maintenance: Replacement with spare part or
correction of alignment etc.
 Corrective palliative maintenance: Application of forced cooling,
replacement of oil.
This activity is normally unplanned and the result is only temporary.
It is mainly followed by a consecutive failure analysis and also nec-
essary planning and improvement, if necessary.
In the following some examples will be described to illustrate the corrective palliative
maintenance

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Module 3: Maintenance Procedures for Kiln Supports

3.4.1 Emergency intervention on a hot kiln bearing.

In the case of sudden setting of the foundations or intervention in the bearing alignment,
sudden temperature increases can take place usually due to too high thrust between col-
lars on the bearing or sometimes due to some local scoring between liner and journal.

In such cases it is imperative to act quickly especially if the kiln has a history of previ-
ous bearing overload situations.

The typical equipment that should be available at all times locally could be:

1. Special spanners and jacks for bearing adjustment.

2. Emergency cooling equipment. As shown in fig 3.1.
3. Emergency new oil drums with the necessary higher viscosity, preferably of a
synthetic type and preferably a mixing oil with the existing oil quality.
Some synthetic oils like polyglycols can attack rubber seals and sometimes the
internal paint of the bearing.
4. The presence of ready available dry film additives like molybdenum disulfite,
graphite powder or pure sulphur powder is also an advantage to have.
These dry additives are excellent lubricators due to either their spherical or la-
mellar molecular structure.
This application should be followed up by an oil change.
5. The installation of axial cooling fans on the outside of the bearing may also be
an alternative.
6. Additional radiation protection of the bearing is also a possibility.

Fig 3.1 Typical oil cooling arrangement

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3.5 Preventive maintenance. Procedures for kiln supports in-

cluding live rings and live ring supports.

Preventive maintenance is defined as all the maintenance activities which aim at reduc-
ing the probability of failure or degradation of an equipment or its function.

This kind of maintenance activities implies an early intervention in order to avoid un-
foreseen stoppages of the equipment or degradation of the functionality of the equip-
ment.

Three kinds of differentiated types are envisaged:

 Systematic preventive maintenance PM.

 Work generated by the preventive maintenance. PG.
 Work generated by predictive maintenance. PD

What should we be looking for?

 Cracks in shafts or rolling contact surfaces
 Temperature increases
 Lubrication (leaks, degradation)
 Cooling water.
 Changes in axial thrust / positions
 Unfamiliar sounds or smells
 Condition of tyre supports and side guides

3.5.1 Systematic preventive maintenance. PM. 1st level inspections.

Systematic preventive maintenance activities are maintenance inspections and work, as

scheduled by a master plan based on units (Hours, tons etc) of operation. 1st level in-
spections or specific inspections, lubrication, controls requested by regulations, as well
as systematic replacement are examples of such activities.

A support consists of a base plate (04), two supporting rollers (02), four journal bear-
ings (03), and a live ring (01) with supporting blocks and retainer rings. See Figure 3.2.

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Kiln System Maintenance
Module 3: Maintenance Procedures for Kiln Supports

The support may also be provided with a thrust device.

The maintenance procedures described in this module refer to kiln supports of conven-
tional design. Undoubtedly, the procedures to a great extent can also be applied in the
maintenance of kiln supports from other sources. However, it must be stressed that the
maintenance manuals from the individual suppliers at each plant must be consulted.

01
02
02
03
04

Fig 3. 2 Typical kiln support

3.5.1.1 Inspections during operation.

3.5.1.1.1 Live ring support blocks and side guides.

Migrating live rings:

Depending on kiln axial load, especially at the thrust device the wear on the side guide
blocks or rings can be considerable. Excessive wear disturbs the operation of the kiln
support and thrust device and must be reduced to normal values. It may be necessary to
reduce the live rings lubrication intervals. See figs 3.4

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If the kiln axis is not properly aligned (cranks or deformed kiln shell at the support or
shell constriction due to forced start-up) the edge pressure between live ring and support
blocks will be enormous and result in metal sizing. Steel chips or even “nuggets” can be
found on the base plate structure indicating the above mentioned condition. See fig 3.3.
The total clearance between live rings and side guides/rings should be of (Both sides of
the live ring) 4 to 10 mm max.

Fig 3. 4 Wear on side guides Fig 3. 3 Chips from live

rings/Support pads

Spline or tangentially attached live rings:

For spline live ring designs it is important to look at the condition of the wedge springs,
whether the springs, spindles or nuts are loose or broken.
It is also important to look at the condition of the spline plates and “dog bones” welded
on the kiln.
See fig 3.5.

”Dog bones” Tensioning

spring

Wedges

Spring plates

Fig 3. 5 Spline steel cast live ring design with spline plates

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In the tangential live ring design, the through-going stud-bolts for the attachment of the
steel cast live ring brackets should be looked through together with the springs, spindles
and nuts. Also the steel cast brackets should be inspected. See fig 3.6.

Fig 3. 6 Tangential suspension steel cast live ring design with steel cast brackets

3.5.1.1.2 Contact surface condition.

The condition of the contact surfaces of live rings and rollers should be inspected. The
appearance can be smooth and mat with the grey appearance of the graphite lubrication
which should be the ideal condition. See fig 3.7

Fig 3. 7 Surface in good condition

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If a “fish scale” appearance is noted on the contact surfaces and there are visual drop-
pings on the surface of the base plates, it could indicate an overload situation on the sur-
faces coming from shear overload forces indicating alignment problems. This “fish
scales”, or spalling should not be mistaken with graphite lubrication scales or clinker
dust compression scales. See fig 3.8
Too high a Hertz pressure between the contact faces can result in the development of
fatigue grooves called “Pitting” and it should be dealt with as fast as possible by an
alignment check followed by an adjustment of the support. See fig 3.9
Wobbling of the live ring will also create a wear pattern as shown in fig 3.9 with con-
cave profile on the roller and convex profile on the live ring.
A machining of the surfaces could be necessary if the damage has become extensive
enough.

Fig 3. 9 Surface with heavy wear Fig 3. 8 Surface with spalling

spalling and “pitting”

3.5.1.1.3 Kiln position i.e. live ring axial position on rollers.

It is important that the live ring remains within narrow tolerances inside the original
layout position in order to maintain the proper function of the in- and outlet kiln seals
and also for the position of the kiln girth gear with respect to the pinion and the kiln
girth gear casing seals.
If the kiln is equipped with a hydraulic thrust device, the kiln position monitoring de-
vice is commanding the kiln position. The proper function of this equipment should be
checked.
Changes in the operating kiln shell temperature due to process variations may lead to
changes in the thermal expansion of the kiln and perhaps some modifications of the kiln
position may be required.

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3.5.1.1.4 Live ring migration

Migrating live rings on support blocks are live rings which have a clearance with re-
spect to the support blocks and which, because of kiln rotation, will displace themselves
on the periphery relative to the support blocks.
In theory the displacement should happen as pure rolling without sliding, but because
the deformation of the kiln shell due to ovality and the thermal process variations slid-
ing and some times gripping between live rings and blocks takes place. Therefore some
kind of lubrication is necessary.
The live ring migration and thereby the clearance between live ring and support blocks
and again the tolerated ovality by the bricks is listed in table 3.10 bellow and ovality
diagram 3.11:

Minimum Ideal Maximum

Live ring migration 5 mm/rev 10 mm/rev 20 mm/rev
Diametrical clear- 1.6 mm 3.2 mm 6.4 mm
ance
Ovality % See table on fig 3.11 (Shell test ovality values % )
Fig 3. 10 Live ring migration and ovality

Fig 3. 11 Ovality as a function of kiln diameter.

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3.5.1.1.5 Temperature monitoring of bearings.

Oil temperature.

The temperature is normally monitored by instrumentation in the form of slide shoes

with built-in PT-100 temperature sensors. The slide shoes are located on the side of the
bearing journals, see fig 3.12, embedded (screwed-in) in the sides of the bronze liners,
or placed in the oil sump of the bearing, see fig 3.13. In some designs there are also lo-
cal visual temperature indicators electronically connected to the sensors.

Oil temperature

Fig 3. 12 Temperature monitoring Fig 3. 13 Temperature monitoring

For bearings with easily removable inspection covers it is possible to monitor the inter-
nal bearing temperature with a laser guided optical pyrometer. There should be taken
much care not to introduce any foreign body inside the bearing while the kiln is in op-
eration.
Normally the bearing inspection covers are either bolted or protected with safety grids
that allow to view the internal parts but not to introduce a foreign body or the hand.
What should the normal working temperature of the bearing be? The response to this
question is that it depends on the local ambient temperature, the oil viscosity and the
quality of the lubricating oil employed and in some degree on the cooling water tem-
perature. A graph as shown in fig 3.14 gives some aide in decision making.
The tables in figures 3.15 and 3.16 show different lubricant types and viscosities corre-
sponding to the values in the graph.

Minimum
value

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Fig 3. 14 Oil film thickness relationship with temperature and oil viscosity

ELEMENTS OF TRIBOLOGI

Fig 3. 15 Typical kiln lubrication gear oils from Mobil Oil

Fig 3. 16 Typical kiln lubrication synthetic oils from Mobil Oil

Cooling water flow and temperature.

See fig 3.17 and 3.18.
Most kiln bearings are water cooled through channels or jackets inside of the bearings
usually cast integral either with a bottom liner seat or a swivel bearing socket.
Water inlets and outlets are provided with shut-off and flow regulating valves together
with visual or electronic monitoring flow meters.
The water supply system can be either closed (pressurized) or open i.e. discharging the
water to an open funnel. This also serves as a visual monitoring device.
In extreme cold climates a closed cooling water pipe system is used. The water piping
can be heat traced and insulated and by adding ethylene glycol to the water to prevent
freezing during stand-still the risk of damage to pipes and bearings can be avoided.
A closed cooling water system is also used combined with cooling towers to reduce
temperature and is used in arid and hot climates.

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The closed cooling water system also permits to treat the water by filtration and if
needed to eliminate some carbonate hardness.
The registration of a temperature difference of more than 10° C is a sign that the bearing
is thermally overloaded.
After two to three years of operation it is a good idea to use an acid-wash process to
clean the water channels of the bearings.

er temperature

Fig 3. 18 Simple cooling water system. Fig 3.17Cooling water system with tem-
perature indication.

3.5.1.1.6 Lubrication

3.5.1.1.6.1 Live ring/support blocks lubrication

Whenever the migration reaches values bellow the minimum stated in the table on fig
3.10 it is always advisable to lubricate between the tyres and blocks. This is a condition
always prevailing during start-up as thermal expansion of the kiln shell is much faster
than the expansion of the thicker live ring.
The types of lubricants recommended are listed in table 3.19:

Manufacturer Brand Name

Klüber Lubrication Grafloscon Suspension-02
Reiner Chemie Ceplattyn HT
Molub-Alloy 491-C
Chesterton Nickel Anti-Seize Compound
Achesons Colloids Company Oildag

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Never-Seez Compound Corp. Never-Seez

Paul Products Ltd. PBC
Fig 3.19 Recommended live ring lubricants.

Lubrication should be carried out by means of a pump to ensure that the lubricant is dis-
tributed over the entire contact face, see fig 3.20. Lubricant should be applied once or
twice a month.

Fig 3.20 Hand pump

for live ring lubrica-
tion.

Never-Seez, which is supplied as a paste, can be mixed with oil to improve its flow be-
tween live ring and live ring pads/side guides/kiln shell. The mixture ratio is to be
approx. 40% Never-Seez and approx. 60% oil, and the oil used must have a high flash
point.

It is also recommended to lubricate between guide rings and tyres.

The lubricant employed is based on grease with different dry film additives such as
graphite, molybdenum disulfide, metallic compounds such as copper and nickel.

3.5.1.1.6.2 Lubrication of contact faces between rollers and live rings.

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The contact faces are lubricated with graphite blocks using graphite lubricators as
shown in fig 3.21 and 3.22.

In the old days it was common to lubricate and cool the surfaces with water. However
this practice has been abandoned a long time ago due to the formation of hydraulic pit-
ting on the contact faces. Lubrication with oil has the same effect and promotes the
formation of facets. See fig 3.23 and 3.24

Fig 3.21 Graphite block lubricator. Fig 3.22 Graphite block lubricator.
Position of lubricator

Fig 3.23 Water cooling of roller. Fig 3.24 Oil lubrication of roller surface
with indications of facet building

3.5.1.1.6.3 Bearing lubrication.

Most kiln bearings are of the slide bearing types with oil circulation lubrication.
Therefore the operator should be looking for:

 Oil level.

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(Sight glass). The correct level is usually marked on the glass, some times there can be
two level marks: At standstill and during operation. See fig 3.25. In some cases dip
sticks are used instead of an oil level sight glass.

Fig 3.25 Oil level glass with level marking

 Oil leakages.

Oil leakages are to be eliminated as they represent two dangers: Lack of lubrication
through reduction of oil level and damage to the concrete structure as concrete does not
normally tolerate oil and its additives.

3.5.1.1.7 Internal examination of kiln bearings.

Some bearings are equipped with easily opened inspection covers permitting to check
the internal parts.

3.5.1.1.7.1 Oil circulation.

Check the oil circulation from the oil cups through the distribution pan and the covering
pattern on top of the journal.

3.5.1.1.7.2 Journal condition.

Check the condition and coloration of the journal surface.

Typical examples are shown in figures 3.26 and 3.27.

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Fig 3.26 Journal in good condition Fig 3.27 Damaged journal

3.5.1.1.7.3 Bearing seals.

Some bearings are equipped with internal oil scrapers usually of rubber, the condition
can be monitored from the inside if the bearings are equipped with easy access inspec-
tion covers. The same applies to the rubber lip seal that some times can be viewed from
the inside. See fig 3.28 and 3.29

Fig 3.28 Scraper and seal. Fig 3.29 Lip seal.

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3.5.1.1.7.4 Axial thrust.

Depending on the alignment of the rollers, the bearing liner thrust collar can be in con-
tact with one or the other thrust ring on the bearings. The position can be checked in
some bearing designs through the bearing covers. See fig 3.30

Thrust
Ring

Contact
Gap

Bearing
Liner

Fig 3.30 Position of thrust collar and ring

3.5.1.1.8 Measurements.

3.5.1.1.8.1 Live ring migration.

Some modern kilns are equipped with tyre migration monitoring systems; but other-
wise, as stated in module one, a manual tyre migration measurement is possible, either
by simple chalk marking as shown in fig 3.31 or by utilising the live ring migration
measuring instrument shown in fig 3.32.

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Fig 3.31 Live ring migration measurement

Live ring migration measurement and top clearance

Fig 1.12A Live ring migration measurement

Fig 3.32 Live ring migration measurement and top clearance.

3.5.1.1.8.1 Live ring wobbling.

Measuring of the axial wobbling of live rings forms part of the evaluation of the contact
between live ring and supporting rollers. Heavy wobbling of live rings indicates poor
contact between live ring and supporting rollers, resulting in an increased Hertz pres-
sure. This causes wear, convex roller paths, rolling-out of the roller paths, as well as a
risk of pitting or flaking. Permissible wobbling of newly installed live rings is  1 mm.

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Fig 3.33 Measuring of wobbling of live ring.

The wobbling is best and most accurately measured with a length transducer connected
to a laptop computer with a program which automatically corrects the measurement for
any axial displacement of the kiln during the rotation. See fig 3.33

As rough measurement of wobbling, a dial gauge can be used but in order to obtain
accuracy the measurement must be carried out in the same manner as for erection con-
trol of girth gears i.e. with two dial gauges located on the same side of the tyre/live ring
diametrically opposed. See fig 3.34.

Measuring axial misalignment requires that two dial

indicators be used, 180º apart, to cancel out the
longitudinal movement of the kiln shell or mill.

Fig 3.34 Measuring of Wobbling of Live Ring

3.5.1.1.8.2 Lead wire tests.

See section 3.5.1.2.3.

3.5.1.2. Inspections during kiln stop.

During a shutdown of the kiln further inspection can be carried out as mentioned bel-
low.

3.5.1.2.1 Measurement of wear on live ring support blocks and side

guides.
See under section 3.5.2.1 Work generated by preventive or predictive maintenance.

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3.5.1.2.2 Measurement of linearity of rollers/live ring faces

Standing on the support structure, it is possible to check the linearity of both faces with
a precision straight-edge in 4 or 8 positions of the kiln to assess the condition of the two
faces.

3.5.1.2.3 Lead wire test

One method used to assess the contact conditions between rollers and live rings is the
lead wire test. See fig 3.35.
Some kilns are so covered-up around the rollers for heat protection that it is almost im-
possible to access the position on the sides of the rollers necessary to insert the lead
wire.

Lead wire

Fig 3.35 Lead wire test.

Lead wire tests are carried out by inserting a piece of 2-3 mm diameter lead wire be-
tween the supporting roller and the tyre while the kiln is rotating. The lead wire is then
rolled flat.
The shape of the rolled lead wire will give an impression of the pressure conditions be-
tween tyre and supporting roller on the generatrix along which rolling takes place.
It is very difficult to assess a single lead wire test since many different factors will have
contributed towards the rolled shape of the lead wire.
Under normal conditions it will be sufficient to carry out the lead wire tests approx.
every 3 months. During the first time after start-up of a new kiln, shorter intervals will,

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however, be recommendable so that any settling of the kiln foundations can be ascer-
tained in time.
A complete set of lead wire imprints consists of six imprints from each support, wiz,
three imprints from each supporting roller. The three lead wire imprints are to be made
of three generatrix marked out on the kiln tube at intervals of 120 degrees.
When the three generatrix are to be marked out on the kiln tube, it will be most expedi-
ent to let generatrix I lie in the diametrical plane passing through the centre of the man-
holes, while the other generatrix should be offset through 120 degrees from this plane.
Note the numerical order relative to the direction of rotation.
Cut the lead wire into lengths corresponding to the tyre width with an addition of 200-
300 mm. Insert the lead wire between roller and tyre, just as one of the marked-off gen-
eratrix passes the supporting roller. Mark off the rolled wire carefully with date, support
No., right- or left-hand roller (viewed from the burner platform), and the number of the
generatrix in question.
Place the tag at the end of the lead wire which is nearest to the kiln outlet end.
Storage of the test wire imprints can be effected by fixing a piece of cardboard to them
with tape, but it will also suffice to trace the outlines of the lead wires on a piece of pa-
per with a pencil. The most important thing is correct marking. See fig 3.36 and 3.37.

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Fig 3.36 Lead wire test

Fig 3.37 Lead wire test. Examples

3.5.1.2.4 Internal examination of kiln bearings.

The same inspections carried out for bearings with easy access inspection covers are
carried out during kiln standstill for bearings with difficult access to the internal parts.

Removing top bearing covers or for closed designs end covers; the condition of the
bearing liners can be inspected. See fig 3.38 and 3.39.
The clearance (see items S1, S2, S3, S4 on Figure 3.40 and 3.41) between supporting
roller shaft and bearing liner is based on the principle of hydrodynamic lubrication of
the bearing. See fig 3.42. Information on the clearance may be obtained from the sup-
plier. An example of the clearance applicable for each size of bearing journal diameter
is shown in the attached table fig. 3.43

Bearing inspection can be facilitated by the preparation

of two rods on which to slide off the end cover.

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Fig 3.38 Closed bearing housing. End cover

Fig 3.39 Split bearing housing

S1, S2, S3, S4

Figur 1 Fig 3.40 Bearing liner clearances.

Oil pocket

Measuring face

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Fig 3.41 Detail of measuring faces

.

Side
Clearance

Oil
Film

Insufficient side clearance will prevent oil from being drawn

into the bearing. Excessive side clearance will result in the
load being spread over too small an area, with a reduction of
the oil film thickness at the bottom of the shaft.

Fig 3.42 Bearing lubrication.

Fig 3.43 Bearing clearance tolerances.

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3.5.1.2.5 Ultrasonic examination of live rings.

Whenever there is suspicion of cracks on the live ring due to overload or pitting forma-
tion, an examination of the live ring with ultrasonic equipment should be carried out

Fig 3.44 Ultrasonic inspection of live ring.

This inspection is best carried out by ultrasonic testing both with an angle probe as well
as with a normal probe. See fig 3.44.

3.5.1.2.6 Ultrasonic examination of roller shafts.

The roller shafts are exposed to great dynamic loads and some times overloads due to
“crank” deformation of the kiln shell, either of a permanent character or due to a passing
thermal overload of the kiln shell.

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Therefore it is important to check the condition of the shafts for cracks. The usual sensi-
tive areas of the shaft are shown in figs 3.45 and 3.46

Fig 3.45 Sensitive areas Fig 3.46 Sensitive areas

The next two pictures show examples of the examination.

Fig 3.47 Deflector positions

Fig 3.48 Signal peaks and crack indication

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Assessment of measured results.

A crack in a supporting roller shaft will most certainly develop into a fracture, but it is
impossible to foresee if it will happen, or how long it will take before it happens.
A fracture in a supporting roller shaft will always be due to fatigue, and experience
shows that the residual area of fracture never exceeds 50% of the cross sectional area.
Residual area of fracture means the fracture area created by the actual crack.
Fig 3.49 is a graphic representation of the size of the residual area of the fracture as a
percentage of the total cross sectional area plotted against the number of broken sup-
porting roller shafts.
It appears from the graph that, from a purely statistical point of view, there should be no
risk of rupture, provided the residual area is larger than 50% of the total cross sectional
area, and only a minimum risk down to 35-40%.
It can be seen from the table that, even in the case of small shafts, a circular crack of
this size hardly presents any immediate risk of rupture, but rather warns of replacement
before long.

Fig 3.49 Residual area

3.5.2 Work generated by the preventive maintenance.

3.5.2.1 Correction of live ring clearance/shell ovality.

In consequence of the values of live ring migration registered during a longer period of
kiln operation and any other observations of side guide wear and/or deformation of live
ring support blocks due to seizing or to shell constriction due to thermal overload, it
may be necessary to reduce the clearance between live ring an support blocks, to replace
side guides and to replace support blocks. In designs with bolted support blocks it may

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be necessary to replace broken bolts especially if the kiln stop is combined with kiln
lining repairs or replacement.
In some cases the shell constriction can be so severe that a replacement of the kiln shell
is advisable in order to be able to maintain a reasonable life time for the bricks under-
neath the live ring.

Shims
Replace stop blocks when wear becomes excessive. Do
Excessive clearance can be removed with the not use shims as shown, as they probably won’t last.
installation of shims beneath the support pads.

Fig 3.51 Installation of shims Fig 3.50 Replacement of side guides

3.5.2.2 Measuring of clearance and thickness of supporting blocks.

Before determining the final shim thickness, it is required to determine which value the
final live ring migration is to have. This must be based on the latest measurements of
the migration on the kiln. The thickness of the supplied supporting blocks has been de-
termined on the basis of measurements of the thickness of the existing blocks.
The thickness of the single shims must be determined in 4 operations.
1. Calculation of the average reduction/increase of the thickness which the existing
blocks must have to obtain a given live ring migration after replacement of the
blocks.
2. Check of the kiln shell for bulges to be compensated for during replacement of
the blocks and compensation for the adjustment of the live ring migration as
specified in item 1.
3. Measurement of thickness of the existing blocks.
4. Calculation of thickness of the single shims when the new supporting blocks
have a given thickness.
The supporting blocks must be numbered indicating the accurate position of the blocks.
This is required so as to be able to place a shim with a calculated thickness under the
supporting block to match.

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3.5.2.2.1 Calculation of correction of block thickness based on live ring

migration measured on hot kiln.

To obtain a representative live ring migration, it is required to measure it over a period

of minimum one week during normal operation, preferably 2-3 weeks. The period must
be prolonged if the live ring migration is unstable. Compare the measurements to previ-
ous measurements.

Based on the measured values, find the smallest live ring migration f and compare it to
the above live ring migration of 10 mm/rev.
The correction of thickness ∆t of the original blocks is calculated to be:

f - 10
∆t =  ( mm) rounded off to whole mm.
2*

∆t = Correction of block thickness.

f = Smallest measured live ring migration.

If ∆t is negative, the supporting block thickness must be reduced by ∆t.

The above calculation is based on measuring the live ring migration on a hot kiln. This
method must be considered the most correct one for determining the thickness of the
correction of the blocks.

3.5.2.2.2 Measuring of clearance.

Make the following measurement to find out whether there are any local kiln shell de-
formations:
The clearance between supporting block and live ring must be measured for each indi-
vidual block. Measurement of each single supporting block must be done with the sin-
gle block in top position. Measure the clearance of each block in 4 places, a-d, see Fig
3.53 and fig 3.54, and find the mean values A and B. Enter the results in the Inspection
Form shown in Fig 3.55.
It is important to make sure through these measurements that there is no air gap between
kiln shell and supporting block. The supporting block must lie true against the kiln
shell. Check this with thickness gauges. An air gap is indicative of kiln shell or support-
ing block deformation.

3.5.2.2 Measurement of existing supporting blocks.

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Measure the thickness of the existing supporting blocks in the 4 corners of the zone
which was covered by the live ring (it is important to measure the thickness where there
has been contact with the live ring, because the block may be worn here), see Fig. 3.52.

Fig 3.52 Measurement of existing supporting blocks.

Fig 3.53 Support blocks, clearance measurement.

Outlet Inlet

Fig 3.54 Support blocks, clearance measurement.

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Fig 3.55 Table of values.

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Fig 3.56 Table of values.

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Fig 3.57 Table of values.

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The calculations and explanations of the table input, the resulting values, explanations
and polar diagram is contained in the Excel sheet included in this package, see the pre-
amble and examples shown in fig 3.55 to 3.57.

3.5.2.2 Machining of contact faces between live rings and rollers.

Depending on the wear registered in the course of the kiln life span, there can be the ne-
cessity to rectify the surface by machining. The normal defects which can motivate for
such a big intervention are:
Big pittings, convex/concave surfaces due to wobbling, tapered wear, steps due to dis-
placement of tyre (thermal changes in the process) and facet building on the surfaces.
Repair should be carried out when the contact face between live ring and supporting
roller has been reduced by 10% or more, or if a supporting roller and/or a live ring have
been worn conically to an extend where it is impossible to obtain the correct roller posi-
tion.
The first step of any machining is to determine the size of the deformation. This can be
done with an instrument as shown in fig 3.58.

Fig 3.58 Measurement of roller profile

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The assessment on how much material can be removed from the surface of rollers and
live rings is very much dependent of the original design parameters, such as ovality and
bending stresses on the live rings and wall thicknesses on the chamber type roller design
together with the roller edge projection thickness. The conclusion must be that if the
equipment is subjected to considerable material removal or if the operation for some
reason has been repeated several times it is necessary to have the supplier evaluate the
remaining strength of the final machined equipment. See Fig 3.59

Fig 3.59 Remaining thickness

3.5.2.2.1 Lathe machining.

See fig 3.60, 3.61 and 3.62.

The lathe is used when a bigger amount of material has to be removed but due to its
sensitivity to vibrations it requires experienced operators and it is almost inevitable that
a second grinding process is necessary.

Rollers and tires may be re-conditioned by machining or

grinding. Shown above is a lathe adapted for this purpose.

Fig 3.60 Lathe.

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Rollers are re-conditioned while the kiln is in operation.

Fig 3.61 Lathe, machining of roller.

Machining a kiln tire while the kiln is in operation.

Fig 3.62 Lathe, machining of live ring.

3.5.2.2.2 Machining with a belt grinding machine.

The belt grinder is used for surface finishing jobs after the use of the lathe, or to smooth
edges on rollers or live rings. See fig 3.63. The belt grinder produces a beautiful finish
but unfortunately does little else. If cosmetic improvement is all that is required this
method is adequate. Usually a considerable amount of material needs to be removed
from specific areas, the high spots, in order to flatten the surface. Belt grinding removes
material indiscriminately. Material removal is slow and it is not just removed from the
high spots.

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Fig 3.63 Belt grinder.

3.5.2.2.3 Machining with a disc or cup grinder.

This is used instead of a lathe machine especially when surface hardness is too great for
a good operation of a lathe. See fig 3.64

Fig 3.64 Disc grinder

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A cup grinding stone, whose cutting position is firmly indexed on a fixed arc guided by
the tire surface itself, is the technique whereby a flat surface and a true cylinder can be
cut back onto the tire even though it rotates without a true centre.

3.5.2.2.4 General.
Since removal of material from the rolling surfaces produces immediate reactions of the
unit, appropriate roller adjustments are required in order to avoid the risk of bearing
failures. Before reconditioning the rollers are usually over-skewed. As reconditioning
progresses, the surface contact improves and the over-skewed position will create very
high thrust loads. These must be relieved.

3.5.2.3 Other maintenance work carried out on support components.

Tools and procedures.

Most maintenance works carried out on the supports imply the lifting of the kiln live
ring from the supporting rollers. This job is carried out by the insertion under the live
ring of two to three hydraulic jacks connected by distributor valves to a common hy-
draulic pump station. The jacks must be fitted with lock nuts on the piston and a swivel
head.
To transmit the load from the live ring to the jacks, a yoke is inserted between the jacks
and the live ring as shown in fig 3.65.

Yoke
Jack

Fig 3.65 Lifting tools

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To remove a roller from the support it is necessary to move the bearings away from the
centre of the kiln in order to get them free from the live ring as shown in fig 3.66, there-
fore it is necessary to remove the adjustment screws from the base plate. To ease the
removal the design can be as shown in fig. 3.67. The screw bracket can be removed
when pressure has been released from the adjustment screw.
Most base plate designs are fitted with transversal beams to reinforce the base plate axi-
ally. The position of the beam must be sufficiently low as to allow the withdrawal of the
roller or it must be detachable. See fig 3.68

Fig 3.66 Lifting tools.

Fig 3.68 Adjusting screw Fig 3.67 Transversal detachable beam

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3.5.2.4 Replacement of bearing liner.

If the proper oil is used at the correct bearing temperature, full liquid friction between
journals and liners can be obtained. This prevents the wear of the liners. There are ex-
amples of kilns, which have been in service for more than 15 years without any notice-
able wear of the liners.
Nevertheless if replacement of a liner should become necessary, various conditions
must be considered.
Normally, the liners are supplied with a bore corresponding to the original diameter of
the supporting roller journal, with a suitable large clearance between liner and journal.
The clearance (see items S1, S2, S3, S4 on Figure 3.69) between supporting roller shaft
and bearing liner is based on the principle of hydrodynamic lubrication of the bearing.
Information on the clearance may be obtained from the supplier. In a typical design the
clearance will be from 0.15 mm for a 240 mm bearing up to 0.85 mm for an 850 mm
bearing.

S1, S2, S3, S4

Figur 2 Fig 3.69 Bearing liner clearances.

Oil pocket

Measuring face

Fig 3.70 Detail of measuring faces

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In theory, the shaft rests on a line at the bottom of the bearing liner. At sufficient rota-
tional speed of the shaft, the oil will be sucked into the wedge-shaped clearance be-
tween shaft and liner, so that the shaft is supported by a thin oil film. Depending on
speed and temperature this oil film thickness will be 0,01 – 0,02 mm. Very careful ad-
aptation of the bearing liner is therefore required. The oil film pressure development is
shown on Figure 3.71.

Side
Clearance

Oil
Film

Fig 3.71 Oil film pressure

The bearing designs are basically of three different types :

1. Split housing with ball and socket liner support.
2. Split housing with the liner support integrated into the bearing
bottom part.
3. Closed housing with the liner support integrated into the bot-
tom of the housing. Access to the liner on the installed bear-
ing is done through the rear cover.

The liner configurations of the two first bearing types are similar consisting of a cylin-
drical shell with one or two thrust collars at the ends and side oil pockets.
The third design is of same configuration but the collar is used to bolt the liner to the
seat on the bottom housing.

Normally the liner covers 180° of the shaft journal, but some designs cover 120°.
The materials are either bronze or aluminium-zinc alloys.

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Fig 3.72 Typical liner design.

For the ball and socket bearing designs, a new liner can be mounted as follows:
 Clean and wipe the new bearing liner and check that it has not been damaged
during transport. Remove any dents and scratches by light polishing.
 Check that there is a smooth transition from the oil pocket (see Figure 3.70) to
the radial, as well as the axial supporting face. (See Figure 3.70).
 Dismount the ball socket of the bearing and mount the liner in the ball socket
so that the chamfered thrust collar of the liner faces the thrust plate. Check by
means of retainer pieces that the bearing liner is fixed carefully in the ball
socket, is flushed with same, and that there is no clearance between bearing
liner and ball socket. See Figure 3.72.
 Remove any traces of metal from the old liner from the journal of the support-
ing roller shaft.
 Fit eye bolts at the corners of the ball socket so that the ball socket and the
liner can be suspended with the liner hanging downwards. See Figure 3.73.
 Wipe the supporting roller shaft carefully and apply a very thin layer of mark-
ing colour along the entire journal length and across a width covering approx.
120°.
 Wipe the bearing liner thoroughly and carefully place the liner fixed to the
ball socket on the supporting roller shaft, using the thrust ring as guide during
lowering.
 Reciprocate the liner axially a few times (10 – 20 mm) while resting on the
journal. Measure the clearances between the liner and journal as shown on
Figure 3.75 and check the clearance as per table 3.43.
 Lift the liner and ball socket away from the journal and examine the contact
between the journal and liner by inspecting the colour marking on the liner.
The figures 3.73 to 3.81 shows a procedure in how to rectify wrong contact by
scraping. Only a narrow strip in the bottom of the liner is permitted.
 Check that the transitions between the oil pockets and supporting faces of the
bearing liners are smooth. When everything has been checked and found in

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order, pour the same type of oil as used in the bearing over the supporting
roller journal and the bearing liner. Place the roller in position and finish
mounting the bearing. To make the bearing oil-tight, smear all joint faces with
sealing agent "Tonite" or similar.

Fig 3.74 Testing of liner Fig 3.73 Testing of liner

Fig 3.75 Testing of liner. Fig 3.76 Testing of liner

Fig 3.78 Scraping of liner. Fig 3.77 Final result.

Contact
zone

Fig 3.80 Ball/Liner deformation. Fig 3.79 Testing of liner

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First cut

Second cut

Thirt cut Final cut

No
scraping

Fig 3.81 Scraping of liner

The contact between the back face of the liner and the liner seat in the housing should
be inspected to ensure full contact.
Fig 3.79 shows a sketch illustrating the possibility of seat deformation of the bearing
ball or liner seat depending on bearing design caused by bearing overheating in con-
junction with the water cooling and which can produce a closing effect on the liner,
making the liner unusable, or at least demanding a lot of scraping work which will pro-
duce a poor result.
After the roller has been installed back into the bearing housing the alignment of the
roller should be checked, especially the inclination, see module 5 of this package.
If extensive scraping work is needed it should be carried out as shown in fig 3.81.
For bearing designs with a fixed liner seat or enclosed bearing type, the testing and
scraping procedures are similar to the procedure already described.
The liner seat should be tested on the bearing housing to ensure an externally perfect
seat. Liners can deform due to transport damages or inherit stresses which were not re-
leased properly during manufacture.
The liner should afterwards be checked on the roller journal with Paris blue in the same
way that the ball and socket liner is checked. See figs 3. 80.
After the liner has been checked and found acceptable, the liner is inserted in position
on the bearing seat and locked into position with the provided liner attachment tools.
The alignment of the bearing houses and roller is checked both in horizontal direction
and inclination. In horizontal direction by checking the clearances on the four corners of
the liners as shown in fig 3.69.

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The inclination is checked by using an appropriate precision inclination gauge originally

supplied with the kiln.
Any corrections needed are done either with the bearing adjustment screws or by insert-
ing appropriate shims under the bearings.
One of the prerequisites of the fixed liner bearing design is that the base plate is de-
signed as an I-profile beneath the bearings as to allow for the I-profile to pivot and
thereby to permit the bearing liner to adjust under load to any minor misalignment.
In some designs with fixed liner seats the bearing are unattached to the bearing base
plate, they are only held in position by side guide plates and adjustment screws or the
bottom bearing part is machined with a groove that fits into the corresponding machined
flanges of the base plate.
The ball and socket type bearings are fixed to the base plate by screws on slotted open-
ings in the base plate. Guides on the sides are provided by bars welded to the base plate.

3.5.2.5 Rectification of roller journal.

The kiln rollers can operate for many years without major operation problems but from
time to time accidents can happen in the form of bearing overload either thermal or me-
chanical which can result in damaging both the liner and journal surfaces.
In such cases the normal intervention is to replace the roller with a spare roller to reduce
kiln downtime.

Due to the big weight of a kiln roller, it will not be possible in most cases to machine a
kiln roller on a lathe. And due to the strong shrink-fit between a roller and its shaft, it is
almost impossible to remove the shaft from the roller.

Most often the solution chosen is to use a locally installed honing machine which in
most cases, will serve well as only few tenths of a millimetre will need to be removed.
Of course, if such an operation is chosen a new undersized liner is required to match the
new journal. See fig 3.82 and 3.83.

Fig 3.83 Shaft honing machine Fig 3.82 Shaft honing machine

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3.5.2.6 Correction of alignment.

See module 5 of this package.

3.6 Thrust devices.

There are different types of thrust devices as follow:

 Mechanical: Axially stationary, they can be single sided or double-sided i.e. one
roller on each side of the live ring and with sleeve or antifriction bearings. See fig
3.84 and 3.85

 Hydraulically commanded on one or two supports: the support nearest the drive sta-
tion is the master while the second one acts as a slave and follows the position of the
tyre. See fig. 3.86, 3.88 and 3.89

Fig 3.85 Mechanical double thrust device Fig 3.84 Mechanical single thrust device

Position
Sensor

Hydraulic Cylinder Guide Bar

Fig 3.86 Hydraulic thrust device

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3.6.1 Systematic preventive maintenance. PM. 1st level inspec-

tions.
3.6.1.1 Inspections during operation.
The important inspections to carry out during operation are:

3.6.1.1.1 Kiln position.

For kilns installed with double mechanical thrust devices the kiln position is permanent
at the support with the thrust device and the displacement on the rest of the supports is
only dependent of thermal variations of the kiln shell.
Single sided mechanical thrust devices are normally installed with a position indicator
in the inlet side of the live ring. That activates different microswitches indicating the
kiln position and in the end, stopping the kiln if the kiln is leaving the contact with the
thrust device and migrating too far towards the kiln inlet. See fig 3.87.

Fig 3.87 Mechanical single thrust device with position indicator

It is of the utmost importance that kilns with mechanical thrust devices are barred regu-
larly during cooling or heating up to avoid overload of the device rollers/shafts or bear-
ings.
Hydraulically commanded thrust devices are made with displacement systems accord-
ing to two different principles:
1. The hydraulic system maintains the kiln in a fixed position during operation.
The hydraulic system serves only as a spring allowing the kiln to be dis-
placed until the pressure in the hydraulic cylinder falls below the pressure
switch setting, during cooling-down of the kiln. The displacement will trig-

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ger an alarm through the position transducer, indicating to the operator that it
is time to activate the barring gear to allow the friction forces between roller
and live rings to be released and to return the kiln into its original position.
2. The hydraulic system allows the kiln to be displaced up and down ± 25 mm
approximately on the roller in order to distribute the wear uniformly across
the width of the rollers/live rings. The cycle for one full travel is approxi-
mately 8 to16 hours depending on the system.
It is important that the inspection registers a full sequence during operation.

Fig 3.89 Double hydraulic thrust device for Fig 3.88 Single hydraulic thrust device for station-
axial kiln displacement. ary axial kiln position

3.6.1.1.2 Operating oil pressure.

The operating oil pressure can be monitored both on thrust devices with mechanical de-
sign and sleeve bearings and on hydraulically operated devices. Some equipment are
supplied with remote monitoring.
To monitor the oil pressure on the sleeve bearing design the hydrodynamic pressure is
used as reference
Normal oil pressure: 40 to 60 bar. If the hydraulic thrust device is equipped with pres-
sure accumulator, the pressure variations due to live ring wobbling is reduce to half.

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3.6.1.1.3 Bearing house oil level.

Thrust devices with sleeve bearings or antifriction bearings have bottom closed houses
with oil lubrication, breather arrangement and oil sight glass. As there is no oil circula-
tion or oil cooling arrangement in the housing, heavy lubrication oil is used ISO VG
1000 and preferably equivalent synthetic oil. See fig 3.91

3.6.1.1.4 Graphite block lubrication.

As shown in figure 3.90 and 3.91 the thrust device is usually equipped with a graphite
block lubricator.

Breather

Oil Level
Sight Glass

Guide Bar
Grease
Fittings

Fig 3.91 Lubrication of thrust device Fig 3.90 Graphite lubricator for thrust device

Hydraulic cylinder
LVT transducer

Pressure
Manometer accumulator

Pressure
transducer

Overpressure
valve

2-way solenoid Oil filter

valve

Brider filter Oil tank

Suction strainer
Oil level
indicator
Pressure regulated
valve

Fig 3.92 Pump station for thrust device

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3.6.1.1.5 Pump station.

The hydraulic thrust device is provided with a pump station in which the following
items (shown in fig 3.92) should be checked for:
1. Hydraulic cylinder leakage.
2. LVT transducer or other kiln position indicator.
3. Hydraulic oil pressure.
4. Accumulator operation (Nitrogen pressure)
5. Overpressure valve (Leakages)
6. 2-way solenoid valve.
7. Filter condition.
8. Pump condition.

3.6.1.1.6 Condition of contact.

Contact problems have the same origin as for the support rollers and live rings.
Alignment faults can often be identified from the surface of the roller/live ring in the
same manner as for the support rollers; they are be listed below:

1. “Pitting” due to an alignment problem.

2. Top or bottom contact. Also due to an alignment problem.
3. Facet building which can be caused by:
 Vibrations of the kiln drive on kilns with girth gear drive. (Resonance).
 Wrong roller alignment.
 Overload and stick-slip effect on the tyre roller lubrication.

Roller Tilted to Left Roller Tilted to Right

Roller Offset to Left Roller Offset to Right

A misaligned thrust roller will result in vertical forces

on the roller as shown above.

Fig 3.93 Thrust device alignment

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Fig 3.94 Thrust device alignment

3.6.1.1.6.1 Vibrations.

Depending on the wear pattern of the gearing teeth and the consequent excitation of
resonance frequencies together with increased backlash, vibrations can be the result;
usually with the tooth frequencies and perhaps the 2nd harmonic.
The vibrations can be harmful to the kiln components and also result in facet building
on supporting rollers and thrust rollers.

3.6.1.1.6.2 Wrong roller alignment.

As it is seen from fig 3.93 and 3.95 the proper alignment of the thrust device has a great
influence, not only on the surface pressure and wear of the rolling surfaces, but also on
the bearing load, both in the radial and axial directions.

Further, the angle of inclination on the contact faces must also follow certain geometri-
cal design rules as shown in fig 3.95, to avoid skewing of the contact faces.
Figures 3.96 to fig 3.99 show different facet patterns and the assessed reason for their
appearance.

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Centre lines

Fig 3.95 Thrust device alignment. Geometrical relations

Fig 3.96 Thrust device.”Facets” building due to Fig 3.97 Thrust device. “Facets” building
alignment fault. due to girth gear problems.

Fig 3.98 Thrust device. “Facets” building due to “stick-slip” fric-

tion forces (Alignment).

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4. Step on the roller surface.

Normally the rollers are installed with the bottom face 10 mm lower than that of
the live ring to ensure that any step building due to wear is on the roller. It is
easier to remove the step on the roller by grinding than on the live ring. See fig
3.99.

10 mm

Fig 3.99 Thrust device alignment

3.6.1.2 Inspections during kiln stop.

3.6.1.2.1 Measurement of linearity of rollers/live ring faces

Check with a precision straight-edge that the linearity is correct. This can additionally
be verified with a lead wire test. See section 3.5.1.2.3.

3.6.1.2.2 Lead wire test

The test can be carried out in the same manner as for the supporting rollers.

3.6.1.2.3 Internal examination of thrust device bearings.

In order to get access to the main bearings, it is necessary to take out the thrust device.
This is done first along the kiln centre onto a plinth on skates or the likes and then by
displacing the assembly sideways perpendicular to the kiln axis until the roller is free to

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be lifted off the housing, unless the hole assembly is moved to the workshop with the
intervention of a mobile crane or a forklift. See the example on fig 3.100.

Fig 3.100 Thrust device alignment

3.6.1.2.4 Ultrasonic examination of roller shafts.

The shafts should be examined whenever the bearings are checked and there is access
to the shaft from above. The examination should be done in a similar manner as for the
support rollers.

3.6.1.2.5 Replacement of bearings.

The repair/replacement work of any bearing should be carried out in a clean workshop
and the necessary tools should be available.
For thrust devices with sleeve bearings the replacement sleeve and bottom pressure
washer are normally made of the same material as for the support roller bearings. These
should be checked for dimensions and surface quality. The transition from any lubrica-
tion access grooves to the cylindrical surfaces should be checked for smoothness. The
shaft condition should be checked, any major damage to the shaft surface requires an
immediate replacement. The rollers can be manufactured as cast in one piece with a hol-
low shaft or a forged shaft can be shrunk fitted to the roller. See figs 3.101 and 3.102.
It is important that the cast parts are checked for cracks with dye-penetrant liquid or
with the dry method using magnetic particle equipment .

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The roller bearings used in antifriction thrust devices should be checked for axial and
radial clearance. The surface condition of the rings and roller surfaces should also be
checked. The condition of the locknut should be checked as well.

Fig 3.101 Thrust device with sleeve bearing

Key to sketch fig. 3.101

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Fig 3.102 Thrust device with antifriction bearings

Key to scketch fig 3.102

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