webinarinspections.pdf

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Kiln & Dryer Maintenance

INSPECTIONS/

TROUBLESHOOTING

IKD Training Webinar

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Presenter Bio

JOHN ROSS

•

30+ years of experience servicing rotary equipment

(kilns, dryers & ball mills) in the mining, cement,

lime, chemical, fertilizer, food, and asphalt

industries

•

OEM certified kiln / dryer maintenance instructor.

•

Alignment specialist, who has authored, and

published maintenance articles.

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RULES of the WEBINAR

•

This is our first live session

– –

please be

please be patient and tell us

patient and tell us

how we did.

•

If you encounter technical difficulties during this session,

call

877-316-6140

and mention “webinar and mention “webinar troubles.troubles.” Y” You wilou willl

be transferred to someone who will help!

•

We encourage your questions! Your microphones will be

muted for the most part of the webinar. Please

type your

questions

questions inside the box in your control panel (right side of

inside the box in your control panel (right side of

screen).

Questions will be answered

Questions will be answered during several breaks

during several breaks

in the presentation.

•

Session will be recorded. A link to the recording will be

available to you after the webinar.

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Kiln & Dryer

Maintenance

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Daily Inspections

 A maintenance walk-by inspection performed daily

 Check the Dryer drive amperage for sudden increases  Check the bearing temperatures for changes

 Check the riding ring/support roller faces for new wear  Check the drive system for vibration and visually inspect

the drive gear and pinion alignment

 Check the axial thrust of the Dryer, (uphill or downhill)

 Check lubrication on support & thrust rollers  Check the gear lubrication systems

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Weekly Inspections

 Check the Dryer drive amperage for the past several days for

fluctuations

 Check the relative movement of the riding rings on floating

style (creep) on all piers

 Check dryer seals and shell run-out on the feed and discharge ends of kiln

 Check the welds on filler bars, retaining blocks/rings and on shell section seams

 Check the temperature of the gear and pinion mesh

 Check the temperature of the riding ring & support roller contact area

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Monthly Inspections

 Check the pitch line separation between the drive gear and pinion/s for changes in the gear mesh

 Check dust filters on air intakes of drive motors

 Inspect gear reducer oil levels and all drive bearings for high operating temperatures

 Perform vibration analysis of the gear and

pinion, gear reducer and drive system bearings

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Quarterly Inspections

 Check the pitch line separation between the drive gear and pinion/s for changes in the gear mesh

 Check dust filters on air intakes of drive motors

 Inspect gear reducer oil levels and all drive bearings for

high operating temperatures

 Perform vibration analysis of the gear and pinion, gear

reducer and drive system bearings

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Annual Inspections

 Piers-Check Elevation and Alignment

 Check Dryer Alignment

 Carrying Roller-Check Adjustment  Gear Flange Bolts-Check Tightness  Gear Joint Bolts-Check Tightness

 Pinion-Check Radial Alignment

 Drive-Check Alignment

 Gear and Pinion Teeth-Condition

 Support Frames-Condition

 Gear Guard (W/Spray System)-Lubricant Build-Up

 Support roller and Thrust Mechanism

 Inspect and Service Speed Reducers, Motors, etc., per Manufacturer's Instructions.

 Ultra-sound Roller Shafts

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»CONCAVE AND CONVEX WEAR PATTERNS

»CONICAL OR RADIAL TAPER WEAR PATTERNS

»UNEVEN WEAR ON SURFACES

»SPALLING AND PITTING ON WEAR SURFACES

»VARIOUS OTHER WEAR CONDITIONS

Types of wear on

Tires/Rollers

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CONCAVE AND CONVEX WEAR PATTERNS

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CONCAVE AND CONVEX WEAR PATTERNS

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CONCAVE AND CONVEX WEAR PATTERNS

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TAPERED/CONCIAL WEAR PATTERNS

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GAP

BETWEEN TIRE &

RETAINERS

TAPERED/CONCIAL WEAR PATTERNS

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CONCAVE AND CONVEX WEAR PATTERNS

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• Hot bearing temperatures will generate from excessive thrust

on the internals of the bearings.

• Hot bearings can cause the bearing internals to overheat and

lose lubrication and cause a premature failure..

• Excessive thrust can overload thrust roller mechanisms and

cause failure or damage.

• Wear will be accelerated on the surfaces of the tires and

support rollers. This will make minor support roller moves next to impossible.

• Serious mis-adjustments will cause high axial loads of the tire

against the retaining blocks/rings.

• Mis-adjusted support rollers will create a drag on the kiln

shell & increase the kiln drive loads.

• Unit alignment will be affected by long-term misadjustment

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UNEVEN WEAR PATTERNS

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UNEVEN WEAR PATTERNS

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DIAGONAL WEAR PATTERNS

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DIAGONAL WEAR PATTERNS

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HORIZONTAL WEAR PATTERNS

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HORIZONTAL WEAR PATTERNS

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HORIZONTAL WEAR PATTERNS

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OTHER WEAR PATTERNS

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EXCESSIVE AXIAL THRUST

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» Filler bar & retaining block/ring welds

» Kiln shell weld seams

» Hot spots and shell deformation

»

Kiln shell “crankshaft” or run

_-out

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SLIGHTLY APART ACCEPTABLE TANGENT ACCEPTABLE OVERLAPPING UNACCEPTABLE

SCRIBE PITCH LINE SETTING FIGURE 21

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Girth Gear Bottoming in

Pinion Gear

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Scuffing- transfer of metal by adhesion and welding Root to tip interference _{Loaded on both flanks}

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Abrasion dirty lube

Tooth Hammer excessive backlash & dual drives

Rippling poor lubrication heavy load

Pitting poor lubrication or heavy load