140129343 Fuller KilnErection

(1)

Orientation & Common Terminology for Reporting Kiln Details

A - Indicates down-turning side of kiln and in-running rollers.

B - Indicates up-turning side of the kiln and out-running rollers.

(Straight Spur or Single Helical) Referred to as “Girth”, “Bull” or “Main” Gear. Indicate “left” or “right” side of the kiln when looking uphill towards feed end. Gear Gear Right Right Kiln Discharge End Kiln Discharge End Material discharge (spill ) Material discharge (spill ) A A A B A A B B B B Clockwise (Right-hand) Left Left B A Kiln thrust tire(s) with

tapered side-faces. Kilns with hydraulic thrust assemblies will utilize a tire with a taper on the downhill

side-face only. Kiln thrust roller assemblies.

Both sides of the thrust tire except when units are hydraulically controlled. Kiln drive pinion(s). Arrows

indicate position of pinion when a single drive arrangement is used for kiln rotation(s) as shown. Pinions shown at outside positions are for dual-drive assemblies. Kiln Support Rollers also called “Carrying Rollers”, Trunnions”, “Wheels”, and

“Rolls”.

Plain tires, or riding rings (with straight side-faces). "Rolling" or "Contact"

surfaces (faces). Do not refer to "compass" directions or local geography when reporting problem zones.

In d ic at es p ie r n u m b er s st ar ti n g a t d is ch ar g e o r fe ed e n d 3 1 2 2 1 3 KILN OVERHEAD 001.CDR

Feed End of Kiln(s) (Also referred to as “Uphill” or “High-End” Area)

Counter-Clockwise (Lefthand)

Maintenance S eminar

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Elevation F D D B _G Elevation C Elevation E Elevation A 2 4 3 1 F ra m e C L F ra m e C L P ie r C L B o lt C L B o lt C L (A p p ro x .) 2 ”

Kiln Support Frame Setting Reference

1 - 2” Allowance for grout between frame and rough pier top.

2 - Elevation reference plug. Set in pier on beam-web CL. Locate plug 6” outward from end of beam. 3 - 5” long shims. (Refer to kiln installation instructions).

4 - Anchor bolts added to prevent “rolling” of beams.

A - Reference elevation for support assembly.

B - Frame height (may vary after machining, use design dimension for calculation of top surface elevations). C - Elevation A plus dimension B. (Not for actual test work).

D - Calculate rise or drop from frame CL to high or low beam CL to suit designed slope of equipment. E - Elevation = C plus rise for D.

F - Elevation = C minus drop for D.

F = Required elevation at C_{L on machined top surface of beam minus reference plus elevation.}

Use dimension G for setting elevation of control beam. Use precision straightedge with slope test block and machinists level or inclinometer for follow-up slope adjustment of the frame.

Refer to foundation drawing and roller assembly drawings for elevations, frame dimensions and slope of the kiln.

(3)

Frames must be aligned on C_L’s parallel to each other.

Refer to installation

instructions for dimension tolerances and test

procedures. NOTE:

Use a precision spirit level for test work. A stainless steel v-block is supplied for test work, or use an inclinometer.

Roller assemblies are to be set before grouting frames. Final test for slope is made on top of each roller.

NOTE:

Slope tests require a sturdy and accurate straightedge that will totally span both beams of all frames in the arrangement.

Refer to installation instructions for preparation of shims. Stacks must be tight. Elevation tolerance +_ 1/16” or +_ 1.50 mm for frame.

Slope tolerance 0.002” per foot or 0.15 mm / 1000 mm. Straight-edge must be parallel to frame C_L.

Maximum gap 0.004” / or 0.10 mm under straightedge.

Cross-level tolerance 0.002” or 0.05 mm per foot at bearing zones (0.15 mm / 1000 mm at bearing zones). A B C D E F

-Kiln Support Frame Adjustment and Tests

D F B E C A

KILN OVERHEAD 003.CDR Maintenance S eminar

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Kiln Support Frame Spacing Test Points

NOTE: “Support Roller Assembly” drawing numbers for each pier are shown on the “Foundation”

drawing. Refer to the correct drawings for piers being checked. These drawings show the dimension from (frame& roller dimensions may vary from pier to pier).

Add half-frame dimensions for piers being checked and subtract total from slope dimensions shown on foundation drawing to obtain test dimension (as shown above in sketch).

Use spring scale to apply 20 to 25 lb’s or 9 - 12 kg. tension to tape line (depending upon wind conditions). Check tape line temperature and make allowances for possible variation for dimension being checked.

frame CL to beam CL for each assembly

Slope Dimension (Shown on Foundation Drawing) Erecting Test Dimension

Base Dimension Support Frame

(Shown on Foundation Drawing)

NOTE NOTE Kiln Support Pier Kiln Support Pier

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Kiln Support Frames Spacing, CL & Parallelism Tests

* Use spring scale at 20 to 25 lb’s or 9 - 12 kg. tension on tape line. Check tape line temperature and allow for expansion or contraction of line.

KILN OVERHEAD 005.CDR

NOTE - Frame dimensions shown on “roller assembly” drawings. Align frames on CL’s, adjust for elevation, slope and cross-level.

Dimension A - Nominal dimension from frame CL, measured and marked equally at all test points (in field at time of installation). Dimension B - Test dimension from frame spacing and parallelism. (Tolerance

Dimension C - X-Test to verify frame CL alignment.

1/16” or 1.50 mm). Slope Dimension (from foundation drawing)

Diam eter C Diame ter C Diameter B * Diameter B * D ia m et e r A D ia m et e r A D ia m et er A D ia m et er A

Erecting test dimension

Kiln and Frame C_{L Marked on Piers by Layout Engineer}

K iln S u p p o rt F ra m e K iln S u p p o rt F ra m e A ll B ea m CL ’_s m ar k ed at fa_c to ry CL’_s M ar k ed o n a ll P ie rs b y L a y o u t E n g in ee r NOTE NOTE

Measured and Marked on Piers by Layout Engineer

(6)

A - Establish offset reference lines at both edges of frame. Offsets must be parallel to, and symmetrical about the verified true kiln C_L. B - Use adjustment screws to set roller assemblies parallel to the kiln C_L.

C - Measure from plumb lines to offset lines.

Testing New Kiln Support Roller Installations,

or Re-Aligning Older Equipment

Slope

-gauge V-bar with 12”, graduated vial, machinist level. Kiln may be on slow rotation if plumb bob is suspended in oil.

Slope gage block to be accurate within 0.0005’ in 12” length or 0.05 mm / 1000 mm.

Use tight wire or straightedge for projection of offset line across beams.

Plumb bobs in oil

Measuring to plumb lines is not completely accurate (rollers may be tapered).

Install boards at inner edges of beams for ramming high strength non shrink grout from outside edges of beams.

Fill anchor bolt sleeves with high strength grout. Adjust shims

as needed for final true-up of frame.

(Slope & transverse-level tolerance @0.002” per foot or 0.15 mm / 1000 mm).

This methold applies only when roller surface is cylindrical. Or use slope block on shafts. The inclinometer is also an accurate method.

C

B A

(7)

Recommended Water Piping Arrangement

for Kiln Support Roller Assemblies

A - Roller adjusting assembly. Keep these zones open for roller re-setting work.

B - Flexible lines to allow for possible 4” to 5” or 100 mm to 150 mm movement.

C - Inlet water master value.

D - Control value at inlet line to each water jacket.

E - Funnel arrangement for drain lines.

NOTE

Keep lines clear of end plates to allow for bearing inspection and maintenance work.

NW ARD ADJU STME NT OF RO LLER ASSE MBLY I NW ARD ADJU STME NT OF RO LLER ASSE MBLY I B A E D C B

(8)

A B B C A A B C Pads A B

Handling Kiln Tires for Installation on Pads with Slide Bar Arrangement

A - Timbers in place between ground and tire.

B - Rubber belting for protection of tire surfaces.

A - Kiln tire section on elevated saddles. Set level as possible.

B - Tire in position for resting on shell section. C - Set tire on 4” by 4” timbers for removal of wire rope and belt material.

A - Circumferential sling for moving tire into position on pads. Place wire rope inside rubber hose split lengthwise and tied with baling wire.

B - Use 4 spacer bars with centering gussets and end set-screws.

A - Longer timbers for clean and soft rolling surface.

B - Belt wrapped around tire and tied with wire.

C - 3 wraps of 1” wire rope hitched to crane hook.

“Plumb” position of tire after pick-up.

(9)

Crane Hitch Arrangements for Handling Kiln Shell Sections

(Off-Loading and at Assembly Area)

Preferred arrangement, using a spreader beam and two cradle slings. Two cranes should be used for longer shell sections with two heavy padded sections for riding rings.

Acceptable hitch arrangement, but anti-creep gussets should be installed to prevent wire ropes from crawling toward each other when the crane starts to pick up the load. Calculate the sling tension for the included angle & use an adequate capacity slings.

(10)

Crane Hitching for Kiln Shell Sections

Hitch Angles and Stress on Lines

Diameter Diameter 1000 lbs. 1000 lbs. 2000 lbs. 1 Part line Weakened Splice kinks shell Kiln Shell

“Choker” no good for handling kiln shells.

Kiln Shell 2 parts of line

Go with “Cradle” for Handling Kiln Shells

Sling hitching angles and stress on lines for each ton to be hoisted.

Diameter 2000 lbs. 1415 lbs . ₁₄ 15 lb s. 45° 45° 90° Diameter 2000 lbs. 1155 lbs . ₁₁ 55 lb s. 60° 60°

(11)

Kiln Shell Support

Long itudin al Weld Long itudin al Weld

Longitudinal welds at ends of shell sections are to be set 180° apart for field joints unless shown otherwise on erection

drawings.

1” X 4” X 24” strongback bars may be used to guide shell section

into position for field joint connection. Locate at spaces required for

setting all strongback bars for joint. _{Typical crib stack shown with jack, steel plate and}

saddle arrangement for adjustment work.

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Alignment Fittings

Edges of adjacent shell sections Strong-back “Push” - “Pull” Adjust Bolts Adjusting lug

(13)

Gauge Blocks

Field Joints

Feed End

Batter Board with Center Hole and Card

Batter Board Locations

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Checking Alignment

Tumble or rotate instrument 180° for test at discharge end target.

Instrument cross-hairs or center of a laser beam must be within 3/32” or 2.5 mm of target center at all test positions. Feed End Field Joints Gauge Blocks Discharge End Transit Replacing Batter Board

(15)

Steel Spider (1 of Several Types)

2” X 6” Board

Wood Wedges _{2” or 50 mm Diameter Hole}

Drilled at C_{L ’s} 2” or 50 mm Diameter Hole Drilled at C_L’s (2) 1/4” Diameter Bolts at Each Plate 1/4” X 4” X 4” Steel Plates 2” X 6” Board

Kiln Shell Alignment Test Batter Boards

(16)

A - 4” X 6” index card held in place by thump tacks (or staples) and push pin.

B - Shows card turned and pinned to clear 2” or 50 mm diameter hole for through sight to next targets. Card can be returned precisely on starting position for target re-check.

A

B B

Kiln Alignment Target and Layout Trammel

Cut beam to form pointed end.

New kilns

only-In tire sections - use steps in machined reference plates as guide point for trammel layout on targets.

3/4” X 1 1/2” trammel beam (wood) Sharp pencil in trammel clamp.

(17)

Details on card: Center by first set of quarter points Center by second set of quarter points Selected center B1 A1 A2 B2 A3 B3 A4 B4 Second set of quarter points identified by “B”s

First set of quarter points identified by “A”s

Shell

Center points

Arcs and diagonals for first points are solid, dashed for the second set

Card on batter board 45° offset

Locating the Center of the Shell

(18)

Kiln Shell Section Alignment Tests (Alternate Arrangement)

After aligning and tack-welding span “A”, as for 2-section 2-support kiln (figure kiln overhead 014.cdr) or when this length has been factory built, alignment of following spans can usually be achieved by adjusting support rollers.

completion of joint in span “A” will eliminate need for support at joints in following spans. Actual support requirements will depend on section design for shipping.

Usually

Actual sequence of installation and alignment must be determined on-site to suit actual number of shipping sections.

For Alignment of Kiln with Sections as Shown Above

Finish span “A” as in test for 2-section, 2-support kiln (shown in figure kiln overhead 014.cdr). Set transit on kiln axis. Lock on target 5. Cross-check on targets 4, 3, 2, 1.

Lock transit on target 8. Back-check on 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of site within 3/32” or 2.50 mm of target centers.

Lock transit on target 11. Back-check on 10, 9, 8, 7, 6, 5, 4, 3, 2, 1. Adjust rollers, if necessary, to bring line of sight within 3/32” or 2.50 mm of target centers.

Minor errors on short fore-sight will “grow” on each following target. Avoid errors, save time and avoid confusion by working from most-distant far-sight.

1 2 3 4 5 6 7 8 9 10 11

Span “A”

Pier 1 Pier 2 Pier 3 Pier 4

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Kiln Shell Field Joint Bracing and Tack Welding

Weld remaining end of strongback after kiln shell alignment is acceptable.

Prewelded end

Tighten all nuts in push/pull bolt arrangements.

Edges of adjacent shell sections

Tack weld in bevels, at least 6” or 150 mm long, at fixtures used for alignment of adjacent plates. Deposit root weld bead.

(20)

Riding Ring Location

Thrust Discharge

end

Change pier numbers to suit actual arrangement

The dimensions indicated are specified on the foundation drawing. The tolerance on the location of each ring is +_ 1/4 inch (6.35 mm).

“Cold” dimensions on the foundation drawing are at 70° F (21° C). Record shell temperature for

calculation of expansion or contraction relative to the control temperature for adjustment of allowance for expansion at each support roller position.

(21)

Temporary Support Chair for a Kiln Spring Gear

1 ½” axial adjustment bolts. 6” long (typical).

Typical gear chair ( 1 of a set ) for temporary duty. 2” X 6” (or to suit) bolt

for gear radial adjustments.

Kiln Shell

Chair in position to support and adjust the gear for correction of axial and radial runout. Kiln gear with tangential springs

KILN OVERHEAD 021.CDR _{Maintenance S eminar}

(22)

Gear Guard and Splash Band Assembly

C F _F D C E A B Feed End

A - Gear guard section

B - Flange joint for removable panel C - Splash band sections

D - Spring plate for gear E - Kiln shell plate F - Spacer guides

Splash band installation notes:

1 - Prepare and install spacer guides. 2 - Install segments with care.

3 - Align and tighten flange joints.

4 - Align and tach weld panel butt joints. 5 - Verify straightness and clearance all around.

6 - Weld flanges to shell. Must be oil tight. 7 - Remove scraps. Clean off weld spatter.

NOTE:

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Kiln Support Roller Adjustment and Testing

Low end of kiln (discharge)

Bearing end plate with thrust washer

Roller shaft should be in contact with this thrust washer. End plate should sound “solid” when tapped near center with a hammer.

Roller shaft should not be in contact with this thrust washer. End plate should sound “hollow” when tapped near center with a hammer. Bearing end plate with thrust washer Low end of kiln (discharge) Kiln moves

toward feed end

Rollers move toward discharge end

Rotation In In Support Roller Riding Ring

View toward feed end

Kiln moves toward feed end

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Ideal Roller Skewing:

All rollers should be pushing uphill slightly or neutral.

With a two thrust roller system (as here) the kiln should be floating between the thrust rollers.

With a one thrust roller system there should always be contact between thrust roller and tire pressure 200-800 psi or 15 to 60 bar.

Drive

Lower Thrust Roller Feed End

Discharge End

(25)

Beam

top Support_roller _Plumb

lines Plumb bobs in oil B B A Kiln may be on slow rotation if plumb bob is suspended in oil * Dial-indicators (1 at each bearing base) are used

for control of final true-up alignment work and for all skewing adjustments.

Bearing Base

A

Offset reference line (may be a tight wire or a straightedge at established reference marks).

Support Roller Assembly Alignment Control

Hightemperaturemetalsurfaces cancausesevereburns.

Moving(rotating) machinerycan

causehandsandarms tobecomecaught. Avoid personal injury.

* - This procedure is not valid if the roller is cone shaped or distorted on the rolling contact surface.

A-Scribebeamsurface atedgeof bearingbasetoestablishreferencepointsformeasuringbearingmovementduring

therollerrelocationworkperiod.

B - If it is possible to work simultaneously at both bearing positions, use 2 plumb lines for measuring movement.

(26)

Rotation B

Rotation A

180° bearing bushing

Kiln Support Roller Bearing Bushing Lubrication

Sketch shows recessed zones of bushings filled with oil for formation

of oil “wedges” which taper to “a few mils” film thickness at the longitudinal pressure line. Wedges are shown for both directions of shaft rotations. A B Shaft Rotation Shaft Rotation B A Roller Shaft Recessed Zone (Both Edges)

(27)

Temporary Kiln Support Jacking Kiln Shell to Unload Support Rollers

“Chord Length” does not apply when designing a saddle for under a riding ring. A saddle for a riding ring must straddle a tie beam between support frame beams and must be designed to fit between rollers on that frame. Saddle width should be same as width of nearest tire but not less than 12”.

Rule of thumb:

72° = 5 spaces @ 0.587785 X outside diameter = Chord Length Shell Diameter (outside)

Kiln Shell

All pieces from 1 1/4” plate

Saddle for Kiln/Shells Chord Length 72° 36° V ar ia b le KILN OVERHEAD 027.CDR

Kiln Saddle Dimensions

(28)

Jacking Kiln Shell to Unload Support Rollers

Drive wedges and/or filler plates between tire and pads to eliminate top clearance for early pick-up of the tire when jacking against the saddle.

Shell Brace

Shell Saddle Arrangement Clearance

Slow Rise Edge

Prepare 12 or more

On Pier Surface Tire

(29)

Jacking Kiln Tire to Unload Support Rollers

Preferred Jacking Arrangement ( when possible)

Refer to the foundation drawing for the kiln for the pier loading figure at the tire to be raised; jacking capacity for that area will be indicated by the vertical load shown for that pier.

Shell Brace Clearance Tire

(30)

Familiarization

Kiln Support Roller Bearing Oil Level and Leakage

A - No oil leaks at downhill shaft seal except when overfilled, dirt and rainwater enter housing when seal is bad, as when a liner is badly damaged.

B - Shaft seals are not dams. Oil level must not reach seals at uphill bearing assemblies. Pier Surface

Pier Work Point Maximum oil level in the downhill housing Maximum oil level in the uphill housing

Imaginary Level Line A

B

(31)

Support Roller With Journal

Self Aligning Ball and Socket Type Bearing FLS “58”

“Type RA” Design Bearing

Felt Seal Oil Trough Oil Cup Thrust Ring Liner Oil Gauge Spherical Liner/ Water Jacket Stop Block Heat Shield Oil Scraper

(32)

Kiln Support Roller Adjustment and Testing

Bearing end plate with thrust washer

Roller shaft should be in contact with this thrust washer. End plate should sound “solid” when tapped near center with a hammer.

Roller shaft should not be in contact with this thrust washer. End plate should sound “hollow” when tapped near center with a hammer. Bearing end

plate with thrust washer

(33)

Kiln Support Roller Adjustment and Testing

KILN OVERHEAD 035.CDR Low end of kiln (discharge) Kiln moves

toward feed end

Counterclockwise Rotation Rotation In In Support Roller Riding Ring

(34)

Kiln Support Roller Adjustment and Testing

Kiln moves toward feed end

(35)

Kiln Support Roller Skewing

Roller Adjustment Rule of Thumb

Moving (rotating) machinery.

Personal contact can cause hands and arms

to become caught in pinch points.

Counterclockwise Kiln Rotation

KILN OVERHEAD 037.CDR In In In In Bearing Bearing Bearing Bearing Support Roller Support Roller Kiln Kiln Kiln Kiln Rotation High End Maintenance S eminar SM

(36)

Kiln Kiln

Kiln Support Roller Skewing

Roller Adjustment Rule of Thumb

Clockwise Kiln Rotation In In In In Bearing _Bearing Bearing Bearing Support Roller Support Roller Rotation High End

Moving (rotating) machinery.

Personal contact can cause hands and arms to become caught in pinch points.

(37)

Normal Offset Position of Thrust Rollers

Thrust rollers must be offset from the true frame longitudinal centerline toward the down - turning side of the kiln for normal (safe) operation.

Down Down Down Kiln Centerline Roller Centerline Correct Idle KILN OVERHEAD 039.CDR Rotation Maintenance S eminar SM 1/16” to 1/8”

(38)

Wrong Offset Position of Thrust Rollers

Thrust rollers will rise, or try to rise, out of their bearing bases when their centerlines cross over the true frame centerline toward the up-turning side of the kiln, and when the kiln shifts toward its own downturning side. Idle Up Up Up Wrong Rotation Kiln Centerline Roller Centerline Any amount

(39)

Plain Roller Support Assembly

KILN OVERHEAD 041.CDR Detail Roller Shaft R o ll er C L Inspection Port Oil Seal (See Detail) Oil Tray Bearing Housing Oil Bucket Wheel

Thrust Washer

Oil Level and Oil Fill Pipe

Feed End

Adjustment Plate Bearing

(40)

Thrust Roller Assembly

Two Thrust Roller System

Detail Oil

Seal

Oil Level & Oil Fill Pipe

Thrust Roller Housing

Thrust Riding Ring

Feed End Thrust Rod Shims Spherical Roller Bearings Thrust Roller Thrust Roller Shell See Detail

(41)

Thrust Roller Assembly

Thrust Roller Frame C

C

C - C

(42)

Oil Seal

Detail

Hydraulic Thrust Roller Assembly

Shell

Thrust Roller

Frame _{Upper Thrust}

Housing Support Thrust Housing Support Rod Drain Plug Feed End Lower Thrust Housing Support Spherical Roller Bearings “A” (Sht.

Fixed Uphill Stop

with Brass Plate Support

Rod Boot Thrust Riding Ring Thrust Roller Housing Thrust Roller Movement Thrust Roller Thrust Button Hydraulic Cylinder Stroke Adjuster

NOTE: Oil Pipe & Graphite Lubricator Included but Not Shown

To Hydraulic Power Unit See

(43)

Bumper Assembly _Riding Ring K il n C L A - A

Hydraulic Thrust Roller Assembly

Operation of Limit Switches

A - Stops Hydraulic Pump Set B - Pressure in System Relieved C - Sounds Alarm

D - Shuts Kiln Drive Down E - Starts Hydraulic Pump Set F - Sounds Alarm

G - Shuts Kiln Drive Down

Pier 3 Pier 2

Hydraulic Cylinders Hydraulic

Power Unit

Hydraulic Thrust Orientation

(Single Hydraulic Cylinder May be Used) + + + + + + +

D C B A E F G

Thrust Roller Thrust Riding Ring

C L R o ll er S u p p o rt & T h ru st R id in g R in g Feed End Cam Follower Limit Switch Assembly A A C L Maintenance S eminar SM

(44)

Routine Checkout at Kiln Tire Sections

Shell Cold: Clearance for expansion at top of kiln

Shell (pads) rest in normal position inside the tire Allowance for Shell Expansion View at

(45)

E x p an si o n Shell Overheated and Choked Inside Tire

Routine Checkout at Kiln Tire Sections

Shell overheated and choked inside tire. Shell expands proportional to internal heat, but must bend at sides of tire.

Tire retainers on bend pads bite into the tire, tire and retainers become worn. When shell temperature returns to normal, shell pad to tire clearance is excessive.

No shell migration may eventually be followed by permanent kiln shell choke-down deformation.

(46)

Field Installation of Kiln Tire Section Spider Bracing

When the pre-welded end of Brace No. 1 is at the top of the shell after 90° of rotation, shell sag moves the loose end against the bottom of the shell and in position for welding.

Brace No. 2, and possibly No.’s 3 and 4, will be needed for pad replacement work requiring frequent rotation of the shell.

Spider bracing is for holding the shell as round as possible for pad replacement work. Before welding bracing to the shell, verify roundness by using trammel layout work for marking the shell axis on Brace No. 1 to establish a reference point for radius measurements.

Brace No. 1

Pre-Welded End @ 90° From Start

Now Tight Second

Weld Brace No. 2

(47)

Routine Checkout at Kiln Tire Sections

Shell Hot: Normal Operation

Check (frequently) each tire section in the kiln arrangement. When shell migration in not recorded, the kiln shell is very near the point of serious deformation damage plus shell and refractory breakdown problems.

KILN OVERHEAD 052.CDR Almost zero clearance. Shell continues to migrate within the tire. View at Top Position Maintenance S eminar SM

(48)

Routine Checkout at Kiln Tire Sections

When normal coating builds up on refractory, the main shell returns to normal diameter but the permanently deformed tire section shell is small in relation to the tire bore diameter.

With the tire in a normal alignment position the kiln shell is misaligned at the low-riding deformation zone. Excessive down tire follows choke-down deformation.

(49)

Field Installation of Kiln Tire Section Spider Bracing

1 - Install support plates at both sides of the shell.

2 - Lift bracing leg onto support plates. Check squareness.

3 - Hold end of brace against the shell for welding.

4 - Rotate shell 90° to place weld at top center position. Shell sags away

from the tire

Clearance Spreads

Horizontal Major Axis

1 1 2 3 4 Maintenance S eminar SM

(50)

Field Installation of Kiln Tire Section Spider Bracing

New measurement problems must be considered when/if internal bracing holds the shell in a perfectly round condition.

If the riding ring rests on support rollers, ovality will not have changed; now measurements will be between a round shell and an oval riding ring.

When the riding ring is on the support rollers, and the kiln shell is round (after bracing), measure clearances at both sides at the horizontal centerline, and at top-dead-center between shell pads and the riding ring bore surface. Add dimensions recorded for these three check points, then divide the total by two to determine the actual diameter for shell pads and riding ring bore.

Clearance

0.6125”

Clearance 0.6125”

Shell held in round condition by internal bracing

True roundness is a goal Seldom - if ever - Reality Clearance

0.775”

Riding ring on rollers and a 0.3% ovality

(51)

Jacking a Kiln Shell to Unload Support Rollers

Clearance between the tire and pads at the top of the shell is usually overlooked when all other details have been considered in arrangements for jacking up the kiln shell to take a tire off the support rollers for maintenance work on the roller assemblies in position on the support frame, or for lifting out one or both assemblies for work at ground level or in the maintenance shop.

Saddle Under the Kiln Shell

Clearance Tire

Shell Brace

(52)

Jacking a Kiln Shell to Unload Support Rollers

Two to four times the jacking capacity anticipated for lifting the shell will be required if tire to pad clearance is not considered (especially when excessive).

By the time the upper pads touch the tire jacks are fighting all shell weight to adjacent tire sections. Saddle under the kiln shell

(53)

Jacking a Kiln Shell to Unload Support Rollers

NOTE: The tire will not rise until top area clearance is eliminated by the rising shell. Excessive pad to tire clearance is a handicap for jacking up kiln shell.

Saddle under the kiln shell

NOTE:

(54)

Jacking Kiln Shell to Unload Support Rollers

Shell Brace

Shell Saddle Arrangement Clearance

Slow Rise Edge

Prepare 12 or more

On Pier Surface Tire

(55)

Typical Procedure for Removing Roller Assemblies

from the Support Frame

1 - Spider bracing (installed before locking out the kiln drive system, including the auxiliary drive arrangement).

2 - Timber cribbing stack with hydraulic jacks in place under steel saddle. Saddle and jack arrangement must raise the kiln shell just enough ( 1/32”, 1 mm, or less ) to be fully loaded for removal of both roller assemblies. * 3 - Install steel or hardwood columns for security of the temporary support arrangement during the pad removal and replacement work period.

* - If the tire is rising with the shell. If clearance between the tire and shell pads was not accounted for, excessive jacking will be required to lift the tire away from the support rollers.

1

2 3

3

(56)

Typical Procedure for Removing Fuller/Traylor Roller Assemblies

from the Support Frame

“Cutaway” view of roller assembly bearing bases shows internal arrangement of components with critical clearances. Whenever roller and bearings are to be lifted as a complete assembly, hitching arrangements must hold bearings in full-line contact with shafts, and with no contact at shaft seal zones.

A - Remove shaft seals. Insert wood or rubber wedges between shaft and seal inset in housing. Secure these wedges with at least one wrap of duct tape (or similar material).

B - Edges of frame beams have machined insets for control of shaft clearance between bearing end plates. Key bars at bottom positions on housings hold bearing housings in position against machined edges for operation of the assembly. One or both keybars must be removed to avoid interference when the complete roller assembly is moved toward the outside end of the support frame.

Slope Line Pier Top Pier Work Point Level Line Reference

(57)

Typical Procedure for Removing Fuller/Traylor Roller Assemblies

from the Support Frame

Prepare hitching material similar to the arrangement shown in these sketch sheets. Distance between connecting points must place the crane hook, spreader bar and shackles far enough above the kiln horizontal centerline for flexibility in the lines for lift-out maneuvering.

Remove all cooling water input and drain pipes from bearing bases. Remove bearing adjustment lug and screw combinations from frame beams. Prepare beam surfaces for outward travel of the roller assembly.

Jack or pull the assembly outward on the frame until motion is stopped by roller contact against the tie-beam at the end of the frame.

KILN OVERHEAD 062.CDR _{Maintenance S eminar}

(58)

Typical Procedure for Removing Fuller / Traylor Roller Assemblies

from the Support Frame

Place timbers at the ground level work area for support of the assembly with the roller off the ground The low-end bearing housing will touch down, and hitching will become loose, before the other bearing housing rests on its own support timbers.

(59)

Move bearing housing:

Removing and/or resetting a bearing housing at ground level

Typical Procedure for Removing Fuller/Traylor Roller Assemblies

from the Support Frame

Look for stencil-letter identification of the feed end area of the roller.

IN / ON OUT / OFF

Uphill ( or feed end ) bearing housing

FEED E_N D

(60)

Typical Procedure for Removing Fuller/Traylor Roller Assemblies

from the Support Frame

Move the roller into its realignment position and into a load carrying condition. Reassemble all pipe fittings, guards and other items which may have been removed for crane handling maneuvers. If internal fittings had not been reinstalled at ground level, remove end plates for final fit-up work. Re-fill bearing lubricant reservoirs. Remove pedestals, jacks, saddle and cribbing.

(61)

New Pads for Choked-Down Tire Sections

Align the kiln shell before shutting down for repair work. Cold-condition external alignment procedures are not acceptable unless excess clearance and other deviations are accounted for. Kiln shell section alignment is critical at all tire positions, alignment of tires is not necessarily kiln shell section alignment.

KILN OVERHEAD 070.CDR Tire (Clearance Exaggerated for Clarity) Thrust Roll Roller at Far Side Level Slope

True Kiln Axis

Thrust Roll

Tire C_L

Shell C_L

(62)

New Pads for Choked-Down Tire Sections

Preparation:

1 - Install spider bracing. (See bracing installation procedure on other sheets). Bracing must be installed before the kiln auxiliary drive system is secured, along with the main drive motor, to prevent accidental rotation during the repair work period.

2 - Remove retainers at the side of the tire toward the direction of movement away from pads. Grind off weld scraps.

3 - Remove thrust roller assemblies. Level Slope 2 1 3 1

(63)

New Pads for Choked-Down Tire Sections

Preparation:

1 - Install steel saddle and two (or more) hydraulic jacks in a convenient location that will not interfere with work.

2 - Back support rollers away from the frame center line to let the tire move downward.

3 - As rollers move outward, check tire to shell clearance all around. Stop roller adjustment work when the tire is in balanced position around the shell.

4 - Install skid bars at the top of the shell. Use shims for adjusting bar height for smooth movement of the tire.

5 - Mark the shell to indicate original position of tire.

KILN OVERHEAD 072.CDR Level Slope 3 5 4 1 2 Maintenance S eminar SM

(64)

New Pads for Choked-Down Tire Sections

Preparation:

1 - Install a tight arrangement of steel or hardwood pedestals between the support surface and saddle.

2 - Start to jack or tug the tire off pads and onto skid bars. Level

Slope

2

(65)

New Pads for Choked-Down Tire Sections

Preparation:

1 - Move the tire far enough onto skid bars to allow for installation of new extra long pad plates.

2 - The bottom of the tire will swing toward a “plumbed” position if not restrained. Install gusset plates at the bottom of the shell to hold the tire away from the pad zone.

3 - Remove both roller assemblies for free access to the shell.

4 - Start pad removal work.

Level

Slope

(66)

New Pads for Choked-Down Tire Sections

Preparation:

1 - Finish pad removal work. Grind down weld scraps. Remove caked dirt, rust and oil from the shell at the pad zone.

2 - Use a straightedge or a tight line for measurement from undamaged shell surfaces to the top of the depressed shell. Measure at several points around the shell for a realistic approach for planning and preparing filler material.

The depressed zone must be filled for support of new pads. Any unfilled space, however small it may be, will allow new pads to bend to fill the spaces as soon as rotation starts after the kiln is returned to the production department.

Level

Slope

(67)

New Pads for Choked-Down Tire Sections

A “typical”, but unsatisfactory shim stack arrangement for filling spaces between shell and pads is shown at the bottom of the shell. Since “all-position” fit-up work is necessary, shim stack installation is tedious (and frustrating) work. Shim stacks are rarely, if ever, tight enough to prevent pad distortion when the work is called “finished”. A more acceptable filler arrangement is shown at top of the shell, a rolled plate, at a thickness determined by prior measurement, is used with appropriate thickness-adjustment shims for a more secure packing arrangement. In this arrangement filler plates are welded to pad plates, not to the shell.

STRAIGHTEDGE

KILN OVERHEAD 076.CDR KILN OVERHEAD 076.CDR

New Pad Plate

Stacked Shim Plates Rolled Filler Plate

Level

Slope

(68)

Lubricate

Level

Slope

Lubricate New Shell Pads

When new pad plates, with fillers, are secure around the shell, lubricate surfaces to facilitate movement of the entire to the predetermined operating position for that particular tire.

(69)

New Pads for Choked-Down Tire Sections

1 - Adjust tire position in relation to original reference lines.

2 - Install temporary gusset plates to lock the tire for rotation.

3 - Return support rollers to positions on the frame. Adjust for recalculated set points which consider new

conditions at the tire.

4 - Move the thrust roller into position at the clear area.

5 - Remove skid bars: Grind down weld scraps.

New Shell Pads

(70)

Welded End Do Not Weld Gusset to Pad Welded End Welded End Welded End

Loose End Loose End

Loose End Loose End Pad Pad Pad Pad Tire CL TYP TYP 3/8 to 3/4 3/8 to 3/4 _{3/8 to 3/4} A A Tire 1 Dia. Spacer Pad (Loose End) A - A Hold Down

Gusset Retainer Block

4” X 4” X Variable Length to Suit Spacer Pad

New Pads for Choked-Down Tire Sections

Alternate tire retainer arrangement. Semi-floating pad design. 1/16”

(71)

New Pads for Choked-Down Tire Sections

1 - Be sure that rollers are carrying the load of tire and shell.

2 - Remove pedestals, jacks and saddle.

3 - Reset thrust roller assembly.

4 - Adjust thrust roller assemblies for proper clearance in relation to the tire and in relation to support roller centerlines.

5 - Kiln rotation is required for testing for tire wobble.

6 - After tire wobble has been eliminated, install tire retainers.

7 - Remove temporary tire-locking gusset plates.

8 - Remove internal spider bracing. Grind down weld scraps.

KILN OVERHEAD 081.CDR 1 2 3 ₄ 8 7 5 6 8 Tire Tire Slope Roller Thrust Roller Thrust Roller Maintenance S eminar SM

(72)

Inthisarrangementpads arenotwelded totheshell atall.

The shop installed cost for this arrangement is high, but the future field replacement of pads is simpler and less expensive.

Thecontinuouswear ringsinstalledbetweentheridingring endfacesand wearringretainersreducesbearingpressure andgougingintheriding ringend facesandalso increasewear lifeofthecomponents.

Itis veryeasytoreducetirecreep:

Installshimsbetween shellandpads andtackweld newshimstopads.

Floating Pad Design

Min. Min. Wear Ring

1/16” or 2 mm Downhill Side Only Heavy Shell Plate

Riding Ring Pad Length Pad Min. 8” 8” 5” Taper Pad Thickness 1” Wear Ring TYP Shell Thickness Pad Thickness Height of Anti-Rotation Plate A - A

Fillet Weld Size 2-Pad Width 9” TYP. 3 Sides TYP. 3 Sides 1” Chamfer 5/8 Fillet Weld Size A A 5” 8” Anti-Rotation Plate

Must Make Contact on 1 Side

Wear Ring Retainer 1” TYP

TYP 1/4”

Pad Guide Bar 1” Thick

Axial Pad Retainer 1” Thick R 3/4

R 3/4

1/8” Gap

(73)

Using Wedges for Longitudinal Shifting of Tire

Weld Wedge to Tire

Opposed Wedges. Smooth slide surfaces per machine shop procedures.

Mo lyk

ote Lu

be

Weld Wedge to Pad

Rotation & Creep

Creep (Mark on Pad) Mark on Tire

Move Tire Cold Kiln

(74)

Using Chains for Longitudinal Tire Movement

No push or pull mechanical assistance.

No wedges.

No “assist” from roller thrust reaction on tire. Ignore triangle in chain hook-up Tire Roller 24” Straight Line 2” 3/8” 24” Maintenance problem:

Tire in offset operating position on rollers. 2” move required in longitudinal direction on shell

Clearance - tire to pad at TDC is 3/8” for this example.

C_L C_L Chain

(75)

1 2 3 4 5 6 7 8 9 10 11 12 13 0.750 ” 1.500 2.250 3.000 3.750 4.500 5.250 6.000 6.750 7.500 8.250 9.000 9.750 23.988 ” 23.953 23.894 23.812 23.705 23.574 23.419 23.238 23.031 22.798 22.537 22.248 22.937 0.012 0.047 0.108 0.188 0.295 0.428 0.581 0.782 0.988 1.202 1.482 1.751 2.070

Rev. Number Total Creep New “X” Dimension Draw

Clearance tire to pad at TDC = 3/8” 3/8” . .5 = 0.2387324”

Diameter X = 0.750” creep/rev. Must shift tire 2”

  Tire Tire Draw Start 24” Straight Line Shell Creep/Rev. 3/4 (Constant) 24” Constant “X” Changing

Using Chains for Longitudinal Tire Movement

Approximately 13 revolutions to move tire 2”. No allowance for elongation of chain under load. Calculate for actual creep and length of chain(s).

Right triangle re-calculation to suit creep @3/4”/rev. X number of revolutions: 24” chain constant hypothenuse. .

(76)

As Seen From Under the Kiln Shell Measure Amount of Creep

Shell Advances Inside Tire

Count kiln revolutions after placing matchmarks. Measure distance between matchmarks after “X” number of kiln revolutions, then divide that dimension by kiln revolutions during the test period to determine shell migration (creep) for each revolution of the kiln.

Measurement of Shell Migration

(77)

A

B End

Start

Tracing Arrangement for Recording Pad-to-Tire

Clearance and Migration (Creep)

A - Magnetic base with post for spring-loaded pencil holder

B - Magnet-backed tracing surface holding panel

The kiln shell migrates within the tire; It is not the tire that “creeps”.

In the sketch above, the tracing surface is set on the side of the tire and the magnet-supported pencil is placed on the trailing edge of the card as determined by rotation direction of the kiln.

Height of wave patterns is a recording of actual clearance between shell pads and tire bore. This dimension when divided by 1/2 Pi, indicates actual pad-to-tire diameter.

Distance between start/stop points indicates shell migration within the tire for each kiln revolution. Shell migration divided by Pi ( ) indicates pad-to-tire diameter, but this dimension is not valid for follow-up calculations when affected by lubrication.

NOTE: Kilns with floating shell pads --- DO NOT PLACE MAGNETIC BASE ON A LOOSE PAD.

(78)

Spring-Loaded Pencil Holder for Pad/Tire Clearance

and Creep Tracings

Pencil must move freely in tube (no slop).

Ret/G post & block (tackweld). Drill, ream, tap.

Spring to be retained at end shown.

Tire clearance & creep tracing-pencil holder. Magnet Ret/G Block Ret/G Post Cap Screw Holder Spring Pencil General - #351-6 1/2” Hex Bar X 2” LG 1/2” Hex Bar X 1” LG (Slotted) 10-24 X 3/4” LG Chromed Tubing (Plumbing)

5/16” Diameter X 1 1/2” LG (Medium Ten.) Standard HB (No Eraser)

(Berol Black Warrior #372)

Description Material

Standard Pencil Pencil Holder

(Tubing)

Drill & Tap 10-24 X 1” Deep

10-24 Slotted

Capscrew X 3/4 Long

Permanent Horseshoe Magnet (10 Lb. Pull)

Retainer Block & Post Spring

5/16” Diameter X 1 1/2” (Retained)

6” 1 1/2”

(79)

Tracing-Paper Surface for Pad/Tire Clearance

and Creep Tracings

Tire clearance & creep tracing board

Cut strips of manila file folder sheets to fit on hardboard surface. Hold strip in place with spring clips.

8 1/2”

1” TYP.

1/8” Tempered Hardboard

Permanent Horseshoe Magnet 10 Lb. Pull (General #351-6) Drill & Countersink

To Suit 10-24 Csk Screw (TYP) 2 places

Bolt&Nut toMagnet

2 1/2”

Two Spring Clips (Small)

(80)

E _G H F h h 1 5 . Recorder System “Holderbank” Ovality: = 2 (a - b) 3 = 4.d2 .

h

=

Shelltest Diagram

=

₁₅ a Distorted Cross-Section Principle of Distortion Measurement

Shelltest Measuring Unit “Holderbank” System

b d d A B h B D C L = 1m

(81)

D C B 1, 2, 3, Shell Lines A, B, C, D Measuring Planes A 1 1 1 2 2 2 3 3 3 KILN OVERHEAD 091.CDR 1 2 3 Diagram of One Measuring Plane

Ovality

Maintenance S eminar SM

(82)

Ovality Limits as Function of Kiln Diameter

Kiln Diameter % O v al it y 3 0 % 0.2 0.6 0.4 0.8 4 5 6 m 

(83)

KILN OVERHEAD 093.CDR Allowance for Shell Expansion View at Top Position Maintenance S eminar SM

(84)

A

B

End Start

As Seen From Under the Kiln Shell Measure Amount of Creep

(85)

KILN OVERHEAD 095.CDR Clearance E x p an si o n Shell Overheated and Choked Inside Tire

Permanent Shell Deformation

(86)

Difference in Diameter ( ) Gap at Top (G )† = G† D : Tire Note Note

Note: Deflection also occurs at contact points where the tire rides on support rollers. Distorted Shell Crush Zones for Brick Lining CL _CL Shell Tire

(87)

KILN OVERHEAD 097.CDR 90° Roller CL Radius No Axial Runout (Wobble) Through 360° Rotation All Details Must be Checked Prior to Planning a Schedule for True-Up Grinding

Radius

Roller on Planned Slope Per Test with Gauge Block & Level or Inclinometer

Kiln Properly Aligned Slope is Exactly as Planned. Rollers Set to Compensate for All Dimensional Variables.

Matched Liners Frame Slope True

Planned Slope Level Line 90° Tire CL Hot Position on Roller 180° Liner 180° Liner Maintenance S eminar SM As seen from Frame Long’l CL

(88)

Tire Ovality - Removal of Metal May Not be Feasible

Anticipate refractory problems starting at about 0.5% shell ovality. Some older tires (new) thin and at critical ovality. Ovality increases when tire is cut too thin for roller supported operation.

started Rough Outside Rough Inside M in o r A x is Major Axis To F ind Dia met er Is Bore Worn and Grooved? Measure Thickness (t) t Mea sure Cir cum fere nce

(89)

Ovality When Tire is Too Thin

(and has Bad Inside and Outside Surfaces)

Sag

Shell

When a tire is too thin

the combination of sag, crimping and excessive clearance can account for

shell ovality approaching 0.9%. Checkoutshell ovalityfactorsbefore

arrangingfortiretrue-up. (Mayneedreplacementparts).

Excess Clearance Crimping Rollers Maintenance S eminar SM

(90)

Longitudinal Fractures at Shell Pads

Thin tires and excess clearance contribute to shell ovality and fracture at pad welds or in shell plate at toes of welds. Sag Shell Thin Tire Excess Clearance Crimping Rollers

(91)

Longitudinal Fractures at Shell Pads

Tire section “CHOKE” deformation

Load Concentration

Narrow Tire

Welds Break, Blocks Fall Off

Welds and/or Pads Break and Fall Out & Off

Longitudinal Fracture Lines Form in Shell

(92)

Longitudinal Fractures at Shell Pads

Shell ovality and pads with full length longitudinal welds, may also include pads with intermittent stitch welds. Bending Zones

Laminated Zones Resist Bending Sag F le x Pad Pad Excessive Clearance

Crush Points for Bricks Fatigue Points for Shell

Shell Shell W el d s

(93)

Longitudinal Fractures at Shell Pads

Original longitudinal welds must be removed for repair of fractures. Shell KILN OVERHEAD 103.CDR Tire Pad Fillet Weld Fillet Weld Maintenance S eminar SM

(94)

T 0.7

t

Remove Refractory to Expose Shell for Tracing and Repair of Fractures

Use Rotary Wire Brush to Prepare Clean Surfaces for Gouging & Welding

Shell Inside Surface Refractory

Longitudinal Fractures at Shell Pads

Finish internal repair welds first

F

ra

ct

u

(95)

Gouge

Finish Weld Outside

Inside

Finish External Repair Welds Last

Longitudinal Fractures at Shell Pads

Trace to Ends Tire: Remove

One Set

of Retainers Move_Tire

Back Move Tire Away KILN OVERHEAD 105.CDR Maintenance S eminar SM

(96)

Hollow Tires & Rollers

Excessive cutting & grinding on faces of cored tire and rollers has been known to put holes in surfaces above hollows. Do not reduce original diameters of hollow tires & rollers more than 3”.

Hol low Hol low Hol low Hol low Bore Zone Old Style Hollow Tire Old Style Hollow Roller Real Thickness Varies

Real Thickness Varies Tr Tr Ta Ta Apparent Thickness Apparent Thickness

(97)

Cold Flow Ridges on Tires and Rollers

Ridges must be removed. Sided of tire and rollers must be scraped clean for test with a try square. High ridges must be removed. Tool must be indexed for surface grinding parallel to shaft CL and true axis of tire.

Kiln moves inside the tire with thermal changes in the shell

Cold flow of surface metal forms ridges that may snap off and take along a chunk of surface metal

Tooling is not complete without the capability for removing ridges and cutting edge radius or chamfer.

Retainer blocks wear off at both sides of tire to relieve pressure. Tire is “locked” in place on rollers by the surface ripple pattern.

Kiln shell expansion & contraction KILN OVERHEAD 107.CDR Maintenance S eminar SM

(98)

Warped Kiln Shell and Tire Runout

1 2 _A A Hot Shell Slope Line Concave Up Convex Up Slope Line Heavy Load Hot Shell C C B B

(99)

Tire Wobble When Kiln Shell is Warped

This condition a valid reason for grinding a tire for improved contact across roller faces.

Find and eliminate for wobble.

Do not arrange for cutting or grinding when axial wobble exceeds 0.125”.

is not reason KILN OVERHEAD 109.CDR Neutral Wobble 3/16” 3/16” Wobble Gap 0.0275” Gap 0.0275”

Assume tire wobble (measured total) @ 3/8”. Tire outside diameter 16’. Tire face 28” (2.333’).

0.357” : 16’ = 0.0234” per ft. X 2.333’ = 0.055” : 2 = 0.0275” v-gaps 180° apart in cross-over cycles. Grinding will form a “parallelogram” tire profile, pads will become deformed.

(100)

Wobble Neutral Wobble

3/16” 3/16”

Gap

Formation of Concave/Convex Surfaces

Tire wobble not eliminated. Tire face becomes convex, roller faces become concave. Surface true-up is needed but wobble should be eliminated before any cutting/grinding work is scheduled.

Roller faces will wear into concave contour. Tire face will wear into convex contour. With expansion/

contraction of the shell, large zone of tire moves onto a larger zone of the roller(s). Bearings are overloaded, shell suffers from reaction to vertical misalignment.

(101)

Aftereffect of Grinding a Tire with Axial Runout

Important Note:

Shell migrates inside tire. Starting with matchmarks AA and BB, first180° of rotation does not show significant change of tire contact on rollers. In a regular cyclic sequence with migration of the shell, when original matchmarks are 180° out of phase (BA & AB) original contact crossover v-gap will have been doubled.

Two (2) full contact zones will be seen at crossover points 180° apart on the rotating tire. A A B B A A A A CL A B B B B Parallelogram Tire Profile After Grinding 180° From Start Start Rotation Maintenance S eminar SM Runout Runout Runout True Axis True Axis True Axis

(102)

Tires & rollers need true-up grinding plus realignment, but ripples on shaft & bearing surfaces may interfere with adjustments when high points meet and generate heat.

Obvious need for surface true-up, but feasibility of metal removal should be verified by ovality analysis. As Seen From Below Tire

Tire

Roller Roller

Long Term Toe-In Condition Tire & rollers become cone shaped. Ridges form at edges. Surfaces become deeply spalled. Opposite thrust direction of rollers plus high pressure and heat can destroy roller assemblies.

Plastic flow may form ripples on shafts & bearings. Shaft true-up will require shop work. Will need new bearing liners.

(103)

Grinding Prior to Kiln Shell Replacement Work

A - Assume tire not centered on rollers because of wrinkles or other shell problems. Repair work will move the tire to normal operating position on rollers.

B - Typical wear pattern after long-term operation with tire in offset position.

Tire & rollers must be trued up before shell repair work is started, or to eliminate overload & misalignment in case of over-expansion or changing position of the thrust tire.

Roller set points must be recalculated to suit tire & roller dimensions after finishing the grinding process.

A B

(104)

Unacceptable

Cone shaped roller. Surface not parallel to C_L.

“Squareness” Control for Rollers

Surface parallel to C_L. Acceptable

(105)

“Squareness” Control for Tires

KILN OVERHEAD 115.CDR Tire C o n tr o l C o n tr o l C o n tr o l Surface is parallel to bore Acceptable 90° Tire Tire Tire CL CL CL Neutral Neutral Unacceptable Surface is not parallel to bore

For control of surface concentricity, test with extra large square and measure circumference at 3 control points across the face.

CL

(106)

Kiln Shell Damage and Temporary Repair

Repair of badly damaged kiln shell

Fillet Weld Bad Repair Good Repair Shell Repair Section Shell Wrapper Not Recommended Temporary First-Aid only Longitudinal Butt Weld Void Zones Double “V” Butt Weld Fillet Weld

(107)

Longitudinal fractures at ring segments

Kiln Shell Damage and Temporary Repair

Typical Field Cut

Kiln Shell Suppor t S_u pp or_t S u_p p_o rt Suppo rt Kiln Shell Fillet Welds Reinforcement Band (Full Circle)

Reinforcing Band

(108)

Tire and Pad Lubricant

for Rotary Kilns and Dryers

(109)

Kiln Shell Patch Plates Are Nothing More Than Temporary Band-Aids

When a patch plate is installed between a riding ring and the end of the shell, anticipate warp-related runout at the end of the shell and in the seal arrangement.

When a patch-plate is installed in shell between riding rings, anticipate riding ring wobble at the nearest ring (or both) and also at the seal in most situations.

Start planning for shell replacement when two or more patch plates have been or must be installed.

Cumulative effect of weld shrinkages will warp patch-plate and surrounding

shell plate inward.

Circumferential Weld Shrinkage Circumferential Weld Shrinkage L o n g it u d in al W el d S h ri n k ag e L o n g it u d in a l W el d S h ri n k ag e Patch Plate Insert Kiln Shell Maintenance S eminar SM

(110)

In sketch all welding is done double-Vee (butt joints)

Patch plate is restrained at all edges.

Transverse weld shrinkage for plate thickness is shown in chart. Yield point of adjacent plate surfaces would be exceeded if the shell would not be free to move in any direction in reaction to weld shrinkage stress forces. In actual installation and welding of shell patch plates and other inserts, limited shell plate movement is possible but combined weld shrinkage stress forces warp the surfaces within and around the patch plate or “add-on” fixture. Base metal at the welds is not far from the yield point after welding.

Transverse weld shrinkage at patch plate double-vee butt welds. Radius instead of 90° cornersminimizes,butdoesnot eliminatestressconcentration

points. Circumferential Weld Shrinkage 0 t 1/4 1/2 3/4 1 1 1/4 1 1/2 0.05 0.10 0.15 Circumferential Weld Shrinkage L o n g it u d in al W el d S h ri n k ag e L o n g it u d in al W el d S h ri n k ag e Patch Plate Insert Kiln Shell 60° Single V 60° Double V

t = Plate Thickness (in.)

T ra n sv er se S h ri n k ag e ( in .)

(111)

B

Rotary Kiln Installation and Maintenance Repair

Equations For Calculating

(shrinkage perpendicular to the axis of a weld) is particularly important when the shrinkage of individual welds is cumulative as, for example, in the shell-to-shell connections between rotary kiln (and similar machines) riding ring positions (support points). Unless allowances are made for transverse weld shrinkage - usually by spreading the joint open by the amount it will contract after welding - the cumulative shrinkage of several shell-to-shell connections could be great enough to significantly shorten the span between preset riding ring retainer locations or scribed reference lines.

For a given weld thickness, transverse shrinkage increases directly with the cross-sectional area of the weld. The large included angles in (A) are for illustrative purposes only.

Source - Adapted from text in “The Procedure Handbook of Arc Welding” published by the Lincoln Electric Company.

Transverse Weld Shrinkage

A

(112)

Arrangement for Removing Bearing Housing End Plate

Prepare rods (cold rolled steel) for installation as shown, nuts are shown in position for safety stops, but washers or short bars may be welded at end of rods for equally good results. Rods should not be more than 24” long.

Housing end plate with thrust washer and oil level pipe.

Remove tap bold from end plate to verify thread pitch and diameter.

Kiln support roller bearing base.

(113)

Place match marks or reference line at side of tire

Note rotation direction.

Use trailing end of retainer block for placing a soapstone mark (line) on the side of the tire.

Measurement of Shell Migration

to Determine Shell Pad to Tire Diameter

(114)

(115)

Stop Block

FLS Bearing 74, Type RB

20 X 20 X 200 mm KILN OVERHEAD 201.CDR 5-6 mm Clearance Zero Clearance Discharge End Feed End Maintenance S eminar SM

(116)

“Feed” stencil mark wiped (or ground) off of the end of the shaft.

“Feed” stencil mark wiped (or ground) off of the rim. Chamfer @

1/8” X 45°

Downhill side of roller

If original “feed” stencil marks have been eliminated by rubbing or by shop cleanup procedures, look for the 1/8” X 45° chamfer at one end of the roller bore zone. This chamfer will indicate the larger diameter of the 2-diameter bore for the roller.

The step-diameter lockup of roller and shaft requires the chamfer, indicating the larger shaft and bore diameter, to be aimed toward the low, or discharge, end of the kiln.

“Last resort” checkout of support rollers for correct installation on support rollers. FIGURE:

(117)

450 mm Oil-Lubricated Supporting Roller Bearing

(Old Design)

(118)

FLS Bearing Clearances in mm

850 -0,1 710 -0,1 630 -0,1 560 -0,1 500 -0,1 450 -0,1 400 -0,1 360 -0,6 320 -0,1 280 -0,1 240 -0,1 850 +1,6 710 +1,3 630 +1,1 560 +1,0 500 +0,9 450 +0,8 400 +0,7 360 +0,6 320 +0,5 280 +0,5 240 +0,4 850 710 630 560 500 450 400 360 320 280 240 0,85 0,7 0,6 0,55 0,5 0,45 0,4 0,35 0,3 0,3 0,25 1,6 1,3 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,5 0,4 1,88 1,83 1,75 1,79 1,80 1,78 1,75 1,67 1,56 1,78 1,67 1,24 1,00 0,84 0,76 0,69 0,61 0,53 0,45 0,37 0,38 0,30 1,46 1,41 1,33 1,36 1,38 1,35 1,32 1,25 1,16 1,35 1,25 0 0 0 0 0 0 0 0 0 0 0 +1,5 +1,2 +1,0 +0,9 +0,8 +0,7 +0,6 +0,5 +0,4 +0,4 +0,3 0,75 0,6 0,5 0,45 0,4 0,35 0,3 0,25 0,2 0,2 0,15 =0,36 0,30 0,26 0,24 0,21 0,19 0,17 0,15 0,13 0,12 0,10 d Journal

Kiln erection Supporting rollers / bearings: Various tolerances in mm

Linear Clearance at side minimum maximum Mean clearance dp - dt cold Mean clearance dp - dt hot Mean value (dp X dt X 1000) d dt dp     



x



_cold



hot d  X) expansion at t = 35° : d   35 X 0,0012 X 1000 0,42 mm / m

(119)

Fig. 4 KILN OVERHEAD 205.CDR Fig. 1

FLS Bearing

Fig. 3 Fig. 2 0 mm 5-8 mm 3 0 mm T Maintenance S eminar SM

(120)

Uneven Load Distribution

Hertz Pressures at Supporting Rollers

Parallel Skewed Only

Skewed and Change of Slope