140129343 Fuller KilnErection

Orientation & Common Terminology for Reporting Kiln Details Feed End of Kiln(s) (Also referred to as “Uphill” or “High-End” Area) CounterClockwise (Lefthand)

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.

3

2

1

Indicates pier numbers starting at discharge or feed end

Gear

1

B

A

2

B

A

A

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.

Clockwise (Right-hand)

A

B

A

B B

Kiln Support Rollers also called “Carrying Rollers”, Trunnions”, “Wheels”, and “Rolls”.

B

(Straight Spur or Single Helical) Referred to as “Girth”, “Bull” or Gear “Main” Gear. Indicate “left” or “right” side of the kiln when looking uphill towards feed end.

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

A

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

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

3 Left

Kiln Discharge End

Right

Material discharge (spill )

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

Left

Kiln Discharge End

Right

Material discharge (spill ) SM

KILN OVERHEAD 001.CDR

Maintenance S eminar

D

D Elevation E

Elevation C

(Approx.)

Elevation F

B

Elevation A

G

4

Frame CL

Bolt CL

Bolt C L

3

Pier CL

2”

1

Frame CL

Kiln Support Frame Setting Reference

2

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.

Refer to foundation drawing and roller assembly drawings for elevations, frame dimensions and slope of the kiln. 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 C L to suit designed slope of equipment. E - Elevation = C plus rise for D. F - Elevation = C minus drop for D.

Carefully check and record elevation at top of plug. F = Required elevation at CL 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. SM

KILN OVERHEAD 002.CDR

Maintenance S eminar

Kiln Support Frame Adjustment and Tests NOTE: Frames must be aligned on C L’s parallel to each other. Refer to installation instructions for dimension tolerances and test procedures.

F

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

D

C

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

E

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

A - Refer to installation instructions for preparation of shims. Stacks must be tight. _ 1/16” or + _ 1.50 mm for frame. B - Elevation tolerance + C - Slope tolerance 0.002” per foot or 0.15 mm / 1000 mm. D - Straight-edge must be parallel to frame C L. E - Maximum gap 0.004” / or 0.10 mm under straightedge. F - Cross-level tolerance 0.002” or 0.05 mm per foot at bearing zones (0.15 mm / 1000 mm at bearing zones). SM

KILN OVERHEAD 003.CDR

Maintenance S eminar

Kiln Support Frame Spacing Test Points Slope Dimension (Shown on Foundation Drawing) NOTE

Erecting Test Dimension

NOTE

Support Frame Kiln Support Pier

Base Dimension

Kiln Support Pier

(Shown on Foundation Drawing)

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 CL to beam CL for each assembly (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.

SM

KILN OVERHEAD 004.CDR

Maintenance S eminar

Kiln Support Frames Spacing, CL & Parallelism Tests

ete r

C

Kiln and Frame CL Marked on Piers by Layout Engineer Diameter A

ter me a i D

C

Diameter B * Erecting test dimension

NOTE

All Beam CL’s marked at factory

Dia m

Kiln Support Frame C’s Marked on all Piers by Layout Engineer L Diameter A Diameter A

Diameter A

Kiln Support Frame

Diameter B *

NOTE

Slope Dimension (from foundation drawing) Measured and Marked on Piers by Layout Engineer

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

1/16” or

1.50 mm).

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

KILN OVERHEAD 005.CDR

Maintenance S eminar

Testing New Kiln Support Roller Installations, or Re-Aligning Older Equipment This methold applies only when roller surface is cylindrical. Or use slope block on shafts.

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

Slope gauge V-bar with 12”, graduated vial, machinist level.

The inclinometer is also an accurate method.

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

Kiln may be on slow rotation if plumb bob is suspended in oil.

Plumb bobs in oil

B

C

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

Adjust shims as needed for final true-up of frame. (Slope & transverse-level tolerance @0.002” per foot or 0.15 mm / 1000 mm). Fill anchor bolt sleeves with high strength grout.

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

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

KILN OVERHEAD 006.CDR

Maintenance S eminar

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.

D AR NT U J LE AD ROL LY OF SEMB AS

I NWSTME R

B

B D AR NT JU LE AD ROL LY OF SEMB AS

I NWSTME R

A E D C

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

KILN OVERHEAD 007.CDR

Maintenance S eminar

Handling Kiln Tires for Installation on Pads with Slide Bar Arrangement A

A

C

B

B

A - Longer timbers for clean and soft rolling surface.

A - Timbers in place between ground and tire.

B - Belt wrapped around tire and tied with wire.

B - Rubber belting for protection of tire surfaces. Pads

B

A

C

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

“Plumb” position of tire after pick-up. A

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

B

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

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.

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

KILN OVERHEAD 008.CDR

Maintenance S eminar

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.

SM

KILN OVERHEAD 010.CDR

Maintenance S eminar

Crane Hitching for Kiln Shell Sections Hitch Angles and Stress on Lines Diameter 1000 lbs. 1 Part line

Splice kinks shell

2000 lbs. Diameter 2 parts of line

Kiln Shell

60°

. lbs

115 5

Kiln Shell

5 115

lbs .

Weakened

60° 2000 lbs. “Choker” no good for handling kiln shells.

1000 lbs.

Go with “Cradle” for Handling Kiln Shells

Diameter

1 s. lb 90° 415 15 l 14 45° 45° bs. 2000 lbs. Diameter

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

KILN OVERHEAD 009.CDR

Maintenance S eminar

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

al din u t i ng Lo ld We

l ina d u t ngi Lo ld We

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.

SM

KILN OVERHEAD 011.CDR

Maintenance S eminar

Alignment Fittings

Adjusting lug

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

SM

KILN OVERHEAD 012.CDR

Maintenance S eminar

Batter Board Locations

Feed End Field Joints Gauge Blocks

Batter Board with Center Hole and Card

SM

KILN OVERHEAD 013.CDR

Maintenance S eminar

Checking Alignment

Feed End

Field Joints Gauge Blocks Discharge End

Transit Replacing Batter Board

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.

SM

KILN OVERHEAD 014.CDR

Maintenance S eminar

Kiln Shell Alignment Test Batter Boards

Steel Spider (1 of Several Types) Wood Wedges

2” or 50 mm Diameter Hole Drilled at CL’s

2” X 6” Board 1/4” X 4” X 4” Steel Plates

(2) 1/4” Diameter Bolts at Each Plate

2” or 50 mm Diameter Hole Drilled at CL’s

2” X 6” Board SM

KILN OVERHEAD 015.CDR

Maintenance S eminar

Kiln Alignment Target and Layout Trammel

Sharp pencil in trammel clamp. “Starrett” No. 59 or similar.

A

3/4” X 1 1/2” trammel beam (wood)

Cut beam to form pointed end.

New kilns onlyIn tire sections - use steps in machined reference plates as guide point for trammel layout on targets.

B

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. SM

KILN OVERHEAD 016.CDR

Maintenance S eminar

Locating the Center of the Shell First set of quarter points identified by “A”s Second set of quarter A1 points identified by “B”s B4

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

45° offset

B1 Card on batter board

A4

A2 Details on card:

Shell

Center points B3

B2

Selected center

A3

Center by second set of quarter points

Center by first set of quarter points

SM

KILN OVERHEAD 017.CDR

Maintenance S eminar

Kiln Shell Section Alignment Tests (Alternate Arrangement) 1

Pier 1

2

Span “C”

Span “B”

Span “A” 3

Pier 2

4

5

6

7 8

Pier 3

9

10

11

Pier 4

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. Usually 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. 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. SM

KILN OVERHEAD 018.CDR

Maintenance S eminar

Kiln Shell Field Joint Bracing and Tack Welding Weld remaining end of strongback after kiln shell alignment is acceptable.

Edges of adjacent shell sections Prewelded end

Tighten all nuts in push/pull bolt arrangements.

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

KILN OVERHEAD 019.CDR

Maintenance S eminar

Riding Ring Location

Discharge end

Thrust

Change pier numbers to suit actual arrangement The dimensions indicated are specified on the foundation drawing. The tolerance on the location of each _ 1/4 inch (6.35 mm). ring is + “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. SM

KILN OVERHEAD 020.CDR

Maintenance S eminar

Temporary Support Chair for a Kiln Spring Gear Kiln gear with tangential springs

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

Kiln Shell

Chair in position to support and adjust the gear for correction of axial and radial runout. Typical gear chair ( 1 of a set ) for temporary duty. 2” X 6” (or to suit) bolt for gear radial adjustments. SM

KILN OVERHEAD 021.CDR

Maintenance S eminar

Gear Guard and Splash Band Assembly 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

A

Splash band installation notes:

C

C F

F

D

E

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: If conduit must pass through bands to reach a thermocouple, install before guard assembly work.

SM

KILN OVERHEAD 022.CDR

Maintenance S eminar

Kiln Support Roller Adjustment and Testing Riding Ring

View toward feed end Kiln moves toward feed end

Support Roller Rotation

Riding Ring In

In

View toward feed end Kiln moves toward feed end

Rotation

Low end of kiln (discharge)

In

Support Roller

Rollers move toward discharge end

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.

In Rollers move toward discharge end

Bearing end plate with thrust washer

Low end of kiln (discharge)

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

KILN OVERHEAD 023.CDR

Maintenance S eminar

Skewing Rollers

Discharge End

Lower Thrust Roller

Drive

Feed End

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.

SM

KILN OVERHEAD 024.CDR

Maintenance S eminar

Support Roller Assembly Alignment Control Dial-indicators (1 at each bearing base) are used for control of final true-up alignment work and for all skewing adjustments. Beam top

Support roller

Plumb lines

A

Kiln may be on slow rotation if plumb bob is suspended in oil *

Bearing Base

A B B High temperature metal surfaces can cause severe burns. Moving (rotating) machinery can cause hands and arms to become caught.

Plumb bobs in oil

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

Avoid personal injury. A - Scribe beam surface at edge of bearing base to establish reference points for measuring bearing movement during the roller relocation work period. B - If it is possible to work simultaneously at both bearing positions, use 2 plumb lines for measuring movement. * - This procedure is not valid if the roller is cone shaped or distorted on the rolling contact surface. SM

KILN OVERHEAD 025.CDR

Maintenance S eminar

Kiln Support Roller Bearing Bushing Lubrication

Rotation B Rotation A Roller Shaft 180° bearing bushing

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.

B A

Recessed Zone (Both Edges)

Shaft Rotation B

Shaft Rotation

A

SM

KILN OVERHEAD 026.CDR

Maintenance S eminar

Temporary Kiln Support Jacking Kiln Shell to Unload Support Rollers Shell Diameter (outside) Kiln Shell

All pieces from 1 1/4” plate

Variable

36° 72°

Saddle for Kiln/Shells Chord Length

Kiln Saddle Dimensions 72° = 5 spaces @ 0.587785 X outside diameter =

Chord Length

Rule of thumb: “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”. SM

KILN OVERHEAD 027.CDR

Maintenance S eminar

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.

Tire

Slow Rise Edge

Prepare 12 or more

On Pier Surface

Clearance

Shell Brace

Shell Saddle Arrangement SM

KILN OVERHEAD 028.CDR

Maintenance S eminar

Jacking Kiln Tire to Unload Support Rollers Tire

Clearance

Shell Brace

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.

SM

KILN OVERHEAD 029.CDR

Maintenance S eminar

Familiarization Kiln Support Roller Bearing Oil Level and Leakage Maximum oil level in the downhill housing

Maximum oil level in the uphill housing

B A Slope Line

Pier Surface Pier Work Point

Imaginary Level Line

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. SM

KILN OVERHEAD 031.CDR

Maintenance S eminar

Self Aligning Ball and Socket Type Bearing FLS “58” “Type RA” Design Bearing Support Roller With Journal Felt Seal

Oil Scraper

Oil Trough Oil Cup Heat Shield

Thrust Ring Liner

Oil Gauge

Stop Block

Spherical Liner/ Water Jacket

SM

KILN OVERHEAD 032.CDR

Maintenance S eminar

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.

Bearing end plate with thrust washer

Low end of kiln (discharge)

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

SM

KILN OVERHEAD 034.CDR

Maintenance S eminar

Kiln Support Roller Adjustment and Testing View toward feed end Riding Ring

Kiln moves toward feed end

Support Roller In Rotation

Low end of kiln (discharge) In Rollers move toward discharge end

Counterclockwise Rotation

SM

KILN OVERHEAD 035.CDR

Maintenance S eminar

Kiln Support Roller Adjustment and Testing

View toward feed end Riding Ring

Kiln moves toward feed end

In Rotation

Low end of kiln (discharge) In Support Roller

Rollers move toward discharge end

Clockwise Rotation SM

KILN OVERHEAD 036.CDR

Maintenance S eminar

Kiln Support Roller Skewing Roller Adjustment Rule of Thumb High End In In Kiln

Bearing

Bearing

Kiln Support Roller Kiln

Bearing

Support Roller Rotation

Bearing

Kiln In

In

Moving (rotating) machinery. Personal contact can cause hands and arms to become caught in pinch points. Counterclockwise Kiln Rotation SM

KILN OVERHEAD 037.CDR

Maintenance S eminar

Kiln Support Roller Skewing Roller Adjustment Rule of Thumb High End In In Kiln

Bearing

Bearing

Support Roller

Kiln

Support Roller

Bearing

Rotation

Kiln Bearing

Kiln In In Moving (rotating) machinery. Personal contact can cause hands and arms to become caught in pinch points. Clockwise Kiln Rotation SM

KILN OVERHEAD 038.CDR

Maintenance S eminar

Normal Offset Position of Thrust Rollers Rotation

Idle

Down

Correct

Down

Down 1/16” to 1/8”

Roller Centerline

Kiln Centerline

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

KILN OVERHEAD 039.CDR

Maintenance S eminar

Wrong Offset Position of Thrust Rollers Rotation

Up Idle

Wrong

Up

Up Any amount

Kiln Centerline

Roller Centerline

Counterclockwise Kiln Rotation

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. SM

KILN OVERHEAD 040.CDR

Maintenance S eminar

Plain Roller Support Assembly Oil Tray

Inspection Port Oil Seal (See Detail)

Bearing Housing Oil Bucket Wheel

Feed End

CL Roller

Thrust Washer

Detail Oil Level and Oil Fill Pipe

Bearing Roller Shaft Adjustment Plate

SM

KILN OVERHEAD 041.CDR

Maintenance S eminar

Thrust Roller Assembly Two Thrust Roller System Thrust Riding Ring Thrust Roller Oil Level & Oil Fill Pipe

Feed End

See Detail

Shell Thrust Roller

Thrust Roller Housing Shims Thrust Rod

Oil Seal

Spherical Roller Bearings

Detail SM

KILN OVERHEAD 042.CDR

Maintenance S eminar

Thrust Roller Assembly

C

C-C C

Thrust Roller Frame

SM

KILN OVERHEAD 043.CDR

Maintenance S eminar

Hydraulic Thrust Roller Assembly Shell

Fixed Uphill Stop with Brass Plate

Support Rod Boot

Thrust See Riding Thrust Roller Ring Detail Thrust Roller Thrust Roller Movement Housing

Thrust Button

Hydraulic Cylinder

“A” (Sht.

To Hydraulic Power Unit Stroke Adjuster

Thrust Housing Spherical Roller Thrust Support Rod Bearings Roller Frame Upper Thrust Drain Plug Housing Support

Lower Thrust Housing Support

Feed End

Oil Seal Detail

NOTE: Oil Pipe & Graphite Lubricator Included but Not Shown SM

KILN OVERHEAD 044.CDR

Maintenance S eminar

Hydraulic Thrust Roller Assembly Feed End

A

Cam Follower

Limit Switch Assembly D

B

A

E

F

Thrust Roller

G

+ + + + + + +

CL Kiln

Bumper Assembly

C

Thrust Riding Ring

CL

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

C L Roller Support & Thrust Riding Ring

Operation of Limit Switches

Riding Ring

A Pier 3 Hydraulic Power Unit

A-A

Pier 2 Hydraulic Cylinders

Hydraulic Thrust Orientation (Single Hydraulic Cylinder May be Used) SM

KILN OVERHEAD 045.CDR

Maintenance S eminar

Routine Checkout at Kiln Tire Sections

View at Top Position

Allowance for Shell Expansion

Shell Cold: Clearance for expansion at top of kiln Shell (pads) rest in normal position inside the tire SM

KILN OVERHEAD 046.CDR

Maintenance S eminar

Routine Checkout at Kiln Tire Sections

Expansion

Shell Overheated and Choked Inside Tire

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.

SM

KILN OVERHEAD 047.CDR

Maintenance S eminar

Field Installation of Kiln Tire Section Spider Bracing

Brace No. 1 Sag

Pre-Welded End @ 90° From Start

Brace No. 2 Now Tight

Second Weld

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. SM

KILN OVERHEAD 049.CDR

Maintenance S eminar

Routine Checkout at Kiln Tire Sections

View at Top Position

Almost zero clearance. Shell continues to migrate within the tire.

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.

SM

KILN OVERHEAD 052.CDR

Maintenance S eminar

Routine Checkout at Kiln Tire Sections

Clearance

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.

SM

KILN OVERHEAD 053.CDR

Maintenance S eminar

Field Installation of Kiln Tire Section Spider Bracing

Shell sags away from the tire Clearance 3

Spreads Horizontal Major Axis

1

2

1

4

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.

SM

KILN OVERHEAD 054.CDR

Maintenance S eminar

Field Installation of Kiln Tire Section Spider Bracing Riding ring on rollers and a 0.3% ovality (example only).

Clearance 0.775”

Shell held in round condition by internal bracing

True roundness is a goal Seldom - if ever - Reality Clearance 0.6125”

Clearance 0.6125”

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. SM

KILN OVERHEAD 055.CDR

Maintenance S eminar

Jacking a Kiln Shell to Unload Support Rollers Clearance

Tire

Shell Brace

Saddle Under the Kiln Shell 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. SM

KILN OVERHEAD 056.CDR

Maintenance S eminar

Jacking a Kiln Shell to Unload Support Rollers

Saddle under the kiln shell

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

SM

KILN OVERHEAD 057.CDR

Maintenance S eminar

Jacking a Kiln Shell to Unload Support Rollers

NOTE:

Saddle under the kiln shell

Excessive pad to tire clearance is a handicap for jacking up kiln shell.

NOTE: The tire will not rise until top area clearance is eliminated by the rising shell.

SM

KILN OVERHEAD 058.CDR

Maintenance S eminar

Jacking Kiln Shell to Unload Support Rollers Clearance Tire

Slow Rise Edge

Prepare 12 or more

On Pier Surface

Shell Brace

Shell Saddle Arrangement

SM

KILN OVERHEAD 059.CDR

Maintenance S eminar

Typical Procedure for Removing Roller Assemblies from the Support Frame

1

3

2

3

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. SM

KILN OVERHEAD 060.CDR

Maintenance S eminar

Typical Procedure for Removing Fuller/Traylor Roller Assemblies from the Support Frame

Slope Line

Pier Top Pier Work Point

Level Line Reference

“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. SM

KILN OVERHEAD 061.CDR

Maintenance S eminar

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. SM

KILN OVERHEAD 062.CDR

Maintenance S eminar

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. SM

KILN OVERHEAD 065.CDR

Maintenance S eminar

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. FEED E

ND

Move bearing housing: OUT / OFF IN / ON

Uphill ( or feed end ) bearing housing Removing and/or resetting a bearing housing at ground level

SM

KILN OVERHEAD 067.CDR

Maintenance S eminar

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.

SM

KILN OVERHEAD 069.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections Tire

Level

Tire CL

Slope

(Clearance Exaggerated for Clarity)

Shell CL

True Kiln Axis

Thrust Roll

Thrust Roll Roller at Far Side

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.

SM

KILN OVERHEAD 070.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections 2

Level

1

1

Slope

3

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. SM

KILN OVERHEAD 071.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections 3

4

5 Level Slope

2

Preparation:

1

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. SM

KILN OVERHEAD 072.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections 2

Level Slope

1 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. SM

KILN OVERHEAD 073.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections

Level Slope

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. SM

KILN OVERHEAD 074.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections STRAIGHTEDGE

Level Slope

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. SM

KILN OVERHEAD 075.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections New Pad Plate Rolled Filler Plate STRAIGHTEDGE

Level Slope

Stacked Shim Plates 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. SM

KILN OVERHEAD 076.CDR

Maintenance S eminar

Lubricate

New Shell Pads Level Slope

Lubricate

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.

SM

KILN OVERHEAD 077.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections

New Shell Pads

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.

New Pads for Choked-Down Tire Sections Welded End Loose End Welded End Loose End

CL Tire

Do Not Weld Gusset to Pad 3/8 to 3/4 Pad

Loose End

Hold Down Gusset Spacer Pad (Loose End)

Pad

3/8 to 3/4 Pad

TYP

Pad

Welded End Loose End Welded End

A

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

3/8 to 3/4 TYP

Dia. Tire 1

1/16”

A A-A Alternate tire retainer arrangement. Semi-floating pad design. SM

KILN OVERHEAD 080.CDR

Maintenance S eminar

New Pads for Choked-Down Tire Sections 5 6

7

Tire 1 - Be sure that rollers are carrying the load of tire and shell. 2 - Remove pedestals, jacks and saddle. 3 - Reset thrust roller assembly. 8

Slope 8

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.

Thrust Roller

Tire

7 - Remove temporary tire-locking gusset plates. Thrust Roller

8 - Remove internal spider bracing. Grind down weld scraps. 3

Roller 2

4 1

SM

KILN OVERHEAD 081.CDR

Maintenance S eminar

5”

TYP. 3 Sides Fillet Weld 2Size Pad Width

Floating Pad Design 8”

R 3/4 Anti-Rotation Plate 1” TYP

9”

Must Make Contact on 1 Side

1/4” TYP

R 3/4

A

R 3/4

TYP. 3 Sides 5/8

Pad Guide Bar 1” Thick

1/8” Gap

A

Axial Pad Retainer 1” Thick Wear Ring Retainer

1” Chamfer

Min. 5”

8” Min.

Pad Length

Riding Ring

8” Min.

Wear Ring

Pad Thickness

Wear Ring 1”

Height of Anti-Rotation Plate

Pad Taper

Shell Thickness TYP

Pad Thickness

Heavy Shell Plate

1/16” or 2 mm Downhill Side Only

Fillet Weld Size A-A

In this arrangement pads are not welded to the shell at all. The shop installed cost for this arrangement is high, but the future field replacement of pads is simpler and less expensive. The continuous wear rings installed between the riding ring end faces and wear ring retainers reduces bearing pressure and gouging in the riding ring end faces and also increase wear life of the components. It is very easy to reduce tire creep: Install shims between shell and pads and tack weld new shims to pads. SM

KILN OVERHEAD 082.CDR

Maintenance S eminar

Cold Kiln

Molyk ote

Lube

Using Wedges for Longitudinal Shifting of Tire

Weld Wedge to Tire Weld Wedge to Pad Move Tire

Mark on Tire

Rotation & Creep

Creep (Mark on Pad)

Opposed Wedges. Smooth slide surfaces per machine shop procedures.

SM

KILN OVERHEAD 083.CDR

Maintenance S eminar

Using Chains for Longitudinal Tire Movement 24” Ignore triangle in chain hook-up

Chain

2” 3/8”

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. Tire 24” Straight Line

CL

No push or pull mechanical assistance. No wedges.

Roller C L

No “assist” from roller thrust reaction on tire.

SM

KILN OVERHEAD 084.CDR

Maintenance S eminar

Using Chains for Longitudinal Tire Movement Clearance tire to pad at TDC = 3/8” . 3/8” . .5  = 0.2387324” Diameter X  = 0.750” creep/rev. Must shift tire 2”

Start 24” Straight Line Tire Shell Creep/Rev. 3/4 (Constant)

Draw 24” Constant

Tire

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

Total Creep

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

New “X” Dimension 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

Draw 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

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

KILN OVERHEAD 085.CDR

Maintenance S eminar

Measurement of Shell Migration to Determine Shell Pad to Tire Diameter

Shell Advances Inside Tire Measure Amount of Creep As Seen From Under the Kiln Shell

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.

SM

KILN OVERHEAD 086.CDR

Maintenance S eminar

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.

A

Start

B

End

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.

SM

KILN OVERHEAD 087.CDR

Maintenance S eminar

Spring-Loaded Pencil Holder for Pad/Tire Clearance and Creep Tracings Spring 5/16” Diameter X 1 1/2” (Retained)

Retainer Block & Post

1 1/2”

6”

Pencil Holder (Tubing)

Standard Pencil

Drill & Tap 10-24 X 1” Deep 10-24 Slotted Capscrew X 3/4 Long Permanent Horseshoe Magnet (10 Lb. Pull)

Description Magnet Ret/G Block Ret/G Post Cap Screw Holder Spring Pencil

Material 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)

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.

SM

KILN OVERHEAD 088.CDR

Maintenance S eminar

Tracing-Paper Surface for Pad/Tire Clearance and Creep Tracings

2 1/2”

1” TYP. 8 1/2” Drill & Countersink To Suit 10-24 Csk Screw (TYP) 2 places Bolt & Nut to Magnet

1/8” Tempered Hardboard

Permanent Horseshoe Magnet 10 Lb. Pull (General #351-6) Two Spring Clips (Small) Cut strips of manila file folder sheets to fit on hardboard surface. Hold strip in place with spring clips. Tire clearance & creep tracing board SM

KILN OVERHEAD 089.CDR

Maintenance S eminar

Shelltest Measuring Unit “Holderbank” System Distorted Cross-Section

Principle of Distortion Measurement d

b

d

a

h B

A

L=

1m

D

Shelltest Diagram

==

C

= 2 (a - b) = 4 .d 2 . 3

h

Ovality:

15. h

E G

B

15

h

Recorder System “Holderbank”

h

F

H SM

KILN OVERHEAD 090.CDR

Maintenance S eminar

Ovality A

B

C

D 1

2 1, 2, 3, Shell Lines A, B, C, D Measuring Planes

Diagram of One Measuring Plane

3 1

2

3 1

12

3

2

3

SM

KILN OVERHEAD 091.CDR

Maintenance S eminar

Ovality Limits as Function of Kiln Diameter

% 0.8

% Ovality

0.6

0.4

0.2

0 3

4

5

6

m

Kiln Diameter

SM

KILN OVERHEAD 092.CDR

Maintenance S eminar

View at Top Position

Allowance for Shell Expansion

SM

KILN OVERHEAD 093.CDR

Maintenance S eminar

Shell Advances Inside Tire Measure Amount of Creep As Seen From Under the Kiln Shell

A Start

End B

SM

KILN OVERHEAD 094.CDR

Maintenance S eminar

Permanent Shell Deformation

Expansion

Shell Overheated and Choked Inside Tire

Clearance

SM

KILN OVERHEAD 095.CDR

Maintenance S eminar

Difference in Diameter (

)

Tire

†

Gap at Top (G ) D

= G† : Distorted Shell Crush Zones for Brick Lining Tire

Note

CL

CL Shell

Note

Note: Deflection also occurs at contact points where the tire rides on support rollers. SM

KILN OVERHEAD 096.CDR

Maintenance S eminar

All Details Must be Checked Prior to Planning a Schedule for True-Up Grinding No Axial Runout (Wobble) Through 360° Rotation Radius Radius

Hot Position on Roller Tire CL

90° 90°

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

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

Roller CL

180° Liner

As seen from Frame Long’l CL

Matched Liners Frame Slope True Planned Slope

180° Liner

Level Line

SM

KILN OVERHEAD 097.CDR

Maintenance S eminar

Tire Ovality - Removal of Metal May Not be Feasible

Rough Inside

Minor Axis

Rough Outside

M ea To sur Fi e C nd irc Di u m am fe ete ren ce r

Major Axis

Is Bore Worn and Grooved?

t Measure Thickness (t)

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

SM

KILN OVERHEAD 098.CDR

Maintenance S eminar

Ovality When Tire is Too Thin (and has Bad Inside and Outside Surfaces) Excess Clearance

Shell

Sag When a tire is too thin the combination of sag, crimping and excessive clearance can account for shell ovality approaching 0.9%. Check out shell ovality factors before arranging for tire true-up. (May need replacement parts). Crimping

Rollers

SM

KILN OVERHEAD 099.CDR

Maintenance S eminar

Longitudinal Fractures at Shell Pads Excess Clearance

Thin Tire

Shell Sag

Crimping

Rollers

Thin tires and excess clearance contribute to shell ovality and fracture at pad welds or in shell plate at toes of welds. SM

KILN OVERHEAD 100.CDR

Maintenance S eminar

Longitudinal Fractures at Shell Pads Load Concentration

Narrow Tire

Welds Break, Blocks Fall Off Welds and/or Pads Break and Fall Out & Off Longitudinal Fracture Lines Form in Shell

Tire section “CHOKE” deformation

SM

KILN OVERHEAD 101.CDR

Maintenance S eminar

Longitudinal Fractures at Shell Pads Excessive Clearance Sag Bending Zones Crush Points for Bricks Fatigue Points for Shell

Pad

Shell

Welds

Flex

Laminated Zones Resist Bending

Pad

Shell

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

KILN OVERHEAD 102.CDR

Maintenance S eminar

Longitudinal Fractures at Shell Pads Tire

Fillet Weld

Fillet Weld

Pad Shell

Original longitudinal welds must be removed for repair of fractures. SM

KILN OVERHEAD 103.CDR

Maintenance S eminar

Longitudinal Fractures at Shell Pads

Refractory

Fracture

0.7 t

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

Finish internal repair welds first

SM

KILN OVERHEAD 104.CDR

Maintenance S eminar

Longitudinal Fractures at Shell Pads Tire: Remove One Set of Retainers

Move Tire Away

Move Tire Back

Trace to Ends

Shell Outside Surface

Gouge

Outside

Finish Weld

Inside Finish External Repair Welds Last SM

KILN OVERHEAD 105.CDR

Maintenance S eminar

Hollow Tires & Rollers

Ta

w Ho llo

Ho llo

w

Bore Zone

Old Style Hollow Tire

Tr Real Thickness Varies Apparent Thickness Apparent Thickness Real Thickness Varies

Ho llo w

Tr Ho llo w

Ta

Old Style Hollow Roller

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”. SM

KILN OVERHEAD 106.CDR

Maintenance S eminar

Cold Flow Ridges on Tires and Rollers Tooling is not complete without the capability for removing ridges and cutting edge radius or chamfer.

Kiln moves inside the tire with thermal changes in the shell

Kiln shell expansion & contraction

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

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

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 a nd true axis of tire.

SM

KILN OVERHEAD 107.CDR

Maintenance S eminar

Warped Kiln Shell and Tire Runout Convex Up

1

A

B

C

Hot Shell Slope Line

Concave Up

2

A

B Hot Shell

Heavy Load

C

Slope Line

SM

KILN OVERHEAD 108.CDR

Maintenance S eminar

Tire Wobble When Kiln Shell is Warped

Gap 0.0275”

Wobble

Neutral

Wobble 3/16”

3/16”

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. This condition is not a valid reason for grinding a tire for improved contact across roller faces. Find and eliminate reason for wobble. Do not arrange for cutting or grinding when axial wobble exceeds 0.125”. SM

KILN OVERHEAD 109.CDR

Maintenance S eminar

Formation of Concave/Convex Surfaces

Wobble

Neutral

Wobble

Gap

Gap 3/16”

3/16”

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. SM

KILN OVERHEAD 110.CDR

Maintenance S eminar

Aftereffect of Grinding a Tire with Axial Runout

A A

Parallelogram Tire Profile After Grinding Runout

True Axis

B B

Start Rotation

CL

B B

Runout

B A True Axis

A A

Runout

True Axis

A B

180° From Start

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.

SM

KILN OVERHEAD 111.CDR

Maintenance S eminar

Aftereffects of Improper Roller Skewing Tire & rollers become cone shaped. Ridges form at edges. Surfaces become deeply spalled.

Roller

Tire

As Seen From Below Tire

Long Term Toe-In Condition

Roller

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.

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.

SM

KILN OVERHEAD 112.CDR

Maintenance S eminar

Grinding Prior to Kiln Shell Replacement Work

A

B

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. SM

KILN OVERHEAD 113.CDR

Maintenance S eminar

“Squareness” Control for Rollers

Unacceptable

Cone shaped roller. Surface not parallel to CL. Acceptable

Surface parallel to CL.

SM

KILN OVERHEAD 114.CDR

Maintenance S eminar

“Squareness” Control for Tires Acceptable

90°

Unacceptable

Tire CL

Surface is parallel to bore

Tire

CL Neutral

Surface is not parallel to bore

Tire

Control

Control

Control

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

CL Tire Neutral CL

SM

KILN OVERHEAD 115.CDR

Maintenance S eminar

Kiln Shell Damage and Temporary Repair Fillet Weld

Double “V” Butt Weld

Void Zones Fillet Weld

Shell Repair Section

Good Repair

Shell Wrapper Not Recommended Temporary First-Aid only Longitudinal Butt Weld

Bad Repair

Repair of badly damaged kiln shell

SM

KILN OVERHEAD 116.CDR

Maintenance S eminar

Kiln Shell Damage and Temporary Repair Reinforcement Band (Full Circle) Fillet Welds Kiln Shell

Reinforcing Band

t por p u S

p Sup ort

Kiln Shell Supp ort

t por p u S

Typical Field Cut Longitudinal fractures at ring segments SM

KILN OVERHEAD 117.CDR

Maintenance S eminar

Tire and Pad Lubricant for Rotary Kilns and Dryers

Product Description SM

KILN OVERHEAD 118.CDR

Maintenance S eminar

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

Longitudinal Weld Shrinkage

Circumferential Weld Shrinkage

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

Patch Plate Insert

Longitudinal Weld Shrinkage

Kiln Shell

Circumferential Weld Shrinkage

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. SM

KILN OVERHEAD 123.CDR

Maintenance S eminar

Kiln Shell Patch Plates are Nothing More than Temporary Band-Aids Kiln Shell

Patch Plate Insert Circumferential Weld Shrinkage

Longitudinal Weld Shrinkage

Transverse weld shrinkage at patch plate double-vee butt welds. Radius instead of 90° corners minimizes, but does not eliminate stress concentration points.

Longitudinal Weld Shrinkage

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

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.

t

Transverse Shrinkage (in.)

Circumferential Weld Shrinkage

0.15

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.

60° Single V

0.10 60° Double V 0.05 0 1/4

1/2 3/4 1 1 1/4 t = Plate Thickness (in.)

1 1/2

SM

KILN OVERHEAD 124.CDR

Maintenance S eminar

Rotary Kiln Installation and Maintenance Repair

A

B

Equations For Calculating ShrinkageTransverse Weld Shrinkage (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. SM

KILN OVERHEAD 125.CDR

Maintenance S eminar

Arrangement for Removing Bearing Housing End Plate Kiln support roller bearing base.

Housing end plate with thrust washer and oil level pipe.

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

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. SM

KILN OVERHEAD 126.CDR

Maintenance S eminar

Measurement of Shell Migration to Determine Shell Pad to Tire Diameter

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.

SM

KILN OVERHEAD 127.CDR

Maintenance S eminar

FLS Bearing 74, Type RB Feed End Stop Block

20 X 20 X 200 mm

5-6 mm Clearance

Zero Clearance

Discharge End SM

KILN OVERHEAD 201.CDR

Maintenance S eminar

Desperation

Chamfer @ 1/8” X 45°

Downhill side of roller

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

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

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

KILN OVERHEAD 202.CDR

Maintenance S eminar

450 mm Oil-Lubricated Supporting Roller Bearing (Old Design)

SM

KILN OVERHEAD 203.CDR

Maintenance S eminar

FLS Bearing Clearances in mm Kiln erection Journal d

dt 0 850 -0,1 0 710 -0,1 0 630 -0,1 0 560 -0,1 0 500 -0,1 0 450 -0,1 0 400 -0,1 0 360 -0,6 0 320 -0,1 0 280 -0,1 0 240 -0,1

850 710 630 560 500 450 400 360 320 280 240

X) expansion at KILN OVERHEAD 204.CDR

Supporting rollers / bearings: Various tolerances in mm Mean Mean Clearance Linear clearance clearance at side dp - dt dp - dt minimum dp hot cold maximum x +1,5 850 +1,6 +1,2 710 +1,3 +1,0 630 +1,1 +0,9 560 +1,0 +0,8 500 +0,9 +0,7 450 +0,8 +0,6 400 +0,7 +0,5 360 +0,6 +0,4 320 +0,5 +0,4 280 +0,5 +0,3 240 +0,4  t = 35° :  d

Mean value (dp X dt X 1000) d



cold

 hot

1,88

1,46

1,83

1,41

1,75

1,33

1,79

1,36

1,80

1,38

1,78

1,35

1,75

1,32

1,67

1,25

1,56

1,16

1,78

1,35

1,67

1,25

 d =0,36

0,75 0,85 0,6 0,7 0,5 0,6 0,45 0,55 0,4 0,5 0,35 0,45 0,3 0,4 0,25 0,35 0,2 0,3 0,2 0,3 0,15 0,25

1,6 1,3 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,5 0,4

35 X 0,0012 X 1000 100

1,24 0,30 1,00 0,26 0,84 0,24 0,76 0,21 0,69 0,19 0,61 0,17 0,53 0,15 0,45 0,13 0,37 0,12 0,38 0,10 0,30 0,42 mm / m

SM

Maintenance S eminar

FLS Bearing Fig. 1

Fig. 4 Fig. 2

Fig. 3 T

3 0 mm

5-8 mm 0 mm

SM

KILN OVERHEAD 205.CDR

Maintenance S eminar

Uneven Load Distribution

Parallel

Skewed Only

Skewed and Change of Slope

Hertz Pressures at Supporting Rollers

SM

KILN OVERHEAD 206.CDR

Maintenance S eminar

Uneven Load Distribution

M

a FH FV 30°

RL

M

FV X a

RL

FV / 3 + FH

RR

FV / 3 - FH

RR

SM

KILN OVERHEAD 207.CDR

Maintenance S eminar

Uneven Load Distribution

P L2

L1 L

R1

R2

R1 = (L2/L) P

R2 = (L1/L) P

Load is off Center SM

KILN OVERHEAD 208.CDR

Maintenance S eminar

FLS Conversion Kit Instructions for 1930 Type Bearing Installation of Klozure Seal “A”

1 - Insert Klozure to lower half of seal retainer ring so that the ends of Klozure Seal extend beyond the end of the seal retainer ring with equal distance (see assembly sketch).

Bearing Cap

Drill in bearing cap for 3 5/16” X 1-3/4” countersunk hd. screws with lockwashers for holding top half of seal ring to bearing cap. Locate holes from seal ring.

See Detail “C”

2 - Attach clamping plate loose to retainer seal ring. 3 - Install lower half retainer ring assembly to lower bearing base by sliding the seal retainer ring, starting on the side where bearing socket is below end of bearing base (ref. assembly sketch) until retainer ring is flush with bearing base. 4 - Tighten clamping plate bolts securely.

See Detail “D”

5 - Using upper half retainer ring as template, drill 3 clearance holes for 5/16” bolts through bearing cap.

Bearing Base

6 - Assembly upper half retainer ring to bearing cap. (3 pieces 5/16” x 1-3/4” Long Screw).

A-A

7 - Gradually lower the bearing cap, insert the Klozure Seal in the groove, so that the seal ends close at the top center. B-B

8 - Tighten all bearing bolts securely.

Seal Retainer (upper half) Patt. Number RK 5790A

Seal Retainer (lower half)

Garlock Klozure Split Seal Detail “C” Scale: Full Size

Detail “D”

Bearing cap

Ends of Klozure Seal while being snaked thru bearing base

3/32 thick O.H. Steel clamping plate to be fitted in field

1/4 length Klozure Seal Klozure Seal in position

Bearing socket Clamping plate in position

Clamping plate in position

Klozure Seal assembly

SM

KILN OVERHEAD 209.CDR

Maintenance S eminar

Tracing Clearance Between Kiln Tires and Spacer Pads (Includes Shell Ovality) Kiln Shell with Spacer Pads

Kiln Tire (Riding Ring) “Y” Rotation

“X” C

B

A - The tracing surface and marker may be installed anywhere in the indicated zone. Actual position is selected for convenient and rapid set-up during a brief pause on rotation. B - Although actual conditions are variable, there is no differential shell/tire movement during rotation from position “Y” to position “X”. C - As the shell enters and passes through the configuration shown between positions “X” and “Y”, motion is recorded on the tracing surface. Shell “creep” and pad to tire clearance appear as a wave pattern on the chart.

Roller CL s Sketch (below) shows magnet base with a spring-loaded tracer arrangement mounted on the surface of a spacerpad. Tracing surface is mounted on the flat side-face of the tire (or riding ring). A Since the kiln shell will advance inside the tire during rotation the marker must be placed on the tracing surface at the end of the sheet trailing the direction of rotation. The sketch shows an approximate pattern after four revolutions of the kiln.

Start

Finish High temperature metal surfaces can cause severe burns. Moving (rotating) machinery can cause hands and arms to become caught. Avoid personal contact. SM

KILN OVERHEAD 211.CDR

Maintenance S eminar

450 mm Oil-Lubricated Supporting Roller Bearing

SM

KILN OVERHEAD 214.CDR

Maintenance S eminar

Uphill and Downhill Thrust Roller

1”

1/4”

1/4”

SM

KILN OVERHEAD 224.CDR

Maintenance S eminar

Radial Runout - Polar Diagram Station

Reading

Difference

12

1

215

9

2

213

7

3

211

5

4

211

5

5

209

3

6

206

0

7

207

1

8

209

3

9

208

2

10

212

6

11

214

8

12

216 10

1

215

11

1

10

9

2

3 Approximate Shell Center

8

4

5

7

1

6 Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset also 3 and 9 : 5 and 2 = 1.5 mm offset Low reading - close to fixed reference circle High reading - away from fixed reference circle

KILN OVERHEAD 225.CDR

Not bad - very little shell deformation and a little out of center.

SM

Maintenance S eminar

Radial Runout - Polar Diagram

Station

Reading

Difference

12

1

417

6

2

432 21

3

427 16

4

418

7

5

420

9

6

425 14

7

435 24

8

438 27

9

427 16

10

421 10

11

420

9

12

411

0

1

416

5

1

11

6 mm

21 mm

10

2

16 mm

3

9

7 mm

8

4

7 This is very bad.

5 6

Shell deformation as well as out of center (eccentricity). SM

KILN OVERHEAD 226.CDR

Maintenance S eminar

Radial Runout - Polar Diagram Difference

Reading

Station

12 1

11

10

1

2

2 3 4 5

3

9

6 7 8 9

8

4

10 11 12 1

7

5 6

SM

KILN OVERHEAD 227.CDR

Maintenance S eminar

Kiln Data Sheet Kiln Size: Diameter(s) Process Product Density: Feed Range: Rotation Speed (RPH):

Product TPD,

Lb/Ft3 Kiln Slope Maximum,

Distributed Loads, from Discharge End ( Ft. To Ft ): Refractory Thickness (In’s) Ft. Ft. Ft. Ft. Ft. Typical Coating build-up on Refractory Lining Ft. Ft. Ft. Item Quantity Ft. Tumbler* Ft. Lifter Ft. Lifter Item Quantity Ft. Chain Ft. Chain Ft. Chain Ft. Chain

Length Production Feed Density % or Normal,

TPD 3 Lb/Ft In/Foot, Minimum

Lb/Ft

3

Thick

Lb/Ft3

Size

Length

From (Ft) to (Ft)

* “Tumblers” formed by refractory lay-up. If a “Trefoil” section is in place, or being considered, give dimensions location and Lb/Ft3. Concentrated Loads: Girth Gear Weight (Kips) Refractory Dam @ High (In’s) Tube Cooler Location No. of Tube Coolers Feed End Seal Weight (Kips) Discharge End Cowl & Air Seal Weight (Kips) Discharge End Castings: Quantity

Distance from discharge end

, Diameter (In’s)

, Length

Pounds Each

SM

KILN OVERHEAD 230.CDR

Maintenance S eminar

Laser Kiln Survey Layout of Offset Line

VII II

I .6 .5 .4 .3 .2 .1

Laser X

H

X2

X1

SM

KILN OVERHEAD 231.CDR

Maintenance S eminar

Laser Kiln Survey Step 1 Tire

Offset Line Measuring Points

Step 2 Tire

Slave

At Laser

SM

KILN OVERHEAD 232.CDR

Maintenance S eminar

Laser Kiln Survey Step 3 Common Reference Target Ar1

Ar2

Laser

Step 4

Pmax P1

P2 Laser

SM

KILN OVERHEAD 233.CDR

Maintenance S eminar

PMAX

Laserstråle

C

R 90° ZV

VR

ZA ZH

ZV

H

ZH

VV VH

LR HR

R

Y

X2 OSV.

X1 Y1

SM

Maintenance S eminar

Enter Kiln Length and Dimensions Between Tire Centerlines

Zone Shell I Dia. OHDE Span 1 Span 2 Span 3 Span 4 Span 5 OHFE Transition Cone Diameters &

Basic Plate Span 2

Dim = L4-(3B+4A) Basic Plate Span 3

Linear Feet

Length

L7

L6

5A 5B

Dim = L5-(4B+5A) Basic Plate Span 4

Thickness

5S OHFE

6A 6B Dim = L7-6B

Dim = L6-(5B+6A) Basic Plate Span 5

Feed End

Basic Plate Span 1

Dim = L3-(2B+3A)

4S OHFE

Tire 6

Feed End

Dim = L2-(1B+2A)

3S OHFE

4A 4B

Feed End

2S OHFE

3A 3B

Tire 5 L5

L4

Feed End

2A 2B

Dim = L1-1A Disch End Overhang OHDE

Tire 4

L3

Feed End

Discharge End

1A 1B

Tire 3

Feed End

L2

Feed End

Tire 2

Feed End

L1

Feed End

Tire 1

Feed End

Discharge End

6 - Support Kiln 5 - Support Kiln 4 - Support Kiln 3 - Support Kiln 2 - Support Kiln

Feed End Overhang 6S OHFE

Cone(s) (Yes or No)

Thickness

SM

KILN OVERHEAD 235.CDR

Maintenance S eminar

Kiln Stress Computer Program For a Fuller Company computer data analysis of stress loading at: - Kiln Shell - Roller Assemblies - Riding Ring (Tire) Ovality Data to be obtained from plant-operator personnel, installation drawings, when available, and actual measurements by plant and Fuller Company engineers. CAUTION: Drawings and records are often lost with turnover of plant personnel. Independent job shops and contractors often supply and install replacement material and/or retrofit items which are sub-standard or which change stress and loading factors. With or without original reference information, actual lengths, widths circumferences and thicknesses must be verified per accurate measurement procedures. Use an appropriately calibrated ultrasonic thickness gauge for measurement of shell plate thickness, especially at zones affected by erosion caused by abrasive or chemical reactions(s). Kiln at (Company): Plant Location: Plant Telephone: ( Fax Number: ( ) Data From:

)

Title / Department:

Telephone Extension:

Fuller Company Engineer(s): Checkout Date(s): SM

KILN OVERHEAD 236.CDR

Maintenance S eminar

Heavy

Discharge End 2nd Int.

1st Int.

Side “A” Side “A”

1/2 H 1/2 H

Material Flow 1st Int.

2nd Int.

Side “B” Side “B”

“Heavy” = Heavy shell plate under a riding ring (Tire)

SM

KILN OVERHEAD 237.CDR

Maintenance S eminar

Inch Per Foot

% or

Kiln Slope @

Level Line

Heavy

Discharge End 2nd Int.

1st Int.

1/2 H 1/2 H

Side “A” Side “A” Kiln Shell Dimensions Pier Locations from Discharge End (Thickness X Linear Feet) 1st 2nd 3rd 4th 5th 6th Heavy Plate 1/2 H 1st Int 2nd Int 1st Int + Side “A” or Side “B” Tire Pads (Quantity) Pad Length & Thickness Tire Outside Diameter Tire Width & Thickness Roller Diameter & Width Bearing Diameter & Length

Material Flow 1st Int.

2nd Int.

Side “B” Side “B”

“Heavy” = Heavy shell plate under a riding ring (tire) 1/2 H = CL of heavy plate to either of its ends 1st Int = First intermediate plate 2nd Int = Second intermediate plate 1st Int (+) = First intermediate plate extended for gear Side “A” or “B” = 1/2H + 1st Int + 2nd Int plates

SM

KILN OVERHEAD 238.CDR

Maintenance S eminar

Radial Runout - Polar Diagram for Kiln Shell Station

Reading

Difference

12

1

215

9

2

213

7

3

211

5

4

211

5

5

209

3

6

206

0

7

207

1

8

209

3

9

208

2

10

212

6

11

214

8

12

216 10

1

215

11

1

10

9

2

3 Approximate Shell Center

8

4

5

7

9

6 Stations 6 and 12 : 0 and 10 mm = 5.0 mm offset also 3 and 9 : 5 and 2 = 1.5 mm offset Low reading - close to fixed reference circle High reading - away from fixed reference circle

KILN OVERHEAD 269.CDR

Not bad - very little shell deformation and a little out of center.

SM

Maintenance S eminar