Lead Wire Test

Lead wire Ø 2 ~ 3 mm Keep lead wire at right angle to direction of rotation Information drawn from test i. Sur Surface ace pres pressu surre betw betwee een n tyre tyre & kil kiln rol roller ler. ii. ii. Adu Adust stme ment nt or cutti cutting ng of kiln kiln roll roller er in rela relati tion on to kiln kiln a!is a!is.. iii. iii. "osi "ositi tion on #lat #later eral ally ly$$ of kiln kiln roll roller ers. s. i%. i%. "rop "ropor orti tion onal al loud loud on indi indi%i %idu dual al supp suppor orts ts.. %. ccentricity if any in the kiln tube.

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Lead wire test also shows whether to carry out kiln alignment test with with le%elling instrument.

PROCEDURE

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'ark ( a!is A) * & + on kiln shell , -/0 apart. Se1uence of a!is should be in relation to the direction of rotation of kiln %iewing from burning platform. At each support si! #/2$ lead wire test are made i.e ( at each roller i.e one at each a!is. 3he si! lead wire specimen should be marked as shown in fig. -. 3he length of lead wire specimen should be e1ual to width of kiln roller 4// mm

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D

IAL

F

A

  r   e    l    l   o   r    d   n   a    h    t    f   e    L

IBL B ICL C

IAR

A   n    l    i    k    f   o    t B   e    l    t   u    O

t1

t2

t4

t6

t5 IBR

ICRR IC

C

Width of roller 

-

t7

t8

t9

t10

  e   s    i   w    k   c   o    l   c    &    t   e    l    t   u   o   m   o   r    f

  g   n    i   w   e    i   v   n    l    i    k   r    f   e    l   o    l   o   n   r   o    i    d   n   t   n   l   a    t   a   i   o    h   k   r    f    t   o   f    h   o    t   g    i   e   n    R   l   n   o    i    I    t   c   e   r    i    D

ANALYSIS

5igure. - shows 2 lead wire specimen taken as indicated by marking) at support 6o.-. 'easurement of rolled lead wire is done as follow7 8 9n graph : white sheet) mark off width of tyre. ;i%ide it into e1ual - parts & draw  parallel lines for each a!is of rollers. 3he line in the middle is marked marked centre line of tyre. At e!tremes) mark with ; & 5 for outlet & inlet sides respecti%ely. 6ow place lead wire one by one at right angles to parallel lines with ends of rolled portion o f wires e!actly o%er the two e!treme lines. In this position) lead wires are to be fi!ed & width t-) t etc to  be measured & these measurements are to be relocated in the table.  6ow take a%erage %alue of each half of the lead wire & enter in the table i.e t ; < t- 4 t 4 t( 4 t= 4 t> > t5 < t2 4 t? 4 t@ 4 t 4 t-/ > EXAMPLE Table – 1 Support No1

Bight hand roller C A+era,e Left hand roller C A+era,e

A * +

Outlet e!" #ea$ure" %&"t' t1( t2( t3( t)( t* () () (-) @) @ (>) (=) (=) () ( 2) >) >) =) =

A * +

>) 2) ?) ?) @ ) ) (/) (-) ( /) -) -) ) (

Support I a7&$

t;

A * +

t5

Sum A%erage width of lead wire ;ifference tL 8 tB  tB 4 tL : 

A * +

A+era, e tD (/. ((.= =.@ 20* 2.2 (/. -.= 2-1

I!let e!" #ea$ure" %&"t' t-( t.( t/( t0( t1 ?) ?) 2) =) = () (-) (-) )  =) () () ) -

) (-) () (() (( () (() (=) (=) (> () =) =) >) 2

Table – 2 R&,'t 'a!" roller 8R9 (/. ((.= =.@ >.2 (/.= .2 -2?./ tB <  ?.@(

A+era, e t >.2 (/.= .2 2-2 (-.= ((.2 =.= 20/

D&ere!4e tD 5 t

Let 'a!" roller 8L9 2.2 (/. -.= (-.= ((.2 =.= -2?.2 tL < ?.( 1 ta+ : 2.//



4 = .2 4 ( ./ 4  . 6 33 8 =.@ 8 (.= 8 (./ 5 3.

CUTTIN; O F -. ii$. 5or other support < -./ F -.If the ratio e!ceeds the %alue gi%en abo%e) the support in 1uestion i.e alignment of the kiln will ha%e to be checked by le%elling test and if necessary to be corrected. ?ERTICAL DISPLACEMENT O TYRE Jhere a%erage %alue at any one support de%iates materially from that at the other supports) it may b e necessary to adust the distance between the rollers or in other words) the %ertical position of the tyre. Jhere necessiated by the design or where it is desired to obtain to some e!tent a standardisation of spare parts) a wider tyre is often used there and conse1uently a%erage particular  pressure at a particular support is lower.

A lower a%erage pressure would gi%e no cause for an!iaty but if a%erage pressure is abnormal or greater) an optical le%elling check should be carried out and the alignment of the kiln if necessary be corrected. SUMMARY

Lead wire test is a rough method & this test will show) howe%er whether an optical check is re1uired immedietely. 3he difference between rolled width i.e t; D t5 will depend on the width of tyre and other things and should not e!ceed > G hereof.  An eccentricity present in the kiln k iln tube will gi%e %ariation in a%erage rolled width tA < t; t; 4 t5 t5 of the lead wire wire original originality ity from from the same kiln kiln roller roller.. If the the a%erage a%erage  widt width h %ar %arie iess by by more more than than (/ G) then then the the nat natur uree and and e!te e!tent nt of eccentricity should be in%estigated by other method and correction of kiln tube should be taken under consideration. If the a%erage width of all rolled lead wires coming from the one & same kiln roller e!ceed more then -/ G than the a%erage width of all lead wires coming from the outer roller on same support supp ort #5or support at girth gear it is / G$) than alignment of kiln must be checked by le%elling method. It is general rule that alignment of kiln must be checked by le%elling method if a%erage surface pressure at any one support is un8usually u n8usually great or low in proportion to the surface  pressure at the other support.

2

ANALYSIS O DIERENT CASES

5rom the gi%en figures a F e) e ) of lead wire test passing through straight and obli1ue kiln rollers respecti%ely) the corresponding effect on the a!ial displacement of kiln k iln and wear as the roller faces can be seen from the  below sur%ey. Boller is completely in parallel position & surface pressure is e1ual throughout the width.  _ 3endency for displacement is neutral. If all the rollers were set in in the  position) the component of the kiln load starting downward toward the outlet would soon o%ercome the friction between the rollers and the tyres and kiln would come to rest against thrust roller station and wear will be uniform. Surface pressure is greatest at the center. CASE 8b9  _ 3endency for displacement at indicated direction of rotation towards the right i.e towards the upper side. Jear. If the roller roller has been cut to to e!cessi%e e!cessi%e angle) the centre centre of the roller roller face should be hollowed and pitting any occur. If the longitudinal tra%el of kiln causes series of slides between the roller & tyre faces during e%ery re%olution of the kiln) facetting will occur.  6ote If the angle to which the roller is test) as shown in fig.+ is is kept a minimum so that center line of the roller is only slightly out of parallel with center line of the kiln as in fig. a) the surface pressure distribution will be as fa%ourable and the roller shall push the kiln in the proper direction with suitable force and so assist in maintaining the proper displacement and operation position of the kiln. Surface pressure is highest at the right hand of the roller CASE 849 3endency for displacement is neutral. As for as we ar is concerned a hollow will be produced in the right hand half of the roller face) scaling occurs at the right hand edge which becomes round and pitting may occur. Surface pressure is highest at the right hand end of the roller. CASE 8"9 3endency for displacement shall be at the direction shown in figure i.e towards left i.e upwards and wear shall same as in case d.

CASE 8a9

?

Surface pressure is highest at the left end of roller. 3endency for displacement is at the direction of rotation shown in figure i.e towards right) wear is same as for case d but at the left hand end. end .

CASE 8e9

1

a

2

3

5

6

#

4

d e

@

*y passing a lead wire between be tween the roller and tyre) it is possible from its rolled shape to conclude how the a!ial position of kiln roller must be relation to the tyre. 3he lead wire test should be e!tended so that it will pro%ide more e!act information such as) whether kiln a!is straight) cur%ed or winding and if so as to where the degree of eccentricity is at a ma!imum. If kiln a!is is straight) the surface pressure between the tyres and rollers will be constant or uniform. If the kiln a!is is cur%ed or o r winding) on the other hand) so that there is eccentricity at the center plane of the tyres) the surface pressure i.e width of lead wire will not be same during the whole of kiln rotation. INAL CONCLUSION

In case of any misalignment at one or more of supports) carry out complete realignment and or in case of any regular wear) it may become necessary to return or mo%e kiln roller during operation. In general) any ir8regularity found through systematic checkup) may be rectified by adustment of the kiln rollers.

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