webinarinspections.pdf

Kiln & Dryer Maintenance INSPECTIONS/ TROUBLESHOOTING IKD Training Webinar

Presenter Bio JOHN ROSS •

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30+ years of experience servicing rotary equipment (kilns, dryers & ball mills) in the mining, cement, lime, chemical, fertilizer, food, and asphalt industries OEM certified kiln / dryer maintenance instructor.

Alignment specialist, who has authored, and published maintenance articles.

RULES of the WEBINAR •

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This is our first live session  – please be patient and tell us how we did. If you encounter technical difficulties during this session, call 877-316-6140 and mention “webinar troubles.” troubles.” You You will wil l be transferred to someone who will help! We encourage your questions! Your microphones will be muted for the most part of the webinar. Please type your questions inside the box in your control panel (right side of screen). Questions will be answered during several breaks in the presentation. Session will be recorded. A link to the recording will be available to you after the webinar.

Kiln & Dryer Maintenance

Troubleshooting/Inspections Daily Inspections 

A maintenance walk-by inspection performed daily

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Check the Dryer drive amperage for sudden increases

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Check the bearing temperatures for changes

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Check the riding ring/support roller faces for new wear

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Check the drive system for vibration and visually inspect the drive gear and pinion alignment

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

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Check lubrication on support & thrust rollers

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Check the gear lubrication systems

Troubleshooting/Inspections Weekly Inspections 

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

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Check the relative movement of the riding rings on floating style (creep) on all piers

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

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

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Check the temperature of the gear and pinion mesh

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

Troubleshooting/Inspections Monthly Inspections

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

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 Check dust filters on air intakes of drive motors

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

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 Perform vibration analysis of the gear and pinion, gear reducer and drive system bearings

Troubleshooting/Inspections Quarterly Inspections

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

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 Check dust filters on air intakes of drive motors

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

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 Perform vibration analysis of the gear and pinion, gear reducer and drive system bearings

Troubleshooting/Inspections  Annual Inspections  Piers-Check

Elevation and Alignment  Check Dryer Alignment  Carrying Roller-Check Adjustment  Gear Flange Bolts-Check Tightness  Gear Joint Bolts-Check Tightness  Pinion-Check Radial Alignment  Drive-Check Alignment  Gear and Pinion Teeth-Condition  Support Frames-Condition  Gear Guard (W/Spray System)-Lubricant Build-Up  Support roller and Thrust Mechanism  Inspect and Service Speed Reducers, Motors, etc., per Manufacturer's Instructions.  Ultra-sound Roller Shafts

Types of wear on Tires/Rollers »CONCAVE AND CONVEX WEAR PATTERNS »CONICAL OR RADIAL TAPER WEAR PATTERNS

»UNEVEN WEAR ON SURFACES »SPALLING AND PITTING ON WEAR SURFACES »VARIOUS OTHER WEAR CONDITIONS

Troubleshooting/Inspections CONCAVE AND CONVEX WEAR PATTERNS

Troubleshooting/Inspections CONCAVE AND CONVEX WEAR PATTERNS

Troubleshooting/Inspections CONCAVE AND CONVEX WEAR PATTERNS

Troubleshooting/Inspections TAPERED/CONCIAL WEAR PATTERNS

Troubleshooting/Inspections TAPERED/CONCIAL WEAR PATTERNS

GAP BETWEEN TIRE & RETAINERS

Troubleshooting/Inspections CONCAVE AND CONVEX WEAR PATTERNS

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Hot bearing temperatures will generate from excessive thrust on the internals of the bearings. Hot bearings can cause the bearing internals to overheat and lose lubrication and cause a premature failure.. Excessive thrust can overload thrust roller mechanisms and cause failure or damage. Wear will be accelerated on the surfaces of the tires and support rollers. This will make minor support roller moves next to impossible. Serious mis-adjustments will cause high axial loads of the tire against the retaining blocks/rings. Mis-adjusted support rollers will create a drag on the kiln shell & increase the kiln drive loads. Unit alignment will be affected by long-term misadjustment of support rollers.

Troubleshooting/Inspections UNEVEN WEAR PATTERNS

Troubleshooting/Inspections UNEVEN WEAR PATTERNS

Troubleshooting/Inspections DIAGONAL WEAR PATTERNS

Troubleshooting/Inspections DIAGONAL WEAR PATTERNS

Troubleshooting/Inspections HORIZONTAL WEAR PATTERNS

Troubleshooting/Inspections HORIZONTAL WEAR PATTERNS

Troubleshooting/Inspections HORIZONTAL WEAR PATTERNS

Troubleshooting/Inspections OTHER WEAR PATTERNS

Troubleshooting/Inspections EXCESSIVE AXIAL THRUST

Resurfacing of Wear Patterns

KILN SHELL CONDITIONS » Filler bar & retaining block/ring welds » Kiln shell weld seams » Hot spots and shell deformation »

Kiln shell “crankshaft” or run-out

Gear Design & Wear Issues

SLIGHTLY APART

TANGENT

ACCEPTABLE

ACCEPTABLE

SCRIBE PITCH LINE SETTING FIGURE 21

OVERLAPPING UNACCEPTABLE

Gear & Pinion Pitch Lines

Girth Gear Bottoming in Pinion Gear

False Bottom on Girth Gear

Root to tip interference

Loaded on both flanks

Scuffing- transfer of metal by adhesion and welding

AGMA 1010-E95 Tooth Hammer excessive backlash & dual drives

Pitting poor lubrication or heavy load

Abrasion dirty lube

Rippling poor lubrication heavy load