140129343 fuller kilnerection

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    Orientation & Common Terminology for Reporting Kiln Details

    A - Indicates down-turningside of kiln and in-runningrollers.

    B - Indicates up-turning side ofthe kiln and out-running

    rollers.

    (Straight Spur or Single Helical)Referred to as Girth, Bull or

    Main Gear. Indicate left orright side of the kiln whenlooking uphill towards feed end.

    Gear Gear

    Right Right

    KilnDischarge

    End

    KilnDischarge

    End

    Material discharge(spill )

    Material discharge(spill )

    A

    A

    A B

    A

    A

    B

    B B

    B

    Clockwise

    (Right-hand)

    LeftLeft

    B A

    Kiln thrust tire(s) withtapered side-faces. Kilns

    with hydraulic thrust

    assemblies will utilize a tirewith a taper on the downhill

    side-face only.

    Kiln thrust roller assemblies.Both sides of the thrust tire

    except when units arehydraulically controlled.

    Kiln drive pinion(s). Arrowsindicate position of pinion

    when a single drivearrangement is used for kiln

    rotation(s) as shown. Pinionsshown at outside positions are

    for dual-drive assemblies.

    Kiln Support Rollers alsocalled 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.

    Indicatespiernumbersstartingatdis

    chargeorfeedend

    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 eminarSM

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    Elevation F

    D D

    B G

    Elevation C Elevation E

    Elevation A

    24

    3

    1

    FrameCL

    FrameCL

    PierCL

    B

    oltCL

    BoltCL

    (Approx.)

    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 CL on machined top surface ofbeam minus reference plus elevation.

    Use dimension G for setting elevation of control beam. Use precision straightedge with slope test block and machinistslevel 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.

    Carefully check and record elevation at top of plug.

    KILN OVERHEAD 002.CDR Maintenance S eminarSM

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    Frames must be aligned on CLsparallel to each other.Refer to installation

    instructions for dimensiontolerances and testprocedures.

    NOTE:

    Use a precision spiritlevel for test work. Astainless steel v-blockis supplied for test work,or use an inclinometer.

    Roller assemblies are to beset before grouting frames.Final test for slope is madeon top of each roller.

    NOTE:

    Slope tests require a sturdyand accurate straightedge thatwill 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 CL.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 eminarSM

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    Kiln Support Frame Spacing Test Points

    NOTE: Support Roller Assembly drawing numbers for each pier are shown on the Foundationdrawing. 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 foundationdrawing to obtain test dimension (as shown above in sketch).

    Use spring scale to apply 20 to 25 lbs 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

    KilnSupportPier

    KilnSupportPier

    KILN OVERHEAD 004.CDR Maintenance S eminarSM

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    Kiln Support Frames Spacing, CL & Parallelism Tests

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

    KILN OVERHEAD 005.CDR

    NOTE-Framedimensionsshownonrollerassemblydrawings. AlignframesonCLs, adjust for elevation, slope andcross-level.

    Dimension A - Nominal dimension from frame CL, measured and marked equally at all testpoints (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)

    DiameterC

    Diamet

    erC

    Diameter B *

    Diameter B *

    Diam

    eterA

    Diam

    eterA

    DiameterA

    DiameterA

    Erecting test dimension

    Kiln and Frame CL Marked on Piers by Layout Engineer

    KilnSupportFrame

    KilnSupportFrame

    AllB

    eam

    CLsmarkedatfactory

    CLsM

    arkedonallPiersbyLayo

    utEngineer

    NOTENOTE

    Measured and Marked on Piers by Layout Engineer

    Maintenance S eminarSM

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    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 CL.

    C - Measure from plumb lines to offset lines.

    Testing New Kiln Support Roller Installations,orRe-AligningOlderEquipment

    Slope -

    gauge V-bar with12, graduated vial,machinist level.

    Kiln may beon slowrotationif plumb bobis suspendedin oil.

    Slope gage blockto be accurate within0.0005 in 12 length or0.05 mm / 1000 mm.

    Use tight wire orstraightedge for

    projection of offsetline across beams.

    Plumb bobsin oil

    Measuring to plumblines is not completelyaccurate (rollers may betapered).

    Install boards at inneredges of beams for ramminghigh strength non shrinkgrout from outside edgesof beams.

    Fill anchor bolt sleeveswith high strength grout.

    Adjust shimsas needed for finaltrue-up of frame.(Slope & transverse-leveltolerance @0.002 per foot or0.15 mm / 1000 mm).

    This methold applies only whenroller surface is cylindrical.

    Or use slope block on shafts.

    The inclinometer is also anaccurate method.

    C

    C

    B

    A

    KILN OVERHEAD 006.CDR Maintenance S eminarSM

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    Recommended Water Piping Arrangementfor 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 platesto allow for bearing inspectionand maintenance work.

    NW

    ARD

    ADJUS

    TMENT

    OFRO

    LLER

    ASSEM

    BLY

    I

    NW

    ARD

    ADJUST

    MENT

    OFROL

    LER

    ASSEMB

    LY

    I

    B

    A

    E

    D

    C

    B

    KILN OVERHEAD 007.CDR Maintenance S eminarSM

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    AB

    B

    C

    A

    AB

    C

    Pads A

    B

    Handling Kiln Tires for Installation on Pads with Slide Bar Arrangement

    A - Timbers in place betweenground and tire.

    B - Rubber belting for protectionof 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 ofwire rope and belt material.

    A - Circumferential sling for moving tire into positionon pads. Place wire rope inside rubber hose splitlengthwise and tied with baling wire.

    B - Use 4 spacer bars with centering gussets and end

    set-screws.

    A - Longer timbers for clean and softrolling surface.

    B - Belt wrapped around tire and tiedwith wire.

    C - 3 wraps of 1 wire rope hitched tocrane hook.

    Plumb position of tireafter pick-up.

    KILN OVERHEAD 008.CDR Maintenance S eminarSM

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    Crane Hitch Arrangements for Handling Kiln Shell Sections(Off-Loading and at Assembly Area)

    Preferred arrangement, using a spreader beam andtwo cradle slings. Two cranes should be used forlonger shell sections with two heavy paddedsections for riding rings.

    Acceptable hitch arrangement, but anti-creepgussets should be installed to prevent wire ropesfrom crawling toward each other when the cranestarts to pick up the load. Calculate the sling

    tension for the included angle & use an adequatecapacity slings.

    KILN OVERHEAD 010.CDR Maintenance S eminarSM

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    Crane Hitching for Kiln Shell SectionsHitch Angles and Stress on Lines

    KILN OVERHEAD 009.CDR

    Diameter

    Diameter

    1000 lbs. 1000 lbs.

    2000 lbs.1 Part line

    Weakened

    Splicekinksshell

    Kiln Shell

    Choker no good forhandling kiln shells.

    Kiln Shell

    2 partsof line

    Go with Cradle forHandling Kiln Shells

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

    Diameter

    2000 lbs.

    1415

    lbs

    . 1415 lbs.4545

    90

    Diameter

    2000 lbs.

    1155

    lbs

    . 1155lb

    s.

    60

    60

    Maintenance S eminarSM

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    KILN OVERHEAD 011.CDR

    Kiln Shell Support

    Longitu

    dinal

    Weld

    Longitu

    dinal

    Weld

    Longitudinal welds at ends of shellsections are to be set 180 apartfor field joints unless shown

    otherwise on erectiondrawings.

    1 X 4 X 24 strongback bars may

    be used to guide shell sectioninto position for field joint connection.Locate at spaces required forsetting all strongback bars for joint. Typical crib stack shown with jack, steel plate and

    saddle arrangement for adjustment work.

    Maintenance S eminarSM

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    Alignment Fittings

    KILN OVERHEAD 012.CDR

    Edges of adjacentshell sections

    Strong-back

    Push - PullAdjust Bolts

    Adjusting lug

    Maintenance S eminarSM

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    GaugeBlocks

    Field Joints

    Feed End

    Batter Board withCenter Hole and Card

    Batter Board Locations

    KILN OVERHEAD 013.CDR Maintenance S eminarSM

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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 alltest positions.

    KILN OVERHEAD 014.CDR

    Feed End

    Field Joints

    GaugeBlocks

    DischargeEnd

    Transit ReplacingBatter Board

    Maintenance S eminarSM

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    Steel Spider(1 of Several Types)

    2 X 6Board

    Wood Wedges 2 or 50 mm Diameter HoleDrilled at C

    L

    s

    2 or 50 mm Diameter Hole

    Drilled at CLs

    (2) 1/4 DiameterBolts at

    Each Plate

    1/4 X 4 X 4Steel Plates

    2 X 6Board

    Kiln Shell Alignment Test Batter Boards

    KILN OVERHEAD 015.CDR Maintenance S eminarSM

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    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. Cardcan be returned precisely on starting position for target re-check.

    KILN OVERHEAD 016.CDR

    A

    BB

    Kiln Alignment Target and Layout Trammel

    Cut beam toform pointedend.

    New kilns only-In tire sections - use steps inmachined reference plates asguide point for trammel layouton targets.

    3/4 X 1 1/2 trammel beam (wood)

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

    Maintenance S eminarSM

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    Details on card:

    Center byfirst setof quarterpoints

    Center bysecond set ofquarter points

    Selectedcenter

    B1

    A1

    A2

    B2

    A3

    B3

    A4

    B4

    Second set of quarter

    points identifiedby Bs

    First set of quarterpoints identifiedby As

    ShellCenter points

    Arcs and diagonalsfor first pointsare solid, dashedfor the second set

    Card onbatter board

    45 offset

    Locating the Center of the Shell

    KILN OVERHEAD 017.CDR Maintenance S eminarSM

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    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 lengthhas 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 or2.50 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 within3/32 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 byworking from most-distant far-sight.

    KILN OVERHEAD 018.CDR

    1 2 3 4 5 6 7 8 910 11

    Span A

    Pier 1 Pier 2 Pier 4Pier 3

    Span B Span C

    Maintenance S eminarSM

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    Kiln Shell Field Joint Bracing and Tack Welding

    Weld remaining end of strongbackafter kiln shell alignment is acceptable.

    Prewelded end

    Tighten all nuts in push/pullbolt arrangements.

    Edges of adjacentshell sections

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

    Deposit root weld bead.

    KILN OVERHEAD 019.CDR Maintenance S eminarSM

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    Riding Ring Location

    KILN OVERHEAD 020.CDR

    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 eachring is +_ 1/4 inch (6.35 mm).

    Cold dimensions on the foundation drawing are at 70 F (21 C). Record shell temperature forcalculation of expansion or contraction relative to the control temperature for adjustment of allowance forexpansion at each support roller position.

    Maintenance S eminarSM

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    Temporary Support Chair for a Kiln Spring Gear

    1 axial adjustment bolts.6 long (typical).

    Typical gear chair( 1 of a set ) fortemporary duty.

    2 X 6 (or to suit) boltfor gear radial adjustments.

    Kiln Shell

    Chair in position to

    support and adjustthe gear for correctionof axial and radial runout.

    Kiln gear with tangential springs

    KILN OVERHEAD 021.CDR Maintenance S eminarSM

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    Gear Guard and Splash Band Assembly

    KILN OVERHEAD 022.CDR

    C

    F FD

    C

    E

    A

    BFeed End

    A - Gear guard section

    B - Flange joint for removable panelC - Splash band sectionsD - Spring plate for gearE - Kiln shell plateF - 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:If conduit must pass through bands to reach a thermocouple, install before guard assembly work.

    Maintenance S eminarSM

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    Kiln Support Roller Adjustment and Testing

    KILN OVERHEAD 023.CDR

    Low end of kiln(discharge)

    Bearing endplate with

    thrust washer

    Roller shaft should be incontact with this thrustwasher. End plate shouldsound solid when tappednear center with a hammer.

    Roller shaft should not bein contact with this thrustwasher. End plate shouldsound hollow whentapped near center with ahammer.

    Bearing endplate with

    thrust washer

    Low endof kiln

    (discharge)

    Kiln movestoward feed end

    Rollers movetoward discharge end

    RotationIn

    In

    SupportRoller

    RidingRing

    View toward feed end

    Rollers movetoward discharge end

    Kiln movestoward feed end

    Rotation

    In

    In

    SupportRoller

    Riding

    Ring

    View toward feed end

    Maintenance S eminarSM

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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 pressure200-800 psi or 15 to 60 bar.

    DriveLower Thrust Roller Feed EndDischargeEnd

    Skewing Rollers

    KILN OVERHEAD 024.CDR Maintenance S eminarSM

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    Beamtop

    Supportroller Plumb

    lines

    Plumbbobs inoil

    B

    B

    A

    Kiln may beon slow rotationif plumb bobis suspendedin oil *

    Dial-indicators (1 at each bearing base) are usedfor control of final true-up alignment work

    and for all skewing adjustments.

    BearingBase

    A

    Offset reference line(may be a tight wireor a straightedge atestablished referencemarks).

    Support Roller Assembly Alignment Control

    Hightemperature

    metal

    surfaces

    cancause

    severe

    burns.

    Moving

    (rotating)

    machinery

    can

    cause

    hands

    and

    arms

    to

    become

    caught.

    Avoid personal injury.

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

    A-Scribe

    beam

    surface

    at

    edge

    of

    bearing

    base

    to

    establish

    reference

    points

    for

    measuring

    bearing

    movement

    during

    theroller

    relocation

    work

    period.

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

    KILN OVERHEAD 025.CDR Maintenance S eminarSM

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    KILN OVERHEAD 026.CDR

    Rotation B

    Rotation A

    180bearingbushing

    Kiln Support Roller Bearing Bushing Lubrication

    Sketch shows recessed zones ofbushings filled with oil for formationof oil wedges which taper to a few milsfilm thickness at the longitudinal pressureline. Wedges are shown for both directionsof shaft rotations.

    A

    B

    Shaft RotationShaftRotation

    B

    A

    Roller Shaft

    Recessed Zone(Both Edges)

    Maintenance S eminarSM

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    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 muststraddle 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 piecesfrom 1 1/4plate

    Saddle for Kiln/Shells

    Chord Length

    72

    36

    Variable

    KILN OVERHEAD 027.CDR

    Kiln Saddle Dimensions

    Maintenance S eminarSM

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    Jacking Kiln Shell to Unload Support Rollers

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

    KILN OVERHEAD 028.CDR

    Shell Brace

    Shell SaddleArrangement

    Clearance

    Slow Rise EdgePrepare 12

    or more

    On Pier Surface

    Tire

    Maintenance S eminarSM

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    Jacking Kiln Tire to Unload Support Rollers

    Preferred Jacking Arrangement ( when possible)

    KILN OVERHEAD 029.CDR

    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

    ClearanceTire

    Maintenance S eminarSM

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    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, aswhen 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 oillevel in the

    downhill housing

    Maximum oillevel in the

    uphill housing

    Imaginary Level Line

    A B

    Slope Line

    KILN OVERHEAD 031.CDR Maintenance S eminarSM

    lf li i ll d k i

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    Support Roller With Journal

    Self Aligning Ball and Socket Type Bearing FLS 58Type RA Design Bearing

    FeltSeal

    Oil Trough

    Oil Cup

    Thrust Ring

    Liner

    Oil Gauge

    Spherical Liner/Water Jacket

    Stop Block

    Heat ShieldOil

    Scraper

    KILN OVERHEAD 032.CDR Maintenance S eminarSM

    Kil S R ll Adj d T i

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    KILN OVERHEAD 034.CDR

    Kiln Support Roller Adjustment and Testing

    Low end of kiln(discharge)

    Bearing endplate with

    thrust washer

    Roller shaft shouldbe in contact with thisthrust washer. End plateshould sound solidwhen tapped nearcenter with a hammer.

    Roller shaft shouldnot be in contactwith this thrustwasher. End plateshould sound hollowwhen tapped nearcenter with a hammer.

    Bearing endplate with

    thrust washer

    Maintenance S eminarSM

    Kil S R ll Adj d T i

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    Kiln Support Roller Adjustment and Testing

    KILN OVERHEAD 035.CDR

    Low endof kiln

    (discharge)

    Kiln movestoward feed end

    Rollers movetoward discharge end

    Counterclockwise Rotation

    Rotation

    In

    In

    SupportRoller

    Riding

    Ring

    View toward feed end

    Maintenance S eminarSM

    Kil S t R ll Adj t t d T ti

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    KILN OVERHEAD 036.CDR

    Kiln Support Roller Adjustment and Testing

    Low endof kiln

    (discharge)

    Rollers movetoward discharge end

    Kiln movestoward feed end

    Rotation

    In

    In

    SupportRoller

    RidingRing

    View toward feed end

    Clockwise Rotation

    Maintenance S eminarSM

    Kil S t R ll Sk i

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    Kiln Support Roller SkewingRoller Adjustment Rule of Thumb

    Moving (rotating) machinery.

    Personal contact can causehands and armsto become caught in pinch points.

    Counterclockwise Kiln Rotation

    KILN OVERHEAD 037.CDR

    InIn

    In

    In

    BearingBearing

    BearingBearing

    SupportRoller

    SupportRoller

    Kiln

    Kiln

    Kiln

    KilnRotation

    High End

    Maintenance S eminarSM

    Kil S t R ll Sk i

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    Kiln

    Kiln

    Kiln

    Kiln

    Kiln Support Roller SkewingRoller Adjustment Rule of Thumb

    Clockwise Kiln Rotation

    KILN OVERHEAD 038.CDR

    In In

    InIn

    Bearing Bearing

    BearingBearing

    SupportRoller

    SupportRoller

    Rotation

    High End

    Moving (rotating) machinery.

    Personal contact can causehands and arms to becomecaught in pinch points.

    Maintenance S eminarSM

    N l Off t P iti f Th t R ll

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    Normal Offset Position of Thrust Rollers

    Counterclockwise Kiln Rotation

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

    Down Down

    Down

    Kiln

    Centerline

    Roller

    Centerline

    Correct

    Idle

    KILN OVERHEAD 039.CDR

    Rotation

    Maintenance S eminarSM

    1/16 to 1/8

    W Off t P iti f Th t R ll

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    Wrong Offset Position of Thrust Rollers

    Counterclockwise Kiln Rotation

    Thrust rollers will rise, or try to rise, out of their bearing bases when their centerlines cross over the trueframe centerline toward the up-turning side of the kiln, and when the kiln shifts toward its own downturningside.

    KILN OVERHEAD 040.CDR

    Idle

    Up

    UpUp

    Wrong

    Rotation

    KilnCenterline

    RollerCenterline

    Any amount

    Maintenance S eminarSM

    Plain Roller Support Assembly

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    Plain Roller Support Assembly

    KILN OVERHEAD 041.CDR

    Detail

    Roller Shaft

    Rolle

    r

    CL

    Inspection PortOil Seal

    (See Detail)

    Oil Tray

    Bearing Housing

    Oil Bucket Wheel

    Thrust Washer

    Oil Level andOil Fill Pipe

    Feed End

    Adjustment Plate

    Bearing

    Maintenance S eminarSM

    Thrust Roller Assembly

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    Thrust Roller AssemblyTwo Thrust Roller System

    KILN OVERHEAD 042.CDR

    Detail

    OilSeal

    Oil Level &Oil Fill Pipe

    ThrustRollerHousing

    Thrust Riding Ring

    Feed End

    Thrust Rod

    Shims

    SphericalRoller Bearings

    Thrust Roller

    Thrust Roller

    ShellSee

    Detail

    Maintenance S eminarSM

    Thrust Roller Assembly

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    Thrust Roller Assembly

    KILN OVERHEAD 043.CDR

    Thrust Roller Frame

    C

    C

    C - C

    Maintenance S eminarSM

    Hydraulic Thrust Roller Assembly

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    OilSeal

    Detail

    Hydraulic Thrust Roller Assembly

    KILN OVERHEAD 044.CDR

    Shell

    ThrustRollerFrame Upper Thrust

    HousingSupport

    Thrust Housing

    SupportRod

    Drain Plug

    Feed End

    Lower ThrustHousingSupport

    SphericalRoller

    Bearings

    A (Sht.

    Fixed Uphill Stopwith Brass Plate Support

    Rod Boot

    ThrustRidingRing

    Thrust RollerHousing

    Thrust Roller

    Movement

    Thrust Roller

    ThrustButton

    HydraulicCylinder

    Stroke

    Adjuster

    NOTE: Oil Pipe & Graphite Lubricator Included but Not Shown

    To HydraulicPowerUnit

    SeeDetail

    Maintenance S eminarSM

    Hydraulic Thrust Roller Assembly

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    BumperAssembly RidingRingK

    iln

    CL

    A - A

    Hydraulic Thrust Roller Assembly

    KILN OVERHEAD 045.CDR

    Operation of Limit Switches

    A - Stops Hydraulic Pump SetB - Pressure in System Relieved

    C - Sounds AlarmD - Shuts Kiln Drive DownE - Starts Hydraulic Pump SetF - Sounds AlarmG - Shuts Kiln Drive Down

    Pier 3 Pier 2

    HydraulicCylinders

    HydraulicPower Unit

    Hydraulic Thrust Orientation

    (Single Hydraulic Cylinder May be Used)

    + + + + + + +

    D C B A E F G

    Thrust Roller

    Thrust Riding Ring

    CL

    RollerSup

    port&

    ThrustRidingRing

    Feed End

    Cam Follower

    Limit SwitchAssembly

    A

    A

    CL

    Maintenance S eminarSM

    Routine Checkout at Kiln Tire Sections

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    Routine Checkout at Kiln Tire Sections

    Shell Cold: Clearance for expansion at top of kiln

    Shell (pads) rest in normal position inside the tire

    KILN OVERHEAD 046.CDR

    Allowance forShell Expansion

    View atTop Position

    Maintenance S eminarSM

    Routine Checkout at Kiln Tire Sections

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    Expansion

    Shell Overheatedand ChokedInside 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.

    KILN OVERHEAD 047.CDR

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

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

    Maintenance S eminar

    SM

    Field Installation of Kiln Tire Section Spider Bracing

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    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 looseend 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 rotationof the shell.

    KILN OVERHEAD 049.CDR

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

    Brace No. 1

    Pre-Welded

    End @ 90From Start

    Now Tight SecondWeld

    Brace No. 2

    Sag

    Maintenance S eminarSM

    Routine Checkout at Kiln Tire Sections

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    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 shellis very near the point of serious deformation damage plus shell and refractory breakdown problems.

    KILN OVERHEAD 052.CDR

    Almost zeroclearance.Shell continuesto migrate within

    the tire.

    View at

    Top Position

    Maintenance S eminarSM

    Routine Checkout at Kiln Tire Sections

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    Routine Checkout at Kiln Tire Sections

    KILN OVERHEAD 053.CDR

    When normal coating builds up on refractory, the main shell returns to normal diameter but the permanentlydeformed 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.

    Clearance

    Maintenance S eminarSM

    Field Installation of Kiln Tire Section Spider Bracing

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    Field Installation of Kiln Tire Section Spider Bracing

    KILN OVERHEAD 054.CDR

    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 tireClearance

    Spreads

    Horizontal Major Axis

    112

    3

    4

    Maintenance S eminarSM

    Field Installation of Kiln Tire Section Spider Bracing

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    Field Installation of Kiln Tire Section Spider Bracing

    KILN OVERHEAD 055.CDR

    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 roundshell 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 bothsides at the horizontal centerline, and at top-dead-center between shell pads and the riding ring bore surface. Adddimensions recorded for these three check points, then divide the total by two to determine the actual diameter forshell pads and riding ring bore.

    Clearance0.6125

    Clearance0.6125

    Shell held in round conditionbyinternalbracing

    True roundness is a goalSeldom

    -if

    ever

    -Reality

    Clearance0.775

    Riding ring on rollersand a 0.3% ovality

    (example only).

    Maintenance S eminar

    SM

    Jacking a Kiln Shell to Unload Support Rollers

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    Jacking a Kiln Shell to Unload Support Rollers

    KILN OVERHEAD 056.CDR

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

    Saddle Under the Kiln Shell

    ClearanceTire

    Shell Brace

    Maintenance S eminarSM

    Jacking a Kiln Shell to Unload Support Rollers

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    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 isnot 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

    KILN OVERHEAD 057.CDR Maintenance S eminarSM

    Jacking a Kiln Shell to Unload Support Rollers

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    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

    KILN OVERHEAD 058.CDR

    NOTE:

    Maintenance S eminarSM

    Jacking Kiln Shell to Unload Support Rollers

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    g pp

    KILN OVERHEAD 059.CDR

    Shell Brace

    Shell SaddleArrangement

    Clearance

    Slow Rise EdgePrepare 12

    or more

    On Pier Surface

    Tire

    Maintenance S eminarSM

    Typical Procedure for Removing Roller Assemblies

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    yp gfrom the Support Frame

    KILN OVERHEAD 060.CDR

    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 andreplacement work period.

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

    1

    2 33

    Maintenance S eminar

    SM

    Typical Procedure for Removing Fuller/Traylor Roller Assemblies

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    yp g yfrom 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 infull-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 wedgeswith 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 barsat bottom positions on housings hold bearing housings in position against machined edges for operation of theassembly. One or both keybars must be removed to avoid interference when the complete roller assembly ismoved toward the outside end of the support frame.

    KILN OVERHEAD 061.CDR

    SlopeLine

    PierTop

    PierWork Point

    Level Line

    Reference

    Maintenance S eminarSM

    Typical Procedure for Removing Fuller/Traylor Roller Assemblies

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    yp g yfrom the Support Frame

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

    Remove all cooling water input and drain pipes from bearing bases. Remove bearing adjustment lug and screwcombinations 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 theend of the frame.

    KILN OVERHEAD 062.CDR Maintenance S eminarSM

    Typical Procedure for Removing Fuller / Traylor Roller Assemblies

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    yp g yfrom the Support Frame

    KILN OVERHEAD 065.CDR

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

    Maintenance S eminar

    SM

    Typical Procedure for Removing Fuller/Traylor Roller Assemblies

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    Move bearing housing:

    Removing and/or resetting a bearing housing at ground level

    KILN OVERHEAD 067.CDR

    yp g yfrom the Support Frame

    Look for stencil-letteridentification of thefeed end area of theroller.

    IN / ON

    OUT / OFF

    Uphill ( or feed end )bearing housing

    FEEDEND

    Maintenance S eminar

    SM

    Typical Procedure for Removing Fuller/Traylor Roller Assemblies

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    yp g yfrom the Support Frame

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

    KILN OVERHEAD 069.CDR Maintenance S eminarSM

    New Pads for Choked-Down Tire Sections

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

    KILN OVERHEAD 070.CDR

    Tire

    (ClearanceExaggeratedfor Clarity)

    Thrust Roll

    Roller atFarSide

    LevelSlope

    True Kiln Axis

    Thrust Roll

    Tire CL Shell CL

    Maintenance S eminar

    SM

    New Pads for Choked-Down Tire Sections

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    Preparation:

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

    KILN OVERHEAD 071.CDR

    Level

    Slope

    2

    1

    3

    1

    Maintenance S eminar

    SM

    New Pads for Choked-Down Tire Sections

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    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 isin 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

    New Pads for Choked-Down Tire Sections

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    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.

    KILN OVERHEAD 073.CDR

    Level

    Slope

    2

    1

    Maintenance S eminar

    SM

    New Pads for Choked-Down Tire Sections

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    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.

    KILN OVERHEAD 074.CDR

    Level

    Slope

    Maintenance S eminarSM

    New Pads for Choked-Down Tire Sections

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    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 allownew pads to bend to fill the spaces as soon as rotation starts after the kiln is returned to the production department.

    KILN OVERHEAD 075.CDR

    Level

    Slope

    STRAIGHTEDGE

    Maintenance SeminarSM

    New Pads for Choked-Down Tire Sections

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    A typical, but unsatisfactory shim stack arrangement for filling spaces between shell and pads is shown at thebottom 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 priormeasurement, is used with appropriate thickness-adjustment shims for a more secure packing arrangement. In thisarrangement filler plates are welded to pad plates, not to the shell.

    KILN OVERHEAD 076.CDR

    STRAIGHTEDGE

    KILN OVERHEAD 076.CDRKILN OVERHEAD 076.CDR

    New Pad Plate

    Stacked Shim Plates

    Rolled Filler Plate

    Level

    Slope

    Maintenance Seminar

    SM

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    Lubricate

    Level

    Slope

    Lubricate

    New Shell Pads

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

    KILN OVERHEAD 077.CDR Maintenance S eminar

    SM

    New Pads for Choked-Down Tire Sections

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    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 newconditions at the tire.

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

    New Shell Pads

    New Pads for Choked-Down Tire Sections

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    Welded End

    Do Not WeldGusset to Pad

    Welded EndWelded End

    Welded EndLoose EndLoose End

    Loose EndLoose End

    PadPad PadPad

    TireCL

    TYP

    TYP

    3/8 to 3/4

    3/8 to 3/4 3/8 to 3/4

    A

    A

    Tire1Dia.

    Spacer Pad(Loose End)

    A - A

    Hold DownGusset RetainerBlock

    4X4XVariableLengthto Suit Spacer Pad

    Alternate tire retainer arrangement. Semi-floating pad design.

    KILN OVERHEAD 080.CDR Maintenance S eminar

    SM

    1/16

    New Pads for Choked-Down Tire Sections

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    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 inrelation 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

    12

    3 4

    8

    75

    6

    8

    Tire

    Tire

    Slope

    Roller

    Thrust RollerThrust Roller

    Maintenance S eminar

    SM

    Floating Pad DesignTYP

    5 8

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    KILN OVERHEAD 082.CDR

    In

    this

    arrangement

    pads

    are

    not

    welded

    to

    the

    shell

    at

    all.Theshopinstalledcostforthisarrangementishigh,butthefuturefieldreplacementofpadsissimplerandlessexpensive.

    Thecontinuous

    wear

    rings

    installed

    between

    the

    riding

    ring

    end

    faces

    and

    wear

    ring

    retainers

    reduces

    bearing

    pressure

    andgouging

    in

    the

    riding

    ring

    end

    faces

    and

    also

    increase

    wear

    life

    of

    the

    components.

    Itis

    very

    easy

    to

    reduce

    tire

    creep:

    Install

    shims

    between

    shell

    and

    pads

    and

    tack

    weld

    new

    shims

    to

    pads.

    Min. Min. Wear Ring

    1/16 or 2 mm Downhill Side OnlyHeavy Shell Plate

    Riding Ring

    Pad Length

    Pad

    Min.

    8 8

    5

    Taper

    PadThickness

    1

    Wear

    Ring

    TYP

    ShellThickness

    PadThickness

    Height ofAnti-Rotation

    Plate

    A - A

    Fillet Weld Size

    Maintenance S eminar

    SM

    2-

    PadWidth

    9

    TYP.3Sides

    TYP.3Sides

    1 Chamfer

    5/8

    FilletWeldSize

    A A

    5 8

    Anti-Rotation Plate

    Must Make Contact on 1 Side

    Wear Ring Retainer

    1 TYP

    TYP1/4

    Pad Guide Bar 1 Thick

    Axial Pad Retainer 1 ThickR 3/4

    R 3/4

    R 3/4

    1/8Gap

    Using Wedges for Longitudinal Shifting of Tire

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    KILN OVERHEAD 083.CDR

    Weld Wedge to Tire

    Opposed Wedges. Smooth slide surfaces per machine shop procedures.

    Molyk

    ote

    Lub

    e

    Weld Wedge to Pad

    Rotation & Creep

    Creep (Mark on Pad)Mark on Tire

    Move Tire

    Cold Kiln

    Maintenance S eminar

    SM

    Using Chains for Longitudinal Tire Movement

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    No push or pull mechanical assistance.

    No wedges.

    No assist from roller thrust reaction on tire.

    KILN OVERHEAD 084.CDR

    Ignore trianglein chainhook-up

    Tire

    Roller

    24 Straight Line

    2

    3/8

    24

    Maintenance problem:

    Tire in offset operating positionon rollers. 2 move required inlongitudinal direction on shell

    Clearance - tire to pad at TDCis 3/8 for this example.

    CL

    CL

    Chain

    Maintenance S eminar

    SM

    Using Chains for Longitudinal Tire Movement

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    1

    23456789

    10111213

    0.750

    1.5002.2503.0003.7504.5005.2506.0006.750

    7.5008.2509.0009.750

    23.988

    23.95323.89423.81223.70523.57423.41923.23823.031

    22.79822.53722.24822.937

    0.012

    0.0470.1080.1880.2950.4280.5810.7820.988

    1.2021.4821.7512.070

    Rev. Number DrawNew X DimensionTotal Creep

    KILN OVERHEAD 085.CDR

    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

    Start24 Straight Line

    Shell Creep/Rev. 3/4

    (Constant)24

    Constant

    X Changing

    Approximately 13 revolutions to move tire 2. No allowance for elongation of chain under load. Calculatefor 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.

    .

    Maintenance Seminar

    SM

    Measurement of Shell Migrationto Determine Shell Pad to Tire Diameter

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    As Seen From Underthe Kiln Shell

    Measure Amount of CreepShell Advances Inside Tire

    KILN OVERHEAD 086.CDR Maintenance S eminar

    SM

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

    to Determine Shell Pad to Tire Diameter

    Tracing Arrangement for Recording Pad-to-TireClearance and Migration (Creep)

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    A

    BEnd

    Start

    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 seton the side of the tire and the magnet-supportedpencil is placed on the trailing edge of thecard as determined by rotation directionof the kiln.

    Height of wave patterns is a recording ofactual clearance between shell pads andtire bore. This dimension when dividedby 1/2 Pi, indicates actual pad-to-tirediameter.

    Distance between start/stop points indicates shellmigration 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-upcalculations when affected by lubrication.

    KILN OVERHEAD 087.CDR

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

    Maintenance Seminar

    SM

    Spring-Loaded Pencil Holder for Pad/Tire Clearanceand Creep Tracings

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    KILN OVERHEAD 088.CDR

    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/GBlockRet/GPostCap Screw

    Holder

    SpringPencil

    General - #351-6

    1/2HexBarX2LG1/2HexBarX1LG(Slotted) 10-24 X 3/4 LG

    ChromedTubing(Plumbing)

    5/16DiameterX11/2LG(MediumTen.)StandardHB(NoEraser) (BerolBlackWarrior#372)

    Description Material

    Standard

    Pencil

    Pencil Holder(Tubing)

    Drill & Tap10-24 X 1 Deep

    10-24 SlottedCapscrew X 3/4 Long

    Permanent Horseshoe Magnet(10 Lb. Pull)

    RetainerBlock & Post

    Spring5/16 Diameter X 1 1/2(Retained)

    6

    Maintenance S eminar

    SM

    1 1/2

    Tracing-Paper Surface for Pad/Tire Clearanceand Creep Tracings

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    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.

    KILN OVERHEAD 089.CDR

    8 1/2

    1 TYP.

    1/8 TemperedHardboard

    Permanent Horseshoe Magnet10 Lb. Pull (General #351-6)

    Drill & CountersinkTo Suit 10-24 Csk Screw(TYP) 2 places

    Bolt&

    Nut

    to

    Magnet

    2 1/2

    Two Spring Clips (Small)

    Maintenance S eminar

    SM

    Shelltest Measuring Unit Holderbank System

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    E G

    HFh

    h

    15.

    Recorder SystemHolderbank

    Ovality: = 2 (a - b)

    3= 4.d2 .

    h

    h

    =

    Shelltest Diagram

    = 15

    KILN OVERHEAD 090.CDR

    a

    Distorted Cross-Section

    Principle of

    Distortion

    Measurement

    bd

    d

    A

    B

    h

    B

    D

    C

    L=1m

    Maintenance S eminar

    SM

    DCBA

    Ovality

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    DCB

    1, 2, 3, Shell LinesA, B, C, D Measuring Planes

    A

    1

    1

    1

    2

    2

    2

    3

    3

    3

    KILN OVERHEAD 091.CDR

    1 23

    Diagram of OneMeasuring Plane

    Maintenance S eminar

    SM

    Ovality Limits as Function of Kiln Diameter

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    KILN OVERHEAD 092.CDR

    Kiln Diameter

    %Ovality

    3

    0

    %

    0.2

    0.6

    0.4

    0.8

    4 5 6 m

    Maintenance S eminar

    SM

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    KILN OVERHEAD 093.CDR

    Allowance for

    Shell Expansion

    View at

    Top Position

    Maintenance S eminar

    SM

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    A

    BEnd

    Start

    As Seen From Underthe Kiln Shell

    Measure Amount of CreepShell Advances Inside Tire

    KILN OVERHEAD 094.CDR Maintenance S eminar

    SM

    Permanent Shell Deformation

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    KILN OVERHEAD 095.CDR

    ClearanceExpansion

    Shell Overheatedand ChokedInside Tire

    Maintenance S eminar

    SM

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    KILN OVERHEAD 096.CDR

    Difference in Diameter ( )

    Gap at Top (G )

    = G

    D:

    Tire

    NoteNote

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

    Distorted Shell

    Crush Zonesfor

    BrickLining

    CL CLShell

    Tire

    Maintenance S eminar

    SM

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    KILN OVERHEAD 097.CDR

    90

    Roller CL

    Radius

    No Axial Runout(Wobble)Through360Rotation

    All Details Must beCheckedPriortoPlanningaScheduleforTrue-UpGrinding

    Radius

    RolleronPlannedSlopePerTestwithGaugeBlock&Level

    or Inclinometer

    Kiln Properly AlignedSlope

    is

    Exactly

    as

    Planned.

    RollersSettoCompensateforAllDimensionalVariables.

    Matched LinersFrameSlopeTrue

    Planned Slope

    Level Line

    90

    Tire CL

    Hot Positionon Roller

    180 Liner180 Liner

    Maintenance S eminar

    SM

    As seenfrom FrameLongl C

    L

    Tire Ovality - Removal of Metal May Not be Feasible

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    KILN OVERHEAD 098.CDR

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

    started

    Rough Outside

    Rough Inside

    MinorAxis

    Major Axis

    ToFin

    dDiamet

    er Is Bore Wornand Grooved?

    Measure Thickness (t)

    t

    Measure

    Circumfe

    rence

    Maintenance S eminar

    SM

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

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    (and has Bad Inside and Outside Surfaces)

    KILN OVERHEAD 099.CDR

    Sag

    Shell

    When a tire is too thinthe combination of sag, crimping andexcessive clearance can account for

    shell ovality approaching 0.9%.

    Check

    out

    shell

    ovality

    factors

    before

    arrangingfortiretrue-up.(May

    need

    replacement

    parts).

    ExcessClearance

    Crimping

    Rollers

    Maintenance S eminar

    SM

    Longitudinal Fractures at Shell Pads

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

    KILN OVERHEAD 100.CDR

    Sag

    Shell

    Thin TireExcess

    Clearance

    Crimping

    Rollers

    Maintenance S eminar

    SM

    Longitudinal Fractures at Shell Pads

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    Tire section CHOKE deformation

    KILN OVERHEAD 101.CDR

    LoadConcentration

    NarrowTire

    Welds Break, Blocks Fall Off

    Welds and/or Pads Breakand Fall Out & Off

    Longitudinal FractureLines Form in Shell

    Maintenance S eminar

    SM

    Longitudinal Fractures at Shell Pads

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

    KILN OVERHEAD 102.CDR

    Bending Zones

    Laminated Zones Resist Bending

    Sag

    Flex

    PadPad

    ExcessiveClearance

    Crush Points for BricksFatigue Points for Shell

    ShellShe

    ll

    Welds

    Maintenance S eminar

    SM

    Longitudinal Fractures at Shell Pads

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    Original longitudinal welds must be removed for repair of fractures.

    Shell

    KILN OVERHEAD 103.CDR

    Tire

    Pad

    Fillet WeldFillet Weld

    Maintenance Seminar

    SM

    Longitudinal Fractures at Shell Pads

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    T 0.7t

    Remove Refractoryto Expose Shell forTracing and Repairof Fractures

    Use Rotary WireBrush to PrepareClean Surfaces for

    Gouging & Welding

    ShellInsideSurface

    Refractory

    Finish internal repair welds first

    KILN OVERHEAD 104.CDR

    Fracture

    Maintenance S eminar

    SM

    Longitudinal Fractures at Shell Pads

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    GougeFinishWeld

    Outside

    Inside

    Finish External Repair Welds Last

    Traceto

    Ends

    Tire: RemoveOne Set

    of RetainersMoveTire

    Back

    MoveTire

    Away

    KILN OVERHEAD 105.CDR

    Maintenance S eminar

    SM

    Shell Outside Surface

    Hollow Tires & Rollers

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    KILN OVERHEAD 106.CDR

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

    Hollo

    w

    Hollo

    w

    Hollo

    w

    Hollo

    w

    Bore Zone

    Old StyleHollow Tire

    Old StyleHollow Roller

    Real Thickness Varies

    Real Thickness Varies

    Tr

    Tr

    Ta

    Ta

    Apparent Thickness

    Apparent Thickness

    Maintenance S eminar

    SM

    Cold Flow Ridges on Tires and Rollers

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

    Kiln moves inside the tirewith thermal changes in theshell

    Cold flow of surface metalforms ridges that may snapoff and take along a chunkof surface metal

    Tooling is not completewithout the capabilityfor removing ridges andcutting edge radius orchamfer.

    Retainer blocks wear off atboth sides of tire to relievepressure. Tire is lockedin place on rollers by thesurface ripple pattern.

    Kilnshellexpansion&contraction

    KILN OVERHEAD 107.CDR

    Maintenance S eminar

    SM

    Warped Kiln Shell and Tire Runout

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    KILN OVERHEAD 108.CDR

    1

    2A

    A

    Hot Shell

    Slope Line

    Concave Up

    Convex Up

    Slope Line

    Heavy LoadHot Shell

    C

    C

    B

    B

    Maintenance S eminar

    SM

    Tire Wobble When Kiln Shell is Warped

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    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

    3/163/16

    WobbleGap0.0275

    Gap0.0275

    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.

    Maintenance S eminar

    SM

    Formation of Concave/Convex Surfaces

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    KILN OVERHEAD 110.CDR

    Wobble WobbleNeutral

    3/163/16

    GapGap

    Tire wobble not eliminated. Tire face becomes convex, roller faces become concave. Surface true-up isneeded 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.

    Maintenance S eminar

    SM

    Aftereffect of Grinding a Tire with Axial Runout

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    KILN OVERHEAD 111.CDR

    Important Note:

    Shell migrates inside tire. Starting with matchmarks AA and BB, first180 of rotation does not showsignificant 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 havebeen doubled.

    Two (2) full contact zones will be seen at crossover points 180 apart on the rotating tire.

    A

    A B

    B

    AA

    AA

    CL

    A

    B B

    B B

    ParallelogramTireProfile

    After

    Grinding

    180 From StartStart Rotation

    Maintenance S eminar

    SM

    RunoutRunoutRunout True AxisTrue AxisTrue Axis

    Aftereffects of Improper Roller Skewing

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    Tires & rollers need true-up grinding plus realignment, but ripples on shaft & bearing surfaces mayinterfere 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

    TireRoller Roller

    Long TermToe-In Condition

    Tire & rollersbecome coneshaped. Ridges

    form at edges.Surfaces becomedeeply spalled.

    Opposite thrustdirection of rollers

    plus high pressureand heat can destroyroller assemblies.

    Plastic flow mayform ripples onshafts & bearings.Shaft true-up willrequire shop work.Will need newbearing liners.

    KILN OVERHEAD 112.CDR

    Maintenance S eminar

    SM

    Grinding Prior to Kiln Shell Replacement Work

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    A - Assume tire not centered on rollers because of wrinkles or other shell problems. Repair work willmove 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 grindingprocess.

    A B

    KILN OVERHEAD 113.CDR

    Maintenance S eminar

    SM

    Squareness Control for Rollers

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    Unacceptable

    Cone shaped roller. Surface not parallel to CL.

    Surface parallel to CL.

    Acceptable

    KILN OVERHEAD 114.CDR Maintenance S eminarSM

    Squareness Control for Tires

    A t bl U t bl

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    KILN OVERHEAD 115.CDR

    Tire

    Control

    Control

    Control

    Surface isparallel to bore

    Acceptable

    90

    Tire

    Tire

    Tire

    CL

    CL

    CL

    Neutral

    Neutral

    Unacceptable

    Surface is notparallel to bore

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

    CL

    Maintenance Seminar

    SM

    Kiln Shell Damage and Temporary Repair

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    KILN OVERHEAD 116.CDR

    Repair of badly damaged kiln shell

    Fillet Weld

    Bad RepairGood Repair

    ShellRepairSection

    ShellWrapperNot

    Recommended

    TemporaryFirst-Aidonly

    LongitudinalButtWeld

    Void ZonesDouble VButt Weld

    Fillet Weld

    Maintenance S eminar

    SM

    Kiln Shell Damage and Temporary Repair

    Reinforcement

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    Longitudinal fractures at ring segments

    KILN OVERHEAD 117.CDR

    Typical Field Cut

    Kiln Shell

    Support

    S

    upp

    ort

    Supp

    ort

    Support

    Kiln Shell

    Fillet Welds

    ReinforcementBand (Full Circle)

    Reinforcing Band

    Maintenance S eminarSM

    Tire and Pad Lubricantfor Rotary Kilns and Dryers

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    Product Description

    KILN OVERHEAD 118.CDR

    Maintenance S eminar

    SM

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

    Patch PlateKiln Shell

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    KILN OVERHEAD 123.CDR

    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 nearestring (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 weldshrinkages will warp

    patch-plate and surroundingshell plate inward.

    CircumferentialWeldShrinkage

    CircumferentialWeldShrinkage

    Longitudinal

    WeldShrinkage

    Longitudinal

    WeldShrinkage

    Insert

    Maintenance S eminarSM

    Patch PlateKiln Shell

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

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

    Patch plate is restrained at all edges.Transverse weld shrinkage for plate thicknessis shown in chart. Yield point of adjacentplate surfaces would be exceeded if the shellwould not be free to move in any direction inreaction to weld shrinkage stress forces.

    In actual installation and welding of shellpatch plates and other inserts, limited shellplate movement is possible but combinedweld shrinkage stress forces warp the surfaceswithin and around the patch plate or add-onfixture. Base metal at the welds is not farfrom the yield point after welding.

    Transverse weld shrinkage atpatchplatedouble-veebuttwelds. Radiusinsteadof90

    cornersminimizes,

    but

    does

    not

    eliminatestress

    concentration

    points.

    CircumferentialWeldShrinkage

    0

    t

    1/4 1/2 3/4 1 1 1/4 1 1/2

    0.05

    0.10

    0.15

    CircumferentialWeldShrinkage

    Longitudinal

    WeldShrinkage

    Longitudinal

    WeldShrinkage

    Insert

    60 Single V

    60 Double V

    t = Plate Thickness (in.)

    TransverseSh

    rinkage(in.)

    KILN OVERHEAD 124.CDR Maintenance S eminarSM

    Rotary Kiln Installation and Maintenance Repair

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    B

    KILN OVERHEAD 125.CDR

    Equations For Calculating 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 weldshrinkage - usually by spreading the joint open by the amount it will contract after welding - the cumulativeshrinkage 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. Thelarge included angles in (A) are for illustrative purposes only.

    Source - Adapted from text in The Procedure Handbook of Arc Welding published by the Lincoln ElectricCompany.

    Transverse Weld Shrinkage

    A

    Maintenance S eminarSM

    Arrangement for Removing Bearing Housing End Plate

    Kiln support roller

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    KILN OVERHEAD 126.CDR

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

    Housing end platewith thrust washerand oil level pipe.

    Remove tap bold fromend plate to verifythread pitch and

    diameter.

    Kiln support rollerbearing base.

    Maintenance S eminar

    SM

    Measurement of Shell Migrationto Determine Shell Pad to Tire Diameter

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    KILN OVERHEAD 127.CDR

    Place match marksor reference lineat side of tire

    Note rotation direction.

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

    Maintenance S eminar

    SM

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    FLS Bearing 74, Type RB

    Feed End

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    Stop Block

    20 X 20 X 200 mm

    KILN OVERHEAD 201.CDR

    5-6 mm Clearance

    Zero Clearance

    Discharge End

    eed d

    Maintenance S eminarSM

    Desperation

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    Feed stencil mark

    wiped (or ground)off of the end ofthe shaft.

    Feed stencil mark

    wiped (or ground)off of the rim.

    Chamfer @1/8 X 45

    Downhill side

    of roller

    KILN OVERHEAD 202.CDR

    If original feed stencil marks have been eliminated by rubbing or by shop cleanup procedures, look for the1/8 X 45 chamfer at one end of the roller bore zone. This chamfer will indicate the larger diameter of the2-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:

    Maintenance S eminarSM

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

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    KILN OVERHEAD 203.CDR

    Maintenance S eminar

    SM

    FLS Bearing Clearances in mm

    Kiln erection Supporting rollers / bearings: Various tolerances in mm

    Mean Mean value

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    KILN OVERHEAD 204.CDR

    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 Linear Clearanceat side

    minimummaximum

    Meanclearancedp - dt

    cold

    Meanclearancedp - dt

    hot

    Mean value(dp X dt X1000)

    ddt dp

    x cold hot

    d

    X) expansion at t = 35 : d 35 X 0,0012 X 1000

    100

    0,42 mm / m

    Maintenance S eminarSM

    FLS Bearing

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    Fig. 4

    KILN OVERHEAD 205.CDR

    Fig. 1

    Fig. 3

    Fig. 2

    0 mm

    5-8 mm3

    0 mm

    T

    Maintenance S eminarSM

    Uneven Load Distribution

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    KILN OVERHEAD 206.CDR

    Hertz Pressures at Supporting Rollers

    Parallel Skewed OnlySkewed and Change

    of Slope

    Maintenance S eminarSM

    Uneven Load Distribution

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    RRRL

    M a

    FH

    FV

    30

    KILN OVERHEAD 207.CDR

    F / 3 + FV HRL

    RR F / 3 - FV H

    F X aVM

    Maintenance S eminar

    SM

    Uneven Load Distribution

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    P

    L2

    L

    R1 R2

    R1 = (L2/L) P R2 = (L1/L) P

    L1

    Load is off Center

    KILN OVERHEAD 208.CDR

    Maintenance S eminar

    SM

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

    BearingCap

    A

    FLS Conversion Kit Instructions for 1930 Type Bearing

    1 - Insert Klozure to lower half of seal retainer ring so thatthe ends of Klozure Seal extend beyond the end of the

    l i i i h l di ( bl

    Installation of Klozure Seal

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    Ends ofKlozure Sealwhile beingsnaked thrubearingbase

    Bearingsocket

    Bearingcap

    Clamping platein position

    Clamping platein position

    Klozure Seal assembly

    Klozure Seal

    in position

    1/4 lengthKlozure Seal

    Seal Retainer(lower half)

    3/32 thickO.H. Steelclampingplateto be fittedin field

    Detail D

    A - A

    SeeDetailD

    SeeDetailC

    Bearing

    Base

    p

    B - B

    Seal Retainer(upper half)

    Detail CScale: Full Size

    GarlockKlozureSplit Seal

    Patt. Number

    RK 5790A

    KILN OVERHEAD 209.CDR

    seal retainer ring with equal distance (see assemblysketch).

    2 - Attach clamping plate loose to retainer seal ring.

    3 - Install lower half retainer ring assembly to lower bearingbase by sliding the seal retainer ring, starting on the sidewhere bearing socket is below end of bearing base(ref. assembly sketch) until retainer ring is flush withbearing base.

    4 - Tighten clamping plate bolts securely.

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

    6 - Assembly upper half retainer ring to bearing cap.

    (3 pieces 5/16 x 1-3/4 Long Screw).

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

    8 - Tighten all bearing bolts securely.

    Maintenance S eminarSM

    A Th i f d k b i ll d

    Tracing Clearance Between Kiln Tires and Spacer Pads(IncludesShellOvality)

    Kiln Shell

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    Sketch (below) shows magnet base with aspring-loaded tracer arrangement mounted on thesurface of a spacerpad. Tracing surface is mountedon the flat side-face of the tire (or riding ring).

    A - The tracing surface and marker may be installedanywhere in the indicated zone. Actual positionis selected for convenient and rapid set-up duringa brief pause on rotation.

    B - Although actual conditions are variable, there is nodifferential shell/tire movement during rotation fromposition Y to position X.

    C - As the shell enters and passes through theconfiguration shown between positions X and Y,

    motion is recorded on the tracing surface. Shellcreep and pad to tire clearance appear as a wavepattern on the chart.

    Since the kiln shell will advance inside the tire during rotationthe marker must be placed on the tracing surface at the end ofthe sheet trailing the direction of rotation. The sketch shows anapproximate pattern after four revolutions of the kiln.

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

    KILN OVERHEAD 211.CDR

    Finish

    Start

    A

    Maintenance S eminarSM

    Rotation

    Kiln Tire(Riding

    Ring)

    Kiln ShellwithSpacer Pads

    Roller s

    XY

    B

    C

    CL

    450 mm Oil-Lubricated Supporting Roller Bearing

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    KILN OVERHEAD 214.CDR Maintenance S eminarSM

    Uphill and Downhill Thrust Roller

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    KILN OVERHEAD 224.CDR

    1

    1/41/4

    Maintenance S eminarSM

    Radial Runout - Polar Diagram

    ion

    ding

    ence 111

    12

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    12

    3

    4

    5

    6

    7

    8

    9

    10

    11

    12

    1

    97

    5

    5

    3

    0

    1

    3

    2

    6

    8

    10

    1

    215213

    211

    211

    209

    206

    207

    209

    208

    212

    214

    216

    215

    Stations 6 and 12 : 0 and 10 mm = 5.0 mm offsetalso 3 and 9 : 5 and 2 = 1.5 mm offset

    Low reading - close to fixed reference circleHigh reading - away from fixed reference circle

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

    Stati

    Read

    Differe

    ApproximateShellCenter

    2

    3

    4

    5

    6

    7

    8

    9

    10

    KILN OVERHEAD 225.CDR

    Maintenance S eminar

    SM

    12

    Radial Runout - Polar Diagram

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    KILN OVERHEAD 226.CDR

    Maintenance S eminar

    SM

    1

    2

    3

    4

    5

    6

    7

    8

    9

    10

    11

    12

    1

    6

    21

    16

    7

    9

    14

    24

    27

    16

    10

    9

    0

    5

    417

    432

    427

    418

    420

    425

    435

    438

    427

    421

    420

    411

    416

    Station

    Reading

    D

    ifference

    This is very bad.

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

    1

    2

    3

    4

    5

    6

    7

    8

    9

    10

    11

    12

    6 mm

    21 mm

    16 mm

    7 mm

    Radial Runout - Polar Diagram

    12

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    1

    2

    3

    4

    5

    6

    7

    8

    9

    10

    11

    12

    1

    Station

    Reading

    D

    ifference 1

    2

    3

    4

    5

    6

    7

    8

    9

    10

    11

    KILN OVERHEAD 227.CDR

    Maintenance S eminar

    SM

    Kiln Size: Diameter(s) LengthProcess Product Production TPD

    Product Density: Lb/Ft Feed Density Lb/FtF d R TPD Kil Sl % I /F

    3 3

    Kiln Data Sheet

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    Feed Range: TPD, Kiln Slope % or In/Foot,Rotation Speed (RPH): Maximum, Normal, Minimum

    Distributed Loads, from Discharge End ( Ft. To Ft ):

    Refractory Thickness (Ins) Lb/Ft From (Ft) to (Ft)

    Ft.Ft.Ft.Ft.Ft.

    Typical Coating build-up on Refractory LiningFt.Ft.Ft.

    Item Quantity Thick Lb/FtFt. Tumbler*Ft. LifterFt. Lifter

    Item Quantity Size LengthFt. ChainFt. ChainFt. ChainFt. Chain

    * Tumblersformed

    by

    refractory

    lay-up.

    If

    aTrefoil

    section

    is

    in

    place,

    or

    being

    considered, give

    dimensions

    location

    and

    Lb/Ft .

    Concentrated Loads: Distance from discharge end

    Girth Gear Weight (Kips)Refractory Dam @ High (Ins)Tube Cooler Location

    No. of Tube Coolers , Diameter (Ins) , LengthFeed End Seal Weight (Kips)Discharge End Cowl & Air Seal Weight (Kips)Discharge End Castings: Quantity Pounds Each

    3

    3

    3

    KILN OVERHEAD 230.CDR Maintenance S eminarSM

    Laser Kiln SurveyLayout of Offset Line

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    H

    X

    X1X2

    .3

    .2

    .1

    .6

    .5

    .4

    Laser

    KILN OVERHEAD 231.CDR

    VII

    II I

    Maintenance S eminarSM

    Laser Kiln Survey

    Step 1

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    Tire

    Offset Line

    Measuring Points

    Tire

    Slave

    KILN OVERHEAD 232.CDR

    Laser

    At

    Step 2

    Maintenance S eminarSM

    Laser Kiln Survey

    Step 3

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    Laser

    Laser

    Ar1Ar2

    CommonReferenceTarget

    Step 4

    Pmax

    P2P1

    KILN OVERHEAD 233.CDR Maintenance S eminarSM

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    ZH

    ZAZV

    ZV

    VV

    VH

    ZH

    OSV.

    X2X1

    Y1

    Y

    H

    C

    PMAX

    R

    RHR

    LR

    VR

    90

    Laserstrle

    Maintenance S eminarSM

    Feed

    Fe

    Disc

    FeedE3 - Support Kiln

    4 - Support Kiln

    5 - Support Kiln

    6 - Support Kiln

    Enter Kiln Length and Dimensions Between Tire Centerlines