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PROCEDURES
FOR
MECHANICAL
ANALYSIS OF
ROTARY KILNS
Mustafa
Kamal
Pasha
RECOMMENDED PROCEDURES
FOR MECHANICAL ANALYSIS
OF ROTARY KILNS
TEXT AND ORIGINAL SKETCHES
SAFETY
This text is intended to serve as a practical guide for the
operation and maintenance of rotary kilns and kiln drive systems. It is
not intended to be an instruction manual, and the procedures
discussed in this text are to be performed only by trained personnel
who are fully aware of the dangers involved with the equipment.
Any procedures presented in this text are to be performed with all
guards and safety barriers in place and fully operable. With the
exception of Section B, Gear Alignment, removal of guards is not
required to successfully utilize these procedures.
All equipment must be operated and maintained according to
applicable government safety and health laws and regulations such as
OSHA, MSHA, generally recognized industry standards, plant safety
rules and regulations. All personnel must follow safe working
practices and use good judgement.
The installation, operation and maintenance of rotary kilns and
associated equipment presents many potential unsafe conditions each
4.
111
FOREWORD
The material in this book evolved gradually with the accumula
tion of sketches which were prepared in order to clarify explanations
of work to be done at times when language problems had to be
overcome in various parts of the world.
Field engineers and consultants who specialize in installation and
maintenance problems cannot travel with equipment needed for the
work. It is usually necessary to arrange for acquisition of precision
test equipment from local sources and to prepare various jigs and
fixtures from material available at the plant site.
There are many ways to do the work described in this review of
procedures for kiln survey and mechanical analysis. This work merely
illustrates a few practical and simplified approaches. Some plant
engineers and maintenance supervisors have followed up with custom
made test equipment and fixtures designed for rapid setup for
preventative maintenance test procedures to ensure maximum oper
ating time for their rotary kiln(s).
There are no theories contained in these descriptions of test
procedures and the potential problems for operation and maintenance
of a rotary kiln contained in this material. When certain long
standing practices and/or recommendations are challenged, it is
because for many years I have been called upon to rebuild equipment
that broke down after components were set according to existing
theories and misdirected logic.
This text will call your attention to a few of the less obvious,
often overlooked, problems encountered in kiln survey and mechanical
analysis procedures for maintenance of a rotary kiln. After all, why
should you have to learn the hard way.
R. P. Chapman
iv
ACKNOWLEDGEMENT
TABLE OF CONTENTS
PAGE
A.
B.
C.
23
D.
25
E.
31
F.
G.
PRESHUTDOWN PROCEDURES
ALIGN
41
H.
49
I.
53
J.
61
K.
65
L.
SUMMARY
81
vi
A.
PRESHUTDOWN ROCEDURES
Refer to Figure 1, for typical orientation and common
terminology for reporting kiln details. In long distance
telephone discussions and also in written descriptions of kiln
problem zones, the reporter should clarify pier numbering
sequence (starting count at discharge end or at feed end) and
should avoid local landmarks and/or compass directions when
describing work areas for the kiln.
1. ANAL YZE AND RECORD SHELL
CONDITION
Before a hot, on-stream kiln is shutdown for maintenance
and realignment, observe the shell closely for indications of
dis tortion and runout conditions. If runout is excessive,
espe cially at feed or discharge ends, make arrangements for
cutting the shell for realignment of the afkcted sections.
Sometimes
certain zones of the shellincluding riding ring sections
are
so badly distorted that new shell sections must be installed to
eliminate the maintenance problems.
In addition to observing kiln shell conditions, measure
runout at predetermined test locations along the entire kiln
length. Use these measurements to plot graphic views of
the cross- sectional shape of the shell at the various test
locations; also plot the plan views of the shell at test points
1800 apart on the circumference. Use the following
procedure to measure and plot shell runout:
a.
analysis
for the
If these faces are not flat, smooth and parallel to the axis of the
shaft, arrange for an in-place true-up on the affected surfaces.
Typically, tires and rollers in need of surface true-up will also
be peened outward past the side faces as shown in Figure
6. These protrusions must be removed, and corners must be
rounded at approximately radius.
NOTE
True-up work on tire and roller surfaces should be done in
advance of a planned kiln shutdown for realignment tests and
adjustments. Unless the kiln service crew is familiar with the
procedure for recalculating support set points, and has access
to original reference drawings, tire section misalignment may
occur and cause serious maintenance roblems after the trueup work is finished.
It is not enough to merely move individual rollers a distance
equal to the amount removed from combined radii of tire and
roller. The actual amount will vary according to original
design, but will be somewhere in the range of 1.7 to 2 units
inward for each unit of 1 removed from combined radii of tire
and roller.
Perform true-up work with a belt grinder arrangement to
produce a smooth surface truly parallel to either the roller
shaft axis or the kiln axis in the case of the tires. Standard
machining procedures, if handled carefully, will produce
surfaces that are parallel to the axis of the roller or tire, but
unless the final cut is made with a broad-nose tool, the finish
5
CAUTION
When differential motion between tire and shell pads cannot
be detected, there are two possible reasons for lock-up:
Interference from a slug formation between a spacer pad
the bore of the tire, where metals from one or both surfaces
being gouged deeper and deeper to increase the size of the
as it is drawn across the pad. The slug will eventually fall
7
and
are
slug
free
The kiln shell has already expanded enough for spacer pads to
be choked inside the tire.
A typical reaction to this lock-up condition is to lubricate the
bore of the tire to make contact surfaces slippery enough for
differential rotation movement. Whether or not the bore of
the tire should be lubricated at all (except for application of
dry graphite) is debatable. When differential movement
cannot be detected, the underlying reason must be eliminated;
lubrication will not help.
Knowledge of shell and tire temperature differentials during
normal operation of the kiln is valuable should it become
necessary to prepare for shimming work, spacer pad replace
ment or replacement of the entire tire section shell and pads.
11
12
ALIGNMENT AND
DRIVE PINION(S) MESHING CONDITION
14
NOTE
Conditions described above will be reversed when the thrust
tire moves hard against the lower thrust roller for continuous
operation.
At plain tires, it may be possible to install oversize retainer
blocks to eliminate the undercut tire condition, but at the
thrust tire there may not be sufficient clearance for an oversize
retainer to pass the top of the thrust roller. Alternate action
would be required when there is a clearance problem at the
thrust rollers.
POSITIONS OF
ROLLERS AT ALL
PIERS
10. GHEGK
TIRES
ON
SUPPORT
or lower
c.
center toward its own downturning side, thus having the same
effect as moving the roller in the wrong direction. See Figure
19 & 19-A.
13. CHECK HYDRAULIC THR UST ASSEMBLIES
Kilns with hydraulically operated thrust assemblies may have
thrust arrangements on 1, 2, or 3 piers depending upon the size
of the kiln and the number of support piers.
By utilizing a series of limit switches to control the start and
stop sequence of the pump, the kiln should be moving uphill
and downhill a distance of about 1-Y2 to 2 in continuous
cycles. Normally, support rollers are adjusted in neutral
positions with centerlines either parallel to the kiln centerline
or slightly skewed to relieve some of the gravitational thrust of
the kiln at the thrust roller(s).
Since hydraulic thrust
arrangements generally do not have backup thrust rollers at
the uphill side of the tires, roller skewing must not, in itself,
cause the kiln to travel uphill. See Figures 20 and 21.
If drive amperage rises above normal, check support roller
assemblies for direction of shaft thrust. If one or more roller is
thrusting against the high bearing end plate and thrust
washer, the condition is forcing the kiln downhill and increas
ing the load on the thrust assembly.
14. CHECK FOR OIL
LEAKS AT SUPPORT
ROLLER SHAFT SEALS
With the equipment set at a certain slope angle, oil leaks are
found at the high side bearing assembly. Oil escaping from the
bearing travels down the shaft to the roller side wall and then
to the rolling contact surface, where its lubricity cancels out
the effectiveness of skewing adjustments and so increases the
downhill gravitational thrust of the kiln.
The only time an oil leak is found at a low side bearing
assembly is when the seal is bad and the oil reservoir is over
filled. Under certain conditions, when a shaft seal is bad at a
downhill bearing, dirt and/or rain water can work its way
into the bearing housing. See Figures 22 and 23.
17
NOTE
In addition to items listed in the preceding preshutdown
considerations, the following rocedures are for total survey
and analysis of most mechanical aspects of rotary kilns. Not
all of the items would be checked out as standard and routine
procedures. Actual check-out will be determined by the field
engineer to suit maintenance problems reported by representa
tives of the client.