140129343 Fuller KilnErection
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Transcript of 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)
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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
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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
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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
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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
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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.
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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.
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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
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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.
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Alignment Fittings
KILN OVERHEAD 012.CDR
Edges of adjacentshell sections
Strong-back
Push - PullAdjust Bolts
Adjusting lug
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GaugeBlocks
Field Joints
Feed End
Batter Board withCenter Hole and Card
Batter Board Locations
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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
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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
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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.
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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
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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
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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.
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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
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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.
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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
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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
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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.
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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