2010 10 SMP - Grinding of Kiln Tyre and Roller Surface - Final - V1

Standard Maintenance Procedure
Grinding of kiln tyres and rollers
Version:
v1_10/2010
Content
1.
2.
3.
4.
5.
6.
7.
8.
General.........................................................................................................................2
Recommended Maintenance Procedure ......................................................................3
Necessity / reasons for grinding ...................................................................................4
Grinding of tyre and roller surfaces...............................................................................7
Grinding of tyre edges ..................................................................................................9
Grinding of thrust roller and tyre side surface .............................................................11
Control measurement .................................................................................................14
Annex .........................................................................................................................15
8.1
Recommended periodical maintenance tasks (table) ..........................................15
8.2
Bibliography.........................................................................................................19
smp_grinding of kiln tyre and roller

surface_final_V1.doc
Written by:
F. Hartwig;
HTC CECA
Page 1 of 19
Checked by:
HTC CECA,
Sweden
Valid from: 04.10.2010
Approved
by
HTC CECA

Version:
v1_10/2010
1. General
Kilns are provided by several suppliers (e.g. KHD, Polysius, FLS; recently also Chinese
suppliers) and are employed for burning clinker or (in some cases) lime. Every single
application may require special tailor-made maintenance activities. Generally some
conditions of the kiln which have an impact on the condition of the surface of the kiln tires
and rollers can be monitored by the control system. For example the temperature of the
roller bearings or the position of the tyre on the roller, this can be checked regularly. It is
strongly recommended to cross-check each Preventative Maintenance Program with the
machine operation manual provided by the supplier.
Maintenance instructions and frequencies given in this Standard Maintenance Procedure
(SMP) describe in detail and all-embracing activities to establish a Preventative
Maintenance Program (PMP) for resurfacing of kiln tires and rollers. Over the years of
operation time it could be necessary to adapt the recommended maintenance instructions.
General actions apply to general cleaning and cleaning of specific parts of the kiln.
The preventative maintenance program also includes checks of important and critical
components such as bolts, screws, keys, etc. Operational conditions such as levels of
lubricants, possible leakages and spillage of lubricants and hydraulics must also be
checked. In addition, careful attention must be paid to abnormal vibration, noise,
temperature, and dust expulsion. Instructions for repair are not covered with in this
guideline.
The program recommended by HTC was derived from operation manuals from different
suppliers together with experience from different plants and Maintenance Managers.
For further information or any question contact your Area HTC.

Written by:
F. Hartwig;
HTC CECA
Page 2 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

2.
Version:
v1_10/2010
Recommended Maintenance Procedure
The risk for unexpected wear and crash stops can be minimized by systematic preventive
maintenance of the machinery based on:
Regular scheduled inspection of condition of the surfaces
Observation of abnormal impacts and loads with consequent proof correction
Planning and carrying out stop for maintenance work
Alignment measurements from time to time (esp. before grinding).
The tyres and rollers themselves are not wear parts, i.e. unforeseen impacts or loads only
will affect their service life time. On the other hand, if abnormal damage is avoided, then
they will never wear out. It is important to monitor the impacts and loads and to repair the
surface early when there is minimum wear. The recommended procedure is to grind the
surface with special grinding equipment. Turning (cutting) should only be done on the side
surface edges. Regular crack inspection and crack detection is also important. These
statements are to some extent theoretical and can only be fulfilled by an ideal preventive
maintenance. Some of the recommended activities have to be carried out every day, some
have considerably longer intervals, e.g. monthly or annually. It is mandatory to document
all checks and observations and maintain a historical record (e.g. in SAP PM). In the real
world careful regular condition-check combined with scheduled resurfacing is needed to
ensure steady operation and long service life.
To avoid unforeseen production stoppages of the kiln due to breakdown of a tyre or roller it
is important to check the condition on a regular scheduled basis. This is especially
important because of the expense. The corrective work resulting from the inspections will
contribute to an extension of the service life of tyres and rollers. A chart with Maintenance
instructions and frequencies is available in the Annex chapter 8.1.
Fig. 1+2: before / after grinding

Written by:
F. Hartwig;
HTC CECA
Page 3 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
3. Necessity / reasons for grinding

Grinding is necessary due to deviant geometry and /or damage of tyre and roller surfaces.
Reasons of damage and thus necessity for proof correction and grinding could be:
Lack of preventive maintenance

Problems in production process (permanent coating, shell deformation)
Increased wear of surface due to lack in longitudinal movement of the kiln
Roughness and dirtiness of the surface of tyre and roller
Conical wear due to incorrect positioning of the rollers
Deformation of the surface after welding repair
Local impact and overload on surface due to irregular roller wear
Incorrect adjustment of the longitudinal guidance system of the kiln
Initial cracks in the surface due to plastic material deformation due to local overload
of the surface
Incorrect position of the rollers after repair actions on the kiln shell and support
Foundation downward revision of kiln support
Vibrations due to non roundness of tyres and rollers
Diameter or axis deviation of tyres and rollers (e.g. seen after alignment
measurement)
Possible deviation correction of tires and rollers:
Concave, convex and conical contours
Fig. 3-5: convex / concave wear (left: tyre while grinding process)
Written by:
F. Hartwig;
HTC CECA
Page 4 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
Damage on surface such as grooves and depressions in circumferential direction,

slots crosswise to circumferential direction
Fig. 6: slots on roller crosswise to circumferential direction due to vibrations from driving
system

Written by:
F. Hartwig;
HTC CECA
Page 5 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
Fig. 7+8: grooves and depressions in circumferential direction on roller and tyre due to
incorrect position of roller-axles
Damage on surface due to foreign parts and / or material fatigue
Fig. 9: fish scale wear because of hydro-static pressure of lubrication due to a difference
in diameter of tyre (> 10mm) and incorrect position of roller-axles / pitting on roller
Written by:
F. Hartwig;
HTC CECA
Page 6 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
4. Grinding of tyre and roller surfaces

With special grinding equipment it is possible to repair the damage on surface of tires and
rollers while the kiln is running / in progress. The surface quality will lead to new condition
by grinding. Use of the grinding equipment is independent to the diameter of the tyre /
roller, manufacturer of the kiln and location.
The experience has shown that grinding is the procedure with best / acceptable results.
The question may be asked why not resurface the tyre and roller by turning (cutting) while
the kiln is in progress (shorter procedure). This must be avoided (shown in sketching
Fig. 10). The tyre and roller system (support / pier) gets a reduced contact surface with
progressive treatment. In the course of this, the surface pressure will increase and plastic
deformation on tyre and roller will occur. Microstructure destruction of the material will be
the consequence. The extent of destruction often becomes clear only after years. The
grinding procedure will prevent such damage (only 0.10 mm will be removed at high feed
rate).
sketching
Dont do
this on
surface at
kiln in
progress
tyre
roller
Fig. 10: Cutting of roller, smaller contact surface with progressive treatment (a-b)
Grinding a roller is relatively simple because of its movement in a defined bearing.
Grinding a tyre is much more difficult. The tyre is not rotating in a defined axis; it is kept
Written by:
F. Hartwig;
HTC CECA
Page 7 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
between two rollers. The non roundness of the tyre itself respective to the contour of the
tyre surface causes deflection from the axis. This is also observed when grinding a tyre
after welding repair. A four-roller-positioning grinding system meets this challenge.
Fig. 11: grinding equipment on tyre (important: 4-roller positioning)
Fig. 12: grinding equipment on a tyre in resurfacing procedure

Written by:
F. Hartwig;
HTC CECA
Page 8 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
Fig. 13: grinding a roller in resurfacing procedure

Generally, following important points (cross-check this with the kiln operation manual
provided by the supplier) in relation to the kiln line have to be observed.
While grinding a tyre or roller the rotation of the kiln must be reduced (in a sector of 0.9 to
1.0 Upm) due to the vibrations which have impact on the grinding surface. The grinding
process has to be observed regularly. After grinding the surfaces only must be lubricated if
the kiln does not move longitudinal. The longitudinal movement of the kiln should take
place in a time of eight hours to one day, depends on the experience with the kiln, not
really to the design with or without hydraulic thrust roller system. The kiln lines without
hydraulic thrust roller also have a fixed thrust roller as an end stop. The end positions
normally are equipped with limit switcher and electronic warning system in both cases.
5. Grinding of tyre edges

Additional to the tyres surface the edges of the tyre could be in bad condition and thus
have to be tooled. This could be done in connection with the grinding process (chapter 4),
is often combined with grinding the tyres side surface (and thrust roller, chapter 6). For
example a bevel 25 mm x 30 will be removed. This i s the only action were turning / cutting
Written by:
F. Hartwig;
HTC CECA
Page 9 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
could be used for higher feed rate in a first step. Finishing is done by grinding. The
substructure of the grinding equipment must have a pick up of the longitudinal kiln
movement.
Fig. 14: wear of tyre edges
Fig. 15+16: turning and grinding of tyre edges

Written by:
F. Hartwig;
HTC CECA
Page 10 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
Fig. 17+18: substructure of (tyre) grinding equipment for pickup of longitudinal kiln
movement
6. Grinding of thrust roller and tyre side surface

Grinding the surface of the thrust roller and mating tyre side is quiet difficult.
Thereby the alignment of the thrust roller to the theoretical axis of the kiln has to be
observed. Both surfaces must be removed in one operation.
Correct condition
Tyre
Tyre
Thrust roller
Fig. 19: alignment of thrust roller to the theoretical axis of the kiln

Written by:
F. Hartwig;
HTC CECA
Page 11 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

wrong condition
Version:
wrong condition
v1_10/2010
The inclination of the

thrust roller doesnt fit
to the theoretical
slope of the kiln.
Possible cause:
Foundation downward
revision and
misalignment
Fig. 20+21: possible misalignment of thrust roller to the theoretical axis of the kiln
Due to experience the

offset of the thrust
roller should be a
maximum of 5 mm to
the axis of the kiln
(direction depends on
the direction of
rotation of the kiln).
Determination of the
thrust roller using a
circle.
Fig. 22: determination of position of thrust roller

Written by:
F. Hartwig;
HTC CECA
Page 12 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

A1
Version:
v1_10/2010
A: direction of rotation
of the kiln
B: acceptable offset to
the kiln axis = 2-5 mm
A2
B1
The offset to the kiln

axis should be chosen
so that the rotation of
the kiln pushes down
the thrust roller and
not lift it up.
B2
Fig. 23: offset of thrust roller to the theoretical axis of the kiln
Fig. 24-27: damage at tyre and thrust roller due to misalignment

Written by:
F. Hartwig;
HTC CECA
Page 13 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
Fig. 28+29: grinding equipment of resurfacing tyre and thrust roller
7. Control measurement
Measurements of the existing i.e. worn geometry or macro wear pattern of the support
roller and mating tyre to be resurfaced constitute an important preparatory activity.
The diameter is determined by the circumference. Concentric errors are detected by an
inductive transducer.
Dimensional accuracy after grinding (independent to the diameter):
Support roller:
difference in diameter +/- 0.10 mm

deviation in concentric rotation max. 0.20 mm
Tyre:
difference in diameter +/- 0.15 mm

Written by:
F. Hartwig;
HTC CECA
Page 14 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
v1_10/2010
Fig. 30+31: equipment for diameter measurement
8. Annex
Additional documents
8.1 Recommended periodical maintenance tasks (table)

This program recommended by HTC was derived from Manuals from different suppliers
together with experience from different plants and Maintenance Managers. Some of the
recommended activities have to be carried out every day or every shift, some have
considerably longer intervals, e.g. bi-monthly or annually. It establishes the minimum level
of activities and frequencies. Every single application may require special tailor-made
maintenance activities. It is strongly recommended to cross-check each Preventative
Maintenance Program with the machine manual provided by the supplier. Activities in
thick printed text are directly related to grinding of tyres and rollers.

Written by:
F. Hartwig;
HTC CECA
Page 15 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

Version:
Rate / interval Activity / Task

A) daily / all 24 1) Conduct a walk-by inspection of the kiln:
hours
Are there any noticeable differences since the
last inspection?
Is there any discoloration or hot spot evident
on the kiln shell?
Check and record the temperature profile of
kiln shell and tyres.
Listen for any unusual sounds
A)
2) Check condition of discharge and feed end seals:
Is there any leakage of excess air or product?
What is the condition of the seal support?
A)
3) Check condition of nose ring area:
Are any castings loose, damaged or missing?
Are any of the nose ring brick worn, damaged or
missing?
A)
4) Check condition of each pier top:
Do tires and rollers have full face contact?
Is there any movement between the pier top
and support frame?
Are there any loose anchor bolts on the
support frame?
A)
5) Check condition of the tyre on each pier / support:
Is there any spalling or ridging on the tyre
face?
Does the tyre lift off the roller during any
portion of the kiln rotation?
Has the tyre developed a wobble?
Since the last inspection, has the tyre position
changed relative to the stop blocks?
Are there any broken welds on the retaining
bands or between the tyres and filler bars?
Is the tyre centered over the carrying rollers?
Does the tyre longitudinal move over the
rollers surface in a time of eight hours to one
day?
Observe the limit switchers, may be there is a
warning system, for the long. movement.
Is there a relative movement at the loose tyre in
regard to the shell?
Written by:
F. Hartwig;
HTC CECA
Page 16 of 19
Checked by:
HTC CECA,
Sweden
v1_10/2010
Self/Supplier
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Approved
by
HTC CECA

Version:
A) daily / all 24 6) Check condition of the carrying rollers on each

hours
pier / support:
Are the rollers thrusting uphill or downhill?
Is there any spalling or ridging on the roller
surface?
Are the bearing seals working properly?
Does the surface of the bearing housing feel
unusually warm?
Is the lubricant level of the bearing housing
adequate?
Is there enough cooling water available for the
bearing housings?
A)
7) Check condition of the thrust rollers:
Is the kiln against the uphill or downhill thrust
roller?
Is there any spalling or ridging on the roller
surface?
Observe the hydraulic pressure in case of
hydraulic thrust roller system, may be there is
a warning system.
A)
8) Check condition of the drive system:
Has the pattern of gear contact changed?
Are there any loose or missing flange bolts?
Is the automatic gear lubrication system
functioning properly?
Is there adequate gear lubrication?
Are there any unusual sounds coming from the
drive system?
Is there any new noticeable vibration?
B) Weekly / all 1) Check graphite block lubrication:
200 hours
Are holders clean and free of product or dirt
contamination?
Is the graphite block free and loose in its
holder?
Is the graphite providing an adequate supply of
lubrication?
B)
2) Check creep or gap of tyres on all piers:
Has level of creep increased since the last
inspection?
Grease consumption and dosing quantity
B)
3) Check lubricate between the filler bar and tyre
inner
Written by:
F. Hartwig;
HTC CECA
Page 17 of 19
Checked by:
HTC CECA,
Sweden
v1_10/2010
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Approved
by
HTC CECA

B) Weekly / all
200 hours
B)
B)
B)
C) Monthly /
all 1000 hours
C)
C)
C)
D) Semiannual / all
4500 hours
D)
D)
D)
D)
D)
E) Annual / all
9000 hours
4) Check condition of the rollers on each pier:

Are the rollers thrusting uphill or downhill?
Are the shaft seals still adequate?
5) Clean the pier tops of dirt, oil product spillage
6) Check oil levels of roller and thrust bearings. Make
sure fill pipe / level indicator is not plugged.
7) Start up the emergency drive and run it for at least 30
minutes:
Check the water level of the emergency engine
battery
Check fuel level of the emergency engine.
Check the lubrication system of the gear box and
drive system.
1) Check for pitch line separation and run out of bull gear
and pinion
2) Check condition of attachment (bolts, welds, spring
pads) of gear flange
3) Check excessive tyre and roller wear
4) Check (and lubricate were necessary) the drive
coupling.
1) Change gear lubricant and lean sump and gear area if
necessary.
2) Change grease on pinion shaft bearing if necessary.
3) Change oil in thrust roller bearings if necessary
4) Inspect kiln shell for cracks under tyres
5) Check refractory for wear if kiln can be shut down
6) Inspect drive coupling grid members.
1) Clean and inspect gear and drive unit:
Check oil quality (samples and analysis with
report) of gear box oil
Check gear teeth for abnormal wear
Inspect, clean, repack and change lubrication on
pinion bearings
Change lubrication if necessary
Check drive train couplings for wear and replace if
necessary
Check for loose nuts and bolts on gear mounting
flange
Check radial alignment of gear and pinion
Check brush rigging and electrical components of
drive motor

Written by:
Version:
F. Hartwig;
HTC CECA
Page 18 of 19
Checked by:
HTC CECA,
Sweden
v1_10/2010
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Self
Supplier
Self
Self
Self /
laboratory
Supplier
Self
Self
Self
Self
Supplier
Self
Approved
by
HTC CECA

E) Annual / all
9000 hours
E)
E)
E)
E)
F) As required
/ all 3 years
F)
Version:
2) Clean and inspect roller bearings:

Remove covers and drain lubricant
Check for bearing wear, shaft condition and
bearing liner thickness
Flush with new bearing lubricant
3) Measure and document tyre and roller wear
4) Clean and grease the adjustment screws and wrap
them in burlap
5) Repair (weld) detected cracks in shell, filler bars and
support bands.
6) Replace worn refractory
1)
Check alignment and elevation of each pier
Check alignment and ovality of the kiln
vibration analysis of the drive (report, characteristic
measurement, observed are normally only
characteristic values)
Ultrasonic testing of the bolts of the bull gear
flange
Ultrasonic testing of esp. fixed tyres for initial
cracks from the inner diameter
Resurface tyre and roller surface were
necessary (as detected and measured)
2) Check complete kiln for: complete cleaning and
overhaul e.g. reconditioning (pitting) of open gearpinion (toothing)
v1_10/2010
Self
Self
Self
Self
Self
Self/Supplier
Self/Supplier
Supplier
Supplier
Self/Supplier
Supplier
Supplier
Supplier
Self/Supplier
8.2 Bibliography
[1]
[2]
[3]
[4]
[5]
Rhr, W., Schleifen von Laufrollen und Laufringen; Polysius AG, 2005
Osthoff, U., Schleifen von Laufrollen und Laufringen; Polysius AG, 06/2010
Dominguez, J., Tyre and roller surfaces and how to repair them; FLS, 2009
Teutrine, Service- und Reparaturarbeiten Drehrohrofen, Teutrine Industrie-Technik GmbH, 2002
Phillips Kiln Services (Europe) Ltd, Roller and tyre re-surfacing (grinding), 2010
Contact for more information:

Frank Hartwig
Senior Maintenance Engineer
HTC Maintenance
Telefon +496221 481-330
Fax +49 6221 481-628
E-Mail: frank.hartwig@htc-gmbh.com

Written by:
F. Hartwig;
HTC CECA
Page 19 of 19
Checked by:
HTC CECA,
Sweden
Approved
by
HTC CECA

2010 10 SMP - Grinding of Kiln Tyre and Roller Surface - Final - V1

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

2010 10 SMP - Grinding of Kiln Tyre and Roller Surface - Final - V1

Încărcat de

Drepturi de autor:

Formate disponibile

Standard Maintenance Procedure

Grinding of kiln tyres and rollers

smp_grinding of kiln tyre and roller

Valid from: 04.10.2010

Standard Maintenance Procedure

smp_grinding of kiln tyre and roller

Valid from: 04.10.2010

Standard Maintenance Procedure

Recommended Maintenance Procedure

Fig. 1+2: before / after grinding

Valid from: 04.10.2010

Standard Maintenance Procedure

3. Necessity / reasons for grinding

Lack of preventive maintenance

Possible deviation correction of tires and rollers:

Concave, convex and conical contours

Valid from: 04.10.2010

Standard Maintenance Procedure

Damage on surface such as grooves and depressions in circumferential direction,

smp_grinding of kiln tyre and roller

Valid from: 04.10.2010

Standard Maintenance Procedure

Damage on surface due to foreign parts and / or material fatigue

Valid from: 04.10.2010

Standard Maintenance Procedure

4. Grinding of tyre and roller surfaces

Valid from: 04.10.2010

Standard Maintenance Procedure

Fig. 11: grinding equipment on tyre (important: 4-roller positioning)

Fig. 12: grinding equipment on a tyre in resurfacing procedure

Valid from: 04.10.2010

Standard Maintenance Procedure

Fig. 13: grinding a roller in resurfacing procedure

5. Grinding of tyre edges

Valid from: 04.10.2010

Standard Maintenance Procedure

Fig. 14: wear of tyre edges

Fig. 15+16: turning and grinding of tyre edges

smp_grinding of kiln tyre and roller

Valid from: 04.10.2010

Standard Maintenance Procedure

6. Grinding of thrust roller and tyre side surface

smp_grinding of kiln tyre and roller

Valid from: 04.10.2010

Standard Maintenance Procedure

The inclination of the

Due to experience the

smp_grinding of kiln tyre and roller

Valid from: 04.10.2010

Standard Maintenance Procedure

The offset to the kiln

Fig. 24-27: damage at tyre and thrust roller due to misalignment

Valid from: 04.10.2010

Standard Maintenance Procedure

Fig. 28+29: grinding equipment of resurfacing tyre and thrust roller

difference in diameter +/- 0.10 mm

difference in diameter +/- 0.15 mm

smp_grinding of kiln tyre and roller

Valid from: 04.10.2010

Standard Maintenance Procedure

Fig. 30+31: equipment for diameter measurement

8.1 Recommended periodical maintenance tasks (table)

smp_grinding of kiln tyre and roller