Kiln Maintenance Manual

14/06/2017
OPERATIONS / MAINTENANCE
KILNS MECHANICAL MAINTENANCE
Code..
INDEX OF MECHANICAL MAINTENANCE

PROCEDURES TO ROTARY KILNS
CHAPTER 1
GAP MEASUREMENT AND DISPLACEMENT BETWEEN THE KILN SHELL AND TIRE (KILN TIRES).................2
CHAPTER 2 DEFORMATION AND OVALITY..................................................................................................................10
CHAPTER 3 TIRES AND ROLLERS DIAMETERS MEASUREMENTS.......................................................................22
CHAPTER 4 MEASURING AND ADJUSTMENT OF SUPPORTING ROLLERS AXIAL LOAD...............................26
CHAPTER 5 MEASUREMENT AND ADJUSTMENT OF THE ROLLS INCLINATION............................................38
CHAPTER 6 ROLLERS PARALLELISM AND FLOTATION...........................................................................................44
CHAPTER 7 CONTROL AND EVALUATION OF ALIGNMENT IN HOT (RUNNING) AND COLD

ENVIRONMENT (KILN SHUTDOWN)...................................................................................................................49
CHAPTER 8 CONTROL OF MOVEMENTS (ADJUSTMENTS) TO CORRECT KILN SHAFT................................56
CHAPTER 9 CONTROL OF CONTACT BETWEEN ROLLERS AND TIRES, THROUGH LEAD WIRE...............62
CHAPTER 10 CONTROL OF GEARING BETWEEN GEAR RING AND PINION IN KILN THROUGH LEADEN
HEELS............................................................................................................................................................................71
CHAPTER 11 ALIGNMENT OF THE MAIN TRANSMISSION, GEAR RING AND PINION....................................74
CHAPTER 12 KILN SECTIONS (KILN SHELL) REPLACEMENT, IN WHICH DISTORTION CAUSES

PROBLEMS...................................................................................................................................................................79
CHAPTER 13 MEASURING THE BEARINGS SET FOR KILN TIRES........................................................................84
CHAPTER 14 ROLLER BEARINGS (BRONZE/BABBIT) REPLACEMENT.............................................................88
CHAPTER 15 KILN WELDING APPLICATIONS ANALYSIS AND CONTROL.........................................................94
ATTACHMENTS..........................................................................................................................................................................100
TABLE 5.1 MEASUREMENT AND FIXINGS OF THE ROLLERS INCLINATION.........................................................100
FORM 6.1 . KILNS ROLLERS PARALLELISM AND FLOTATION.............................................................................101
FORM 6.2 .- KILN ROLLERS POSITION........................................................................................................................ 102
FORM 7.1 . HORIZONTAL ALIGNMENT.................................................................................................................... 102
FORM 7.2 . HORIZONTAL ALIGNMENT.................................................................................................................... 104
FORM 7.3 . BASE PLATES LEVELING....................................................................................................................... 105
FORM 7.4 . VERTICAL ALIGNMENT.......................................................................................................................... 106
FORM 9.1 . ALIGNMENT BY MEANS OF LEADEN WIRE TESTS............................................................................109
FORM 10.1.- GEARING CONTROL BETWEEN PINION AND GEAR RING.................................................................110
FORM 11.1 . GEAR RING RADIAL ALIGNMENT....................................................................................................... 111
FORM 11.2 . GEAR RING OR TIRES AXIAL ALIGNMENT.............................................................................................112
357948525.doc Page 1 of 111

14/06/2017
Code..
Chapter 1
GAP MEASUREMENT (Clearance) AND DISPLACEMENT (Control of Clearance) BETWEEN

THE KILN SHELL AND TIRE (Kiln Tires).
1.1 OBJECTIVE AND SCOPE

The objective of this measurement is to count with the necessary information to control displacement
and clearance between the kiln tube and tires due that it is fundamental for the refractory life as well
as for mechanical conditions.
This is a control requiring a lot of caution, and the recommendation is to check at least once per shift.
1.2 METHOD BASIS OR FOUNDATION

There are kilns with tires that due to their design are fixed; i.e., they do not have sliding between the
kiln tube and tire, but in the FLS kilns (F. L. Smidth) rolling rings of "floating" single type or "migrating"
type are used, with certain diameter difference between the kiln tire and the kiln shell (support
blocks).
The kiln tube and the rolling rings are dimensioned so that D internal diameter, of kiln tire, is a little bit
bigger than the d kiln tube external diameter, measured in support blocks (or in the kiln tube). The
diameter difference is necessary considering that the thermal expansion is a little bit bigger than the
kiln tube.
The absolute diameter difference, i.e., the diameter difference between a circular kiln tire and a
circular kiln shell, is named 2s. See Figure number 1.1.
The diameter difference provokes, during the kiln rotation, a relative movement between the kiln tire
and the kiln shell due to the different expanded lengths of both supporting faces.
The kiln tire movement, regarding the kiln shell, is named kiln tire displacement.
Figure 1.1.
The displacement of the kiln tire in a kiln rotation is classified with the letter V.
357948525.doc Page 2 of 111

14/06/2017
Code..
1.2.1 Importance of Clearance

It is important that the clearance between the kiln tube and the kiln tire is maintained within certain values
obtained by experimentation.
If the kiln tube temperature is suddenly increased, so that the temperature difference between the kiln
tube and the kiln tire is substantial, perhaps the clearance between these becomes null or negative. This
way represents a possible choking between the kiln and the kiln tire. In case the choking is very
pronounced, a permanent deformation called "constriction" (or trumpet) will be produced in the reinforced
kiln shell of the kiln tube.
The risk of this situation is higher in the kiln tires, above and below the calcinations zone. Consequently,
it is important that the relative displacement between the kiln and the kiln tires is controlled.
In case of producing permanent deformations on the kiln tube, this can result in, that a diameter extended
difference involves difficulties in coating, with the consequent need to reduce the clearance between the
kiln tires and the support blocks for the ring due to supplements placed below the blocks.
In order to protect the rotary kiln against deformations and / or damages in coating, produced by
overheating during service, it is necessary to control strictly and perform, if possible, service corrections to
maintain the diameter difference, between the kiln and the kiln tire, within an acceptable level, so that the
ovality can be maintained within the admissible maximum and minimum limits.
A control of the current diameter difference, during the kiln service, is made in the simplest and most
accurate mode in order to measure the kiln tire displacement, the kiln tube relative movement regarding
the kiln tires.
1.2.2 Kiln tire displacement Measurement.
As previously mentioned, the supports are built so that there will be in the hot kiln a diameter difference
from 0 to 3 mm between the kiln tube and the kiln tire.
The diameter difference, the clearance between the kiln shell and the kiln tire, provokes, as indicated, a
relative movement between these two components.
The theoretical diameter difference, 2s, produces a relative movement as follows:
Vt = .( 2RL - 2 RO ) RL = Internal radius

RO = External radius
Vt = . 2s
The relative movement or displacement V, between the deformed kiln shell and the kiln tire, according to
acquired experiences will be, 1 1/2 - 2 times the upper clearance d (gap). When dealing with small holes,
it will be 1 1/2 times and 2 times in big size kilns.
The theoretical and real displacement of kiln tire, are in reality the same, whatever the deformation is.
It is not possible measuring the diameter difference in a hot kiln, but, considering that the kiln tire
displacement is a function of the diameter difference, this can be indirectly controlled by the kiln tire
displacement confirmation.
357948525.doc Page 3 of 111

14/06/2017
Code..
1.2.3 Causes of kiln tire clearance reduction
A kiln tire in cold status is never fixed seated over the kiln. The technical reasons related to mounting
explain the need to have certain clearance, so that the kiln tire can move along the kiln.
With the purpose to consider the variable thermal expansions of the kiln shell and kiln tire during the
heating period; the kilns suppliers calculate both diameters so that the clearance between the kiln tire and
kiln, at service temperature, adopts a minimum value. It would be ideal that the kiln, in hot status, would
exert certain pressure over the kiln tire, without being subject to a contraction. This would naturally
demand that the temperatures used for calculation would be really reached during the service. It is
confirmed, based on experience, that it is practically impossible to anticipate the calculation of the
temperatures profile related to a rotary kiln shell.
There is always a danger for the kiln when the kiln shell expands with a higher speed than that of the kiln
tire.
It is easy to understand that this happens when a coating damage occurs under the kiln tire. But it is not
clear, on the other hand, a too quick heating condition, i.e. a start within a record time, can also have
serious consequences. In this case, the kiln tire is relatively cold and the kiln shell is quickly heated, so
that permanent deformations can occur due to the kiln shell contraction. In such cases, the kiln tire
internal heating can lead to an inadmissible increase in the kiln tire clearance.
Figure 1.2 shows the temperature development of the kiln tire and kiln shell during a kiln facility-heating
period.
t mx. is the maximum temperature difference, which can occur between the kiln tire and the kiln shell.
357948525.doc Page 4 of 111

14/06/2017
Code..
752
[0F]
572
Fur nace
Cuirass
392
Rolling Ring
212
Hours
Figure 1.2
T = Thermal stress with obstructed expansion
t max = Maximum temperature difference between the kiln tire and
cover
t s = Operation temperature difference
t = Expansion Coefficient
Temperature curve of kiln tire and kiln shell during a kiln-heating phase
A kiln shell permanent contraction will be produced below the kiln tire when the thermal stress T for a kiln
shell impaired expansion exceeds the elasticity limit F.
sT = E . t . t max < F
This can be the case when the required clearance in cold status sth is little or zero.
In the same way, whenever the maximum temperature difference t max is too high due to an
excessively fast heating situation.
1.3 METHOD DEVELOPMENT
1.3.1 Equipment and tools to be used
F.L. Smidth supplies automatic equipment for kiln tire displacement surveillance and control. In case that
such equipment is not available, it is possible to measure the kiln tire displacement manually.
One of the most utilized methods in Cemex is the use of Displacement and Gap Meter (Figure 1.3). This
measurement appliance is composed by a bracket (02) that, through a magnetic base, is placed on one
of the support blocks. The bracket supports a recording needle (03), under a spring and in horizontal
357948525.doc Page 5 of 111

14/06/2017
Code..
position, pressed against a piece of paper that is, through the usage of adhesive tape, fixed to a plate
(04), that in turn, is fastened to the kiln tire by magnetic blocks.
Additionally the measuring can be made by a manual method, which is described in the procedures
section.
1.3.2 Periodicity
The measuring operation of the kiln tire (tire) displacement and gap is a control requiring the most
caution, and the recommendation is to check it at least once by shift.
When dealing with kiln starts, the measuring operation must be more intensive, i.e. measuring two or
more times per shift.
1.3.3 Procedure, calculation methods and results
1.3.3.1 By the displacement and gap-measuring appliance.
Placing coupled marks in the kiln tire and in the kiln tube can perform, in a very easy way, the simplest
kiln tire displacement measuring method. Whenever the kiln has been spinning, for example, 10 rotations,
the displacement between marks is measured, in this way, the average displacement calculation is
possible.
The clearance can consecutively be found when dividing V by 1.5 - 2, i.e.:
V
= -------------
1.5 a 2
If the displacement average V is divided by , the result is :
V/ = 2s, it means
The theoretical clearance in the circular kiln tube / kiln tire.
1.3.3.2 Using the displacement and gap meter.
A method even more practical for measuring V and , utilized by CEMEX, is performed with a single
appliance named: displacement and gap meter, shown in Figure 1.3, described as follows:
The appliance is placed as illustrated in Figure 1.3 and during the kiln rotation; the recording needle will
draw a curve, as illustrated in Figure 1.4, corresponding to the kiln base where the kiln is to be measured.
The curves shown are equivalent to 5 kiln turns or rotations illustrated in Figure 1.4, the values V and S
can be directly measured in the curve.
357948525.doc Page 6 of 111

14/06/2017
Code..
As previously mentioned, it is important that the clearance between the kiln shell and the kiln tire is
maintained within determined values.
Figure 1.3
Figure 1.4
If the recording needle, during the kiln starting process, begins to draw smaller and smaller curves, means
that V and S tend to null value, and it can be necessary to participate in order to prevent "constriction".
1.3.4 Interpretation of results.
Gap Adjustment
357948525.doc Page 7 of 111

14/06/2017
Code..
As previously mentioned, the big deformations are observed in the zone of the kiln tires having an
important clearance.
In order to reduce deformations, it is necessary to reduce the kiln tire clearance by lower shimming of kiln
tires wear pads, provided that it is constructively possible (kiln tire wear pads are screwed).
In such case, the thickness of plates to be placed must be determined.
The safest method for this purpose is the following:
- Daily determination of a relative movement U and / or during a period sufficiently long (3 months).
- The minimum value U and / or V occurring within this period must serve to determine the mean
clearance of the kiln tire.
- The supplementary plates thickness is obtained from the mean clearance of the kiln tire s th and / or .
U
sth = --------

- As a safety factor regarding the big thermal expansions, the supplementary plates thickness will be
dimensioned so that the clearance in service status is within the order of 3 mm.
Therefore, the thickness for the supplementary plates is the following:
sth - 3
tB = ------------- mm
2
1.3.5 Safety aspects
In order to measure the kiln tire gap and the displacement, the activity must be executed with the kiln
running and in hot condition, as previously mentioned, thereby special caution and attention must be paid
to prevent damage by burning or by touching the equipment in motion.
1.3.6 Condemning or permissible limits
The relative movement or displacement V, between the deformed kiln shell and the kiln tire, must be
according to the acquired experiences, 1 1/2 - 2 times the upper clearance d (gap). When dealing with
little kilns, it will be 1 1/2 times and 2 times for big size kilns.
1.4 COMMENTS AND OBSERVATIONS
As previously mentioned, it is very important to have kiln tire gap and displacement control, this procedure
is therefore classified as general observance and mandatory.
357948525.doc Page 8 of 111

14/06/2017
Code..
1.5 ATTACHMENTS AND USED FORMS
The form used to record information is free, it means the wanted information can be utilized according to
each plant needs.
1.6 REFERENCES
- Control of clearance between the kiln tube and the kiln tires,
Manual F.L. Smidth 19124-01.
- Recommended Procedures for Mechanical Analysis of rotary kilns,
Book of Robert P. Chapman (Fuller Company).
357948525.doc Page 9 of 111

14/06/2017
Code..
Chapter 2
DEFORMATION AND OVALITY
2.1 OBJECTIVES AND SCOPE
The main objective pursued with the deformation and ovality control is to avoid an excessive wear on
the kiln coating or that coating bricks fall down, to meet this goal, the ovality must not exceed certain
service status limits, the measurements are made with the kiln in operation.
2.2.1 Radial deformation and its repercussion
Each rotary kiln in service shows through time certain radial deformations, especially in the kiln tires
zone, it means, the kiln shell adopts various curvature radius during a complete turn.
The deformations can be subdivided into:
- Deformations of kiln tires in the rollers zone, coming from both reaction forces Q/2.
- Deformations of kiln shell, or crushing in the highest point, caused by the clearance between
the kiln shell and the kiln tire.
These deformations are transferred to the kiln coating and therefore influence essentially its duration.
Due to the constant variation of kiln shell curvature radius, the so-called crushing process is
produced during a spin.
For this reason the kiln coating bricks are strongly requested in the side areas, with the potential
consequence of an elevated wear or bricks falling down. In order to prevent these difficulties, it is
essential to know these deformations magnitude, by measuring them regularly to take the necessary
steps on time. See Figure number 2.1.
DEFORMATION OVALITY
357948525.doc Page 10 of 111
14/06/2017
Code..
dM = Ovality of kiln cover Circle Perimeter Uk = Ellipse Perimeter

dL = Kiln tire distortion
Sth = Clearance of the kiln tire Uk = d * UE = (a+b)*
Q = Base or station load d=a+b
Ovality W= 2 ( a - b )
Figure 2.1 Figure 2.2
2.2.2 The rotary kiln ovality
The term ovality is applied to the dimension or deformation degree. If is considered that the kiln
circular shell adopts the elliptical form when deforming, the ovality can be defined as twice the
difference between both semi-shafts (axis). See Figure number 2.2.
Ovality W = deformation degree.
Previous Condition:
Periphery of ellipse UE = Periphery of circle UK
UE = (a + b) UK = d .
Definition:
W = 2a - 2b = 2(a - b)
In order to compare among themselves the ovality values for different sizes, the ovality is shown in %
of kiln internal diameter (kiln shell plate).
357948525.doc Page 11 of 111

14/06/2017
Code..
The radial deformations of a kiln shell in service can be recorded through any measuring appliance
for deformations of kilns in usage:
- Measuring Appliance Shell test with Holderbank design
- Measuring Appliance Ovality Beam with Phillips design
2.3.1.1 Shell test appliance
The measuring principle of this appliance can be described in the following manner. See Figure
number 2.3.
A bridge (A), where a magnet series (B) has been provided on every end, is attached to the rotary
kiln in vertical position to the central shaft. The bridge covers a circle segment with a basis length 1 =
1 m. and an arch height h. The recorder (C) is placed in the beam center.
During the measuring , its feelers point (D) must rest over the kiln shell, in order to obtain the height
h change transmission (caused by the curvature radius r change) to the pencil (E9. The pencil is
moved within a pantograph guide transmitting the deviations h in a 1:15 rate.
The polar diagram disk (F) is screwed to the pendulum disk (G) in the recorder shaft. This is
permanently maintained in the same perpendicular position due to the weight (H). In this way a
relative movement is produced between the pencil and disk of diagram. This movement remains
synchronized with the rotation angle variance.
After a revolution in the diagram a closed line appears. This line is the polar representation of the
height h change in function of the rotation angle , meaning a graphic geometrically similar to the
deformed section of the kiln (Shell test diagram).
Measurement Unit Shelltest Transverse Section Strained

Figure 2.3 System Holderbank
Principle of strain meas.
t
8f
3 .2
Registering Syst. Diagram Shelltest

Holderbank
Ovality:
These diagrams can be evaluated in the first place qualitatively.
The deviation regarding the circular form allows forming an idea about the deformation. The
deformations can be located by the curve position regarding the polar coordinates system. The kiln
357948525.doc Page 12 of 111

14/06/2017
Code..
vertical shaft corresponds to the diagram vertical shaft, which is identified through a small hole
provided above the coordinates center.
The appreciation results very easy due to the polar representation, as the curve constitutes an image
geometrically similar to the kiln transversal section deformed.
It is possible to recognize quickly, for example, if a big deformation exists in the kiln tires (rollers)
zone (this is the case when the kiln tire is not sufficiently rigid), or when the kiln shell deformation is
on the highest point, in this case there is a too big clearance of the kiln tire.
The utilization of this method does not allow a real measuring in the sense of absolute values. What
is recorded is the variation of arch height h according to the polar system, being only interesting the
maximum deviation or maximum difference between both semi-axis of the ellipse contained in the
diagram. For the diagram evaluation the following concepts are important:
- Deformation degree = ovality w, defined as twice the difference between both semi-axis of the kiln
transversal section, deformed in ellipse form.
a = big semi-axis
W = 2 (a-b)
b = small semi-axis
- Deformation Dimension , the biggest difference between both semi-axis of the ellipse contained
in the diagram.
The mathematical relationship between the ovality W and deformation dimension is obtained
based upon the following formula deducted by G. Rosenblad.
W = 2 (a - b) = 4/3 * d 2 * (mm)
where: W = Kiln ovality

d = External diameter of kiln shell (m)
l = Base length 1 m.
= Measuring maximum deviation (mm)
W r = W / di * 100
where: W r = Relative ovality ( % )

di = Kiln internal diameter
2.3.1.2 Ovality Beam Appliance
The kiln shell ovality is measured more easily by using the Ovality Beam electronic appliance.
357948525.doc Page 13 of 111

14/06/2017
Code..
The appliance is quite similar in construction to the Shell test, but the main difference consists in the
handling of measuring, instead of plotting it directly into a diagram, it is recorded in an electronic
recorder, as illustrated in Figure 2.4.
The recorder stores the entire bar positions. And the maximum and minimum values are utilized to
determine .
R2 R1
Detection of the furnace cuirass

Represented by a graph
Figure 2.4
This value can be mathematically related to the maximum change in kiln radius. This is shown as
R in Figure 2.4, and is equal to R 2 - R1, where R2 is the highest radius of the deformed kiln during its
revolution, and R1 is the lowest radius of the kiln deformed in the same revolution, from this the
following deduction is obtained: W = kiln ovality
W = 2 (a-b) a = big semi-axis = 2 R2
b = small semi-axis = 2 R1
The mathematical relation between ovality W and deformation dimension is obtained based on
the following formula deducted by F. G. Rosenblad.
W = 2 (a - b) = 4/3 * d 2 * (mm)
where : W = Kiln ovality

d = Kiln shell external diameter (m)
l = Base length 1 m.
= Measuring maximum deviation (mm)
and Wr = W / di * 100
where: W r = Relative ovality ( % )
di = Kiln internal diameter
2.3.2 Periodicity
357948525.doc Page 14 of 111
14/06/2017
Code..
The kiln shell ovality measurement must be made once in a year, or before depending on the
deformation and displacement measurement results.
2.3.3 Procedure, calculation method and results
2.3.3.1 Preparation Steps
The kiln rotary deformations reduce as long as the kiln tire distance increases. Therefore, the Shell
test measurement must be performed always close to the kiln tires (kiln tire shell), as much as
possible on both sides. Whenever the protection shields against heat are mounted too close to the
kiln shell, a removal of them will be necessary.
The kiln must be in steady operation conditions for all the measurements to be taken. And all the
readings must be taken (at the entrance or exit) in the same position for future reference.
In order to be able to get a clear idea about the deformations dimensions, the measurement of every
drawing must be performed on three points located in casing lines displaced in 120, see Figure
number 2.5. Also for later measurements it is the recommended to use always the same drawings
and measuring points.
- Mark with chalk lines all along the measuring points, precisely on those points where is the
measuring appliance feelers tip.
- Every time it is necessary, clean the support points of the magnet with a wire brush.
2.3.3.2 Measuring Procedure with the Shell test appliance
It is required to fix the diagrams disk in a manner that it is fastened against spinning, with the
coordinates network at the inscribing pen side.
The small hole in the middle, is used for disk fastening, points out to it, over the diagram, the highest
point (kiln shell highest point) of the measured transversal section.
The appliance will be prepared now for measuring in the following way, or it will be adapted to the kiln
diameter.
Drop the sleeves in form of a star and displace the magnet carrier so that the inscribing pen is
located in horizontal position when the appliance is placed. The inscribing pen must be fixed in the
first notch (disconnected position).
- At the same time of kill spinning, place the measuring appliance in a marked position (point 1)
and confirm if the appliance adhesion force is sufficient. The diagram image side (coordinates
network) must indicate always in the same kiln entrance direction.
- Place the inscribing pen, through the precision adjustment screw, so that the three curves of a
measuring plan (points 1, 2 and 3) have enough space in the same diagram. For the first
measuring, place the inscribing pen slightly upwards, for the second measuring in the middle
and for the third measuring slightly downwards.
- In the disconnected position of the recorder, the appliance must remain disconnected during
two or three kiln turns, in order that the feelers tip can extend because of the kiln shell
temperature, which does not influence the diagram.
357948525.doc Page 15 of 111

14/06/2017
Code..
- Through a slight pressure, carry the inscribing pen till the second notch, so that the inscribing
pen is supported over the diagram.
- After one turn (measuring time), remove the inscribing pen to the disconnected position, by
pulling at the pulsating button.
- Remove the Shell test appliance, fix it in the next measuring point and proceed in the same
way as before.
- Once all the measuring operations are finished, place the protection plates over the magnets.
2.3.3.2 Measuring procedure with Ovality Beam Appliance
The measuring sequence is similar to the described in the previous point by utilizing the Shell test
appliance, with the difference that the data are electronically recorded, and these are transferred to a
computer, which will provide us with a graphic that practically is the extended ovality curve as
illustrated in the right side of Figure number 2.4.
The readings of every kiln base are used (the appliance can store data for maximum 8 bases).
These readings are stored separately from the kiln running parameters.
The detailed operation is not explained here because it is too long; therefore it will be necessary to
refer directly to the appliance manual.
Shell or tube kiln lines

Medition Plains
Diagram of a measuring chart
357948525.doc Page 16 of 111

14/06/2017
Code..
Figure 2.5
2.3.4 Interpretation of results
2.3.4.1 Results evaluation
The evaluation through calculation, this means that the ovality calculation from the Shell test diagram
or the Ovality Beam graphic, is performed based on the following relations:
2
4 * d
357948525.doc Page 17 of 111
14/06/2017
Code..
Absolute Ovality = wa = ----------- * mm

3
4 * d 2
Relative Ovality = wr = ----------- * * 100 %
3 * dN
= / 15 (mm) measured in the Shell test diagram.
d = kiln shell external diameter (M), (dN + 2t)
dN = kiln shell internal diameter (mm)
- In a kiln with an ideal behavior, the three ovality values measured in a drawing would be super
positioned. Nevertheless, these values are slightly deviated between them in practice, as
there are weak points located on the kiln cover.
2.3.4.2 Shell test
The Shell test diagram, as a polar representation of the height variations for the h segments, offers
the advantage that it also allows, immediately, a qualitative evaluation of the measurements by
people with little experience, as the diagram represents an geometrical image similar to the kiln
deformed transversal section (elastic line), with the only difference that the radial variations are
recorded with an increase of 15 times.
In order to appreciate the deformations diagram, it is essential to consider them correctly.
If the coordinates network indicates, during the measurement in the kiln entrance direction, the
diagram must be observed during its kiln entrance side appreciation, in order to match the
corresponding sides. The small hole in the diagram disk must be located in the12 hours position, as
this position marks the vertical axis, as well as the highest point of the measured transversal section.
Data legend:
dN = Kiln nominal diameter (internal diameter).
d = Kiln shell diameter.
= dN + 2 . t
t = Plate thickness.
wL = Ovality calculated of kiln tire.
jL = Kiln tire inertia moment
357948525.doc Page 18 of 111

14/06/2017
Code..
w = Ovality measured with Shell test appliance.
U = Relative movement.
Sth = Kiln tire clearance.
2.3.4.3 Ovality Beam
The Ovality Beam appliance generates a Cartesian graphic in X-Y format. This represents the radial
deformations occurring during the kiln rotation, in a turn, as illustrated (exaggerating the deformation)
in Figure number 2.6
Top of the furnace
4 6
55
6 Spin
6 4
Giro 4
11 3 1 3
3
22
5
Left roller Right roller

Figure 2.6
The trace begins with the recording of the first data at the kiln side when spinning downwards, just
before reaching the first roller.
The position 1 of the curve represents the reference point #1. The position 1 coincides when
crossing through the first roller. The depression in the curve is caused by the support roller reaction
over the tire. The ovality W is a tire ovality transfer over the kiln shell. The tire is deflected by the
roller and this to the tire, and this in turn to the kiln shell, causing a reduction in the kiln shell
curvature.
Immediately after the first roller, the bar passes to position 2, which is the kiln lower central part.
Between the rollers, the shell curvature is appreciated as normal.
In position 3, the bar reaches the second roller. And the kiln reaction is similar to the position 1.
Again the kiln shell is crushed, and the curvature is reduced.
From position 3, the ovality appliance passes to the kiln ascending lateral upper part. The kiln
curvature is increased at its maximum, just in the vertical tangent point.
The position 5 is the kiln top. The kiln shell is crushed in this position, and the curve indicates a
curvature reduction.
357948525.doc Page 19 of 111

14/06/2017
Code..
The position 6 is a mirror of position 4, excepting that it corresponds when the kiln goes downwards.
The maximum and minimum points are used to calculate the ovality.
It is always dangerous to work close to a rotary kiln. Due to that it is necessary to take the ovality
measures close to the running kiln, it is important to put on the appropriate clothing, and use safety
goggles, safety shoes, gloves and safety shields.
Make sure that the measuring bar whether is Shell test or ovality beam or that everything is free
around the shell. The upper half must be inspected to prevent obstructions. It is possible that there
is no view from the base upper part, and the remarks must be made from an other point of view.
The shell area where the bar magnets are located, must be polished with a wire brush in order to
assure their correct fastening.
Avoid the magnets placement over the kiln shell welding cords as it can lead to incorrect readings.
The determination of an ovality limit value, i.e. a limit from where it is possible that coating damages
can follow, and it is difficult and depends on the kiln size and the existing coating conditions. Figure
number 2.7, shows the existing relation (obtained from experience) between the admissible ovality
and the kiln diameter in good coating conditions.
In a 3.5 m kiln the approximate limit is 0.3%.
In a 6.0 m kiln the approximate limit is 0.5%.
When the ovality limit value does not exceed the corresponding kiln diameter, the coating request will
be insignificant as consequence of the kiln shell deformation.
1.0
0.8
Oval shape ( % )
0.6
0.4
0.2
0.0
118.11 157.48 196.85 236.22 275.59
78.74
357948525.doc Page 20 of 111
Furnace diameter (inch )
Acceptance Range
14/06/2017
Code..
Figure 2.7
Ovality Limit Values
The ovality measurement is an extremely important factor that must never be overseen for the good
preservation of a rotary kiln.
Thanks to experience, there are data available that help preventing from major damages, as the
ovality graphics can determine the following:
- Kiln cracks
- Excessive clearance between kiln tire and shell
- Kiln misalignment ( run out )
- Rollers misalignment (different deformations on both rollers)
- Tire with over or sub load
2.5 USED ATTACHMENTS AND FORMS
The used format is free, although basically a reliability module must be followed at the kiln.
2.6 REFERENCES
- Manual of Holderbank Shell test

- Users guide of Phillips Ovality Beam
- Detecting and Measuring Deformations of Rotary Kilns by F.G. Rosenblad,
Rock Products. August 1954.
357948525.doc Page 21 of 111

14/06/2017
Code..
Chapter 3
TIRES AND ROLLERS DIAMETERS MEASUREMENTS
(In cold and hot environment).
This procedure indicate us the form of higher precision measuring and count with the exact
diameter of rollers and tires (kiln tires), in order to determine their wear based upon their original
dimensions, and in turn to utilize such measures for other calculations such as alignment, etc.
3.2.1 Support rollers and tires tracks (kiln tires) wear.
The wear and deterioration of the rollers and tires surfaces can be produced due to:
- Misalignments.
- Tires warping, due to kiln deformations.
- Excessive axial loads on the support rollers.
Due to these causes, the tracks of rollers and tires lose their cylindrical form, that is the condition
of a correct support and load on the bearings and axial device. Therefore it could be eventually
necessary to rectify the tire tracks in order to establish the cylindrical surfaces.
For this purpose, currently exist devices for tire tracks rectification, with the kiln running.
3.3.1.1 Measuring in hot environment
For control of tracks diameters and cylindricity, the measuring equipment illustrated in Figure
number 3.1 is utilized.
F.L. Smidth, has developed this circumferential measuring special equipment, which offers the
advantage to perform such measuring, without kiln shutdown, it means that in full production process
the existing diameters as well as their "conicity" can be determined.
357948525.doc Page 22 of 111

14/06/2017
Code..
As it can be observed in Figure number 3.1, it is composed by some components.
A feeler and / or a movement follower wheel

02) Lens or electronic eye.
03) Magnetic fitting (magnet).
04) Electronic counter.
3.3.1.2 Measuring in cold environment
A metallic tape is utilized to measure the perimeter of rollers and tires surface.
3.3.2 Periodicity
The measuring must be made on annual frequency, or every time when the rollers measuring will be
utilized as precise data, for example in the kiln alignment, etc.
3.3.3.1 Measuring of diameters corresponding to rollers and tires in hot environment
This operation is performed through a direct electromechanical exploration.
Figure 3.1
As preparation to perform this measuring, it is necessary to adapt a support in form of "U" inverted,
with 2 x 2 x 1/4" as angle, on every kiln base, as it can be observed in Figure number 3.1.
In this support the follower element (01) is defined, which send the movement signal to us, this
element will make contact with the roller, at the moment when this element (01) has made the
contact, the spinning begins. Care must be observed to assure the follower wheel is in correct
position, at 90 regarding an imaginary horizontal line, this can be made, by adjusting the 3
setscrews placed at every 120 regarding the follower wheel (01) diameter, another important point is
357948525.doc Page 23 of 111

14/06/2017
Code..
to adjust the 3 mm. Setscrew, fixing the feeler wheel coupling and shaft in order to assure an uniform
movement between both components.
It is convenient, to note that the feeler element, must be placed in three different positions along the
contacting surface width, in order to get an idea about the roller conicity.
The next step is to place the element (03), magnet, with its fitting, (in the left roller, right roller and in
the tire), depending on which one is being analyzed, this element is placed in the lateral face of the
bodies to be analyzed, and it must be made during the first turn passing free, in order to prevent
reading mistakes.
Once the above is done, place the electronic eye (02), by support with the dial indicator magnetic
base; the appropriate position is when the element (03) placed in the roller and / or tire, crosses
freely the magnetic eye and this one detects it as from this point the signal will begin to count the
number of turns, according to the selection made in the electronic counter.
Once the previous points are confirmed, proceed to connect the electronic counter, which has a
digital screen where the analyzed wheel perimeter measuring will be read, whose units are shown in
mm.
This counter has a selector to elect the number of turns wanted to be analyzed, normally one turn is
considered to obtain the roller or tire perimeter.
After every measuring, control must be reestablished in order to pass again the fitting (03), through
the magnetic eye, the count down is restarted, repeat this operation 2 - 3 times and get an average.
Note that the circumference-measuring appliance allows obtaining the perimeter, for roller as well as
for tire, thereby the following formula is utilized to obtain the diameter:
P
D = ------

3.3.3.2 Measuring method for diameters of rollers and tires in cold environment.
This is the traditional method, where a metallic tape is utilized to measure rollers and tires surface
perimeter. It is necessary to mention that it is not very reliable, due to the access limitation to pass
the tape and its placement along the circumference, as well as the stress applied on it in every
measuring operation.
357948525.doc Page 24 of 111

14/06/2017
Code..
The most reliable measuring for rollers and / or tires diameters is the measuring applied in hot
environment, as it complies with the real running conditions.
It is always dangerous to work close to a rotary kiln. When rollers and / or tires diameters must be
measured it is necessary to work close to a running kiln; appropriate clothing, safety goggles, safety
shoes, gloves and safety shields must be utilized.
Every kiln manufacturer, has a maximum or minimum tolerance in the rollers and tires diameter, but it
is considered that a tire or roller has reached its service life limit, when it shows 5 % reduction in its
nominal diameter, and in that case it must be replaced and send for outfitting or recovery to nominal
dimension, depending on its feasibility.
The measuring of rollers and tires is very useful, to perform another type of kiln inspections and / or
analysis, real data will be utilized.
3.5 ATTACHMENTS AND FORMS UTILIZED
The format utilized is free, although basically a log for each kiln must be maintained.
3.6 REFERENCES
- Manual of F.L. Smidth equipment for rollers and tire diameter measuring.
357948525.doc Page 25 of 111

14/06/2017
Code..
Chapter 4
MEASURING AND ADJUSTMENT OF SUPPORTING ROLLERS AXIAL LOAD
(kiln tires)
The main objective pursued is to measure during the kiln running, the force of the supporting rollers
or kiln tires to exercise influence in axial direction over the bearings, in order to take care about
excessive loads in them which could provoke damages.
4. 2 METHOD BASIS OR FOUNDATION
The supporting rollers bearings heating (support rollers) is due to very diverse causes.
The most common problems can occur when:
- The bearing is exposed to irregular axial or radial loads at abnormally high temperatures.
- Change in the geometrical forms of the shaft trunnion shaft and the bearing gland (bronze).
- The oil type utilized does not have the prescribed viscosity.
From the cited problems, the most frequent is the bearing heating due to excessive axial loads.
The axial reaction is originated when the kiln tires are not in parallel position regarding the kiln shaft
or they have a divergent inclination, i.e. when parallelism does not exist between the kiln tires and
the tread ring shaft.
In case the axial loads exceed the allowed limits, an adjustment will be made during the running
operation displacing the supporting bearings in horizontal sense.
The cited adjustment guarantees also a correct load in the retaining system and a good tread of the
detention kiln tires with the ring. The wear is reduced at the minimum, as 100 % contact exists
between the surfaces of ring and kiln tires.
357948525.doc Page 26 of 111

14/06/2017
Code..
4.3 DEVELOPMENT OF THE METHOD
To maintain these axial loads within the permissible limits for every one of the sizes of the bearings.
F. L . Smidth has developed special equipment, making possible to measure, during running, the
force of the kiln tires exercising their influence in axial direction over the bearings.
The axial measuring equipment is utilized to measure the force of the kiln tires exercising over their
bearings in the axial sense.
4.3.1.1 Equipment description.

(See the figure 4.1)
The equipment for axial measuring is composed by a pressure tip screw (04), a pressure cylinder
(13) and fastening pieces. The pressure tip screw is placed on the fastening pieces, which are
suspended on hinges (02) of the supporting bearings box. The tip screw is activated by the pressure
cylinder (13) when the latest is placed under pressure.
It is also composed by a hand pump (12), provided with a manometer (11) and connected by a hose
(19) and a coupling piece to the pressure cylinder (13).
The hand pump is additionally provided with a pressure-limiting valve, which prevents, that the
cylinder pressure can exceed 580 bars, which is equivalent to a force of approximately 8 tons.
4.3.1.2 Measuring principle.
The measuring has, in principle, by effect that the pressure cylinder presses the tip screw against the
kiln tires shaft end, with a force opposed to the kiln tires reaction and sufficiently big to exceed the
latest, so that a permanent space is produced among the pressure ring and the pressure neck in
both sides of the kiln tires.
Once this condition is satisfied, these both forces are compensated between each other, and the
axial reaction can be calculated through the cylinder pressure and the piston area.
4.3.2 Periodicity
The rollers pressures revision, must be made once a year minimum or every time observing an
excessive heating (or tendency to it) on the bearings.
357948525.doc Page 27 of 111

14/06/2017
Code..
4.3.3.1 Mounting
Mount the hinges (02) on all the kiln tires bearings, as illustrated in Figure number 4.1. Use the long
pins of degree 5 (quality 8.8). The hinges must remain permanently in the bearings box.
Mount the shot sections (03) and the console (07) through the four 20 mm pigs (01).
Dismount the cap of the supporting bearing center.
Mount the distance tube (06) and the fastener (05) for the pressure tip screw (04).
Place the pressure cylinder (13) in the fastener, place the centering pig (08) in the hole for the tip
screw, in the kiln tire shaft, and stretch the cylinder.
357948525.doc Page 28 of 111

14/06/2017
Code..
Figura 4.1
Mark and drill and appropriate hole exactly in the kiln tires center, if it is not provided in advance of a
hole to introduce the tip screw.
Connect the cylinder with the hand pump through the hose (10) and the coupling piece.
357948525.doc Page 29 of 111

14/06/2017
Code..
4.3.3.2 Dismounting
Remove the pressure to the equipment, by opening the return valve of the hand pump.
Dismount the hand pump and hose.
Remove the pressure tip screw and cylinder.
Dismount the shot sections and four pigs (01), so that only the hinges remain in the bearing box.
Mount the cap with monogram in the bearing box.
Apply anticorrosive oil to the hinges.
4.3.3.3 Procedure
In general, the rotary kiln tires must be parallel to the kiln shaft, when it is equipped with hydraulic
guiding device, so that a normal tread is produced, without axial reaction between the kiln tires
washer and the tread ring.
This is impossible in practice, it is necessary to orient the kiln tires so that all of them have a little
tendency to press the kiln upwards. The axial reaction to be produced as consequence of this, must
be within determined maximum and minimum values, for the different types and sizes of bearings, as
indicated in the table number 4.1.
The axial force is transmitted to the supporting bearings through a pressure ring in the kiln tires shaft
and a corresponding pressure neck in the gland. It is possible to control the sense of the axial force
when verifying in which bearing there is a clearance between the pressure ring and the pressure
neck of the bushing. See the Figures number 4.2 to 4.5.
The measuring of the axial forces and the kiln tires adjustment must only be made when the kiln is
under normal running conditions.
4.3.3.4 Bearings, model 1958
When dealing with this type of support it is necessary to have a clearance between the pressure ring
and the pressure neck, in all the bearings oriented downwards or the bearings in the exit side of the
tread ring when the kiln tires are correctly placed, it means, with a little tendency to press the kiln
upwards against the entrance.
Previous to proceed with the measuring and the adjustments, a note must be made in writing which
ones are the kiln tires pressing the kiln upwards, and which ones are pressing it downwards.
The pressure sense of kiln tires pressing the kiln downwards changes its direction and the measuring
is performed.
This procedure is performed through a determined method, so that the guiding kiln tires are not
reloaded in any moment. Read, therefore, the hydraulic pressure on the guiding kiln tires
manometers before and after every adjustment.
357948525.doc Page 30 of 111

14/06/2017
Code..
Measuring in each one of the bearings is performed in the following manner:
Place the measuring equipment in the bearings box hinges, as described in point 4.3.3.1 (see Figure
number 4.1).
Begin the measuring operation by pumping the cylinder up to the maximum pressure for the
corresponding bearing size. See the table number 4.1.
In a time term of approximately 10 minutes the pressure in the cylinder will be adjusted to a value
mediating among the maximum and minimum pressure, if the supporting washer is correctly
adjusted. At the same time, a permanent clearance will be produced on both pressure necks of the
bearings.
The pressure could vary a little bit during the kiln rotation due to the tread ring warping, etc., thereby
a mean value of the read pressure must be available. If the marked pressure does not decrease
below the maximum pressure, or if it decreases below the minimum, the kiln tires position must be
modified according to the indications contained in Figures number 4.2 and 4.3.
4.3.3.5 Bearings, model 1974
In this case, the measuring equipment is placed also in the bearings oriented downwards. In these
bearings, where the supporting washer pressure rings are placed between the bucket and the gland,
a clearance must exist between the pressure ring and the pressure neck of the gland in the bearings
oriented upwards.
The rest of the procedure is such as described in the point 4.3.3.3. The indications concerning the
corrections are located in the Figures number 4.4. and 4.5.
Every correction in the kiln tires position (rollers), will be based upon the indications of the figures 4.2
to 4.5, depending upon the corresponding type of support.
4.3.5 Safety concerns
It is always dangerous to work close to a rotary kiln. To measure the axial pressure of the rollers
requires to work very close to an operating kiln; appropriate clothing, safety goggles, safety shoes,
gloves and safety helmet must be used.
This is High-pressure hydraulic equipment ,care must be observed to never bend the hoses;
additionally special caution must be taken for their conditions, as the usage of defective hoses
implies a serious risk of personal injury.
357948525.doc Page 31 of 111

14/06/2017
Code..
Also as in point 4.3.4, they will be based upon the indications of Table 4.1.
The axial measuring equipment as a whole, requires maintenance, in this case this maintenance
consists of the following:
- Fill the hand pump with hydraulic oil.
- The spherical axial bearing, in the pressure tip screw, is of perpetual greasing and does not
require any lubrication.
- The equipment must be mounted after utilizing it, as well as plug all the hydraulic couplings and
place the equipment in an appropriate transportation case.
- The fastening pieces must be well painted with anticorrosive paint.
4.5 ATTACHMENTS AND FORMS USED
Table number 4.1, indicates the maximum and minimum values of the axial load in the kiln tires as
AXIAL PRESSURE ON BEARING FOR SUPPORTING PULLEY WHEELS
well as an adjustment value, which is an intermediate value between the maximum and minimum
values. Bearing Model 1974
Bearings model 1958
Axial pressure
. in tons
The tables also indicate the hydraulic pressure, corresponding to the axial loads, when a cylinder
valid for a standard
with a piston area of 16.6 cm2 iswith
cylinder utilized.
a 16,62 cm
piston area .
The Figures 4.2 to 4.5, instruct how to control the kiln tires position through the placement of a
Admissible Adjustable
clearance and axial
Bearing thepresin
hydraulic to howAdmissible
pressure value, in additionBearing
axial presin to obtainAdjustable
the desired position for the
axial presin axial presin
kiln tires.
dxt ( tons.-bar) ( tons.-bar) dxt ( tons.-bar) ( tons.-bar)
max. min. average max. min. average
120 x 180 0.3 - 0.1 0.2 240 x 290 1.0 - 0.2 0.6
18 - 6 12 60 - 12 36
150 x 220 0.5 - 0.1 0.3 280 x 340 1.3 - 0.3 0.8
30 - 6 18 78 - 18 48
180 x 260 0.6 - 0.1 0.35 320 x 390 1.7 - 0.3 1.0
36 - 6 21 102 - 18 60
210 x 300 0.8 - 0.2 0.5 360 x 430 2.0 - 0.4 1.2
48 - 12 30 120 - 24 72
400 x 480 2.5 - 0.5 1.5
240 x 350 1.1 - 0.2 0.65
150 - 30 90
66 - 12 39
450 x 540 3.2 - 0.6 1.9
280 x 400 1.5 - 0.3 0.9
192 - 36 114
90 - 18 54 500 x 600 4.0 - 0.8 2.4
320 x 460 2.0 - 0.4 1.2 240 - 48 144
120 - 24 72 560 x 680 5.0 - 1.0 2.4
360 x 510 2.5 - 0.5 1.5 300 - 60 180
150 - 30 90 630 x 760 6.4 - 1.3 3.8
400 x 570 3.0 - 0.6 1.8 384 - 78 228
180 - 36 108 710 x 850 8.0 - 1.6 4.8
450 x 650 4.0 - 0.8 2.4 482 - 96 288
240 - 48 144 790 x 950 8.0 - 1.6 4.8
500 x 720 5.0 - 1.0 3.0 482 - 96 288
300 - 60 180 880 x 1060 8.0 - 1.6 4.8
560 x 800 6.0 - 1.2 3.6 482 - 96 288
360 - 72 216 970 x 1160 8.0 - 1.6 4.8
630 x 900 7.5 - 1.5 4.5 482 - 96 288
452 - 90 271 1060 x 1270 8.0 - 1.6 4.8
710 x 1000 8.0 - 2.0 5.0 482 - 96 288
482 - 120 300 1150 x 1380 8.0 - 1.6 4.8
482 - 96 288
850 x 1150 8.0 - 2.0 5.0
1240 x 1490 8.0 - 1.6 4.8
482 - 120 300
482 - 96 288
Table numb. 4.1 1340 x 1610 8.0 - 1.6 4.8
357948525.doc Page
NOTE: The measurements and the indicated values will be only valid in normal 32 of 111 conditions,
lubrication
,
it means, a mere lubrication , graphite between the supporting pulley wheels and the rolling rings
with
.
14/06/2017
Code..
357948525.doc Page 33 of 111

14/06/2017
Code..
Right Supports, model 1958

(Right Rotating Orientation ).
Spin
It is a necessary condition for a correct adjustment,
based on the measurement , that the pulley wheel axis
and the roller ring axis have the same slant
.
Most of the cases, they are meaningless adjustments

of the supporting bearings .
A 1/6 spin of the adjustment screw likely yields

a result .
Before and after each adjustment the pressure on the

guide pulley wheel manometer must. be read
The adjustment sequence is chosen according to such
Outlet readings so that we can avoid overload the guide, pulley
wheels , .
Right Pulley Wheel

.
1. Play beside A No adjustment

.
The pressure between . max. and min
2. Play beside "A". Loosen the bearing A until we get an average pressure
The pressure is so high .
3. Play beside "A". Loosen the bearing B until we get an average pressure
The pressure is so low .
4. Play beside "B". Loosen the bearing
B B until a play beside A appears
Pump continually and adjust the pressure to an average value

Left Pulley Wheel.
5. Play beside "D". No adjustment

.
The pressure between max. and min
6. Play beside "D". Loosen the bearing C until we get an average pressure
7. Play beside "D". Loosen the bearing D until we get an average pressure
8. Play beside "C". Loosen the bearing D until a play beside D appears
Figure 4.2
357948525.doc Page 34 of 111

14/06/2017
Code..
Left Spin Supports, model 1958

(Left Rotating Orientation ).

.


a result .

(Right Rotating Orientation).
Spin
OUTLET Itreadings
is a necessary
so that condition for aoverload
we can avoid correct adjustment,
the guide, pulley
based on the measurement
, , that the
. pulley wheel axis
wheels
. Right Pulley Wheel
.
Most of the
1. Play cases,
beside A they are meaningless
No adjustments
adjustment
.
of the supportingThe
bearings . max. and. min
pressure between
2. Play beside "A". Loosen the bearing B until we get an average pressure
A 1/6 spin of theThe
adjustment
pressure screw likely
is so high . yields
3. Play beside "A". Loosen
a result the bearing. A until we get an average pressure
4. Play beside "B". BeforeLoosen the bearing
and after A until a play
each adjustment the beside B appears
pressure on the
guidePump
pulley wheel manometer
continually and adjust must
. be readto an average value
the pressure
Left Pulley Wheel
.
OUTLET
readings
5. Playso that we
beside "D".can avoid overloadNothe guide, .pulley
adjustment
wheels , .
6. Play beside "D". Loosen the bearing D until we get an average pressure
The pressure is so Right
high .Pulley Wheel .
7. Play beside "D". Loosen the bearing C until we get an average pressure
1. Play beside BThe pressure is so low .
No adjustment .
8. Play beside "C". Loosen theThe pressure
bearing between
C until . max
a play beside. andDmin
appears
2. Play beside B". Loosen the bearing A until we get an average pressure
Pump continually and adjust
The pressure thehigh
is so pressure
. to an average value
3. Play beside B". Loosen the bearing B until we get an average pressure
The pressureFigure
is so low4.3 .
4. Play beside A". Loosen the bearing
B B until a play beside B appears

Left Pulley Wheel.
5. Play beside C". No adjustment

.
6. Play beside C". Loosen the bearing C until we get an average pressure
7. Play beside C". Loosen the bearing D until we get an average pressure
8. Play beside D". Loosen the bearing D until a play beside C appears
357948525.doc Page 35 of 111
Figure 4.4
14/06/2017
Code..

(Left Rotating Orientation ).
Spin
.


a result .

OUTLET
readings so that we can avoid overload the guide, pulley
wheels , .
Right Pulley Wheel

.
1. Play beside B No adjustment

.
The pressure between . max. and min
2. Play beside B". Loosen the bearing B until we get an average pressure
3. Play beside B". Loosen the bearing A until we get an average pressure
4. Play beside A". Loosen the bearing
B A until a play beside B appears

Left Pulley Wheel.
5. Play beside C". No adjustment
.
6. Play beside C". Loosen the bearing D until we get an average pressure
7. Play beside C". Loosen the bearing C until we get an average pressure
8. Play beside D". Loosen the bearing D until a play beside C appears
357948525.doc Page 36 of 111
Figure 4.5
14/06/2017
Code..
4.6 REFERENCES
- Manual of axial measuring equipment F.L. Smidth. Manual 19054-01.
- Manual of high pressure jacks for kiln tire adjustment F. L.
Smidth. Manual 19114-02
357948525.doc Page 37 of 111

14/06/2017
Code..
Chapter 5
MEASUREMENT AND ADJUSTMENT OF THE ROLLS INCLINATION
(or support sheaves)
5.1 OBJECTIVE AND REACH
The objective of this procedure is to have a good contact between rolls (support sheaves), and the
tread hoops (rims),
5. 2 BASIS OR SUSTENTATION OF THE METHOD
A deficient contact can be due to an incorrect inclination of the sheaves in relation to the tread
hoops, the correct inclinations in theory may be calculated using an inclinations meter, the inclination
can be controlled and the proper adjustment performed.
The inclinometer (see figure 5.1) is used to measure the inclination of a plane, that means, the
absolute deviation of the vertical or horizontal plane.
The inclinometer is made up of a magnet holder (09), mounted to a bubble level holder (02),
using a spike (08). Both carriers are manufactured in an aluminum body.
The Magnet holder supports two cylindrical magnets (10) and an adjustable top screw (13) with
spherical tip.
The Bubble Level holder has a micrometric screw (05) and four bubble levels. A spring (11)
supports the micrometric screw against the top screws spherical tip.
357948525.doc Page 38 of 111

14/06/2017
Code..
Figure 5.1
The bigger bubble levels (03) and (04) are used to measure deviations of the vertical and horizontal
plane inclination, respectively. The bubble levels are mounted in such a way that they can be
regulated using the adjustment screws (06).
The small bubble levels (01) and (07) are directional levels used to control the position of the
inclinometer in the plane.
When the inclinometer has to be used in rounded surfaces for example, trunnions of rollers, the
Magnet Holder can be provided with a support bridge that can be attached to the magnet holder
using a milano tail (12).
The distance between the micrometric screw (05) and the spike (08) is exactly 100 mm. Therefore,
the millimeter graduation of the micrometric screw will correspond to the inclination percentage, so, 1
mm is equivalent to 1% of inclination.
In the micrometric screw 0.002 mm, its equivalent to an inclination of 0.002%, or 0.02 mm, by 1000
mm
The reach of measurement of the micrometric screw is 0 - 25 mm, nevertheless, the hinge, between
the Magnet Holder (09) and the bubble level holder (08), limits the clinometers reach of
measurement to 0 - 20 mm, that is about + / - 10 mm
357948525.doc Page 39 of 111

14/06/2017
Code..
5.3.1.1 Control of the adjustment
The inclinometer is provided by the supplier already fixed, however, the adjustment must be
controlled before using the inclinometer. The adjustment must be verified always if the device has
been used previously.
The adjustment can be considered as correct when the inclinometer is in horizontal plane, the
bubble is centered and the micrometric screw is placed in 10.000 mm
The adjustment demands a high degree of exactitude and can be difficult if a precise angular plane
is missing, for example from a machine tool or a mark end.
When it is only necessary to measure in vertical plane, for example in ends of support sheaves axis
definitively mounted, that is our case, it will be more advisable to perform an adjustment in the top
screw with sphere (13) until assure that the bubble level (03) is in perpendicular position to the
magnets support face, when the micrometric screw is adjusted to 10.000 mm
5.3.2 Frequency
The measurement of the rollers inclination must be made annually.
5.3.3.1 Measurements of rolls inclination (support sheaves)
The device must be handled carefully. For example, the arm does not have to hit with excessive
force the edge, such a blow can modify the adjustment of the inclinometer.
Hold the inclinometer in the inclined plane using magnets (10).
Control with the directional levels to have the inclinometer parallel to the inclination direction. In
measurements due in trunnions, the inclinometer must be on vertical position upon the axis line in the
same axis.
Turn now the micrometric screw until the bubble of the chosen level is centered. Read the value h
in the micrometric screw and calculate the inclination percentage V as following:
V = 10 - h %
The sign depends on the inclination sense and the inclinometer position, nevertheless, the sign has
not any meaning considering that the inclination is indicated in percents and the inclination sense has
been established.
- Measure in both trunnions. In unloaded support sheaves the measurements must be

identical, that is to say that the deviation degree of 10,000 must be the same one if the
measurement has been performed correctly. In support sheave under load a difference of a
few thousandths of percentage between the two measurements may appear.
357948525.doc Page 40 of 111

14/06/2017
Code..
Control, at the same time, if the axis ends are perpendicular to the trunnions. This can be important
during later measurements that only can be made in the axis ends
When measuring the inclination of definitively mounted support sheaves, normally the inclinometer is
placed over the turned axis ends of the support sheaves and it is measured, at the exit end of axis as
in the entrance end, an average value is then calculated.
It is necessary to be assured against inaccuracies as a result of irregularities in the mechanized of

the axis ends measuring in both sides of the axis center and use the average value of the two
measurements. See the figure number. 5.2.
The inclinometer must be placed in such a way that the line in the magnet holder flank (09) is
located exactly upon the horizontal line of axis of the same axis, as shown in figure. 5.3.
If the inclination in a support sheave under load is measured, according to the described method,
an insignificant divergence between the measurements of both axis ends can be appraised (as
previously mentioned), as a consequence of the bent in one of the support sheaves. This is not an
anomaly symptom and applying the average measurements when performing the inclination estimate
is compensated by this divergence.
Figure 5.2
357948525.doc Page 41 of 111

14/06/2017
Code..
5%
4
3
2
6 7 8 9 11 13 14
12
Ro Ri
Figure 5.3
5.3.3.2 Operation Procedure.
Carefully clean the axis ends before perform the measurements.
Measure firstly the superior axis end, next to the entrance of the furnace. Measure both sides of
the axis center and compute the average value R i . See figure 5.3.
Next, measure next in the end of inferior axis, nearest to the output, and compute the average
value R 0 based on the measurements conducted here.
The numerical value of the two measurements will be in the proximities of the value for the
horizontal plane, as shown in figure 5.3 and the inclination of the support sheave could consequently
be established as:
Ri -Ro
R m = ------------ %
2
Once the two measures R i and R 0 have been taken, it will be necessary to establish their
deviation of 10,000, that means the inclination percentage for both axis ends
Being an unloaded sheave of support, both percentages must be identical, and in a support sheave
under load the reciprocal difference does not have to surpass 0,02%. In case of having a superior
divergence it means that the measurements have not been taken correctly and, therefore, will have
to be repeated.
The difference between the inclination percentage in the entrance and exit extremes of the support
sheave must surpass the 0.02%. As well as the maximum deviation of parallelism between support
sheaves (rollers) and the tread hoops (rims) must be 0.02%.
In all cases the indications of maximum inclinations the mentioned in the position plane
corresponding to furnace must be followed.
357948525.doc Page 42 of 111

14/06/2017
Code..
5.4 REMARKS AND OBSERVATIONS
In some cases the end faces of the rolls cannot be used as a base for the inclination measurement,
as in the case of furnaces operating in good condition during a long period. The measurement of the
inclination can be performed, doing double measurements in each end of the axis, while the support
sheave is turned 90 between the two double measurements.
In the case that this operation does not offer a sufficiently reliable result either, it will be precise to
disassemble the superior part of the rowlock, in order to be able to perform a control measurement
on the trunnions.
5.5 ANNEXED AND USED FORMS
In Table 5.1 is the form used for measurement and fixings of the rolls inclination of the furnace.
5.6 REFERENCES
- Fls inclinometer Type 83. Instructive F. L. Smidth 19924-06

- Fls inclinometer, Instructive F. L. Smidth 19921
357948525.doc Page 43 of 111

14/06/2017
Code..
Chapter 6
ROLLERS PARALLELISM AND FLOTATION
(Or kiln tires)
The objective is to maintain the rollers (or kiln tires) in correct position in order to control the axial
pushing exercised by them.
The kilns by design require an inclination to operate, and for this reason a status must be maintained
so that the axial pushing is controlled in order to maintain the kiln free of pressure or floating.
Different types of kiln design exist, which have different needs to maintain the kiln in flotation.
6.2.1. Floating kilns
In these kilns the requirement is fundamental in the adjustment of support rollers by inclinating them,
to carry the axial gravitational pushing and by this way maintaining the kiln in a floating position. In
this position, the tire (kiln tire) does not have contact with any axial pushing rollers (candlesticks),
when the kiln has load and when the temperature conditions are considered as normal as long as the
material is being processed. From this floating position, the kiln is displaced upwards or downwards
until getting contact with the axial pushing rollers (candlesticks).
6.2.2. Kilns with gravitational or complete axial pushing
These kilns are usually long, heavy, and with antifriction bearings on the axial pushing assemblies
(candlesticks), and they are capable to allow axial gravitational loads, with all the kiln support rollers
on a neutral position, with the longitudinal shaft parallel to the kiln shaft.
6.2.3. Kilns with axial pushing hydraulically operated
The arrangements where the hydraulically operated axial pushing is utilized, consist essentially in a
hydraulic jack positioning the kiln and pushing it upwards when the pump is activated and when the
kiln is to be lowered or returned to its position, the pump is stopped. The constant travelling of kiln
intends to eliminate the unequal wear of tires (kiln tires), and the gearings teeth in transmission.
357948525.doc Page 44 of 111

14/06/2017
Code..
- Measuring tape
- Impact wrench to move rollers bearings
- Dial Indicators (watches)
6.3.2 Periodicity
The axial pushing revision must be made every 6 months as minimum, although a daily inspection
per shift will provide a clear idea about the need to make adjustments in the rollers inclination in order
to prevent overloads in the axial pushing rollers.
6.3.3.1 Floating kilns
In these kilns the axial pushing rollers must not be forced to perform pushing operation, only check
that it does not have overload.
The bearings movement must be monitored by watch (dial) indicators in order to prevent an over
adjustment of any assembly, and having all the support rollers with an approximate equal load. See
Figure number 6.1
Upper.
Ri m Upper Ri m
Ri m
Lower
. Lower
.
Lower
. It need to have contact
0.236 inch (typical)
0.236 inch (tipical )
Contact (normal)
Axial push roller Axial push roller
Axial push roller
Floating push
Co mplete push Hydraulic push
Figure 6.1
The adjustment begins with a known neutral position, by positioning the rollers longitudinally parallel
to the kiln shaft, the rollers start inclination, as required by the kiln rotation direction, to move the tires
upwards or downwards, beginning to displace the kiln shell, reacting to the rollers movements. See
Figures 6.2 and 6.3.
The variances in material quantity inside the kiln, affect the rollers and the kiln axial movement. With
rollers inclined for a long period in typical conditions, the heaviest production loads will increase
reloads in the axial pushing roller (candlestick) in the direction(s) determined by the inclination angle.
Heavy loads cause severe reactions, light loads cause light loads.
6.3.3.2 Kilns with complete gravitational axial pushing

357948525.doc Page 45 of 111
14/06/2017
Code..
As the axial pushing assemblies are capable to carry gravitational axial loads, it is required that the
support rollers are in a neutral position and parallel to the kiln shaft.
In order to make corrections, the best practice is to make small movements regarding the rollers
neutral position, by deliberately inclining the rollers to make their pushing plates push downwards. In
many cases, this can be done by inclining them 0.125 mm - 0.250 mm in the parallel position correct
direction.
THE FURNACE MOVES TOWARDS

THE FEED SIDE
RIM
INSERT
ROTATION
INSERT FURNACE OUTLET
Figure
THE ROLLERS MOVE TOWARDS THE6.2
OUTLET
THE FURNACE MOVES TOWARDS

THE FEED SIDE
RIM
INSERT
ROTATION
FURNACE OUTLET
INSERT
FigureTHE
THE ROLLERS MOVE TOWARDS 6.3 OUTLET
6.3.3.3 Kilns with hydraulically operated axial pushing
357948525.doc Page 46 of 111

14/06/2017
Code..
Due that the movement is made here with the hydraulic system the support rollers must be parallel to
the kiln shaft, to make the kiln traveling freely.
To make adjustments, the procedure is equal to the previous case, moving the screws to their neutral
position. This can be made by a slight inclination to lighten part of load in the axial pushing hydraulic
system to move the kiln to its upper position.
It is extremely important that the inclination adjustments in the support rollers do not cancel totally the
kiln gravitational pushing; in this manner it is possible to move the kiln upwards without the help of
the hydraulic system.
The movements performed must be recorded in the attached forms, and this will serve for future
movements, which will strongly depend on the kiln type and its load.
6.3.5 Safety concerns
It is always dangerous to work close to a rotary kiln. Due that measuring and compare the
parallelism and flotation of kiln rollers it is required to work very close to the kiln, the appropriate
clothing, safety goggles, safety shoes, gloves and safety helmet must be utilized.
6.3.6.1 Floating kilns
The point to be observed here is to never let the axial pushing rollers be overloaded, it means that
the 6 mm separation must exist between the tire or tread ring and the axial pushing rollers.
6.3.6.2 Kilns with gravitational axial pushing
As in the previous case, but with the difference that in the lower axial pushing roller contact must be
made with the tire (kiln tire) tread ring, and the separation with the other axial pushing roller, will be
maintained in 6 mm.
6.3.6.3 Kilns with hydraulically operated axial pushing
The kiln must normally be allowed to travel a distance between 38 and 50 mm, from the lower
position to the upper position.
The rollers assemblies adjustments require patience, the work must not be done carelessly. Every
roller is moved to its neutral position (without inclination or pushing in any direction) and then the
357948525.doc Page 47 of 111

14/06/2017
Code..
adjustment movements must be made from 0.125 mm to 0.250 mm at the same time, followed by a
waiting period to let the kiln react, until the moment when the axial pushing conditions are corrected
by the supporting rollers, and for kiln arrangement.
A rule of thumb exists to perform the movements, and it consists in the following:
1.- Place a hand as though you were holding (grasping) the roller in favor of its spinning sense.
2.- The index and thumb are extended.
3.- The index finger indicates the bearing pushing, and the thumb indicates the adjustment or
movement caused in the kiln.
4.- As the thumb indicates the direction towards the movement will be made, from here can be seen
what hand is used, left or right, and corresponding to the left bearing and right bearing respectively (if
the roller is seen from the front position).
The most commonly used forms are the following:
Form 6.1 -Parallelism and flotation of kiln rollers.
Form 6.2 -Position of kiln rollers.
6.6 REFERENCES
- Recommended procedures for mechanical analysis of rotary kilns,

Book by Robert Chapman, edited by Fuller Company.
- Support bearings and kiln tire alignment, Manual F. L.

Smidth No. 18074-07
357948525.doc Page 48 of 111

14/06/2017
Code..
Chapter 7
CONTROL AND EVALUATION OF ALIGNMENT IN HOT (RUNNING) AND COLD
ENVIRONMENT (KILN SHUTDOWN).
The objective of the present procedure consists in presenting the most useful methods to perform the
kiln alignment control increasing its service life.
With in a well aligned kiln, advantage exists that it will not be submitted during the running operation
to hazardous flexion stresses, nor will it gravitate in some kiln tires (tires), a bigger part than the
provided in the kiln load, producing disturbances as for example the facets (marks) and punctures (or
pitting) formation on the bearing (tires) support faces and the kiln tires. A kiln without correct
alignment, will have a force consumption exceeding the normal consumption. Therefore, the kiln
must be timely realigned, in order to locate the centers again on a straight line.
Within the methods utilized for rotary kiln alignment control and evaluation, are the following:
- In running operation or in hot environment alignment.

- In cold environment with the kiln shutdown or out of running.
In both cases the kiln is examined based on vertical and lateral leveling.
After determining the required alignment correction as the case may be, there are factors to be
considered: The clearance between kiln tires and the kiln tube, the tube ovality and gearing set from
the teeth gearing. These procedures are seen separately.
7.2.1 Alignment in hot environment (running operation)
There are more growing demands regarding the rotary kilns alignment, to prevent shutdowns in the
productive cycle, this method has been developed to prove the vertical and horizontal shaft of a
rotary kiln, with the kiln running. The immediate advantage of this method consists in the fact that
the data collected, over which the kiln status is determined, correspond to its real running conditions.
The correction of eventual mistakes can be instantaneous or can be planned, according to
convenience for an anticipated kiln shutdown.
In the measuring system development, the technicians have been struggling in complying with this
new technique utilization with respect to the following demands:
357948525.doc Page 49 of 111

14/06/2017
Code..
1. The instruments are simple, accessible, transportable and easy to handle.
2. The method is assured against erroneous handling of instruments by the operator, through
incorporated control devices.
3. The expenses originated by the measuring are part of a very competitive order regarding the
traditional measuring methods, considering specially that with the new system it is not
necessary to interrupt the clinker production.
4. The method is based on different data composition in order to determine the kiln definite shaft,
which will be commented as follows:
7.2.2 Alignment in cold environment (kiln shutdown)
This method is very similar to the hot environment method, with the difference that a shutdown of 48
hrs. is required as minimum.
The essential instruments and devices to develop the corresponding work, are the following:
- Theodolite with 10 sec. Minimum precision.

- Precision level.
- Target graded or rule (level rod) in mm.
- Universal combination square.
- 600 mm. mechanical square
- Metallic metric tape (measuring tape).
- Measuring equipment for rollers diameter (or support rollers).
- Pyrometer for temperature measuring
- Magnetic tips
7.3.2 Periodicity
The kiln shaft alignment verification must be contemplated in the preventive maintenance activities,
corresponding to the median repairs, otherwise annually.
In case of any eventuality or doubt in the operation due to excess of current intake in the kiln main
motor, overload in rollers, checks must be made to know if the cause is due to kiln misalignment.
In order to determine the kiln alignment conditions, the kiln position (mounting) drawing must be
available, where the support rollers (tire) diameters are indicated, as well as the distance between
the kiln base or foundation.
357948525.doc Page 50 of 111

14/06/2017
Code..
The temperatures of the kiln shell and tires are also involved, which are obtained with a pyrometer,
as well as the tires diameters.
7.3.3.1 Alignment in hot environment (running)
7.3.3.1.1 Horizontal alignment.
This leveling can be made as long as the kiln is running. Through a leveling instrument, special optic
measuring (with level), a height elevation is marked in all the base or foundation.
The above involves taking away the bearings by the lateral parts, in order to place the magnetic tips
on the shaft, once they are placed, the level rod or rule is placed, where a level must be placed, to
check if it is well leveled.
See Figure number 7.1, which illustrates the form to place instruments.
The height elevations form a horizontal plane, from where are determined, through horizontal straight
rules, the measures "a" and "b" to be used in determining the height H measures.
Once this data is known and taken as sighting line, both magnetic tips of the same side (entrance
and exit) are placed, and a verification of separation between rollers trunnion shafts centers is made.
In the position plane appear marked corresponding height measures series, which have likely been
calculated from another horizontal plane. Therefore, the differences between the height measures of
the different kiln supports shall be the same, as long as the kiln was correctly aligned, while the
differences between them directly indicate how much the deviation is of the kiln shaft from the
straight line
Examinations also can be made for the height differences H-H 1 = a. They will be corrected in the
same way that is in the oblique sighting (Figure 7.2), and the deviations will be alignment mistakes.
For the determination of the corrected shaft kiln exist the following relations:
a4 = A4 - A1 a3 = a4 (L1 + L2) / L
a2 = a4 L1/L a1 = 0
The correction distances "a" can also be determined by means of drawings.
Afterwards the theodolite is placed aside the kiln close to the lower support, and the distance
between the optic sighting line
V and a vertical level rod (or plank) is measured. The "n" measure is
directly measured, after this procedure the lateral measures "b" will be determined.
b
1/2 D
n m
Rule
Niveau
90
1/2 D
Level mark on the base b

357948525.doc C1 C2 Page 51 of 111
a
V
14/06/2017
Code..
Figure 7.1
Slanted line of aim

a4
a2 a3
A1 A2 A3 A4
I II III IV
L1 L2 L3
L1 + L2
L 1 + L 2 + L3
Figure 7.2
The measures V can also be determined, by measuring the distance between an optic sighting line
and the kiln shaft determined with basis on supports positions measuring. If both support rollers
have the same diameter, then the result will be it and C2. If little difference exists between both
support rollers (or supports) diameters, the calculation can be made approximately just with the
condition that the lowest is closer to the kiln shaft than the other as much as the difference between
both diameters.
Two forms types (7.1 and 7.2) exist. The format to be utilized, depends on how sighting line was
traced, i.e. it depends on the discrepancy of the line traced by theodolite regarding a kiln shaft
parallel line.
Once this data is checked, they are transferred to the form 7.1 or 7.2 depending on the place where
the sighting line was traced, and by triangles difference a 1, a2, etc.. are determined, as previously
mentioned.
357948525.doc Page 52 of 111

14/06/2017
Code..
Knowing this data (from shaft line to sighting line), the kiln normal axis was plotted by taking a kiln
ideal axis as reference.
7.3.3.1.2 Vertical Alignment
A special optic measuring is made (with level) for level differences between the N number of base or
foundation of the kiln, taking as point of reference the kiln tires base metallic plate (or rollers), of
support, in the entrance side, (see Figure number 7.1 and form 7.3), although it is most
recommended to take also the base plate exit point, in order to average both readings and obtain
more real data, as the case may be that the base plate is just unleveled on an end, unfortunately this
is not possible for the majority of the cases, due to the place where the appliance is placed does not
allow to have an appropriate angle to see and take these two readings.
The recommendation is to place the appliance over a firm place, without any vibration, as well as to
protect the appliance from kiln heat radiations to prevent reverberation, with this we can assure to
have real data, in order to obtain this, it is necessary to be well coordinated with the person who
stops the level rod in the indicated place, which must be two levels, one of them to control the lateral
position and the other to control the frontal position. It must be perfectly leveled.
In Figure number 7.1, is illustrated the form in which the appliances must be placed in order to
measure, whereas in Form number 7.3, is schematically illustrated the procedure, and are noted
down the values checked as well as the drawing data related to how it remained originally (in the
mounting operation).
Once the calculations of form 7.3 are made, we will calculate the data required in Form 7.4, where
the temperatures are involved, for the kiln shell as well as the tires, which are obtained with a
pyrometer, as well as the tires diameters and the displacement, determined through the appropriate
procedure, as well as position drawing (mounting operation) data.
Once the final data (A = Y - F) is determined from Form number 7.4, we transfer the data to Form
number 7.5, where the data of the form number 7.3 is also written, in the section of Form number
7.6, that asks us to make a foundation "0", preferably base III is considered, in order to prevent as
much as possible to have movements influencing the axial device as well as in the gear ring, we can
finally obtain the values indicating the vertical position of the kiln, and with these values, we proceed
to plot it in the lower part of the form. See Form 7.5.
7.3.3.1 Alignment in cold environment (running)
Unlike the method for the hot environment, by means of this procedure if it is necessary to count with
a kiln shutdown and a minimum time (48 hours); to get the kiln totally cold this method is almost
unused, just as reference, because the data obtained in cold environment conditions, varies
considerably from the data obtained under normal running conditions. As in cold environment only a
picture of a kiln position is obtained, it is recommendable in doubt cases, to obtain the alignment in
cold environment conditions on several positions.
The equipment utilized in this method is very similar to the ones used for the method in hot
environment conditions, additionally to the same recommendations that must be followed in order to
prevent mistakes.
357948525.doc Page 53 of 111
14/06/2017
Code..
7.3.3.2.1 Horizontal alignment.
A special optic alignment is made (with theodolite) for this purpose; first mark the tire center and then
find the geometrical center related with the kiln shaft. See Figure number 7.1.
The information obtained in this process, is stated in Form number 7.1 and 7.2 (depending on the
place where the sighting line is traced), corresponding to the format for horizontal alignment under in
cold environment conditions, in this figure, a clear and detailed sight can be obtained, as well as in
the method in hot environment conditions, this calculation is also made through similar triangles.
7.3.3.2.2 Vertical alignment.
The special optic measuring (with theodolite), unlike the method in hot environment conditions, in this
case the measuring must be made over the kiln, where the level rod is placed to trace the sighting
line over the upper part of the tire. Another difference in this method, is that in this case the
clearance between the shell and the tire can not be obtained through the gap and displacement
metering appliance because the kiln is shut down, and this is one of the necessary values to
determine the vertical alignment, this data is obtained by measuring directly the clearance in the
upper part of the shell, through shims. Once all the required parameters are obtained, they are
transferred to Form number 7.6, and the next step is to calculate the kiln shaft location in vertical
position.
When the kiln alignment is revised, it is very important to program its correction, if needed, due to the
exposed reasons.
It is always dangerous to work close to a rotary kiln. To measure the kiln alignment it is required to
work very close to it; Appropriate clothing, safety goggles, safety shoes, gloves and safety shield
must be utilized.
The error average in the kiln shaft determination will be maintained in the majority of cases within +/-
1.5 mm., in the horizontal plane and +/- 2.5 mm. in the vertical plane, otherwise the necessary
correction must be made.
357948525.doc Page 54 of 111

14/06/2017
Code..
This procedure requires the execution of other procedures, therefore the person who performs the
control operations, must know the procedures. The related procedures are the following:
H-001 Measuring the gap (clearance) and displacement (clearance control), between the
Kiln shell and the tire (bearing tires).
H-003 Measuring the rollers and tires diameters (in cold and hot environment conditions).
H-005 Parallelism and flotation of rollers (or kiln tires).
The alignment correction, is very linked to the previous procedures, thereby its observation must
have extreme care to perform any adjustment in the alignment.
When performing corrections, the transmission must be observed in order to make the necessary
adjustments.
The utilized forms are the following:
7.1 Horizontal Alignment

7.2 Horizontal Alignment
7.3 Base Plates Leveling
7.4 Vertical Alignment
7.5 Vertical alignment
7.6 Vertical Alienation
Two format types exist for horizontal alignment, depending on the manner how the sighting line was
traced, i.e. the discrepancy of the line traced by theodolite with a line parallel to the kiln shaft.
For vertical alignment, there are three format types and they are utilized in combination.
7.6 REFERENCES
- Alignment control through trials with lead wire.

Manual F.L. Smidth 17.394
- Recommended procedures for mechanical analysis of rotary kilns,

Book by Robert Chapman, edited by Fuller Company.
357948525.doc Page 55 of 111

14/06/2017
Code..
Chapter 8
CONTROL OF MOVEMENTS (ADJUSTMENTS) TO CORRECT KILN SHAFT.
Perform the necessary displacements of support rollers bearings, in the transversal sense in order to
correct deviations detected in the kiln alignment revision, through the use of high-pressure jacks.
The kiln shaft alignment adjustment can be performed during the normal operation, through a special
2000 bar high-pressure jack, if the intention is to move up the kiln shaft, or simply to loose the screws
fastening the kiln tires, to make the kiln shaft descend.
The high-pressure jacks are utilized for tire bearings displacement in the connection kiln transversal
sense with the position adjustment for the kiln tire or the kiln shaft alignment.
The jacks can be also used when performing a change of kiln tire or a tire bearing.
These high-pressure jacks are mostly utilized in the F.L. Smidth bearings types 58, 74 and 80.
The equipment is composed by a manual pump (01) with an oil tank, 2 high pressure cylinders (02)
(high pressure jacks), a high pressure manometer (07), a distribution piece (11), and also three high
pressure hoses (06), and three quick couplings (03) and (04). See Figure number 8.1.
The equipment also includes an angular meter (15). See Figure number 8.2.
357948525.doc Page 56 of 111

14/06/2017
Code..
07 Fold radius=11.811inches
02 08
04
03 05
09
10
05
06 11
03
04
05
06
05
01
13 -
Pressure escapevalve
Ventilation screw 30
12 MA
N.
- Open during 2000
the service Oil filling screw
- Close during
the transport
Figure 8.1
Figure 8.2
Both cylinders are interconnected and are placed on each side of the adjustment screw (14), of tire
bearing, between the bearing base and the fastening piece (16). See Figure number 8.2.
The cylinders are connected to the distribution piece and the manual pump through the hoses.
The adjustment screw (14) is the component, which determines the tire bearing position in the kiln
transversal sense, so that, a bearing position modification, is performed when spinning the
adjustment screw. As a consequence of the enormous load coming from the kiln tire, the kiln tube,
the coating and filling operation, the bearings are pressed towards their adjustment screws, with so
much force, that they can hardly spin. See Figure number 8.3.
Both jacks help to relieve the pressure acting over the adjustment screws, whenever a spin on the
screws is wanted.
8.3.2 Periodicity
357948525.doc Page 57 of 111

14/06/2017
Code..
This procedure is utilized provided that the kiln shaft position correction is desired as result of its
alignment review.
8.3.3.1 Mounting and operation
When placing the equipment (see Figure 8.3) attention must be paid that the high-pressure hoses
can only bent with a radius not lower than 300 mm.
The trajectory of piston, high-pressure jacks, is 10 mm., for this reason it can be necessary to place
supplements (shims or wedges) between the jacks and the fastening piece (or tightening).
It is very important that the faces, where the jacks pressure is exercised, are completely parallel, as
otherwise the jacks could be damaged.
Figure 8.3
Before starting the operation must be determined, how much and in what sense must the
corresponding bearing be displaced and calculating, according to that, the equivalent spin to apply to
the adjustment screw.
Utilize the following formula:
L X 360
G = ------------
S
Where G is the number of degrees to spin the adjustment screw, L is the wanted distance to displace
the bearing measured in millimeters, and S is the screw thread passage, also measured in
millimeters.
For example if the desire is, to displace a bearing 0.2 mm towards the kiln theoretical shaft and the
adjustment screw thread passage is 4 mm., the screw must be spinned:
357948525.doc Page 58 of 111

14/06/2017
Code..
0,2 X 360
---------------- = 18 to the right
4
This operation is performed in the following manner:
a) Loosen the supporting bearing fastening pins.
b) Open the manual pump ventilation screw (12), (see Figure number 8.1) and start pumping, at
the same that the manometer pressure is maintained under continuous observation.
In Table number 8.1 is specified the maximum admissible pressures for distinct bearing sizes. These
colors must not be exceeded as this condition can cause rupture in the fastening piece fixation
screws.
On small frequent cases, where the admissible pressure is not sufficient to lighten the adjustment
screw so that it can be spun, will it be necessary to fasten with welding application the reinforcement
irons to the seat plate placed behind the fastening piece. In these cases a 10 - 20 % pressure
increase can be accepted.
c) As soon as the adjustment screw can be spun, place the angular meter over the screw head, by
spinning the screw as many degrees as necessary in the correct direction.
d) Open the manual pump unload valve (13) The bearing will quickly slide outwards until the
moment when it has contact again with the adjustment screw.
e) Tighten again the bearing fastening screws.
It is important that the operation must be realized as quickly as possible in order to prevent bearing
heating condition. The adjustment result must be controlled with axial measuring equipment, as
mentioned in the pertinent directions.
The supporting bearing movement, during the operation, can be eventually controlled through a
micrometer with quadrant placed in the bearing base.
357948525.doc Page 59 of 111

14/06/2017
Code..
Table 8.1
8.1 pressures
Max. admissible
Bearing Type Bearing Type Bearing Type
2 58
x 100 2 x 200 2 74
x 100 2 x 200 80 2 x 50
Diam. Tons. tons bar tons bar Tons. tons bar tons bar Tons. tons bar
160 17 300
200 27 485
240 31 310 149 26 260 125 44 775
280 42 420 202 35 350 168
320 55 550 264 47 470 226 68 120
360 68 680 327 58 580 278 85 0
150
400 85 850 409 72 720 346 105 0
185
450 109 109 524 90 900 433 0
500 134 0
134 644 112 112 538
560 167 0
167 803 142 0
142 682
630 211 0 101 178 0
178 855
710 264 4
126 225 0 108
790 9 2
850 364 175 279 134
880 0 347 1
166
970 419 8
201
106 500 4
0
115 590
0
124 688
0
134 803
0
After every roller movement or adjustment wait for some time to let the kiln stabilize itself in order to
observe its behavior, by doing this the kiln shaft will move to its correct position.
Care must be given to observe that the hoses are absolutely intact, as the usage of defective hoses
implies serious risk to personal damages.
It is very dangerous to work close to a rotary kiln. As when performing the lead trials it is required to
work very close to it, appropriate clothing, safety goggles, safety shoes, gloves and safety shield
must be utilized.
357948525.doc Page 60 of 111

14/06/2017
Code..
Whenever the rollers movement is executed the following must be observed:
- The support rollers cut must not be higher than 2 mm.

- Cutting operation for support rollers with pine shape are not allowed.
- The cutting operations must be executed in one or two rollers group at a time.
- Whenever the support roller diameters difference is 20 mm or higher, its surface must be
rectified.
The rollers movement must be made carefully, as otherwise kiln uncontrolled critical situations will
arise.
No format is established for this procedure.
8.6 REFERENCES
- High-pressure jacks for kiln tire adjustments, Manual F. L. Smidth

19114-02
357948525.doc Page 61 of 111

14/06/2017
Code..
Chapter 9
CONTROL OF CONTACT BETWEEN ROLLERS (support rollers) AND TIRES (kiln tires),
THROUGH LEAD WIRE.
Confirm and control the kiln supports positions during the kiln running or normal operation, through
trials with wire lead.
9.2.1 Principle
The method is based on analyzing the crushed lead wire form, after introducing it between the kiln
tire and the support roller, which will provide the following information:
a. The surface pressure between the kiln tire and the support roller
b. b. The inclined position of support screws (rollers) regarding the kiln shaft (its intersection).
c. The support rollers position in the lateral sense.
d. The relative load on every support.
e. The kiln tube warping, if existing.
9.2.2 Method utility
The trial through lead wire can be utilized in the mounting operation to confirm the kiln tires
inclination, but its primary objective is the kiln supports positions control during the normal running
operations.
The compressed wire form will serve as illustration for the pressure conditions existing between the
kiln tire and the support roller along the surface where the crushing will take place.
A trial isolated with lead wire is extremely difficult to be evaluated as are there are many factors
contributing to provide the lead wire with its crushed form, as mentioned subsequently.
The trial results are easier to be evaluated when intending to perform a comparison between two
trials, for example, performed before and after a supports position correction. The difference
between these both trials will provide an authentic image of the correction effects.
Also, trials performed systematically and methodically when compared against other periodic
measuring, will clearly show eventual modifications in the kiln alignment.
The trial with wire lead alone must only be considered as a relatively simple remedy for the kiln
mechanical preventive maintenance, and there are series of factors influencing the result, for
example:
The very hot kiln roller (tires), can cause higher crushing than the own pressure.
The supporting faces poured (cast) and deformed in the kiln tires and the support rollers will
give a false image of the pressure conditions.
357948525.doc Page 62 of 111

14/06/2017
Code..
The wire leads quality and diameter.
The running conditions of the same kiln, i.e. rings formations, load distribution, formation of
crusts and other adhesions, refractory status and nature, special internal installations to
improve the kiln economy, etc..
- Vernier or thickness gauge
Additionally a wire lead with 2 - 3 mm diameter is required. Cut the wire lead in pieces of a length
equivalent to the kiln tire width. 20 - 30 cm bigger makes it easier to fasten it.
9.3.2 Periodicity
Under normal conditions it will be sufficient to perform the trial with wire lead every 3 months period.
Nevertheless, during the first period of a new kiln running, the recommendation is to perform trials
with shorter intervals in order to discover timely eventual settlements of kiln foundations or bases.
As a wire lead trial also discloses, if the kiln tube is warped, it must be always made jointly with a
normal alignment of the kiln supports and, depending upon the case, consideration must be made for
the kiln tube straightening.
9.3.3 Procedure, calculation method and results
The method to follow for the trial with wire lead is to introduce, as long as the kiln is in service, a wire
lead of 2 - 3 mm, between the supporting roller and the kiln tire, therefore the wire is compressed, as
illustrated in Figure number 9.1.
0.0787 to 0.1181 inch lead wire .

Figure 9.1
357948525.doc Page 63 of 111

14/06/2017
Code..
9.3.3.1 Practical method execution
Immediately after starting and the first set in service for a new or just aligned kiln, i.e as long as the
alignment is correct, it is recommendable to perform a trials set for all the supports with wire lead.
These trials set will form the comparison basis for all the subsequent trials.
A complete set encompasses six crushed wires coming from each support, three of them for each
kiln tire. The trial with these three wires is made in front to three generatrixes, marked in the kiln tube
with a space of 120 degrees between each of the, such as illustrated in the Figure number 9.2.
Figure 9.2
When the three generatrixes are marked in the kiln tube, it is more convenient to leave the generatrix
A in the diametral plane, crossing through the man entrances center, and the other generatrixes
displaced at a distance of 120 from there. Observe the letters sequence regarding the rotation
sense.
Introduce the wire lead between the support roller and the kiln tire just in the moment when one of
the generatrixes crosses through the kiln tire.
Provide, carefully, the crushed wire with date, support number, specify if it is right or left tire (seen
from the kiln operator) and also write the corresponding generatrix number.
DATE :
SUPPORT (OR BASE) NUMBER :
SIDE: RIGHT/ LEFT
GENERATOR : FLATTENED LEAD
OUTLET END
Figure 9.3
357948525.doc Page 64 of 111

14/06/2017
Code..
Place the tag on those wire lead end closest to the kiln exit end, see Figure number 9.3.
The result of wire lead trials can be preserved fixing it with adhesive tape to a carton piece, or simply
limiting to transfer, carefully, the wire leads contour to a paper and maintain it as illustrated in Figure
number 9.4.
With support on Figure 9.4, which we section in 10 equal parts, to be identified as variables t,
from t1 to t5, which is the exit side and we identify them as t U and from t6 to t10, which is the entrance
side identified as tJ, see Figure number 9.5, the only recommendation is that the marking must be
correct.
Subsequently, with the obtained measures the results are introduced in Form 9.1.
The mean values for every wire lead half are calculated, and the result is written in Form 9.1.
t1+t2+t3+t4+t5 t6+t7+t8+t9+t10
Tu = 5 Tj = 5
Left pulley wheel Right pulley wheel

}
}
INLET
A B C A B C
L
C Center line
Rolling ring ( Rim )
Rolling ring width KILN Number _____

Support Number _____
Date: ________
OUTLET Figure 9.4
357948525.doc Page 65 of 111

14/06/2017
Code..
Left pulley wheel Right pulley wheel
}
}
INLET
A B C A B C
J
t10
t9
t8
t7
Center line
t6
t5
C
L Rolling ring ( Rim )
t4
t3 Rolling ring width
t2
t1 Furnace Number_____
Support Number____
U
Date :________
Figure 9.5
Immediately proceed to calculate OUTLE T
the values t u - tj for each generatrix and its mean term is
calculated, which is the value utilized to make comparisons.
The mean term results of t u and tj are written on the upper part and in the lower left table, the next
step is to make the addition and the average is again obtained for every tire (right and left),
subsequently the tire difference is calculated and the average t L is obtained.
The value of t L found, is compared with the value t L of the supports rest, specially with the mean
terms previously confirmed for the corresponding support.
9.3.4.1 Supporting washers intersection
The kiln tire intersection i.e. how correct is the kiln tire and the support roller orientation regarding the
kiln spinning or rotation.
In order to make comparisons the mean term t u-tj is used, if the kiln shaft is rectilinear (without
warping), and the different supporting faces are in good conditions, the three differences t u-tj , one
for each generatrix result almost equal.
Both kiln tire for a same support must be always of opposed intersection, when the kiln tires are
located at parallel positions.
357948525.doc Page 66 of 111

14/06/2017
Code..
As rule can be specified, that the intersection must not exceed the following values:
Intersection
Bearing width
(Mean term)
mm mm
500 2.5
600 3.0
700 3.5
800 4.0
900 4.5
1000 5.0
A too big intersection results in a very big surface pressure, in a material overload, and the wanted
effect to retain the kiln in the axial sense through an uniform axial pressure of the kiln tire is not
obtained.
9.3.4.2 Kiln tire position in the lateral sense
The mean values calculated in the upper part of Form 9.1 are transferred to the lower left part, and
the mean crushed widths tH and tV are calculated.
The values tH and tV specify he mean surface pressure, the values are compared, and if the
difference exceeds 10%, the tires must be adjusted in the lateral sense. Nevertheless, in the support
close to the gearing set a 20 % difference can be admitted.
9.3.4.3 Load over individual supports
Finally the mean width t L of all the wire leads crushed by the kiln tire are calculated. The value t L
represents an expression of the kiln tire total pressure over the corresponding support.
The value tL found is compared against the value t L of the supports rest, specially with the mean
terms previously confirmed for the corresponding support.
9.3.4.4 Kiln tire inclination
If the lead wire trials insinuate that the tire or roller intersection is normal, whereas an examination on
the tire supports show that the tire presses the roller downwards, the cause will be that the tire
support face is not parallel to the kiln shaft. The tire or roller inclination must be corrected, through
wedges (or shims) under one of the supports.
Additionally with the lead wires trial detection of irregularities as the following can be made:
9.3.4.5 Kiln tube warped

357948525.doc Page 67 of 111
14/06/2017
Code..
If the kiln tube (or shell) is curved, the pressure will vary between a kiln tire (tire) and the
corresponding rollers during the kiln rotation, generating different crushing on every generatrix.
B B
C
Figure 9.6
If the kiln shaft is warped, an idea about the warping sense can be generated, by drawing the
following diagram:
D Beginning from "O" point the three lines OA, OB and OC

B
b
are traced with 120 angles between them. Then for
every tire or roller can be calculated the following:
ma x
V
tU + t J
M tA =
a
A 2
O
i.e. the lead wire mean width after crushing it in the

generatrix A.
c Also the values tB and tC are determined. tU and tJ are
C taken from the Form 9.1.
Now in the diagram are traced (for example in scale of 2 : 1), the values tA = Oa, tB = Ob and tC =
Oc. A circle is traced by crossing the points a, b and c with its center in M. From Pole O a line is
traced crossing M, cutting the circle in D.
A wire trial of lead wire performed in the generatrix D kiln, located at V from generatrix A in direction
towards B, will mark the maximum crushing, i.e. equal to OD distance, measured in the diagram.
If the major mean width tD, divided by the minor one, generates as result a major value of 1.3 , then
the kiln tube must be straightened.
If the lead wires crushing in a tire is higher in one roller than in another one, the reason is because
the rollers have been laterally displaced. The pressure coming from the sprocket and the kiln load
can generate an unequal crushing and therefore, the rollers position in the lateral sense must not be
corrected until the moment when confirming, through a control optic leveling, the kiln shaft.
The maximum surface pressure between the washer and the kiln tire can result as big as with risk of
"pitting" or "punctures" generation, if the kiln tube is not straightened.
9.3.4.6 Tires laterally displaced
357948525.doc Page 68 of 111

14/06/2017
Code..
If the wire lead crushing in a support is higher in one tire than on another, is because the tires have
been laterally displaced. The pressure coming from the sprocket and the kiln load can have by
effect an unequal crushing and therefore, the rollers (or tires) position in the lateral sense must not
be corrected until the moment when, through a control optic leveling, the kiln shaft is verified.
The mean values tH and tV are divided, the highest by the lowest, and in this surfaces pressures
ratio the following values can be expected:
In the support where the transmission is: 1.05 - 1.2

In the other supports: 1.0 - 1.1
If a higher ratio is checked, a support control leveling must be verified (i.e. the kiln alignment) and
make a correction.
9.3.4.7 Kiln tire (tire) displaced in the vertical sense
If the mean width t L in one of the supports differ essentially from the others, correction must be made
in the distance between both tires of each set, i.e. correct the kiln tire position height.
It is always dangerous to work close to a rotary kiln. As when performing the lead wire trials it is
required to work close to it, appropriate clothing, safety goggles, safety shoes, gloves and safety
shield must be utilized.
The differences in the crushing width, it means the values t u-tj or tj-tu, respectively, depend, among
other factors, upon the kiln tire width, and 5 % of it must not be exceeded.
The kiln tube warping provides the mean width variance of the lead wires crushed of a same tire. If
the mean width vary more than 30 %, the warping character and extension must be examined
differently, considering a kiln tube straightening. If the mean width of all the lead wires crushed of a
washer exceed more than 10 % then the mean width of all the lead wires of the other tire
corresponding to the same support (but 20 % in the gearings set), the kiln must be submitted to a
control leveling.
The wire trial can be realized quickly and efficiently, but its results are not as exact as to exempt the
kiln alignment checking through a leveling instrument.
357948525.doc Page 69 of 111

14/06/2017
Code..
But the trial by itself evidences, if the optic control is immediately required:
It is not possible to determine in advance an admissible variance of the mean superficial pressure
from one support to another, but it is valid as a general rule that if the mean surface pressure of a
support apparently is extraordinarily big - or small - regarding the superficial pressures on the other
supports, the kiln must be submitted to a control leveling operation.
Form 9.1 Alignment through lead wire trials
9.6 REFERENCES
- Alignment control through wire lead trials

Manual F.L. Smidth 17.394 (1).
Chapter 10
CONTROL OF GEARING BETWEEN GEAR RING AND PINION IN KILN
THROUGH LEADEN HEELS
357948525.doc Page 70 of 111

14/06/2017
Code..
The main objective of this procedure is to maintain a good contact between the gearings teeth
(pinion / gear ring), in order to increase the transmission service life.
The transmission objective is to transmit the motor spinning momentum from the kiln reducer to the
kiln tube.
One or two pinions and a sprocket, composed by two or four parts, compose the transmission. The
sprocket is subject to the kiln tube through the sprocket springs.
10.2.1 Activating gear ring and pinion wear
The problems occurring with kiln pinions and gear rings are generally originated by:
- Axial warping of sprocket.
- Radial warping of sprocket.
- Lubrication.
The faults previously mentioned, are normally consequences of a permanent or thermal deformation
in the kiln tube, causing an overload of gear ring teeth generating as result the contact (support)
reduction in teeth width as well as in teeth height.
10.2.2 Gearing failures cause
The gearing failures cause is mainly due to wear on the support rollers, kiln tires, supports, etc.,
which can mean a reduction of distance between centers between sprocket and pinion, with the
effect that the distance between the tooth top and the tooth bottom is too small, i.e. lower than 6 - 12
mm, according to the kiln size.
- Leaden heels (24 pieces), according to Fig. 10.1

- Thickness gauge (Vernier)
Lead
1/8 inch long rod
6 1.5
357948525.doc Page 71 of 111
Figure 10.1
14/06/2017
Code..
10.3.2 Periodicity
The recommendation is to perform this measuring once a year, or every time the kiln alignment is
made.
First of all the screws set tightening must be reviewed, and in order to control the teeth gearing, the
clearance between the tooth top and the tooth bottom must be the same on both sides (entrance and
exit).
In order to monitor the clearance between pinion and gear ring, the lateral caps above the pinion
must be removed. In case of having two pinions, this measuring operation must be repeated for the
other pinion.
The gear rings springs, or their fastening pins, are marked with the consecutive numbers from 1 to
12.
24 leaden heels are manufactured, according to Figure number 10.1.
The leaden heels are marked in 2 sets, with the numbers from 1 to 12; a set corresponds to the
entrance side and the other corresponds to the exit side.
The heels are inserted at the pinion back, crossing through the gear ring every time a pin fastens the
supports to the gear ring. During this operation, the kiln in hot and / or cold environment, must be
spun with the slow spin.
The heels are measured and the measures are recorded in a scheme (polar diagram), see Form
number 10.1.
The gearing teeth must be absolutely examined, before determining the kiln definite alignment. It
can be confirmed that what follows is what there is in the mounting between the teeth top and teeth
base:
Module Step (mm) Clear. (mm) Set

48 151 12 Gearing teeth
45-42 141-132 11
40-35 126-110 10 Pinion
30-20 95-63 8 Step
357948525.doc Page 72 of 111

14/06/2017
Code..
If the confirmed set is not in accordance with these values, an adjustment must be made, duly
considering the teeth wear, with arrangement to the clearance indicated above, i.e. that it must be
considered when the new kiln shaft is determined. Given the case an incorrect gearing can be
corrected by displacing the pinion through command supports intermediate sheets (or shims)
thickness modification.
If the contact between the teeth is not correct, this means that the teeth are not in uniform contact
along the entire surface, one of the pinion supports could be displaced in horizontal sense. The
original position of the support is indicated by chisel strikes in the support basement, and in the seat
plate. The supports position can be adjusted through the adjustment screws.
it is always dangerous to work close to a rotary kiln. Due that measuring and compare the
parallelism and flotation of kiln rollers it is required to work very close to the kiln, the appropriate
clothing, safety goggles, safety shoes, gloves and safety helmet must be utilized.
The maximum permissible clearance available must be 12 mm, and 6 mm as minimum, and in the
teeth parallelism confirmation case, the maximum deviation will be 0.01 mm.
The kiln transmission gearing control is basic for its durability, although it is very important to develop
this control when the kiln is steady, i.e. that there is not existing material accumulated in zones.
-Form 10.1, Gearing control between pinion and gear ring.
10.6 REFERENCES
- Manual: Transmission type 82 with one pinion, F.L. Smidth 18114-13

- Manual: Transmission type DL-5, SL-5, DL-7 and SL-7, F.L. Smidth 18111-17
Chapter 11
ALIGNMENT OF THE MAIN TRANSMISSION, GEAR RING AND PINION
11.1 OBJECTIVE AND REACH
The main objective of this procedure is to maintain the transmission aligned, in order to have a good
contact between the gearing teeth, to have a more silent transmission and increase the transmission
running life.
357948525.doc Page 73 of 111
14/06/2017
Code..
The transmission objective is to transmit the motor spinning momentum from the kiln reducer to the
kiln tube.
A pinion and a sprocket, in two or four parts, compose the transmission. The sprocket is fastened to
the kiln tube through the sprocket springs.
The problems occurring with the pinions and gear rings of the kiln are generally originated by the
following:
- Sprocket axial warping.
- Sprocket radial warping.
- Lubrication.
The faults previously mentioned, are normally due to a permanent or thermal deviation in the kiln
tube, causing an overload of the gear rings teeth as a consequence of the support reduction in the
teeth width and teeth height.
- Three stopwatches, two for axial measuring and one for radial measuring, with the necessary
brackets, magnetic bases, vises, etc.
11.3.2 Periodicity
The recommendation is to perform this measuring operation once a year, or every time the kiln
alignment is performed.
In the sprocket, 12 visible marks must be painted in the kiln shell, at a distance of 30 between each
of them. Number the marks from 1 to 12. The position 1 must be located at level with the inspection
or man entrance holes, for future references.
During these measuring operations the kiln must be spin, as much as possible through the
transmission, as this provides the safest results.
Three people perform the measuring operations at the same time, in a same kiln revolution.
357948525.doc Page 74 of 111

14/06/2017
Code..
Continue the slow spinning during a whole additional revolution, and control that the measuring
operations results provide the same deviations level.
11.3.1 Radial eccentricity measuring.
For radial eccentricity measuring a stopwatch or depth measuring device is utilized, as illustrated in
the Figure 11.1. During both methods of execution it is important that the measuring operation is
performed from a persistent bracket, firmly fastened to the base plate, in order to prevent vibration-
reading mistakes. First is measured the distance to the turned measuring face of the sprocket.
Figure 11.1
Spin the kiln tube one turn and read the stopwatch / depth meter in front of every mark in the kiln
shell. Write the values, by utilizing Form 11.1.
Trace a polar diagram based on the measuring operations. The radial eccentricity sense and size will
be detached from the diagram; this will also show if the big deviations are caused by ovality or
eccentricity.
When adjusting the sprocket a distortion by tightening it must not be provoked. I.e., when tightening
one side the other side must be equally loosened.
11.3.2 Axial warping (run out) measuring
The axial warping can be measured during the same spin of the sprocket.
Two stopwatches must be utilized for the axial warping measuring operation. They are placed on
each kiln side, displaced 180 one from each other, but on the same side of the sprocket (both
stopwatches will be placed in the entrance or exit side). See Figure 11.2.
357948525.doc Page 75 of 111

14/06/2017
Code..
Figure 11.2
Both brackets, where the stopwatches are placed, must have good stability, in order to have a good
measuring result. Both persons necessary to read the stopwatches must be standing up in a bracket
or platform, independently from the bracket where the stopwatches will be located, so that the
persons movements do not influence the measuring operations.
The reason why two stopwatches are utilize, is in order to compensate for failures generated as
consequence likely to the kiln tube axial misalignment, during the slow spinning. Which can be better
appreciated by seeing the Figure 11.3.
The Figure 11.3 shows that the sprocket counts with a total eccentricity W, meaning that if the kiln is
spun 180, A will generate a positive deviation (+W) and B a negative deviation (-W), i.e. if the kiln
has not been displaced in axial sense during the slow spinning.
+W -W
A B A B
Figure 11.3
Now suppose that the kiln, during a slow 180 spinning has been displaced (F) mm in the sense
indicated by the arrow in Figure 11.4.
F+W F-W
A B
357948525.doc Page 76 of 111

14/06/2017
Code..
Figure 11.4
The stopwatch A indicates F+W and the stopwatch B indicates F-W.
In order to find the W value, the value we are interested in, the following method is utilized:
The deviation of stopwatch B (F-W) indicates a negative symbol, it means -(F-W) = -F+W and it is
added to the deviation (F+W) in the stopwatch A.
Indication in stopwatch B: -F+W

Indication in stopwatch A: +F+W
Adding 2W
W is obtained by dividing by two.
The method is also valid when the kiln is spun any number of degrees instead of 180, and as it is
compensated mathematically by the axial displacement; the displacement sense does not have any
sense.
If the sprocket is flat, the curve will always have a sinusoidal form.
In the Form 11.2, the measuring operations results are written. The axial warping must not exceed
+/- 0.75 mm.; despite in recent dates (new kilns) a higher demand exists (to increase even more the
transmission life), as this value must not be higher than +/- 0.5 mm.
The gearing teeth must be absolutely examined, before determining the definite kiln alignment.
Whenever it is necessary to align the gear ring, this must be made immediately, and the gearing of
gear ring with pinion must be revised by following Procedure H-010.
It is always dangerous to work close to a rotary kiln. To measure and control the parallelism and
flotation of kilns it is required to work very close to it; appropriate clothing, safety goggles, safety
shoes, gloves and safety shield must be utilized.
The radial eccentricity must not exceed +/- 1.50 mm, which is the mounting tolerance.
The axial warping (run out) must not exceed +/- 0.75 mm.; despite in recent dates a higher demand
exists, as this value must not be higher than +/- 0.5 mm.
In case of exceeding the previous values, a correction must be immediately made.
357948525.doc Page 77 of 111

14/06/2017
Code..
The kiln transmission alignment revision is basic for its good running operation, and in order to
assure the measuring operations are correct, special care must be given to fix correctly (and never
move them during the measuring operation) the dial watches or stopwatches, to prevent erroneous
readings.
Form 11.1 Radial eccentricity calculation.

Form 11.2 Sprocket axial warping calculation.
11.6 REFERENCES
- Manual: Transmission type 82 with a pinion, F.L. Smidth 18114-13

- Manual: Transmission type DL-5, SL-5, DL-7 and SL-7, F.L. Smith 18111-17
- Manual: Rotary kilns, kiln alignment, F.L. Smidth 669800
357948525.doc Page 78 of 111

14/06/2017
Code..
Chapter 12
KILN SECTIONS (KILN SHELL) REPLACEMENT,
IN WHICH DISTORTION CAUSES PROBLEMS.
This procedure, intends to cover whatever is needed when a kiln tube section or kiln shell must be
replaced.
When the kiln tube section or kiln shell must be replaced, this is due first of all to the need of
having a good surface for the refractory brick correct placement.
The fault shown by the kiln section or kiln shell requiring its replacement, is normally due to a
permanent or thermal deformation in the kiln tube, causing additionally damages in the bricks as
mentioned, showing irregular overloads in the support rollers.

12.3. 1.1 Equipment and tools
- Portable oxyacetylene cutter, with all its implements, such as rails or guides, blowtorch or gun,
etc.
- Welding equipment, with its fittings.
- Alignment sevens or irons or jacks or pins (see Figure 12.1)
- Mounting angles or angular consoles with their adjustment screws (see Figure 12.1)
- Micrometer, with its magnet carrier.
- Punch.
Kiln Pins Aproximate

Diameter Number number of
(m) adjustment
irons
1) Tensioning pins
2) Mounting irons
3) Adjustment
irons
357948525.doc Page 79 of 111

14/06/2017
Code..
12.3.1.2. Support equipment
- Ultrasound equipment.
- Support beams, to support the kiln shell, they could be railroad mudsills, etc.
- Crane to perform maneuvering, capable to support the kiln shells.
12.3.1.3 Work materials
- Welding application
12.3.1.4.Supporting materials
- Kiln position plan or drawing

- Plan or drawing of disposition, holes for internal installations, etc.
12.3.2 Periodicity
The eventuality in the kiln shells or kiln sections replacement, is made whenever so required, due to
problems caused by it when being distorted or deformed.
First the kiln shell or kiln section size or kiln tube section size are determined, manufactured, the
damaged kiln shell is removed, and the new one is placed. Now, next are described in more detail the
measuring and kiln shell replacement activities.
12.3.3.1 Determination of damaged kiln tube section measure
1.- The kiln shell diameter and length are determined, with special care that this measuring is made
when the kiln is in cold environment conditions, and with these dimensions, and supported by the
kiln drawing, a kiln shell can be manufactured in accordance to reality. Caution must be observed
in the consideration of rivets, pumped welding applications, splice plates, etc.
2.- With the kiln shell or kiln section dimensions, the new kiln shell can be ordered to Manufacturing.
12.3.3.2 New kiln shell manufacturing and handling
The kiln shell is ordered for manufacturing according to the material and thickness specifications indicated
in the manufacturer drawing. '
It must be inspected when being received, by measuring the diameter at the ends through a rule assuring
it is perfectly circular, and provided with a reinforcement cross, in order to prevent its damage during the
transportation and handling. If the kiln shell is thick (higher than 2.85 m.), it must have an extra cross
placed in the middle point.
It is recommended to leave the reinforcement cross on its place in the kiln shell, until the moment when it
is joined by angles and pins (or alignment pins) with the adjacent kiln shell. As soon as the pins (or jacks)
for kiln shells union, and once the joint is centered through the adjustment irons, the reinforcement
crosses can be cut, or can be left until after the first bottom cord.
357948525.doc Page 80 of 111

14/06/2017
Code..
If the circular form of the new kiln shell has been deformed previous to the mounting operation, the
shoring crosses joists are cut before proceeding to the kiln shells union. Jacks or tensioning pins must be
utilized to make the kiln shell return to its circular form. If this work is made during the mounting
operation, exclusively tensioning pins are utilized.
The shoring crosses situated in the middle point of a thick kiln shell, must not be removed until finishing
its total mounting and welding operations.
When the kiln shell is to be utilized, the chamfers provided for the welding joints must be perfectly clean.
All the paint, when burned produces gases and reduces the welding application quality must be removed.
12.3.3.2 Preparation steps
Previous to proceed with the kiln shell removal, and the new kiln shell placement, it is necessary to
examine:
a) The possibilities to transport the pieces, before and during the kiln shell removal, and the new kiln
shell mounting.
b) The elevation devices available, such as cranes, hydraulic jacks, etc.
c) The possibilities to spin the kiln during the alignment and welding operations. It is recommended to
perform spins with the slow spinning device, and in case of utilizing tackles or hoisting machines,
observe that the traction is upwards in order to reduce the supports friction.
12.3.3.3 Damaged kiln shell removal, and surfaces preparation
1.- In a convenient extension around the repair place the material, the refractory and the internal
installations are removed.
2.- Spinning the kiln, supporting against just one of the guide roller (or candlestick), lines are
traced on the kiln shell corresponding exactly to the new kiln length. 100 mm away from each
side of these lines, two reference lines are traced, see Figure 12.2. The reference lines are
provided with punch marks. Identify at the same time, if a kiln shell warping correction is
needed.
3.- The kiln tube is supported as illustrated in the beginning in Figure 12.2, and the kiln shell is cut
with the automatic oxyacetylene cutting equipment, and the kiln shell is dismounted.
4.- The kiln tube cut edges are chamfered such as indicated in Figure 12.3.
5.- In case the kiln shell being changed, contains a kiln tire (or tire), this is the time to perform its
change, from the old or damaged kiln shell to the new one.
12.3.3.3 New kiln shell mounting
1.- The new kiln shell is placed in its site, and besides the cut in the kiln tube nearest to the
entrance, mounting angles are welded, as many as depending on the kiln shell diameter and
length.
Normally the adjustment irons are welded in the kiln shells internal wall, with limitation to the
number of irons absolutely necessary, see Figure 12.1.
2.- The kiln shell is aligned regarding the kiln lower part (the part towards exit), considering the
eventual warping mentioned in Paragraph 2 of the previous point 12.3.3.2. According to the
indicated in Figure 12.4, the measure includes the reference line traced, and is internally
confirmed through a rectilinear rule.
357948525.doc Page 81 of 111

14/06/2017
Code..
3.- Internally and externally in the bottom (or lower part) and above (or upper part) of the kiln shell,
respectively, a welding cord of 800 - 1 000 length is welded. Internally the complete joint is
welded and externally a cord with the same dimensions must be applied, so that, both cords
have the same section, in attention to a uniform contraction.
Figure 12.2
Internal side
Figure 12.3
Control Measurement
Control
Measurement
Figure 12.4
357948525.doc Page 82 of 111

14/06/2017
Code..
4.- The kiln spins carefully approximately 800-1000 mm, and it is again supported, then a new welding
cord with appropriate length can be applied.
5.- Once the joint half is externally and internally finished, the kiln shell alignment must be controlled.
In case the alignment is incorrect, it must be corrected by cutting, beveling and welding part of the
circular joint welded. If in the previous work the reference line measuring has been confirmed and
if the welding application has been executed with equal sections of the internal and external cords,
the kiln shell must be centered.
6.- The bottom cord is chiseled, and the joints are finished.
7.- The upper part (towards the entrance) of kiln is mounted and welded in form analogous to the
explained in the above:
The results under this procedure must be positive, and a kiln tube perfectly aligned and in running
conditions will be available. Each moment the whole kiln tube circumference perfection must be checked
with a rectilinear rule.
It is always dangerous to work close to a rotary kiln. To measure and control the parallelism and flotation
of the kiln rollers is required to work very close to it; appropriate clothing, safety goggles, safety shoes,
gloves and safety shell must be utilized.
The maximum kiln tube alignment deviation allowed is +/- 1.5 mm.
The development of distorted kiln section or kiln shell replacement activity, is a job requiring persons
with long experience, thereby they must be consulted as necessary when performing this procedure.
No attachments are included, and the forms to be used are free.
12.6 REFERENCES
- Heavy kiln shell substitution, Manual, Instructive F. L. Smidth 11.124 (2)

- Mounting of kiln tube and kiln tires, Manual F. L. S. 18094-07
357948525.doc Page 83 of 111

14/06/2017
Code..
Chapter 13
MEASURING THE BEARINGS SET FOR KILN TIRES
(or support Rollers)
The objective of this procedure is to develop a control of sets to have in the kiln tires (support
rollers) bearings, in order to prevent premature damages.
The rotary kiln kiln tires bearings, are of self-adjustable type (spherical base), or without
adjustment (straight base).
The lubrication principle normally, is of a hydrodynamic type, i.e. that during the rotation a support
oil layer is formed between the bearing and the trunnion shaft.
That is the reason why it is very important - due to the kiln low rotation speed - that the difference
between the diameter of the trunnion shaft and bearing is exactly of the same size making possible
the wedge effect, necessary to form the support oil layer under the trunnion shaft.
Consequently, the oil viscosity has decisive influence on the bearing running and, therefore, it is
very important to note down carefully the lubrication directions.
If the correct oil is used at the correct bearing temperature, the perfect liquid friction can be
obtained between the trunnion shafts and the bearings, this prevents wear of bearings. There are
examples of kilns, which have been running during fifteen years, without any possible detection of a
remarkable bearings wear.
Nevertheless, in case a bearing must be replaced, certain actions must be observed.
By general rule, the bearings are provided with a machining application corresponding to the
original diameter of kiln tire trunnion shaft (or support roller), and with an appropriate sized
clearance between the trunnion shaft and the bearing.
The nominal clearance between the kiln tires shaft and the bearing is obtained from Table 13.1 and
it is conformed according to the hydrodynamic lubrication principle of bearing.
The trunnion shaft (or trunnion) of the kiln tire rests, theoretically, in a generatrix at the back of the
bearing. At a sufficient shaft rotation speed, the oil will be introduced in the space between the
shaft and bearing, with wedge effect, so that a thin film will support the shaft. Depending on the
speed and temperature, the thickness of such oil film can be approximately 0.01- 0.02 mm.
The evolution (or course) of pressure in the oil film is illustrated in Figure 13.l
357948525.doc Page 84 of 111

14/06/2017
Code..
Figure 13.1
13.2.1 Self adjustment bearings
In the self adjustable bearings, the spherical seat of the bearings guarantees that there is always a
perfect support for the trunnion shaft (or trunnion), despite one of the bearings is displaced regarding the
other, whether in vertical or horizontal sense.
13.2.2 Straight bearings
The straight bearings, do not allow alignment deviations, therefore the kiln must be checked in its
alignment with higher frequency. These bearings allow only longitudinal displacements, and in the
modern kilns or recently manufactured this type of bearings are not manufactured anymore, but only self
adjustable or spherical.
13.2.3 Bearing cooling
The bearing cooling is made through a constant current of cooling water. Cooling is necessary to prevent
the lubricant oil from turning too hot by reducing its lubrication capacity. The cooling water is supplied to
the kiln tire bearings (or support rollers) through a common admission conduit. The cooling water at the
entrance must not be higher than 10C, in order to assure a low oil temperature. A failure in the bearing
cooling process will damage it, its replacement will be necessary.
13.3.4 Kiln startup
Whenever a kiln is started again after a long duration shutdown, the trunnion shafts (trunnions) of the kiln
tire (or support), can be so dry that it becomes necessary to supply oil to prevent rubbing during the first
rotation until the moment when the bearing lubrication device procures the necessary oil film. In case the
bearing does not receive the oil application, it will suffer premature wear, and its replacement will be
necessary through the time.
- Shimming gauge
- Tools such as wrenches, etc. in order to remove and put the bearing cap.
13.3.2 Periodicity
357948525.doc Page 85 of 111
14/06/2017
Code..
This measuring is made with the kiln shutdown, therefore every kiln shutdown advantage must be utilized,
but at least this measuring must be made monthly.
For measuring, first the bearings are removed, then the measuring for clearance between the kiln tire
shaft and bearing writing such data in Form number 13.1. The data obtained is compared with the Table
13.1, and if there is an out of tolerance condition, its replacement must be programmed.
The results that are made under this procedure must be positive, because when having a new bearing
installed, the kiln will be running correctly.
It is always dangerous to work close to a rotary kiln. If it is required to work close to it, appropriate
clothing, safety goggles, safety shoes, gloves and safety shield must be utilized.
Kiln Tires (Support Rollers) / bearings : Diverse tolerance (in millimeters)

Nominal Trunnion Bearing Lateral Medium Medium Set dp - Medium (dp x dt) x
Diameter of Shaft Set Set
Trunnion
dp 100/d
dt min./ma dp - dt dt
Shaft (d) cold
x. hot t=35
d
cold hot
*Dilation by meter
at
Table 13.1
Whenever exceeding 10 % of the tolerance shown in Table 13.1, the bearing replacement must be
scheduled.

357948525.doc Page 86 of 111
14/06/2017
Code..
The bearings adjustment measuring, is an activity which must be periodically performed, the good running
of the kiln depends on it.
- Form number 13.1 Measuring of bearing set for kiln tires.
13.6 REFERENCES
- Support type 1958, Manual F.L.Smidth 19024-04

- Bearings for kiln tires, Manual F.L. Smidth 18064-13
357948525.doc Page 87 of 111

14/06/2017
Code..
Chapter 14
ROLLER BEARINGS (bronze/babbit) REPLACEMENT
The main objective is counting with a basic and uniform procedure that can be used when the
bearings and / or supports replacement is required.
14.2 METHOS BASIS OR FOUNDATION
The bearings for rotary kiln tires, require an immediate replacement for a good kiln running when
they show wear or damages due to lubrication, cooling or adjustment problems.
- Replacement bearing
- Crane or frame
- Shims gauge
- Tools such as wrenches, etc. to remove and put the bearing cap and lock.
- Ink to mark metals (it can be oil paint, Prussia blue or red colored)
14.3.2 Periodicity
The eventuality of the kiln roller bearings replacement is made when required, because it is
damaged whether by Babbitt or bronze worn, or the need exists to change the roller (or kiln tire), by
trunnion shaft measure change, or by any other reason.
By general rule, the bearings are supplied with a machining application corresponding to the kiln
tire (or supporting roller) trunnion shaft original diameter, and with a clearance appropriately sized
between the trunnion shaft and bearing, therefore if having a roller with lower (or higher) diameter
than the nominal, a bearing must be placed according to this new dimension.
The trunnion shaft (or trunnion) of the kiln tire rests, theoretically, on a generatrix at the back of the
bearing or lining. At a sufficient shaft rotation speed, the oil will be introduced in the space between
the shaft and bearing, with wedge effect, so that a thin film will support the shaft. Depending on
the speed and temperature, the thickness of such oil film can be approximately 0.01- 0.02 mm.
Therefore a very careful bearing adaptation is demanded.
357948525.doc Page 88 of 111

14/06/2017
Code..
First of all, the roller bearing or support cover is removed, and the bearing is dismounted, then, the
placement of a new one can be performed in the following manner:
a. Clean and dry the new bearing, eliminating paint, dirt and anticorrosive oil as well as control that
it has not been damaged during transportation. Eventual damages produced by strikes or a slight
polishing or reaming removes scratches.
Control that the bearing contains a smooth transition since the oil pocket (or deposit) to the
supporting face, on the radial and axial surface, i.e. steps with cutting edge do not exist.
Dismount the support cover and mount the bearing in the bucket so that the pressure neck
chamfered faces the pressure ring.
Control that the bearing, through the fastening pieces (in case of having them), be carefully
fastened to the bucket, at level with it, and no clearance exists between the bearing and the
bucket.
Remove traces left by reaming of the kiln tire (or supporting roller) shaft trunnion.
Place eye screws in the bucket corners, so that, it, with bearing, could be suspended with the
bearing facing downwards. See Figure 14.1.
Figure 14.1
b. Dry the kiln tire shaft carefully and apply a very thin layer of marking ink (it can be oil paint
Prussia blue colored) along all the trunnion shaft length and with a width covering approximately
120.
c. Dry the bearing - fastened in the bucket - and place it carefully in the kiln tire, at the same
time that, the pressure ring is utilized as guide when performing the lowering (or placement).
d. Push the bearing forward and backward with short axial movements (10-12 mm) as long as
it rests over the trunnion shaft. Control the clearance between the bearing and the trunnion shaft,
as illustrated in Figure 14.2.
e. Elevate the bearing and bucket by removing them from the trunnion shaft and control the
foundation between the trunnion and the bearing to inspect blackening or spot of marking ink in
the bearing.
357948525.doc Page 89 of 111

14/06/2017
Code..
Figure 14.2
f. If the contact is shown as a narrow strip interrupted or partially interrupted at the back of the
bearing, it means that the foundation is satisfactory. See Figure 14.3.
Form 14.2
If the contact is only shown as sporadic spots, the projecting parts regarding the bearing must be
removed through slight scrapping and repeating the process until a satisfactory result is obtained.
g. Subsequently, control that the transitions between the oil channels and the support faces of the
bearings are leveled. When everything has been controlled and approved, the same type of oil as
the one utilized for support is poured. The tire is placed in the correct position, and the support
mounting operation is finished. Apply joint paste in all the union faces in order to get the bearing
watertight.
The results under this procedure must be positive and when the new bearing is correctly installed,
the kiln will be working satisfactorily.
357948525.doc Page 90 of 111

14/06/2017
Code..
It is always dangerous to work close to a rotary kiln. Because it is required to work very close to it,
appropriate clothing, safety goggles, safety shoes, gloves and safety shield must be utilized.
In this procedure only successful bearings changes must be made related to the kiln running, and
maintaining the bearing temperature within the range established by the manufacturer.
The development of a bearing replacement activity, is a job requiring persons with long experience,
therefore they must be consulted when required by this procedure execution.
No attachments are included, and the forms to be utilized are free.
14.6 REFERENCES
- Support type 1958, Manual F. L. Smidth 19024-04

- Kiln tire bearings, Manual F. L. Smidth 18064-13
Exit
357948525.doc Page 91 of 111
14/06/2017
Code..
Support Bearing
or Basis Bearing diameter
No. No. (mm)
Trunnion Bearing
Shaft
357948525.doc Page 92 of 111

14/06/2017
Code..
357948525.doc Page 93 of 111

14/06/2017
Code..
Chapter 15
KILN WELDING APPLICATIONS ANALYSIS AND CONTROL
The main objective is counting with directives about how to conduct rotary kiln shell welding
applications inspections, as well as kiln tubes with satellites cooling system, or implant it.
The rotary kiln is a dynamically affected construction, because it consists of plates of different
thickness welded between them.
Considering the kiln size and its running form (spinning in few supports), the multiple welding
applications are subject to long and varied stresses.
When there is a normal operation, such as a kiln shaft replacement, etc., excessive loads can result
on certain welding applications. Whenever these abnormal conditions continue for a long period of
time, the cracks risk increases, especially in terms of cracks under fatigue inside the welding
applications, and around the most critical welding applications in terms of stress loads.
Therefore, it is fundamental to check the welding applications periodically, visually and with
penetrating liquids, magnetic particles, and / or ultrasound.
All the kilns but especially those with planetary or satellite cooling system, containing more welding
applications subject to stresses loads, the following are considered as the most critical in terms of
stress:
a. All the unions in transition between the heavy section (or kiln shell) and the adjacent unions.
Especially in the supports around the burning zone and in the cooling tube suspension
arrangements.
b. The welding applications at the kiln exit (reinforcement frames).
c. The satellite cooling tubes arms welding applications.
e. The reinforcement welding applications around the man entrance frames.
f. The welding application of tires saddles or supports of the kiln tires.
357948525.doc Page 94 of 111

14/06/2017
Code..
15.3.1.1 Inspection
- Wire brush
- Polisher - Hammer
- Penetrating liquids, magnetic particles, and / or ultrasound
15.3.1.2 Repairmen
- Punch
- Arch - air equipment, with 8 mm carbons - Welding AWS 7018
- Welding dry kiln
15.3.2 Periodicity
The union welding applications can only be examined with the kiln out of operation or shutdown
during a determined period of time, thereby try to perform these activities in a time of shutdown
scheduled by production or maintenance area.
The welding applications inspection frequency will depend upon the kiln operation. It must be made
every two years under normal operation conditions.
When the operation conditions are abnormal, the load stresses are increased on the union welding
applications; therefore the welding applications most exposed to these additional stresses must be
inspected.
Every welding application repaired, must be reviewed subsequently every 6 months of kiln operation.
15.3.3. Procedure, calculation method and results
15.3.3.1 Visual inspection
The visual inspection of kiln welding applications is the simplest and most important inspection in
order to know the conditions of a welding application.
At the same time of the visual inspection, a general checking must be made without removing rust or
dirt of the welding application, because many times it is easier to identify the cracks possibilities in a
not cleaned welding application.
After this initial inspection, the welded union surfaces are carefully cleaned, by using a hammer and
a wire brush, and in sometimes a polisher can be required.
Caution must be observed to never confuse the irregularities of a crack welding application.
It is recommended that the unions welded are inspected with penetrating liquids, or with methods
related to magnetic particles, ultrasound, or with another more advanced. method and / or equipment
357948525.doc Page 95 of 111

14/06/2017
Code..
15.3.3.2 Penetrating liquids test
The penetrating liquids are substances with intense color (normally red), that when applied to a
metallic surface, penetrate in every crack, and through the usage of a developer the evidence of a
cracks will increase.
This method is performed in the following form:
a. Remove the grease and dirt from the surface.
b. The penetrating liquid is applied in the same way as you were painting with spray over the clean
area and with a uniform layer (not spilling liquid).
c. Let the liquid penetrate in the possible cracks. Ten (10) minutes are sufficient at a temperature
of 0 to 60 C.
d. The penetrating liquid excess is carefully removed with a piece of cloth or rag. If the liquid is
soluble in water, it must be used, otherwise a cleaning liquid must be used.
The penetrating liquid must never be removed by spraying water or cleaning solvent directly,
the cleaning operation must always be done with the rag or piece of cloth moisted, observing
that fluff is not generated.
e. Wait until the surface is dry, and then apply a thin layer of developer, this is a high absorption
dust, suspended in a volatile solvent.
f. After the solvent is evaporated, the possible cracks will appear with a strong appearance in
form of red lines contrasting on a white base.
Important is that when the cracks are full of grease, oil, etc., this method cannot be utilized.
In this case the magnetic particles method must be utilized.
There where the cracks are extremely deep, the penetrating liquid will penetrate so deep, that the
developer will not function. Assure that sufficient penetrating liquid is applied and provide a
reasonable time period for penetration.
At temperatures below 0C the plate requires to be preheated with a gas burner or a blowtorch or with
hot air and this before the penetrating liquid application.
15.3.3.3 Magnetic particles method
The magnetic particles and magnetic dusts methods are performed covering the area to be examined
by ferromagnetic indicating material (magnetic dust).
A magnetic field is generated in the area, at least in two directions with the highest degree of
perpendicularity between them.
357948525.doc Page 96 of 111

14/06/2017
Code..
The indicating material will not be accumulated in the cracks, and this incompatibility will show the
surface region defects, the defects extend up to 3 mm below the surface.
In order to make the cracks identification easier, before examining, all the area must be painted with a
light of contrasting color.
The inspection with magnetic particles must be performed in a way that the magnetic field efforts in
the area to be examined are within the 2,400 to 4,000 A/m (30-50 Oersted) range. The simplest
method is the usage of an electromagnet with 90 change of phase.
The undermining must be avoided with the magnetization method
15.3.3.4 Ultrasonic inspection
The ultrasound inspection can be performed in case of fissures or internal failures of the unions
welded, in the suspected areas, or where the crack depth must be assured previous to its repair.
The ultrasound inspections must be made after the welding application is repaired.
Normally an ultrasound inspection can be performed with angular testers of 4 MHz at 45 and 70 and
with normal testers of 2 Mhz.
15.3.3.5 Repairmen
Whenever a crack is discovered, the most appropriate method of repair must be determined.
The cracks with a length lower than 10 mm rarely have a depth exceeding 3 mm. Such "minor cracks"
can normally be eliminated with a polisher.
This form of repairmen is sufficient if it is possible to remove the crack by polishing or rabbeting the
material, not reducing the thickness more than 3 - 4 mm or higher than 10 % of the plate thickness, as
long as it is polished, at the same time, the surface must be clean, without splits and with a minimum
radius of 15 mm.
It must be inspected later with magnetic particles, as higher grinding application can be required.
Welding application must repair the major cracks, cracks supposed to have a depth deeper than 3
mm.
Along with the welding application repairmen, these directions must be strictly followed:
a. Mark the crack length.
Mark all the crack length through a punch by marking the crack ends with a dot, so that the welding
operator is capable to identify the dot where the welding application will begin.
b. Preheating
Preheat the area of union to be welded at 100 - 150 C.
357948525.doc Page 97 of 111

14/06/2017
Code..
c. Welding Application
Arch - air must be applied on the welded union, from the cracks ends to its center. The carbon
electrode thickness must be 8 mm, and the welding machine, must have as minimum 400 A power.
The welded union must be undermined as deep as the crack is totally eliminated. For passing
cracks, the depth of the welded union must correspond to 75 % of the plate thickness.
On the base, the width of the welded union must be so that there is enough space left to deposit a
good mooring, or base welding application.
The area to be welded must be perfectly polished, because a not proper polishing application will
generate new cracks. A minimum 1 mm grinding application must be made, in order to eliminate
every trace of carbon. The union must be totally clean from metal.
The union to be welded must be subject to inspection with penetrating liquids or magnetic particles.
Not forgetting the sides of the welded union. In case of existing traces of cracks formation, they must
be eliminated again and the repairmen process must be reinitiated.
The welding application is not ended, until eliminating every trace of defect or imperfection.
Subsequently a preheating of 150 minimum is performed. This temperature can be obtained

through the welding process.
After the welding application is finished, it must be covered with mineral wool, or something similar, in
order to minimize the cooling speed, which could cause generation of new cracks.
The welding operation is performed with dry electrodes AWS 7018.
The minimum electrode thickness to be utilized must be 3.25 mm (118). This requirement is also
applicable to the mooring, as well as to the welding operation.
As the electrodes are highly sensitive to the humidity, they must be maintained in a dry kiln at
temperatures between 200 - 250C at least 3 hours previous to be utilized. In the welding application
place, the welding application must be maintained at 70 - 150 C.
In case of having a passing crack, the previous procedure, is repeated, but now the other side
regarding where just has made the welding application.
In order to minimize the appearance of new cracks, the welding application must be grinded,
eliminating its convex face, leaving a smooth surface.
The repaired area must be finally inspected, in order to assure absence of cracks or defects.
357948525.doc Page 98 of 111

14/06/2017
Code..
The obtained results under this procedure must be positive, and the rotary kiln must be always
without cracks so that there is not danger for personnel and / or machinery.
It is always dangerous to work close to a rotary kiln. As it is required to work very close to it,
appropriate clothing, safety goggles, safety shoes, gloves and safety shield must be utilized.
There is not a permissible crack in the kiln. As soon a crack is detected, it must be immediately
repaired.
The procedure for inspecting welding applications, as well as their repairmen must be made with
highly qualified personnel, and with long experience, thereby sometimes if qualified personnel is not
available in the plant, it must be contracted or the service must be requested to Technology
Management.
Neither attachments nor forms are included.
15.6 REFERENCES
- Inspections of welded unions. Instructive F.L.Smidth 1901 1-01
357948525.doc Page 99 of 111

14/06/2017
Code..
ATTACHMENTS
TABLE 5.1 MEASUREMENT AND FIXINGS OF THE ROLLERS INCLINATION
357948525.doc Page 100 of 111

14/06/2017
Code..
FORM 6.1 . KILNS ROLLERS PARALLELISM AND FLOTATION
ROLLER :
INLET
INLET
C1 C2 C1 C2
GAP
PRESSURE RING PRESSURE RING

BRONZE NECK GAP BRONZE NECK
RIGHT ROL L
LEFT ROL L
FURNACE
C3 C4
C3 C4
OULET
PARA LLELISM IN ROLLS FURNA CE FLOATING
GAP IN THE ROLLS

BASE NUMBER LEFT ROLL RIGHT ROLL
OUTLET INLET OUTLET INLET
I
II
III
IV
V
VI
VII
OBSERVATIONS:
357948525.doc Page 101 of 111

14/06/2017
Code..
FORM 6.2 .- KILN ROLLERS POSITION
INLET
C1 C2
Se
Se
RIGHT ROLL
LEFT ROLL
rI I D rD
Ss
KILN
Ss
C3 C4
OUTLET
BASE GAPS ROLL POSITION FLOATING-PARALLELISM
LFT ROL..RGT ROL rI I rD D C1 C2 C3 C4
I
II
III
IV
V
VI
VII
OBSERVATIONS: FORM 7.1 . HORIZONTAL ALIGNMENT
Plant ________ HORIZONTAL Form 7.1

Slant Line
ALIGNMENT
357948525.doc KILN ________ Cold Cond. ___ Hot Cond. ___Page 102 Date
of 111 ______
Parallel line
Parallel
Slant
lineLine
14/06/2017
Code..
KILN ________ Cold Cond. ___ Hot Cond. ___ Date ______
Plant ________ HORIZONTAL Form 7.2

ALINEACION
Furnace________ Cold Cond ___ Hot Cond. ___ Date ______
FORM 7.2 . HORIZONTAL ALIGNMENT
Leading Line
357948525.doc Page 103 of 111
P arallel line
14/06/2017
Code..
Plant ________ LEVEL MAKING OF Form 7.3

BASE PLAQUES
Furnace________ Cold Cond ___ Hot Cond ___ Date ______
TYPE N 1 + - + -
II-III
I-II
III
R-I II
R I
+ -
TYPE N 2 + -
II-III
III
I-II
I R-I II
R
R-I I-II II-III III-IV IV-V V-VI

DIFFERENCE MESURED IN HEIGHT
HEIGHT DIFFERENCE ACCORDING TO
THE POSITION CHART
FORM 7.3 . BASE PLATES LEVELING
FOUNDATION SETTLEMENT
DEVIATION OF THE FOUNDATION REFERED TO

THE HORIZONTAL LINE
357948525.doc Page 104 of 111

14/06/2017
Code..
Plant ________ VERTICAL Form 7.4

ALINEACION
Furnace________ Cold Cond. ___ Hot Cond. ___ Date ______
Formul a List for Corrections

in the center:
:
D
av
e ra
ge D s 1.- Cold Fu rnace s = 0.4 x
2.- Hot Furnace s = 0.4 x -
r2
d a d
lft b rgt f 3.- Hot Furnace s = 0.2 x V Inch
F
J V = Moving between furnace and

ct rim inch/Rev
q r = Temperature Correction
Outlet
D average x 1.25 x 10 -5 x t
r 1 = _________________
2 x Cos 30
C lft .
C rgt .
r 2 = Furnace Diameter x Cuirass.Temp.

2 x 80,000
SUPPORT No. I II II IV V VI
T / t T E M P E R A T U RE F, FURNACE CUIRASS / RIM
DE / DeRIM DIAMETER, ASSEMBL Y / E X I S T ING
d left. ROLLER DIAMETER, ASSEMBL Y / EXISTING
dright.
right.ROLLER DIAMETER, ASSEMBL Y/EXISTING
q =D I S T A N C I A, ASSEMBLY/EXISTING
Ct = D I S T A N C I A, ASSEMBLY / E X I S T ING = q + (dlft.+ drgt) /2
a =( D e + lft. d )/2 FORM 7.4 . VERTICAL ALIGNMENT
b =( D e + rgt d )/2
C left.= ( a2 - b2+ ct 2 ) / 2 ct
Cright= ct - clft.
f =( a2 - c2 lft. )1/2
J =HEIGHT TO THE BEARING
s =CORRECTION IN CENTER V
r1 = 0 . 0 0 0 0 0 7 2 2 AVERAGx D x Et
Y =f + J - s r +1
F =Gotten from the position chart
DEVIATION OF THE THEORICAL CENTER
A =
357948525.doc A= Y- F Page 105 of 111
LINE
ALL THE DIMENSIONS IN INCHES
FOUNDATION (OR BASE) I II III IV V VI
357948525.doc
DEVIATION OF THE THEORICAL FURNACE CENTER AC
A
CORDING TO THE FORM 7.4
DEVIATION OF THE FOUNDATION REFERED TO THE HORI

B
ZONTAL LINE FORM No.
h CORR. REFERED TO THE FOUNDATION SLANT ACCOR

C
DING TO THE FORM No.
TO TAL DEVIATION OF THE FURNACE LINE CENTER TO

A + B + C
REFERED TO A HORIZONTAL LINE
Plant ________
Furnace________
EVALUATE AND CHOOSE A FOUNDATION AS 0
RESULT OF A VERTICAL DEVIATION REFERED TO A

HORIZONTAL DEVIATION
Cold Cond. ___
VERTICAL
FORM 7.5 . VERTICAL ALIGNMENT

ALIGNMENT
VERTICAL AXIS
EXISTING
Hot Cond ___
PROPOSED
Page 106 of 111

Form 7.5
Date ______
Code..
14/06/2017
Leading Slant Line a
P ARALLEL LINE h
357948525.doc
T CUIRASS H
TEMP. A
t RIM OUTLET r
D
D x 1.25 x 10 -5 x Tt
AVERAGE
r = ________________________
2 x COS 30
0.00000722 x DAVERAGE x Tt
COLD FURNACE: S = 0.4 x d

Plant ________
= 0.2 x V
Furnace________
HOT FURNACE:
V = MOVING BETWEEN RIM AND FURNACE INCH/REV
SUPPORT I II III IV V VI
1 2 1 2 1 2 1 2 1 2 1 2
Cold Cond.___
RIM RADIUS D/2

VERTICAL
DISTANCE FOUND BY LEV EL MAKING h

ALIGNMENT
DISTANCE FROM THE CENTER TO THE LEADING LINE A

CORRECCION DE LINEA DE PUNTERIA a
FORM 7.6 . VERTICAL ALIGNMENT

DISTANCE FROM THE CENTER TO THE PARALLEL LINE H

Hot Cond.___
GAP OF THE HOT/COLD FURNACE
HEIGHT H CORRECTED BY THE GA P H1

CORRECTION CALCULATED BY TEMPERATURE r
HEIGHT H 1 CORRECTED BY THE GA P H2
Form 7.6
Page 107 of 111

DISTANCE FROM THE FURNACE AXIS TO STR. LINE X
Date ______
DISTANCE FROM THE FURNACE AXIS TO STR. LINE X/2

Code..
14/06/2017
14/06/2017
Code..
Plant ________ ALIGNMENT Form 9.1

BY TESTS WITH LEAD WIRE
Furnace________ Date ______
OUTLET INLET
AVERAGE AVERAGE
WIDTH MEASURED WIDTH MEASURED
t1 t2 t3 t4 t5 tu t6 t7 t8 t9 t10 tj tu- tj
RIGHT A
PULLEY B
WHEEL H C
AVERAGE
LEFT A
PULLEY B
WHEEL "V" C
AVERAGE
FORM 9.1 . ALIGNMENT BY MEANS OF LEADEN WIRE TESTS

RIGHT PULLEY
OBSERVATIONS:
LEFT PULLEY
GENERATOR
BASE No.
WHEEL
WHEEL
H V
A
tu B
C
A
tj B
C
SUM
AVER AGE WIDTH t H= tV =
DIFFERENCE
TH + T V = TL
2
Average Pressure t H/t V =
357948525.doc Page 108 of 111
MADE BY:
14/06/2017
Code..
FORM 10.1.- GEARING CONTROL BETWEEN PINION AND GEAR RING
1
12 2
11 3
10 4
9 5
8 6
7
MEASURING IN COLD/HOT
PINION: LEFT/RIGHT
POSITION SIDE
ENTRANCE EXIT
DIFFERENCE
DIFFERENCE
MEASURING (MM) GREATER- MEASURING (MM)
GREATER-LESSER)
LESSER)
1
2
3
4
5
6
7
8
9
10
11
12
1
AVERAGE
357948525.doc Page 109 of 111

14/06/2017
Code..
FORM 11.1 . GEAR RING RADIAL ALIGNMENT
ROLLER :
Direccin de rotacin:
ARotating
favor /Orientation:
Position No. 1 must be in line

en contra
Clockwise/CounterWise
de las manecillas del reloj
with the men entrance

ASSEMBLY TOLERANCE:
7
+ / - 0,75 mm (+ / - 0.030")
1
12
Indicator placed in
interior/exterior
Input / Output
Max. Min.
11
Visto
Seen desde
UPPER VIEW
Pos. Fro m
mm
Inch mm
Inch
la salida
The Outlet
10
X
4
warping)
Left
Izquierda
9
X Lado
Side (X) Lado
Side (X)
Right
Derecha Left
izquierdo derecho
Right
8
ElThe
claro
gap X
Xaccord
de acuerdo al
ing to the
+1.5
-1.5
7
-1.0
dibujo
Draw No.N. ________es is =____mm
Inches Z
+0.5
+1.0
-0.5
.
mm
READING OF THE DEVIATIONS (
mm
+0
12
6
The Assembly
La tolerancia Tolerancees
de montaje is Z
Z=+/ -0.059
= +/- Inches
1.50 mm
11
5
10
4
3
La
Theposicin No.
Position Nu 12 12
mber debe estar
Must enAlnea
Be in conwith
lign ment la entrada hombre
the Man-Size Door
2
DIFFERENCE
DIFERENCIA 12
1
POSITION
POSICION MEASUREMENT
MEDICION S
(MM) 2
BIGGER-SMALLER
(MAYOR-MENOR)
(MM)
1
1 11 3
2
READING A
READING B
3
Position No.
Position No.
4 10 4
5
6
7
9 5
8
CHANGE OF SIGNS TO LINE 4
9
DEVIATION OF LINE 7 X 0.5
10 6
8
SUM OF LINE 5 AND 6
11 7
INDICATOR
INDICATOR
12
1 VIEWDESDE
VISTO FROM LA
THE EXIT
SALIDA
A
REPEAT LINE 2
FORM 11.2 . GEAR RING OR TIRES AXIAL ALIGNMENT

inches
+100
+50
mils
+150
-100
-50
+0
inches
-150
mils
.
357948525.doc Page 110 of 111

.
LINE
1
2
3
4
5
6
7
8
14/06/2017
Code..
357948525.doc Page 111 of 111

Kiln Maintenance Manual

Încărcat de

Informații document

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

Kiln Maintenance Manual

Încărcat de

Drepturi de autor:

Formate disponibile

14/06/2017

INDEX OF MECHANICAL MAINTENANCE

CHAPTER 2 DEFORMATION AND OVALITY..................................................................................................................10

CHAPTER 3 TIRES AND ROLLERS DIAMETERS MEASUREMENTS.......................................................................22

CHAPTER 4 MEASURING AND ADJUSTMENT OF SUPPORTING ROLLERS AXIAL LOAD...............................26

CHAPTER 5 MEASUREMENT AND ADJUSTMENT OF THE ROLLS INCLINATION............................................38

CHAPTER 6 ROLLERS PARALLELISM AND FLOTATION...........................................................................................44

CHAPTER 7 CONTROL AND EVALUATION OF ALIGNMENT IN HOT (RUNNING) AND COLD

CHAPTER 8 CONTROL OF MOVEMENTS (ADJUSTMENTS) TO CORRECT KILN SHAFT................................56

CHAPTER 11 ALIGNMENT OF THE MAIN TRANSMISSION, GEAR RING AND PINION....................................74

CHAPTER 12 KILN SECTIONS (KILN SHELL) REPLACEMENT, IN WHICH DISTORTION CAUSES

CHAPTER 13 MEASURING THE BEARINGS SET FOR KILN TIRES........................................................................84

CHAPTER 14 ROLLER BEARINGS (BRONZE/BABBIT) REPLACEMENT.............................................................88

CHAPTER 15 KILN WELDING APPLICATIONS ANALYSIS AND CONTROL.........................................................94

357948525.doc Page 1 of 111

GAP MEASUREMENT (Clearance) AND DISPLACEMENT (Control of Clearance) BETWEEN

1.1 OBJECTIVE AND SCOPE

1.2 METHOD BASIS OR FOUNDATION

357948525.doc Page 2 of 111

1.2.1 Importance of Clearance

1.2.2 Kiln tire displacement Measurement.

The theoretical diameter difference, 2s, produces a relative movement as follows:

Vt = .( 2RL - 2 RO ) RL = Internal radius

357948525.doc Page 3 of 111

1.2.3 Causes of kiln tire clearance reduction

357948525.doc Page 4 of 111

1.3 METHOD DEVELOPMENT

1.3.1 Equipment and tools to be used

357948525.doc Page 5 of 111

1.3.3 Procedure, calculation methods and results

1.3.3.1 By the displacement and gap-measuring appliance.

The clearance can consecutively be found when dividing V by 1.5 - 2, i.e.:

If the displacement average V is divided by , the result is :

The theoretical clearance in the circular kiln tube / kiln tire.

1.3.3.2 Using the displacement and gap meter.

357948525.doc Page 6 of 111

1.3.4 Interpretation of results.

357948525.doc Page 7 of 111

In such case, the thickness of plates to be placed must be determined.

The safest method for this purpose is the following:

Therefore, the thickness for the supplementary plates is the following:

1.3.5 Safety aspects

1.3.6 Condemning or permissible limits

1.4 COMMENTS AND OBSERVATIONS

357948525.doc Page 8 of 111

1.5 ATTACHMENTS AND USED FORMS

357948525.doc Page 9 of 111

2.1 OBJECTIVES AND SCOPE

2.2 METHOD BASIS OR FOUNDATION

2.2.1 Radial deformation and its repercussion

The deformations can be subdivided into:

dM = Ovality of kiln cover Circle Perimeter Uk = Ellipse Perimeter

Figure 2.1 Figure 2.2

2.2.2 The rotary kiln ovality

Ovality W = deformation degree.

Periphery of ellipse UE = Periphery of circle UK

2.3 METHOD DEVELOPMENT

357948525.doc Page 11 of 111

2.3.1 Equipment and tools to be used

2.3.1.1 Shell test appliance

Measurement Unit Shelltest Transverse Section Strained

Registering Syst. Diagram Shelltest

These diagrams can be evaluated in the first place qualitatively.

357948525.doc Page 12 of 111