Mechanical Maintenance of

Rotary Kilns
Refratechnik June 2015

Copyright © 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This publication makes no offers, representations or www.flsmidth.com
warranties ( express or implied ), and information and data contained in this publication are for general reference only and may change at any time.

FLSmidth USA Inc. Tel: +1 ( 402) 494-6837

P.O. Box 1108 Email: sales@kiln.com
Sioux City, IA 51102
USA
 Walter M. Gebhart graduated from the
University of Toronto in 1969 with a Bachelor of Applied
Science in Mechanical Engineering. Since then, he has
been active in the field of bulk materials handling in
the areas of dust collection, pneumatic conveying and
pyroprocessing. He was employed by Fuller Company
(1972-1986) with responsibilities ranging from project
engineer, commissioning engineer, sales engineer to
Manager of Engineering and Service for Fuller Canada.

Mr. Gebhart has had many technical articles published

in various trade journals covering aspects of hot kiln
alignment, and other mechanical issues of trunnion
supported rotary equipment.

As owner/operator of Hartco Engineering, he developed

the only hot kiln alignment system that has ever
been patented. He holds several patents in the field
of trunnion supported rotary equipment alignment,
including the The Thrust Monitor or support roller
(trunnion) alignment using dynamic thrust balancing.

Mr. Gebhart joined Phillips Kiln Services as Vice President

in 1990.

Phillips Kiln Services Ltd. was acquired by FLSmidth in

August 2011. Mr. Gebhart continues as V.P. Technology
now under the new name FLSmidth USA Sioux City
Operations.

Although the words in this book are his, the material is

really a collection from many sources. Some anonymous
and from contributors too numerous to mention.
Wherever a source or publication is known, specific
acknowledgment is made within the body of the
material.

About the
Author
 Contents
... an excerpt

Especially prepared for

REFRATECHNIK

International Training

June 2015

Hot Alignment Analysis 1

Shell Flexing (Ovality) 31
iv
There are two stages of alignment...
1. Pier to pier alignment
2. Individual roller alignment
Pier to pier alignment is only significant when there
are at least three support piers. In the case a kiln has
only two piers, considering each pier is a support point
with only two points, the piers can always represent a
straight line. In that limited sense, two piers can never
be misaligned. It is only when there are three or more
support points can consideration be given to their being
in line or not.
Pier to pier alignment is the starting point or the
big picture alignment. Once each roller’s center is
positioned correctly, pier to pier alignment is achieved.
However, pier to pier alignment does not reveal how well
the roller is positioned with respect to being parallel to
the supported tire or if it is on the correct slope. This is
individual roller alignment, which is at least as important
as the pier to pier alignment.
Hot Alignment Analysis
Pier to pier alignment, the big picture or macro
alignment, needs rollers’ centers to be located to the
nearest 1/4” (6mm) or so. It’s not critical, but rest assured,
using today’s modern methods, they are located with
much better precision.
Individual roller alignment is by far more critical both
in slope and skew. Here, getting individual bearing
positions of each roller within 0.005” (0.125mm) skew
and slopes within a tolerance of ± 0.002”/ft (0.2%)
of the design slope is essential. Skew cannot be
measured to the required accuracy by any known
method. Establishing skew involves a different approach,
discussed in a subsequent chapter entitled “Roller
Adjustment and Skew”.
When pier to pier alignment is done with the kiln in
normal operation, it is referred to as hot kiln alignment.
When measurements are made when the kiln is cold
and not running, it is called a cold offset alignment.
Establishing alignment for the hot operating kiln is
usually preferred.
1
Why is alignment important?
It is the starting point for any mechanical maintenance
program for a rotary kiln. Without understanding
alignment and the associated mechanical conditions
of the kiln, it is impossible to plan maintenance work
effectively. The life of refractory is directly related to
alignment of the kiln.
Not using alignment as a preventive maintenance tool
invites unpredictable kiln stoppages. It means the
operator cannot fully rely on the mechanical operation
of the kiln and production costs will be higher than need
be.

Alignment measurement, which includes all the

mechanical operating characteristics of the kiln, should
be a preventive maintenance tool. Unfortunately, it is
often used reactively after a serious problem has been
encountered. Once damage has been done to a kiln,
alignment has lost most of its value as a preventive
measure. Not using it as a preventive maintenance tool
means the kiln will be running with less than optimum
conditions. It often means abnormal or high wear
rates of kiln parts and premature refractory failure are
accepted as normal. This means high operating costs
and low kiln availability.

2 Hot Alignment Analysis

 It is highly unlikely alignment measurement will be done
in-house. Instead, it will be contracted out. Therefore
this presentation is not meant to teach procedural
details, but explain the conceptual differences between
the most popular methods. Once it is realized there are
fundamentally different techniques available to choose
from, confidently selecting a method becomes much
easier. Understanding alignment concepts also gives
enough insight to weed out short-cut methods offered
at deceptively low prices.
Rotary kilns have been around for over 100 years. Most
alignment methods are best done statically with the kiln
shut down.
Hot Alignment Analysis
With the arrival of new measurement tools like electronic
distance measurement ( EDM) and portable computing
power, reliable measurements can be made with the kiln
in operation. This gave birth to the term “hot alignment”.
The first hot alignments became available in the early
1980’s and a number of variations evolved. Evolution of
hot kiln alignment techniques were nurtured by the ever
evolving changes and improvements in non-contact
distance measurements and more sophistication with
the traditional theodolite. Combining the standard
function of the theodolite, measuring horizontal and
vertical angles with EDM and incorporating a micro
processor, produced the “total station”. The total station
is a micro GPS system allowing measured points to be
addressed using three dimensional digital coordinates.
3
Since rotary kilns have been around for more than 100
years, aligning their rollers has always been a necessity.
Many different measurement procedures can be
employed to establish where the rollers are positioned
and compared to where they should be. Therefore,
no matter what alignment measurement techniques
are used, the found roller positions are established
with respect to a line. This is the reference line. In
trigonometry, a line is defined as the shortest distance
between two points.

4 Hot Alignment Analysis

 When a third point is introduced, its position can be
measured as a deviation from the reference line in two
directions, horizontal and vertical ( horizontal deviation
and vertical deviation).

Since these points are in three-dimensional space, the

simplest mathematical and graphic way to deal with
this is to split alignment into two planes. The horizontal
plane, often called the plan view, looking down on the
kiln and the vertical plane, often called the elevation
view, looking at the kiln from the side.

Hot Alignment Analysis 5

This idea can be extended to consider a multiple of
points. Once a reference line is defined by two points,
the position of the remaining points can then be
determined in horizontal and vertical deviation from
the reference line. This is a very simple idea. What
must be considered and what is not straight forward, is
how these points are physically established. The most
important thing to realize, is the accuracy with which
these points are established, determines the accuracy of
the alignment. The alignment therefore, is only as good
as the measurements used to establish the position
of these points. Put even more emphatically, the
accuracy of an alignment is only as accurate as its worst
measurement.
6 Hot Alignment Analysis
Each pier, complete with its pair of support rollers,
supports the kiln in a fixed spot. This can only change
when one or more rollers are moved. Therefore, each
pier can be represented as a support point. What
measurements are made to establish these points, is
where the many alignment methods differ greatly. Some
alignment methods work from the inside of the kiln,
and some from the outside. The following pages delve
deeper into the various alignment methods conveying
their fundamental differences, their strengths and their
weaknesses.
 Four ways to do alignment
#1 Internal alignment (bore sight alignment)
This is a simple procedure also applied to other tasks
such as tunneling, and setting large diameter sections of
pipe and so on.
Hot Alignment Analysis
The internal alignment method is an accurate way of
measuring the position of the shell axis. This is often the
way a new kiln is installed. Most times a new kiln shell
is shipped in sections and these have to be assembled
and welded into a straight tube. The method involves
establishing physical centers at each of the supports
using measurements made from the inside surface of
the shell. Once having established these centers, it is
only a matter of viewing them, either by the naked eye,
using a theodolite, or most recently, using a laser to see if
they line up. With this very simple technique, it is easy to
established if all these points are in a straight line or not.
7
Once a kiln has gone into operation, some preparation
is necessary before an internal alignment can be made.
Naturally, this internal method requires the kiln to be shut
down. Not only does the kiln need to be shut down,
but because this method requires free internal line of
sight and the ability to make several turns of the kiln, no
other work can be done on or in the kiln at this time.
Recreating the centers also means removing the coating
and the bricks at each target location to make space for
the support posts. If the kiln has a chain section, a target
must usually be located in it as well. This means tying
back the chains so the work can be done.
To work with accuracy under these conditions with
the limited time available, is difficult. The most difficult
problem is making the time available for the kiln
alignment in the first place. Because alignment time
now adds at least a day or two to a scheduled shut-
down, usually means alignment measurement is not
done on a routine basis but only when damage is
already visible. The value of alignment measurement
as a preventive maintenance tool is therefore lost and is
then only used as a reactionary measure.

In order to get reasonable results, the centers need to

be established using at least three kiln positions. The
changes taking place when the kiln is heated to its
operating condition must be estimated and factored
into the results. These considerations are usually ignored.

8 Hot Alignment Analysis

 The following is a description in concept only. The
fixturing required to do this is not detailed. The concept
is important to understand since it is the fundamental
difference separating the patented Direct Method of hot
alignment from all the others.
Position A
Two target posts are established, each using a single 4”
(100mm) diameter pipe welded to the shell. A small area
of refractory must be removed to do this. Their position
along the length of the kiln will be at the center of a
support tire. A sighting scope or laser is set outside the
kiln on the burner floor, having the fire-hood pulled back
to facilitate this. The scope is positioned so the line of
sight strikes both targets. This is the rough setting. The
position of the target post is significant. The position of
the line of sight is marked on both targets.
Hot Alignment Analysis
Position B
The kiln is rotated approximately 90° so the target post is
at the 9 o’clock position. The targets are re-sighted and
positions on both targets are again marked.
Position C
Rotate -180° so the post position is approximately
opposite position B (3 o’clock ) and mark the positions a
third time.
Please note, the target should never be sighted and
marked with its support post anywhere in the top half
of the shell. This is due to the upper half of the shell
exhibiting the most ovality, which would introduce
errors.
9
The center of rotation is established on each target
based on the three positions of the shell.
1. Connect points 1 to 2 and 2 to 3.
2. Bisect each of the newly created lines.
3. The intersect of the bisects is the center of rotation
based on the three positions. For increased
accuracy, the procedure can be repeated.
10
It should be noted, due to ovality effects in the upper
half of the shell, the selected target positions must avoid
having the post located in the upper half of the kiln.
For added accuracy, the procedure can be repeated.
Since the kiln is not likely to stop in the exact same
three positions as the first set of measurements, a new
set of points and center of rotation is yielded, slightly
offset from the first. Average the two, and the center of
rotation is now based on six points, and so on.
Hot Alignment Analysis
 Final setup
Reposition the scope (the scope was fixed for positions
A to C ) so the line of sight is coincident with the centers
of rotation on both targets. The scope line of sight or
laser, should now be set on the rotational axis of the kiln.
In such a scenario, the instrument would have to be
kept in place for as long as one to two weeks. Since it is
sitting on the burner floor, sufficient care must be taken
to barricade it from vehicular and personnel traffic.

If this were the procedure selected to replace the A more conventional alignment for a new section, is
center tire section of a kiln, the targets would have by joint run-out measurement. However, there are
been positioned at tire #1 and tire #3. Now the kiln can situations which preclude the ability to turn the shell for
be locked out, the center section removed and a new run out measurements, so this is an alternate method.
section with tire placed and aligned accordingly. New
sections intended to be aligned using this method,
would have spiders at both ends of the shell, not only
keeping the shell round for machining and shipping,
but also having centers machined in them for bore sight
alignment purposes.

Hot Alignment Analysis 11

Four ways to do alignment
#2 Using rotation (three point method)

The bore sight procedure uses three or multiples of three All the measurements are made to the kiln shell.
discrete shell positions to find the centers of rotation. Measurements are repeated on both sides of the kiln
With a rotating shell, there is the potential for continuous as well as once uphill and then again downhill of the
measurements of shell positions. The challenge is doing tire. Of significance, this is done without measuring any
this from the outside. The shell rotates about a center diameters of tires or rollers.
which is rarely its physical center, since the shell is not
perfectly round and has axial bends in it. Rotation
centers can be found without knowing the shape of
the shell or considering shell bends. To find the center
of rotation requires only locating three average shell
positions somewhere around its periphery.

12 Hot Alignment Analysis

 The animation illustrates the concept of establishing the
three coordinate points external to the kiln shell, which
represent a unique circle whose center is coincident
to the shell’s center of rotation. This is the bore sight
method done inside out. Since measurements to the
supporting components are not made, the added
benefit is attaining alignment completely independently
of the physical condition of the kiln. Whether it is a
brand new kiln or one in very poor shape, the accuracy
of the alignment is unaffected.

Hot Alignment Analysis 13

Four ways to do alignment
#3 Two point method using tire diameter

A variation of this method is to target only the tire

(not the shell ) and do it only twice, as illustrated. The
tire diameter is then measured independently using
an encoder/decoder. These measurements will also
yield the tire center coordinates. The advantage of this
procedure is measurements are made only once and
only on one side of the kiln. This significantly reduces
the time to measure the kiln axis. Statistically the result
of this shortcut method may not be as accurate as the
previous three point method using rotation. In the
context of pier to pier alignment this difference is not
significant and in no way compromises the validity of the
results.

14 Hot Alignment Analysis

 Four ways to do alignment
#4 External offset alignment
The external alignment procedure is routinely used
for new installations and when components such
as support rollers are replaced. Until hot alignment
made its appearance, it was the only way alignment
was measured. It continues to be a valid method even
though it has its limitations for re-checking alignment on
operating kilns.
With the external alignment method, the kiln still needs
to be shut down.
Hot Alignment Analysis
Centers are established by a series of external
measurements. These are usually the roller and tire
diameters, and the roller spacing etc. This can be
described as alignment by measuring roller support
geometry. The most difficult challenge is measuring
the roller spacing since no easy reference surface may
be available to measure from. On some kilns, where the
rollers and tires are badly worn, diameter measurements
can also be a problem. It must be remembered, the
accuracy of the final alignment is only as good as
the worst measurement made. With kilns in poor
mechanical condition, this type of alignment can easily
give marginal results. Since down-time is still required
and since results are often limited, this method is not a
popular choice as a preventive maintenance tool.
15
The external alignment procedure can be summarized The separate chapter, two pier alignment, covers this
with this illustration. This is referred to as alignment procedure in more detail. It remains a common method
through support geometry analysis. The calculation to for two pier rotary equipment such as dryers, cooler, and
solve the triangle shown is the simplest approach. It is granulators etc.
however, a special case because it is only valid if each
pair of rollers on a pier are exactly at the same elevation.
It is what would be expected, but it would not be the
first time a pier has shifted or a base was poorly installed
in the first place. Correct elevation cannot be taken for
granted and if an anomaly along those lines exists, then
other solutions would be used.

When “H” is the same value for all rollers, alignment is

achieved.

16 Hot Alignment Analysis

 Apparatus
Side shot monopod
A variety of arrangements can be used to measure
the three positions at each cross section of the shell or
two positions for the tire. Photographed here, is one
configuration of the side shot set up. Shown is a single
laser monopod arrangement with a locating prism. This
arrangement is the most convenient for the largest kilns.
It allows the exact location of the laser to be determined
accurately.
Hot Alignment Analysis
The prism is used to optically locate the position of the
monopod within the reference grid. Each laser scans the
circumference of the shell. The total station calculates
the coordinates of the mean shell position. With two
additional points at different locations on the shell, the
shell’s center of rotation can be calculated.
Our newest method is “target-less” whereby the laser
and the optical prism target are no longer needed. This
is also used in the two point method.
17
Total station

The two point method of targeting the tire only requires

a total station, which has target-less capability to get
coordinate addresses for at least two points on the tire.
The target-less designation means the instrument can
shoot to the surface of the tire and acquire an accurate
set of coordinates without the use of a prism. In this
procedure the tire diameter needs to be measured
separately using an encoder/decoder.

18 Hot Alignment Analysis

 Reference prism

With the use of reference prisms located around the

kiln, the entire volume within which the kiln is located
is defined in three directions, to a resolution of 0.040”
(1mm). This is the reference grid. The location of any
point, near or around the kiln, can be identified with a
three-dimensional coordinate ( x, y, z) address to within
0.040” (1mm) in each direction.

The simplified two point method only requires two

reference prisms.

Hot Alignment Analysis 19

A note on accuracy
The limitation on measurement accuracy is not with the
instrument capability, but with the quality of the surfaces
being measured to. The hot alignment approach
has an advantage here because it does not involve
measuring to a center line. Instead, it is a procedure of
measuring relative positions, one with respect to the
other. Over the years, often having measured the same
kiln repeatedly, empirical determination has shown that
locating a center for a given pier is within a sphere of
certainty of about 0.040” (1mm). Locating the relative
position of these centers, given distances between
piers can exceed 100’ (30m), can be reliably established
within an envelope of certainty of 1/8” (3mm). This is
approximately the degree of accuracy required to set
new kilns.

20 Hot Alignment Analysis

 That concludes the overview of pier to pier alignment,
which at the outset was termed “the big picture” or
macro alignment. In practical terms, getting any one
roller into its correct position within ±1/4“ (6mm) is all that
is required. For decades, measurements were made with
measuring tapes and spirit levels and the kilns aligned
this way, ran just fine. Using the latest technology has
allowed significant improvement on this but pier to pier
alignment is not all that determines alignment. Equally
important is slope and skew.
Hot Alignment Analysis
Slope
The vertical position of each roller must match the kiln
slope within a tolerance of 0.002”/ft (0.02%). The kiln
slope is derived from the hot kiln alignment analysis.
The individual roller slope is measured optically or using
digital inclinometers.
Skew
Roller skew cannot be measured to the degree of
fineness needed. This statement must be emphasized.
Only if skew is grossly exaggerated, can it be measured.
Skew, for any size roller from 10” to 10’ (250mm to 3m)
in diameter will be on the order of 0.0” to 0.020” (0mm
to 0.5mm) off parallel. This is the amount one bearing
is moved from the neutral position. Instead, skew is
determined by adjustment. Incorrect roller skewing
can cause a great deal of damage to the kiln. Skew is so
important, a separate chapter is devoted to it entirely.
21
The heart of the alignment report is the two diagrams For plan view alignment, the first point is also the gear
shown above, plus the recommended roller adjustments. plane intersection with the kiln axis. Using this point as
As stated at the outset, any alignment method must a pivot, any second point can be chosen to define the
boil down to reporting the kiln position with respect to reference line including, for example, the center found
a reference line. It was also stated it takes two points on another pier. Most often however, the computer is
to define a reference line. There are many options for allowed to calculate the “best fit” line using “the method
selecting these points. No roller moves should be of least squares”. This is very useful as it produces the
made without considering the gear and pinion mesh. minimum amount of roller adjustments to bring the kiln
Therefore, selecting the gear position as one of the two into line.
fixed points provides this control. Consequently, the first
point to define the reference line is the intersection of
the gear plane with the kiln axis. This ensures the gear
position is not altered unless deliberately chosen to do
so. In the elevation view, the design slope of the kiln is
used instead of a second point to uniquely define the
reference line.

22 Hot Alignment Analysis

 In most instances, the alignment report is not an Also noteworthy, is no adjustments are indicated on the
end in itself. Actual roller adjustments to correct any drive pier. This should not be surprising since the center
misalignment are usually wanted. This illustration shows of the gear is the fixed point defining the reference line.
the actual roller moves required to correct the measured The calculations would show some move at the tire since
misalignment. it is a short distance away. However, moves less than
0.040” (1mm) are not reported. Even a 0.040” (1mm)
The moves are shown per roller rather than per
move is a stretch considering the center of the shell
bearing. The reason for this is, roller skew has not yet
moves up and down at least 1/8” to 1/5” (3mm to 5mm)
been measured. Skew will be determined during
depending on shell temperature. Moves smaller than
the adjustment process and left with the minimum
0.040” (1mm) are considered insignificant.
amount required. Each bearing of a roller will therefore
be moved by slightly different amounts. Their
average move or adjustment however, must equal the
recommended value per this illustration.

Hot Alignment Analysis 23

The basic underlying theme is to use alignment as a Preventive maintenance means frequently checking
preventive maintenance tool. The suggested frequency on the mechanical fitness of the kiln for the purpose of
for alignment measurement is once every three years. addressing issues in their early stages of development
Every year is appropriate under special conditions such before they become significant problems.
as kilns located in earthquake prone regions. Waiting
five years runs the risk of minor problems becoming
expensive repairs. It is also not sensitive to personnel
changes frequently occurring with maintenance staff.
This can lead to lack of communication and loss of
knowledge about the kiln condition.

24 Hot Alignment Analysis

 Using a laser scanning instrument, a shell profile can A shell profile such as this becomes a valuable tool
be generated. In this illustration, a part of a kiln shell in assessing the condition of the shell. An important
has been scanned. Shown are 39 scanned positions. consideration when it comes time to replace a shell
Scans are typically located immediately adjacent to section. The procedure provides documentation to
circumferential weld seems and halfway between seems. what otherwise would only be a visual assessment.
36 readings are taken during one rotation of the shell,
one reading for every 10˚ of rotation. For a 11.5’ (3.5m)
diameter shell, there would be one reading per foot
(0.3m) of circumference. Synchronizing the start points
for the data sets allows the computer to generate the
illustrated mesh. If the shell was truly cylindrical without
distortions, a flat mesh would result. Otherwise there is
an immediate visual impression of the shell distortions,
their magnitude and location. Because the variations
of the shell profile are small compared to the overall
diameter of the shell, they are exaggerated to make the
visualization possible.

Hot Alignment Analysis 25

As stated earlier in the alignment discussion, there is a The procedures used here can differentiate between
difference between the geometric center of the shell profile variations and true axial run-out.
and the center of rotation. This is in fact always the case,
This information, along with the profile, are key analytical
and sometimes it is very significant. The heavy irregular
tools to select the section of kiln to replace and also to
line is the axis of the shell. The straight line up the center
position the kiln for the easiest fit up of the new section.
is the axis of rotation, established by a hot alignment.
The difference is always clear.

When the shell movement is measured, most often it is

all taken to be run-out. In fact, when the kiln shell is not
round, oval for example, it can still rotate on its physical
center. In such a case, the profile is non zero but the
run-out would be zero. Conversely, a true circular shell
not turning on its physical center, having some planetary
motion, would have a zero profile (the mesh would
look flat ) but the run-out would be non zero. Please
also note, this graph is three-dimensional. The angular
occurrence, or phase of the maximum run-outs, is shown
on the column far right.

26 Hot Alignment Analysis

 To give a clearer understanding of the previous run-
out data, animations can be generated. The areas in
red show shell deformation greater than ± 1/2” (12mm)
of the nominal kiln diameter or whatever other limit
the technician chooses. The ± 1/2” (12mm) limit closely
approximates the rolling tolerance for shell fabrication.
In other words, this is what a new shell is expected to be.
Hot Alignment Analysis
In fact, any time a shell profile is measured, the animation
is part of the report. For longer kilns, a “fly-by” version
is also generated. Using a computer video player, the
time line can be scrubbed back and forth to allow
closer scrutiny of any areas of interest. It is a simple, yet
convenient way of keeping track of the health of the kiln
shell.
27
It is strongly suggested a full alignment and shell profile
be carried out on a new kiln. Unfortunately, no kiln
manufacturer supplies a fully documented alignment
and ovality analysis as part of their commissioning
program.
A preventive maintenance program actively involving
kiln alignment and ovality measurement allows the kiln
conditions to be properly monitored, in turn, allowing
maintenance work to be properly planned. This puts the
operator in full control by avoiding surprises.

Why don’t kiln manufacturers provide a document of Done properly, these analytical measures can be revenue
completion, verifying ovalities and alignment as soon as generators.
the kiln is commissioned?

The first alignment is the most important one, since it’s

the one verifying the installation and giving a benchmark
for evaluating future problems should they develop.

New equipment warranties are very short, usually only

one year, but its expected service life should be more
than 25 years. New equipment installations often
have subtle problems that go unnoticed or are even
neglected during the hectic months of commissioning.
Formal certification of mechanical fitness should be
insisted on by every new kiln owner. This is especially
true for the new kilns running three RPM or more. The
half measures acceptable on older, slower kilns cannot
be tolerated by newer kilns.

28 Hot Alignment Analysis

 For the record
Here is a list of OEMs (Original Equipment
Manufacturers) of rotary kilns whose equipment we have
serviced at one time or another.

Hot Alignment Analysis 29

Rotary kiln refractory brick linings depend on the
principal of the continuous arch to stay in place.
Naturally, any forces acting on that arch, such as a flexing
kiln shell, will act to deteriorate the mechanical stability
of the arch. Therefore, it is not uncommon for refractory
to literally fall out in a short time after installation if
excessive flexing of the kiln shell exists.

Ovality measurement is a simple method measuring

how much a kiln shell flexes.

Shell Flexing ( Ovality ) 31

The principle of ovality measurement was established
by a patent in 1952 by Kareby. It is a measurement
developed to monitor the behavior of the shell as it
directly affects refractory.
The steel shell is very flexible when compared to
refractory brick. Shell flexing is usually not a problem
and normally will not cause any cracking in the steel
plate. However, there are defined limits to shell flexing
which should not be exceeded if the refractory is
expected to survive.
32
An instrument, magnetically held to the shell at each of
its ends, can measure the amount of movement of the
shell at its midpoint while the kiln makes a complete
turn. Kareby, in his original patent, published the
relationship between the movement of the shell plate
under the instrument and the flexing of the entire shell.
The development of the mathematical relationship is
attributed to Rosenblad. This is still the basis of the
measurement today, except the process is carried out
electronically.
Shell Flexing ( Ovality )
Ovality measurement is a measurement of the
mechanical stability of the refractory. All kiln operators
need to know the behavior of their kiln under its various
conditions. Routinely making ovality measurements
provides a history of conditions which can be used to
analyze refractory problems. This can be easily done by
plant personnel using the FLSmidth SFX-Beam.

Shell Flexing ( Ovality ) 33

SFX is routinely used as part of a full alignment analysis.
Since this may be done relatively infrequently, perhaps
only once in three years, many plants choose to have
their own instrument to take ovality measurements more
frequently. This is desirable since kiln shell conditions
vary constantly. Only when the full range of ovalities at
each tire is known, will decisions based on ovality data
be fully reliable.
34
SFX operates in conjunction with a PDA via bluetooth
wireless communication. As soon as SFX is removed
from the kiln, the % ovality, data curves and other
captured information, such as speed of shell rotation and
temperature can be reviewed on the spot. This assures
all locations expected to be measured have been done
successfully and correctly.
Shell Flexing ( Ovality )
There are six positions to be measured at each tire. Shell
flexing will be at the highest near the tire, so placing the
instrument as near the tire as possible is important. The
distance from the center of the tire should be recorded
for each set of measurements. Only in this way can
future readings be located in the same place.
Shell Flexing ( Ovality )
Some elect to permanently identify the measurement
positions, six for each tire, by attaching plaques at each
point. This makes future measurements much easier to
do.
This layout is the standard convention adopted over
the years. It is important to get all the measurements
in line down the length of the kiln as shown. This has
significance when the readings are plotted on the
Omega chart.
35
Ovality is not just a consequence, but a design parameter
used by the mechanical engineer when he designs
the kiln tires. The diameter of the tire is dictated by the
process, which stipulates how big the kiln should be.
From the weight of the kiln, the number of supports and
their locations are determined. Using this, the reaction
force at each pier is calculated and the tire thickness
is selected so the bending stress is below allowable
limits. Knowing the tire will be supported by two
rollers, sufficient face width is selected to keep the Hertz
pressure (rolling pressure) below the allowable limit. If
the designer stopped here, the tire dimensions would all
be determined to this point, but the flexibility of the tire
still needs to be considered.
36
The tire will dictate how much the shell flexes. The shell
being so much thinner than the tire, conforms to the
tire shape for the most part. If the tire flexes too much,
so will the shell having severe consequences on the
refractory. The tire ovality is usually calculated at this
point using the formula by Nies*. If the allowable ovality
is too high, the designer will add width, thickness or
both until this last criteria is satisfied. A typical tire design
value for a cement kiln is 0.2% relative ovality. With a
migrating tire, the shell ovality will be higher, perhaps
double.
* “Die Berechnung der Drehofen-Laufringe” by Dr.-lng.
Heinrich W. Nies as published in ZEMENT Wochenschrift fur
Hoch-und Tiefbau 31 . Jahrgang 22. January 1942 Heft 3/4
Shell Flexing ( Ovality )
The tire controls the shape of the shell. However, it can
only do so where the shell is in intimate contact with
the tire. For most kilns, the bore of the tire is somewhat
larger than the shell. This allows room for the shell to
expand since tire expansion will never be quite as much.
This difference in size manifests itself at the top of the
kiln. Because the shell is so much thinner than the tire,
it does not remain a true cylinder but will fill the tire
leaving a flatter spot across the top. As a consequence,
the shell will flex more than the tire as it travels through
this flattened area. Therefore, the shell ovality is always
somewhat larger than the tire ovality. Only when the
shell is unexpectedly overheated to the point where it
expands to completely eliminate this gap, will the shell
ovality be the same as the tire ovality.
Shell Flexing ( Ovality )
Gap, ovality and temperature difference between the
tire and shell (differential temperature) are all related.
When the tire and the shell are at the same temperature,
(shut-down condition) the gap will be at its maximum,
the ovality will also be at maximum and the temperature
differential will be zero. During a rapid heat-up, the shell
will get hot fast, the tire will still be relatively cool and
the gap could disappear. When the gap is zero, ovality
will be at its minimum (equal to the tire ovality) and
the temperature differential will be at the extreme safe,
maximum.
Because the tire bore and the shell will wear over the
years, this gap will increase in size. This could become
dangerous for the refractory because of the resulting
increase in shell flexing.
37
Interpreting ovality curves
The ovality curve would be a straight line if the kiln tire Since the tire and shell are not keyed in these designs,
and the shell were perfectly stiff and did not flex during the tire actually migrates around the shell over a period
rotation. This would be the case if the tire was a solid of time. This movement is commonly called creep. In
disk for example. the area of the gap, which is at the top, the shell assumes
a flatter position than the tire. As the tire passes over the
For most kilns, the greatest amount of flexing occurs
rollers, it also tends to straighten out. The entire weight
at the supports, directly at the tires. Since the shell is
of the kiln shell and its contents acts to push down
much thinner than the tire, it has a far greater flexibility,
causing the sides of the tire to push out slightly. These
so its shape will usually conform to the tire. The shell is
variations of curvature are seen in the graphs above.
much like a bag of water which would take the shape
of the container it was placed in. This is true as long These phenomena are present in every kiln, only their
as the tire and shell are close in size. In the case of magnitude will vary. To protect the refractory, these
floating tires, there is a difference in size, the shell being movements must be kept to a minimum.
marginally smaller than the bore of the tire. This is a
simple mechanism to accommodate differential thermal
expansion between the tire and the shell. This difference
in diameter manifests itself predominantly at the top of
the kiln and is called the gap.

38 Shell Flexing ( Ovality )

Interpreting ovality curves
There are a variety of common variations to the
typical curve frequently displayed by some kilns.
Using the electronic ovality beam, these “signatures”
are easy to see. With a little practice, a great deal of
additional information about the behavior of the kiln
shell can be deduced beyond just establishing the
ovality measurements themselves. The more typical
“signatures” are shown in the graphs above. In the
following slides, actual examples from our files are
shown.

Shell Flexing ( Ovality ) 39

Here all six readings taken at a tire are shown on the The cause for such differential shell sag is usually a
same chart. One would expect the curves would all be significant and unexpected higher load in one span
very similar in shape. However, in this sample, the three compared to the adjacent span. A ring formation and all
downhill curves are distinctly flatter than the three uphill the material it holds back is the most common example.
curves. This is particularly noticeable at the kiln’s top Shortening a long wet kiln to operate as a pre-calciner
dead center, highlighted in the graph above. kiln could have similar consequences if the axial shell
deflection isn’t taken into careful consideration when
This set of curves shows a larger gap on the uphill side of
selecting the cut point.
the tire compared to the downhill side of the tire. This is
possibly caused by the shell not running at right angles
to the tire. This condition will exist when the mid-span
sag of the shell towards the feed end, does not match
the mid-span sag towards the discharge end. We simply
define it as “differential shell slope”. This condition has
been observed to cause severe wear of the side wall of
the tire and on the stop blocks in contact with it, in a
short period of time.

40 Shell Flexing ( Ovality )

Ovality if affected by many factors. Every kiln has an
inherent ovality dictated by its design. Principally, it is the
thickness and width of the tire determining the ovality
at each support. In addition, influences such as shell fit
( gap), shell temperature, shell deformations, kiln loading,
and alignment can have significant contributions to the
ovality. For that reason, it is sometimes difficult to say
which factors may be dominant.
Shell Flexing ( Ovality )
As can be seen from this example, ovality curves can
deviate from the expected pattern when one of these
factors becomes significant. As a result, all the available
tools, visual inspection, alignment measurements,
shell profiling, creep measurement, and temperature
measurement are needed to completely understand the
mechanical operation of the kiln.
41
Damage as seen here, brick capping, occurring in
the tire area is caused by excessive shell flexing, often
referred to as high ovality. The tire area is loosely defined
as a length of shell approximately one shell diameter on
either side of the center of the tire.

Shell flexing decreases with distance from the tire. The

roller impressions quickly disappear when measurements
are made a few meters from either side of the tire. On a
well proportioned tire roller impressions only contribute
about 10% to shell flexing.

42 Shell Flexing ( Ovality )

A case study
A typical kiln was selected to highlight a very common
problem, high shell ovality due to high clearance
between the shell and the tire. This problem is usually
associated with refractory instability. In many cases, the
problem can be rectified without replacing the shell
section under the tire.
Shell Flexing ( Ovality )
If excessive clearance between the tire and the shell
( gap) is solely due to an enlarged tire bore and
worn tire support pads (filler bars, chairs etc.), then a
successful repair without cutting the shell is possible.
Careful inspection for shell deformation under the tire is
required.
If shell deformation is not a contributing factor to
excessive gap, support pad replacement is a more
economical solution and should be considered
thoroughly.
Many kilns have been successfully restored in this
manner.
43
This shows the initial raw data curve indicating a high
ovality. A high creep was measured at the same time.
These two indicators, when observed consistently, are a
sign of high shell-to-tire clearance.
The small negative dips, the roller signatures, are not
equal, this is an indication of roller misalignment.
44
It should be understood, only one curve is shown here
for clarity. A full history of curves is necessary since
ovality can vary widely with kiln conditions. With a
history of curves, typical kiln conditions can be identified
and decisions based on these average conditions can
then be made. Therefore, this one curve has been
selected to show the average condition.
Shell Flexing ( Ovality )
The alignment diagrams show some misalignment
which was properly identified by the ovality
measurements. If no other factors strongly influence
ovality and misalignment is significant enough, the
ovality curves usually reflect the condition of alignment.
Such is the case here in this example.

Shell Flexing ( Ovality ) 45

The acceptable ovality for any kiln is approximated by
taking its diameter expressed in meters, dividing it by ten
and expressing the result as a percentage.
For example, a kiln with a diameter of 3.4m (11' ) has
an expected ovality range that should be centered on
0.34%. In this case, 0.61% was measured, a figure clearly
high of normal.
46
Acceptable ovality is taken from the publication by H.
Erni, B. Saxer, F. Schneider ( Holderbank ) as published
in 1979 by ZKG ( Zement Kalk Gipps). In a subsequent
publication, Saxer suggests this acceptable ovality range
should only apply to kilns up to five meters in diameter.
For larger kilns, a fixed upper limit of 0.5% should apply.
Shell Flexing ( Ovality )
The illustration gives a good example of absolute ovality,
e.g. 25mm (1" ) and relative ovality e.g. 0.5% (of the
nominal diameter).
Even though ovality is calculated using the outside
diameter, convention uses the more readily known inside
diameter. The difference is negligible.
Shell Flexing ( Ovality )
When studying the Rosenblad equations, one realizes
he assumes the shell is a pure ellipse. This is clearly not
the case, so the absolute ovality is an approximation at
best. However, this is of no consequence since what is
acceptable or not has been empirically established over
decades of data collection world wide. Furthermore, it
is the long term trend that can predict when problems
are most likely to arise. Having this data, gives the lead
time needed to plan and budget the inevitable repairs
needed.
47
We clearly see two areas of compression at each side of
the shell, and one area of relaxation at the top. Every
brick undergoes these three cycles with each rotation of
the kiln.
48
Therefore, it is easy to see significant stress placed on the
refractory when the movement becomes excessive.
Although the magnitude of the movement is small, it
is very incessant, which over time, causes the refractory
lining to become mechanically unstable.
Shell Flexing ( Ovality )
A kiln turning three revolutions per minute produces
almost 13,000 cycles alternating compression and
relaxation per day for each brick.

Often the movement of the refractory is audible when

walking along side the kiln. It has a crunch, crunch,
crunch sound. This crunching sound is very similar to
the sound made when walking on freshly fallen snow.

Shell Flexing ( Ovality ) 49

Here is a close-up of the top area of the shell. The
principal cause for a high amount of shell flexing is
usually due to tire bore wear and shell chair wear. This is
a natural and expected consequence of operating with
migrating tires.
If on the other hand the shell is necked, then pad
replacement is futile. In that case, the shell itself under
the tire must be replaced.

When considering restoring the gap to original

dimensions, very careful inspection should be made,
preferably on the inside, to assure the excessive gap is
not due to a "necked down" shell. If the shell is in good
condition, then repairing the shell chair pads can be
considered.

50 Shell Flexing ( Ovality )

By simply removing the old shell pads or filler bars and
replacing them with properly sized new ones, the size
of the gap will be restored to normal. It should be
understood, this procedure should only be performed
when the excessive gap is produced by wear on the filler
bars and/or bore of the tire and not a collapsed shell.
Shell Flexing ( Ovality )
In many instances, shimmed filler bars, where each bar
around the circumference is individually tailored to the
correct thickness, produce a finished result which is
relatively inexpensive and yet, will have many years of
service life.
51
Shown are the ovality measurements before and after
repairs and roller adjustments. A reduction in the
amplitude of each raw data curve is clearly visible.
The peak to peak span of 1.25mm (0.049" ) was reduced
to 0.68mm (0.027" ) - almost cut in half.
52
An improved alignment picture is also evident. The
asymmetry of the curve was not entirely eliminated
however. This is not unusual since, as stated earlier, there
are other factors, such as shell bends, producing similar
symptoms.
Shell Flexing ( Ovality )
The calculated ovality from the new data shows a
reduction to 0.43% ovality.
The rule of thumb indicates, for a 3.353m (11' ) diameter
kiln, an ovality of 0.34% should have been the expected
target. It needs to be appreciated that this rule of thumb
comes from the cement industry. Kilns produced for
other industries usually have slightly different standards.
The calculated ovality is based on the maximum to
minimum values measured. If B improves and C does
not, the ovality is unaltered.
It is reasonable to concluded, the best ovality, the ovality
this kiln was designed to, has been achieved.

Look back at the previous slide and focus on points B

(top of the kiln) and C (roller impressions). Had more
shim been put in place, then point B would undoubtedly
rise higher on the chart. Point C would likely not change
since the weight of the kiln is essentially unchanged.

Shell Flexing ( Ovality ) 53

SFX Report is a Windows® based software providing an
easy way to generate a complete report, including all
the graphs. The PDA managing SFX activity, produces
a single file containing all measured points and other
information, such as shell rotation time, temperatures,
creep and stand-off distance. The latter three are manual
entries made at site.
54
When this file is transferred to a PC, SFX Report
reads it and the information can be reviewed and
printed. Printing in PDF format allows the full report
to be distributed electronically to anyone without the
recipients needing the SFX software.
Shell Flexing ( Ovality )
Data summary table
SFX Report automatically draws an outline of the kiln
corresponding to the number of positions measured.
For each position, the shell plate thickness and the
diameter of the kiln are displayed. This is data from the
instrument. Subsequently, each of the “A”, “B”, and “C”
ovality readings for each measured position is displayed.
An average value follows.
Shell Flexing ( Ovality )
Distance from the instrument to the side of the tire,"Dist
Tyre", shell + tire temperatures, and creep are critical data,
which were manually added into the PDA at the time the
measurements were taken, they are also transferred to
the final file. This adds them permanently to the record
and makes the printed report complete.
It is important to remember, temperatures and creep
measurements enable data comparison from one
time to another. Without this information, the data is
orphaned and cannot be used for comparison purposes.
55
Acceptable upper range or summary
graph
This is a plot of all the “A”, “B”, and “C” values against the
length of the kiln. There are two purposes for doing
this. First, a shaded area is shown, on or below, which
all the values are expected to fall. Values above this
range mean excessive flexing of the shell exists. Values
significantly below this range may indicate the shell
is getting tight in the tire. For both cases, creep and
shell plus tire temperatures need to be reviewed to
understand what is happening.
The second purpose for plotting “A”, “B”, and “C” in this
way, is to see if the lines cross. Crossing lines mean the
kiln shell has a bend in it. It “cranks” as it turns. This
could be a transient condition due to an asymmetrical
shell temperature profile. It could also be a permanent
condition due to permanent shell damage from previous
refractory failures. Only with a series of measurements
under various kiln conditions, over a period of time, will
such a pattern become apparent.

High ovality and high creep are the normal partners.

High ovality and low creep may mean the tire is
mechanically “locked” from rotating by galling material.
It could also mean the tire has an inadequate cross
section for the load it is carrying. The temperature
difference between the tire and the shell may help to
sort this out.

56 Shell Flexing ( Ovality )

Data display
Linear graphs
This form of data graphing provides the most detail
about the behavior of shell flexing. This form is usually
preferred since learning curve interpretation is relatively
simple and comes easily with practice. Standard curve
interpretation is found earlier in the presentation.

Shell Flexing ( Ovality ) 57

Data display
Polar graphs
This form of graphing the data was popular for many
years since it was the only option available before the
introduction of SFX. SFX Report provides this form of
graphing for those who wish to compare readings to old
records.

58 Shell Flexing ( Ovality )

Ovality and brick wearing speed
There are further indications for keeping ovality under
control has an impact on the life of a kiln. In 1995, Yoshiki
Tuchiya, Elichi Nakajima, and Toru Honda of Mino Yogyo
(Ceramic) Co., conducted a study of the interrelationship
between refractory life and kiln shell deformation. In
their paper, presented at UNITECR ‘95, they considered
the mechanical stresses caused by ovalities. The effects
of chemical or thermal stresses were not considered.
The authors gathered data on the measured ovalities
and brick life and analyzed this data statistically to find
the interrelation between them.
Shell Flexing ( Ovality )
In Figures 1 and 2 above, the interrelation between the
measured ovality data and brick life is shown. The linear
regression line is calculated by the least squares method.
Figure 1
Brick life decreases as ovality increases.
Figure 2
No correlation was found for brick life with ovality on
tire #1 (discharge end ). In the burning zone of a rotary
kiln, the bricks are exposed to severe thermal load
conditions and corrode quickly. Bricks in this zone
are usually protected by material coating. When this
coating becomes unstable and fails, it spalls the bricks.
Therefore, brick life varied and no interrelationship was
observed.
59
Figure 3
This better demonstrates the interrelation between
ovality and brick life than figure 2. Although minimum
brick life figures were used, the brick life at tire #1 was
above the linear regression line. This means large ovality
accelerates the wearing speed of burning zone bricks.
60
Conclusions
When ovalities increase in the center zone between tires,
not only are bricks stressed from the shell, but lined brick
rings slip from the shell. Brick life is further reduced in
the center zone.
An acceptable ovality limit for a certain period of kiln
operation was discussed according to the calculations
obtained. The authors confirmed, maintaining tire
ovality within the acceptable range has a positive effect
on brick life.
Further studies are being conducted.*
*Original article was printed in World Cement, April 1996 and
is used by permission.
Shell Flexing ( Ovality )
It is only with routine ovality measurement the behavior
of the shell can be fully understood and refractory life
can be maximized.
Shell Flexing ( Ovality )
Remember...
It is always necessary to take shell and tire
temperatures and creep measurements whenever
ovality measurements are made. There is a strong
relationship between these three, which should be
documented for all kiln conditions. Ovality values vary
due to temperature differences as well as wear. If the
temperature differences and creep are not known, then
high ovality readings cannot be correctly interpreted.
61
62 Shell Flexing ( Ovality )