ASEC Academy

Kiln alignment 1/17

Kiln alignment
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Table Of Contents

Kiln alignment ................................................................................................................................... 1

1. Hot kiln alignment using electronic devices: ............................................................................. 3
1.1 Advantages of this technique: ...................................................................................................3
1.2 Tools and instruments used: .....................................................................................................3
1.3 Measurement procedures using total station:............................................................................4
1.4 General notes: ............................................................................................................................5
2. Grinding of rollers & tyres.......................................................................................................... 8
2.1 Grinding method .......................................................................................................................9
2.2 Grinding machine .....................................................................................................................9
2.3 Circumference Measuring Device for Live Rings and Supporting Rollers .............................11
2.3.1 General ............................................................................................................................... 11
2.3.2 Measuring process using the C.M.D. during the kiln operation ........................................ 12
2.3.2.1 Device description ...................................................................................................... 12
2.3.2.2 The principles of the C.M.D. ...................................................................................... 12
2.3.2.3 Preparing to measure .................................................................................................. 13
2.3.2.4 Measuring steps .......................................................................................................... 13
2.3.2.5 General remarks when using the C.M.D. ................................................................... 15
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1. Hot kiln alignment using electronic devices:

This technique is applied during rotation of the kiln without the need to stop it. It is
considered one of the most modern techniques in this field.

1.1 Advantages of this technique:

1. Reducing kiln stoppage time whereas older techniques require total stoppage of the
kiln.
2. Faster acquisition of results by using a programmed computer for this purpose.
3. Acquisition of coordinates of the center of the kiln at each base, hence, it is possible
to undergo essential adjustments.
4. After accomplishing essential adjustment operations, it is possible to quickly repeat
measurements.
5. Accurate measurements are achieved as it depends on sophisticated electronic devices
and not on manual operations.

1.2 Tools and instruments used:

1. Prisms are placed in various places as reference points.
2. Total station equipped with a transmitter and receiver to measure angles and
distances.
3. PC with the basic information installed.
4. Targets to be placed on rollers (fig. 1).

360° prisms Total station Target with mini-prisms

( fig. 1 )
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It is well known that accurate measurements of rotary kiln alignment is a main task in
measurement and adjustment operations in order to assure trouble-free operation. Therefore,
the proper positioning of tyres and rollers, the relations between them and the interference
between the large and the small gears facilitate proper kiln operation without any problems.

The dislocation of the center of the kiln from the right position due to the dislocation of the
rollers can lead to damaging mechanical parts in addition to great production losses. This
occurs due to the following reasons:
1. Depression of the concrete bases of the kiln.
2. Uneven wear of tyres and rollers.
3. Incorrect positioning of the rollers at installation.

The device we are concerned about here is extremely accurate because it is an electronic
measuring device that can measure three dimensional coordinates for a certain point. This
system is composed of an electronic device that is used by scanners to determine distances, a
programmed computer, prisms, a Circumferential Measuring Device (CMD) and other
assistances.

It is also possible to measure angles using the electronic scanning device depending on
electronic scanning of digital circular glass lenses. The accuracy of the device is 1 mm for
measuring a distance of 100 m.

There is a control program that guides the user in order to eliminate any error that occurs
directly on the device and all of these tools and instruments are designed to work without
electric sources so it can be charged before usage.

1.3 Measurement procedures using total station:

(Steps 1-5 fig. 2)

1.3.1 Prepare and organize tools, instruments and devices necessary for measurement
operation.
1.3.2 Establish a coordinate system to which all designated points are related to.
1.3.3 Fix 360° prisms in various places to connect different designation points as well as
fixing targets on rollers.
1.3.4 Measure special coordinates for targets and prisms.
1.3.5 Exchange the position of the total station by reverse measurement operation for the
pre-designated prisms and accordingly determine the coordinates of the total
station relative to the established coordinate system.
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1.3.6 Measuring diameters of rollers and tyres is extremely essential for all the points
needed to measure the kiln. They are measured using a Circumferential
Measuring Device (CMD) (fig. 3) and will be illustrated later.
1.3.7 Transfer this data to a computer to take it into consideration in addition to
considering temperature because this data are useful in making the alignment
approach the correct position with high degree of accuracy.

1.4 General notes:

• Prisms have to be firmly fixed in order to depend on them to transfer
coordinates.
• It is preferable to designate all prisms from the reference point in order to
minimize error to a minimum.
• Some points are designated more than one time in order to overlap which
minimizes error.
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Total Station measurements

Reference point

Location point
Object point

( fig. 2 )
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( fig. 3 )
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2. Grinding of rollers & tyres

It is well known that any mistakes in the design, installation or maintenance will
directly affect the condition of rollers and tyres where they will be districted or worm,
and hence, repair and maintenance will be a must.
And if the kiln will not move up and downhill, more wear will occur at the area of
contact between rollers and tyres taking the shape of cavity on the roller or tyre
surface ( fig 4 ).
Edge New surface Riding ring Original surface

Carrying
roller

Wear

Fig (4)
The formation of cavities happens more frequently in the rollers rather than the tyres,
this is because of the hardness of the roller surface is lower than that of tyre, however
this cavities must be smoothen and polished.
Wear occurs in the rollers as well. And to compensate it, they are moved inward
taking into consideration the thickness of metal removed during the grinding process.

There are several methods to restore the condition of rollers and tyres depending on
the deviation in radius measurements along their width.
If the deviation is between 1 and 3 mm, then the grinding process is the best, but if
the deviation is more, then special turning machines (lathes) with special cutting tools
should be used, and both methods are performed during the operation of the kiln, and
without any interruption to the production.
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2.1 Grinding method

The success of grinding process is based on the fine adjustment of the position of the
grinding machine on the rollers or tyres.
This can only be done by determining exactly the diameter of the rollers or tyres in
many points along their width, so that the suitable skewing (which is based on the
values of diameters ) of the center line of the grinding machine translation carriage
can be performed to obtain at the end of the grinding process a perfect cylindrical
shape with a maximum tolerance in conical of 0.5 mm in radii along the roller or tyre
width.
The removal of any ovality in the surface of the rollers or tyres can be guaranteed by
using a straight edge on the surface of rollers or tyres, so that the filler blade of 0.2
mm will not pass between this straight edge and the rollers or tyres surfaces along
their widths.
To guarantee an efficient operation of the kiln, the contact area between the tyre and
rollers should not be less than 75% after the grinding process.

2.2 Grinding machine

It is a mechanical device used to grind and clean the surfaces of rollers and tyres and
it is shown in ( fig 5 ).
Before using this device, we must ensure that the wear in the station to be ground is
within the limits and that the productivity of the kilns is over 80% of the nominal
capacity, this is to prevent any more deterioration in its condition.
The grinding machine consists of the following parts:
• Electrical motor 110-500V – 50/60 Hz.
• Switch gear.
• Grinding wheel with transverse motion using geared motor.
• Mechanical fixation levers and elements.
• Electrical connections.
According to the specification of the grinding machine, and to the hardness of the
surface to be ground, it can remove 0.5 mm in each stroke which takes 2 hours/stroke,
depending on the rollers and tyres diameters, taking into consideration the hardness of
the cutting tool, where the consumption is between 2 & 3 wheels/day ( based on 24
working hour/day ).
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Roller grinding machine Thrust face grinding machine

Tyre grinding machine Grinding wheel

Fig (5)
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2.3 Circumference Measuring Device for Live Rings and Supporting Rollers

2.3.1 General

The circumference measuring device is used for measuring live ring and supporting roller
diameters (circumference) while the kiln is in operation. These measurements are used to
determine the kiln axis on a kiln in operation. In connection with machining of supporting
rollers or live rings, the instrument is used for ascertaining any conicity before adjusting the
lathe.

Figure 6. Measuring wheel.

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2.3.2 Measuring process using the C.M.D. during the kiln operation

2.3.2.1 Device description

The device consists of a wheel ( 150 mm ± 0.0 ) with a spring coupling (1) and an
encoder which uses the DC power directly or with backup batteries (2), an infra-red
transmitter-receiver (3), infra-red source with optical wave (4), magnetic base to carry
the infra-red source (5), magnetic base to be fixed on the side of the tyre or roller to
cut the infra-red source (6), optical fiber cable to connect the infra-red source with the
counter (7), optical fiber cable to connect the transmitter-receiver of the infra-red with
the counter (8), on/off switch for the power supply (9), reset switch of the data on the
counter (10), selector switch to select to select the number of revolutions (11), cut-off
indicators with reset switch (12), battery charge indicator (13) and a fixation rod (14)
as shown in( figure 7 ).

4
3

14
7
8

2 1 10 13
9 11
12

(Fig. 7)

2.3.2.2 The principles of the C.M.D.

The concept of this device is to determine the number of turns that the device wheel
made during one revolution of the measured object ( tyre or roller ), therefore the
magnet base (6) must be fixed on the side of the measured object ( tyre or roller ),
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this magnetic base cut the infra-red one time each revolution of the measured object
and hence trigger the counter which start counting exactly at the cutting time, the
counter is connected to the wheel whose diameter is already known from the
beginning therefore the number of turns of the wheel is determined during one single
revolution of the measured object ( tyre or roller ). This is done using an electronic
pulse transmitter and according the cut off is known directly by the counter.

2.3.2.3 Preparing to measure

• Connect the cables to measuring unit specially the cables no. 7,8 according to
the tags written on the cables ends and the measuring unit.
• Fix the source of infra-red on the magnetic base by the fixation bolts and the
rod over the magnet where it is easy to adjust the infra-red source at any
desired direction.
• Make sure the power supply is connected and the batteries are charged.
The measuring device can be connected directly to the power supply using a special
cable or using the batteries which can be charged, the first method is used if the
measuring process is carried out near a power supply source while the second is used
if there is no power supply is available, and in this case the batteries must be charged
one day before.

2.3.2.4 Measuring steps

• Before the fixation of the magnetic base (7) on the measured object ( tyre or
roller ) we must make sure that this base is not adjacent to the rollers or the
temperature shields since any improper fixation of this base will result in
incorrect results and the destruction of the magnetic base where it will be
broken if jammed between the tyre and roller as shown in figure (8).

Tightening rack
wheel

(Fig. 8)
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• Fixation of the measuring wheel as following:

1. The best way to fix the wheel is over the temperature shields or an a
fixed frame over the supporting rollers shields or on the bearing
adjusting screws covers or to fabricate special supporting frames for the
purpose.
2. Adjusting the required pressure on the measuring wheel; the measuring
wheel must be pressurized against the measured object ( tyre or roller )
using the tightening rod. And the leaf spring, when the measuring wheel
touches the measured object it starts turning with it and the amount of
pressure is determined by 2 teeth of the tightening lever.
3. Adjusting the concentricity of the measuring wheel, the measuring
wheel must be perpendicular on the circumference of the measured
object to avoid any mistakes that may happen due to the improper
rotation of the measuring wheel.
4. Taking away the measuring wheel after performing the measurement.
Before moving the measure unit away of the object to be measured (
tyre or roller ), this is done by releasing the pressure of the measuring
wheel and pull it back using the fixation rod on the tightening lever
• Operation of the electronic counter:
1. The unit is operating by turning on the power switch.
2. Resetting the counter to the operation mode the main reset switch or by
individual switch for each counter to increase the life times of batteries
the device is turned off automatically if not used.
3. ( Measuring ) after connecting all the required cables, the counter stands
the count after cutting the source of the infra-red by the magnetic base
fixed on the side of the measured object ( tyre or roller ), the first
counter stops counting after the first turn and the second counter starts
immediately. The reading of the first counter is that of the diameter
directly, and this reading of the second counter is taken exactly as done
for the first counter, this process can be repeated according to the
required number of revolutions for the measured object which is
determined by the revolution number selection no (11) where we can
select (2,4,8) the third counter gives us the average of the diameter
during the number of revolutions. The accuracy of this device is 0.1 mm
when measuring diameter of 6000mm.
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2.3.2.5 General remarks when using the C.M.D.

1. The device temperature should not exceed 50°c and not less than -20°c.
2. To obtain accurate results, the measuring wheel must measure clean an smooth
surface of the measured object ( tyre and roller ).
3. The position of fixing the measuring wheel is selected as shown in the figure
when measuring the tyres diameter and at the same angle regardless the
direction of rotation when measuring the rollers diameters

• Recording the measurements results:

1. Prepare the table shown below
2. Write down the obtained results in the table.
3. Take into consideration that these
measurements are taken at high temperature in 30°
case of comparison.
4. From the above measurements the wear in the
tyres and rollers can be known and hence the
settlement in kiln center line of rotation is determined.
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CR1-RH CR2-RH CR3-RH

OUTLET
INLET RR1 RR2 RR3

CR1-LH CR2-LH CR3-LH

A B C A B C A B C

Measuring Original Measuring dimensions Amb. working

Points dimensions Temp. temp. Remarks
a b c Avg.

Hot
condition

Cold
condition

Rotary kiln no : date / / name:

Sign :
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KILN DRIVES
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Table of Contents
1 - KILN DRIVES .......................................................................................................................... 3
1-1 Introduction .............................................................................................................................. 3
1.2 Girth Gear Mounting Methods ................................................................................................. 3
1.2.1Flange-Mounted Gears ........................................................................................................... 3
1.2.2 Spring-Mounted Gears........................................................................................................... 4
1.3Regular Visual Inspection.......................................................................................................... 5
1.3.1Mesh ....................................................................................................................................... 5
1.3.2Contact .................................................................................................................................... 5
1.3.3Reducer condition ................................................................................................................... 5
1.3.4 Tooth Profile Wear ................................................................................................................ 5
1.3.5 Contact Patterns Due To Assembly Faults Or Operational Conditions................................. 6
1-4 Axial Run-Out ......................................................................................................................... 8
1-5 Radial Run-Out...................................................................................................................... 11
1-6 Girth Gear Lubrication .......................................................................................................... 12
2 - Kiln Friction Drive ................................................................................................................. 14
2-1 Hydraulic Friction Drive ........................................................................................................ 14
2-2 Mechanical Friction Drive ..................................................................................................... 15
3 Kiln Seals ................................................................................................................................... 16
Introduction: - ........................................................................................................................... 16
3.1 Graphite Block Seal ........................................................................................................... 17
3.2 Face plate seal .................................................................................................................... 19
3.3. Outward Leaves Design .................................................................................................... 22
3.4 Inverted Leaves Design ..................................................................................................... 27
4. Kiln Nose Ring ........................................................................................................................ 28
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1- KILN DRIVES

1-1 Introduction

No discussion of troubleshooting kilns, dryers, and other rotary equipment would be

complete with out the inclusion of the special problems of gears, pinions, and drive
trains. Understanding the mechanical function of these parts and the differences in their
design will help to focus on areas that may cause problems in the future, or may already
be causing problems.

The alignment and mesh of the gear and pinion, the lubrication that is used, and the other
components involved in the drive train, are all areas that should be carefully inspected on
a regular schedule.

Covered in this section are the two most common types of gear mounting arrangements,
their pros and cons, and a recommended inspection program. Characteristics, advantages
and disadvantages of different types of lubrication are discussed as well.

1.2 Girth Gear Mounting Methods

1.2.1Flange-Mounted Gears
Most flange-mounted gears are found on older kilns or on equipment such as dryers
and coolers that operate in a lower temperature range. They are generally constructed in 2
to 6 sections, and the mounting flange is typically welded directly to the shell. It is easy
to reverse the gear to maximize service life if the flange is still rotating true and in good
condition.

However, a common problem encountered when attempting to reverse or install a new

flange-mounted gear is that over time the shell has incurred thermal damage because of
refractory failures. Depending upon the location of this damage, it can create a significant
amount of run-out in the shell where the gear is mounted. If this is the case, the mounting
flange must be cut loose and remounted or a new flange must be installed.

In some cases additional centering of the gear can be accomplished by redrilling the
mounting holes in either the gear or the flange. This can also be limited by the way the
flange was originally machined.
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A careful inspection should be made for these factors and consideration given prior to
planning any gear reversal projects.

1.2.2 Spring-Mounted Gears

Spring-mounted gears are the predominant type of girth gear arrangement for kilns.
There are two basic variations, the most common, the tangential spring, and the
horizontal spring bar. The positive aspect of these designs is that they allow the kiln shell
to expand without restriction, unlike the flange-mounted gear.
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Gear rim spring V-shape Gear rim spring standard

When installing a new gear or reversing an existing gear, it is always advisable to replace
the spring plates and the pins. The plates are subjected to thousands of cycles over the
years and as such there is always concern for fatigue failure. Also, since the springs are
welded to the shell, they are usually compromised to some degree during the removal
process. Trying to reuse the spring plates can greatly inhibit the ability to achieve
acceptable gear run-outs.

1.3Regular Visual Inspection

Add life to your gears through regular inspection. Establish a check list for systematic
inspections daily, monthly and annually. The following areas are critical elements of
good gear maintenance

1.3.1Mesh
Proper backlash and root clearance are critical to smooth gear operation. Too much or
too little clearance can cause problems that contribute to accelerated wear and loss of
tooth profile. Also important is the longitudinal relationship of the gear relative to the
pinion.

1.3.2Contact
The contact pattern across the tooth face is a tell-tale sign of gear alignment. If an axial
run-out condition exists, the contact pattern will vary with the rotation of the kiln.
Angular misalignment between the gear and pinion results in partial tooth contact,
concentrated loads and premature gear wear or failure.

1.3.3Reducer condition
Inspect for vibration and elevated temperatures of the reducer. These are usually signs of
worn bearings or gears, or a lubricant problem.

1.3.4 Tooth Profile Wear

If a kiln runs in one position for a long period of time, the gear teeth will develop a wear
pattern based on this position. When the kiln shifts to a new axial position, the gear also
changes its position relative to the pinion and a new wear pattern begins. If the existing
pattern is severe, this will create a greatly reduced contact area resulting in extremely
high pressures. In many cases this extreme pressure will be high enough to cause the
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lubrication to squeeze out and become ineffective. This leads to high sliding friction and
aggressive wear of the tooth profile.

TOOTH PROFILE

The operator may see a high surge in the drive motor amps for the period of time it takes
to wear so the load is again spread across the entire width. During this process, the
portion of the tooth experiencing the high stresses may also experience spalling and,
cracking. As a result of this aggressive wear the lubricant will be contaminated with
metal fragments and shavings, creating a high potential for increases in wear on other
areas of the teeth.

1.3.5 Contact Patterns Due To Assembly Faults Or Operational Conditions

a. Pinion is running out (wobbling). Check fixation of pinion/shaft.

b. Ring gear is wobbling. Assembling and adjustment of ring gear must be checked.
c. Edge pressure. Pinion must be realigned axially or slope corrected.
d. Pressure spot on total circumference ring gear. Manufacturing fault or new pinion
wearing into existing wear pattern of ring gear.
e. Pinion diameter enlarged on both sides due to wrong assembling or ring clamping
devices.
f. Ring gear joints and fixation of both ring gear sections must be checked.
g. Radial run-out of ring gear. The picture of contact is stronger over one half of the
circumference. Radial re- adjustment is necessary.
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h. The ring gear has opened on both sides due to thermal expansion.
i. Ideal pattern.

Gear contact pattern

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1-4 Axial Run-Out

Axial run-out occurs when a gear "wobbles" from side to side as it rotates. Some side-to-
side movement is inherent in the design of rotary equipment, however, the tolerances are
small. Excessive axial run-out will wear gear teeth unevenly, cause uneven pressure on
the pinion, and will magnify other problems that the unit may have.

When correcting gear run-outs, the axial run-out is generally corrected first. It should
always be measured using two dial indicators 180° apart, usually at the horizontal
centerline of the gear. The stands used for the dial indicators must be rigid so as not to
"sway" and give false readings.

The gear should be divided into 12 equally spaced segments and the side rim of the gear
should be cleaned in these areas. As the kiln is slowly rotated, readings are taken on both
indicators, the readings directly opposite each other are then mathematically averaged to
find the amount o' "wobble" in the gear.

The reason for using two indicators is to negate any axial float of the kiln and any
"wobble" of the thrust rollers.

Illustrated on the chart above are typical curves for the amount of acceptable axial run-
out of girth gears for kilns and similar roller-supported machines.
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The allowable axial run-out is a function of the gear diameter. For the most part, gear
manufacturers and OEMs of rotary equipment recommend 0.001" of axial run-out per
foot of pitch diameter, this rule applies to new installations, and to gears running at 5
rpm and over.

Another level of tolerances is shown for new installations with gears running at less than
5 rpm. This is generally a 25% additional run-out allowance.

The "acceptable tolerances" should be applied to installations where the unit has been
heated and expansion has taken place, or wear is present. In this case, it is unlikely that
original tolerances can be attained.

This is just a guide. Values specific for any particular gear should be obtained from
the gear manufacturer.

Gear run-out measurements are used to set the gear originally and can be used anytime
thereafter to check alignment.
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1-5 Radial Run-Out

occurs when the axis of rotation of the gear changes as the kiln rotates.

Some slight change can be expected, but if measurements are taken and show a large
variance, corrective action should be initiated. If the gear is accessible through the
inspection port, a dial indicator should be place on a 2" x 2" angle-iron tripod at the
appropriate position. If this is not possible, part of the enclosure will need to be removed
to provide access.

Measurement of radial run-out is done by dial indicator. Twelve teeth, equally spaced and
numbered around the circumference, that is every 30°, should have their top faces
cleaned. The gear is slowly rotated. While the gear is moving the indicator stem is held
back. The gear is stopped at each of the twelve teeth and an indicator reading is recorded.

A rigid setup is required for the dial indicator and extreme caution should be taken so as
not to disturb the indicator placement during the procedure.

Take the maximum reading and subtract the minimum reading. This is the radial run-out.
Compare this to the acceptable value for your gear. Values exceeding the acceptable
values will reduce the service life of the gear set.

Illustrated in the chart are typical curves for the allowable radial run-out of girth gears
for kilns and similar roller-supported equipment. The allowable radial run-out is, as with
axial run-out allowances, a function of the gear diameter.
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Gear manufacturers and OEMs of rotary equipment typically recommend 0.0015 of radial
run-out per foot of pitch diameter. This applies to new installations and to gears
running at 5 rpm and over.

The level of tolerances shown for new installations with gears running at less than 5 rpm
is calculated by adding an additional 50% to the run-out allowance.

The "acceptable tolerances" should be applied to installations that have been in use for a
period of time. These are unlikely to attain the original tolerances.

This is just a guide. Values specific for any particular gear should be obtained from
the gear manufacturer.

1-6 Girth Gear Lubrication

Spray lubrication of the gearing involves that a lubricant is atomized by pneumatic

pressure and sprayed towards the gearing so that the lubricant covers the pressure tooth
flanks of the pinion with an even and uniform layer. From the pinion the lubricant is
distributed to the gear rim.
The need for lubrication varies depending on the operating conditions of the gearing.
Consequently, the design of the spray system incorporates automatic adjustment of the
lubrication rate in order to meet the specific requirements of the actual mode of
operation.
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Spray lubrication system The spray system proper is available in various makes, though
the working principles are basically identical. The same also applies to the supervision
and control systems.
For the special features of the individual spray system, reference is made to the separate
instruction manual from the manufacturer.

Performance test
Check the spray image once a week.
The design of the gearing guard is such that it is possible to insert a control plate between
spray nozzles and pinion to capture the lubricant discharged.

The plate is placed in two guide-ways on the guard, with a piece of paper glued on at
either end in order that the spray image can be recorded.
Proceed as described in the suppliers manual.
Then evaluate the spray image. The spray system design entails that the amount of
lubricant supplied to the corners of the teeth exceeds the amount supplied to the central
half of teeth. Figure 3.5 shows an example of a stationary spray image.

SPRAY PATTERN
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2 - Kiln Friction Drive

Always use this method of driving for two tyre kilns , for example F.L.S “Rotax 2”
Use hydraulic or mechanical drive unit for two rollers beside kiln thrust device “at inlet
of the kiln”

2-1 Hydraulic Friction Drive

Use a hydraulic p – p to rotate the roller by

a hydraulic motor
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2-2 Mechanical Friction Drive

Use electric motor & planetary gear box

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3 Kiln Seals

Introduction: -

- The kiln is considering the heart of a cement plant. It consumes about 40% of the
total energy
- For thermal economy, it is necessary to prevent as effectively as possible the
infiltration of ambient air into the rotary kiln at the feed (inlet) and at the discharge
(outlet) ends.
- The reason is that, any false air enters the kiln requires additional thermal and
electric energy for the same kiln output.
- In rotary kiln, raw meal is fed through the smoke chamber from the inlet and gets
discharge as clinker into the cooler on the discharge end
- At both ends there are fixed hoods where rotating kiln ends protrude into them.
- Such intrusions into fixed hoods leaves small gaps all around through which false
air can take place
- These gaps need to be closed by providing seals
- Various designs of seals have been available for a long time with varying degrees
of success
- Seals can be a simple design or complicated as plate to plate arrangement powered
by pneumatic cylinders with a bellows expansion joint.
- The most commonly used constructions of seals are:-
• Graphite block seals
• Face plate seals
• Outward leaves design
• Inverted leaves design
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3.1 Graphite Block Seal

- In this design, sealing is affected by one row of graphite blocks, which are
contoured on sit on the kiln shell.
- Graphite blocks are positioned radially, supported by slide holders
- The blocks are spring loaded and the inside of the graphite blocks is cut to the
shape of the desired outside diameter of the kiln shell to ensure perfect contact
Disadvantages of graphite block seal:
- Due to heat and dust contamination, seal components (especially) slide holder and
spring are distorted and badly affecting seal performance
- Example of this type of seal is shown in Fig. 3.1 with the following improvement:
• good sealing efficiency
• relatively complicated design
• seal protection against overheating
- Another example found in fig.3.2 which shows a single row graphite
block seal using a wire rope and pulley mechanism to press the blocks
against the shell
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Kiln Drive Seal & Nose Ring Page 18 / 30

(Fig.3.1)
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Fig.3.2

3.2 Face plate seal

- This design employs the concept of one free floating and one fixed plate.
- The free floating plate is forced by pneumatic cylinder or springs to be in
permanent contact with the fixed end plate.
- Kiln expansion and float is allowed by bellow joint
- This seal design shows the basic principle of an axial pressure seal that ensure all
around circumferential contact
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Face Plate Seal (Fig.3.3)

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(Fig.3.4)
• In fig 3.4 there are inlet and outlet seals of mechanical type (Face Plate Seal)
For kiln inlet seal shown:-
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Kiln Drive Seal & Nose Ring Page 22 / 30

• Seal relatively complicated

• Visual control of seal gap is difficult
For kiln outlet seal:-
• Good cooling efficiency of nose ring segment
• Simple design self adjusting sealing ring
Disadvantages of face plate seal:
• This seal has too many moving parts, which are exposed to dust and heat
• These moving contact surfaces fail to exert constant pressure on the free plate at
all times, due to abrasion and wear out

3.3. Outward Leaves Design

1. This type of seal is a common design at the kiln inlet, Fig (3.5)

(Fig. 3.5)
2. Sealing is performed by leaves which are bolted onto the hood and tightly sit on
the shell. The leaves overlap each other
3. The fish seal is a simple and efficient way to improve he sealing at kiln outlet Fig
(3.6)
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Kiln Drive Seal & Nose Ring Page 23 / 30

(Fig. 3.6)

Disadvantages of Leaves Seal type

- The leaves are damaged due to abrasion of accumulated dust
- Leaves get burnt when the kiln is running at positive pressure in case of upset
condition due to hot escaping gas
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FLS Provide The Following Lamella Seals For Kiln

* Kiln Inlet Lamella Seal
The lamella seal consists of the following items Fig (3.7, 3.8):

(Fig.3.7)
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Kiln Drive Seal & Nose Ring Page 25 / 30

(Fig.3.8)
1. Inner lamella
2. Heat resistance fabric
3. Outer lamella
4. Scooping system
5. Annular manifold
6. Scooping chamber
7. Cooling air chamber
8. Ceramic felt
To prevent overheating of the kiln shell and sealing parts, a separate fan delivers
cooling air to the space between kiln shell and the cooling duct to the cooling air
chamber.

* Lamella Seal at Kiln Outlet

The outlet lamella seal consists of :Fig (3.9,3.10)
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Kiln Drive Seal & Nose Ring Page 26 / 30

(Fig.3.9)

(Fig.3.10)
- Fixed cylindrical ring of steel plates around the kiln on the kiln hood
- Steel lamella fixed to the annular ring and slide on the circular cooling duct.
- Layer of heat-resistant fabric positioned between the inner and outer sets of steel
lamella
- The cooling mantle (duct) is fabricated from heat-resistant plate, and fixed by a
number of spring plates
- Also a separates fan is supplied to prevent overheating of the outlet sectors and
sealing parts
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3.4 Inverted Leaves Design

- This design is similar to the outward design except how the leaves are mounted
- The leaves orient towards the hood. So, the leaves do not come into contact with
the escaping dust, avoiding abrasion of the leaves Fig. (3.11)

(Fig.3.11)
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- Quadrant ring: mounted on kiln shell

- Riding band: is a wear segment and is installed on the quadran ring
- Inverted Leaves: the leaves are overlap each other
- Hopper: cautiously discharge of dust collected from outside cylinder

4. Kiln Nose Ring

The main purpose of nose ring is the following:-

- Good support for discharge end bricks
- Simple segment shape
- The discharge end of the rotary kiln is one of the most difficult sections to outline.
- Kiln section in this hot zone is subjected to thermal stresses which may cause
deformation
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Fig.3.12 FCB Kiln outlet seal with nose ring segments

- Nose ring segments require sufficient cooling air

Nose Ring Segments In Two Parts
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(Fig.3.13)
- Nose ring segment: Segments is composed of:-
- Bottom parts fixed on kiln shell by bolts to protect kiln shell end.
- Protection cap fixed on cooling jacket to prevent cooling air going
to kiln outlet and protect the cooling jacket from heat radiation.
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Kiln shell and Tyers Page 1 of 38

Table Of Contents

1. Kiln Shell Deformation ................................................................................................... 3

1-1. Shell Deformation Causes .......................................................................................... 3
1-2. Shell Deformation measurements using Manual method............................................ 4
2. Crank in Kiln Shell ........................................................................................................ 15
2-1. Mechanical crank ...................................................................................................... 15
2-2. Thermal crank 15
2-3. Elimination or repair of cranks ................................................................................. 16
3. Kiln Shell Ovality ........................................................................................................... 17
3-1. Kiln Shell Ovality Based On Migration ................................................................... 17
3.1.1. Shell Ovality Measurement And Correction ...................................................... 19
3.1.2. Clearance / Live.Ring Migration ....................................................................... 22
3.1.3. Measurement Of Live-Ring Migration .............................................................. 24
3.1.4. Interpreting The Migration ................................................................................. 27
3.1.5. Live-Rings - Reduction Of Migration ................................................................ 27
3.1.6. Kiln Shell With Live-Ring Supporting Blocks .................................................. 28
3.1.7. Kiln Shell Without Live Ring Supporting Blocks ............................................. 28
3.1.8. Live-Ring – Lubrication ..................................................................................... 29
3.2. Kiln Shell Ovality Based On Radial Deformation ................................................... 30
3.2.1 Principle of the measurement .............................................................................. 33
3.2.2. Measurement procedure ..................................................................................... 35
3.2.3. Calculation of the shell ovality based on “Shelltest” records ............................ 35
3.2.4. Interpretation of the Shelltest Record ................................................................ 38
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Kiln shell and Tyers Page 2 of 38

KILN

The rotary kiln is the most important machine at the cement plant, and frequent checks of
the kiln should form an essential part of the maintenance work.

It is a simple task to carry out a series of measurements using advanced methods and then
produce a report comprising mainly a set of numeric test results. This kind of kiln service
is not useful to the client and has no value. Also, kiln service just recommending
correction of the kiln's axis of rotation will in most cases not achieve the desired result
with regard to reliable operation.

In order to be able to make a correct evaluation of the consequences of a possible

deviation from the optimum kiln axis, detailed knowledge of both the rigidity of the kiln
and the strength of the constituent parts of the supports is a necessity. It is extremely
important, of course, that the measurements are earned out under the most realistic
conditions, i.e. while the kiln is in operation.

The Kiln inspection program is designed to disclose the five diseases of the rotary kiln,
these diseases being mutually independent and potentially involving heavy loses, viz.:

• Shell deformation
• crank
• ovality
• unfavorable mechanical balance
• unfavorable alignment
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Kiln Shell and Tyers

1. Kiln Shell Deformation

1-1. Shell Deformation Causes

The comparison between the underformed and deformed kiln cross-section is shown in
Fig.1

Which illustrates
the causes of shell

deformation as follows:-
• Natural deformation of shell and tyre
• Deformation of tyre in the area of the rollers due to point contact and reaction
force Q/2
• Deformation of the shell caused by difference in diameters So between the inside
of the tyre (D) and the shell outside (d) due to the decrease in supporting action
(stiffening effect)
So = D–d (theoretical Gap)
S = F (So , s) actual gap
S > So
• Condition of the brick lining affect the shell deformation
• Coating formation affect the shell temperature which affect the shell deformation
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Kiln shell and Tyers Page 4 of 38

1-2. Shell Deformation measurements using Manual method

Before a hot, on-stream kiln is shutdown for maintenance and realignment, observe
the shell closely for indications of distortion and runout conditions. If runout is
excessive, especially at feed or discharge ends, make arrangements for cutting the
shell for realignment of the affected sections. Sometimes certain zones of the shell-
including riding ring sections- are so badly distorted that new shell sections must be
installed to eliminate the maintenance problems.
In addition to observing kiln shell conditions, measure runout at predetermined test
locations along the entire kiln length.
Use these measurements to plot graphic views of the cross-sectional shape of the shell at
test points 180o apart on the circumference. Use the following procedure to measure and
plot shell runout:
a) Prepare a sturdy support stand for installation on the drive pier. This stand will be
used to hold a piece of chalk in a steady position for marking a straight line around
the circumference of the slowly rotating shell.
Usually catwalks are too far from the kiln for service as testwork platforms. Many
kilns do not have walkways for close-up inspection between support piers. A rigid
work surface, within easy reaching distance of the kiln shell, is necessary for
preparing reference lines and for obtaining actual test measurements. Scaffolds can
be prepared for this work.
b) Although it can be extremely hot and uncomfortable, it is possible to measure and
record the shell runout of an operating kiln. Since some kilns now rotate at speeds
as high as 4 rpm, make arrangements for rotation at no more than 1 rpm during the
testwork period at any single premarked test line. This lower speed reduces the
possibility of misreading the fractional reference marks on a foot rule or scale.
If the production department agrees to reduce kiln speed to 1 rpm while runout is
measured at individual test lines, but returns to faster rotation speeds between
tests, the control room must be advised when the test team is ready and also when
it is finished at each test position.
c) Predetermine the extent of the analysis to be performed, then mark the shell for
testing at positions along spans between tire sections and at both ends as follows:
1) Measure the circumference of the shell at the reference line, then mark off
12 equal spaces around the shell. If the shell contains permanent fixtures
(manholes, thermocouples, etc.) that can be used as reference points for
follow-up work, select one of these items for marking the 0o/360o (or
12:00 position) test line, as shown in figure 2. This line is to be the index
line for marking the entire length of the kiln shell. After marking position
No.12, mark remaining space marks (1 through 11) as they come into
position with rotation of the kiln.
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Kiln shell and Tyers Page 5 of 38

Prepare a combination support and slide surface for service as a fixed

reference point for measuring and recording the shell dimensions at the
twelve test stations on each test line. Arrange the slide surface
perpendicular to the shell at whatever position is dictated by the final
position of the work platform.
Position the end of the slide surface as close to the shell as possible after
determining the approximate shell runout at that test point.
2) Record the number and location of the line being tested and also indicate
the twelve test points in vertical columns, 1 through 6 and 7 through 12
for quick comparison of readings @ 180o apart (1/7,2/8,etc)
3) Move to each test line in turn and repeat the above measuring and
recording procedure at each location. After all test lines have been
processed.
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CAUTION
When measuring runout of a hot kiln shell it is important to know that the
runout is not influenced by a temporary warp condition such as will be
found when the refractory lining and/or material coating is not equally
thick, especially along longitudinal lines 180o apart in random zones of
the kiln.
Uneven shell temperatures, resulting from varying insulation values of
different thickness of the lining, will cause the kiln shell to form a
temporary bow-shaped warp condition. Shell temperature at the thin zone
of lining will be relatively higher than at the heavily coated zones. The
hot side of the kiln shell will expand more than the relatively cool side.
The hot side will form a convex line-for maximum plus runout-while the
cool side @ 180o away on the shell circumference will form a concave
line, or maximum minus runout position.
When recording shell runout, shell temperature at positions 180o apart
must be considered for final analysis of the actual condition of the shell
for rotation relative to a true axis.
Use infrared heat recording equipment, or use magnet-back dial type
contact thermometers for verification of shell temperature at each test
station around the shell at predetermined test lines.
Measurement of a cold kiln will not be influenced by unequal shell
temperatures caused by condition of the lining, but it is important to
consider the possibility of a temporary warp caused by sunlight or from
adjacent operational kilns. The side of the cold kiln exposed to heat
sources will be considerably warmer than the shady side and this
imbalance will cause the shell to become bow-shaped enough for
measurement of significant runout. Shell temperature should be equalized
prior to start of runout tests at idle kilns.
d) Prepare master work report sheets for the following entries:
1) One sheet for test figures and runout comparisons, and for converting "as
read" dimensions to relate to an average figure as though plus and minus
values had been recorded by a dial indicator. See figures 3 and 4 for a
blank sheet and a filled-in example.
2) One sheet (to relate to the figure entry sheet) for plotting a cross-sectional
view of the kiln shell in relation to a true circle, as shown in figures 5
and 6.
3) One sheet for plotting plan views of the shell profile as would be seen at
points 180o apart with each rotational move of 30o of the kiln. See
figures 7 and 8
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Kiln shell and Tyers Page 8 of 38

4) Prepare sufficient copies to cover all test points and the cross-sectional
plot and to allow for probable layout errors when preparing the sheet for
plotting the plan views.
5) Enter dimensional data and plot approximate shell contours on
appropriate work report sheets. With dimensions now being transformed
into graphic patterns, the actual condition of the shell can be analyzed to
determine a plan of action for repair and/or realignment work. Now it will
be possible to decide whether or not to (1) replace any part of the shell (2)
cut and realign the existing shell or (3) to plan on realigning tire sections
and support rollers for improved operation of the kiln.
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 ASEC Academy
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KILN SHELL RUNOUT TEST ECORD

Test Dimensions 189o

Signs Reversed For
RUNOU Above OR Blow Average
mm Plotting
T
174.63 + + -
1 120.65 7 53.975 1 -26.187 7 1 7
5 27.788 26.187 27.788
130.17 + + -
2 8 184.15 53.975 2 -16.662 8 2 8
5 37.313 16.662 37.313
+ + -
3 133.35 9 165.1 31.75 3 -13.487 9 3 9
18.263 13.487 18.263
1 1 1 -
4 146.05 133.35 12.70 4 -0.787 -13.487 4 + 0.787
0 0 0 13.487
168.27 1 123.82 + 1 - 1 +
5 44.45 5 -23.012 5
5 1 5 21.438 1 21.438 1 23.012
168.27 1 + 1 - 1 +
6 114.3 53.975 6 -32.537 6
5 2 21.438 2 21.438 2 32.537
TOTAL = 1762.125 TOTAL RUNOUT = - 37.313 " TO + 32.537 " = 69.850 "
AVERAGE = 146.837 DATE TESTED:24/04/2005 VERIFIED BY : Eng/A.Nader
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 KILN SHELL DISTORTION (AS SEEN 180 APART)

59436

3048 4572 4572 3048 4572 4267.2 3352.8 3962.4 5181.6 4572 4572 4572 4876.8 4267.2
o
0 / 360 +32.537

12

6 -21.438

o
180
o +26.187
30
1

-27.788
7
o
210
o +16.662
60
2
-37.313
8
o
240
o +13.487
90
3
Feed End

9 -18.263

o
270
o +0.787
120
4

10
+13.487
o
300
o
150 -21.438

11 +32.537
o
330

C
L C
L C
L
1 2 3 4 5 6 7 8 9 10 11 12
Kiln shell and Tyers Page 14 of 38
ASEC Academy

Tyre 3 Tyre 2 Tyre 1

fig.(8) See Table fig.(4)
Dimensions in mm
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2. Crank in Kiln Shell

There are two kinds of kiln shell crank, mechanical crank and thermal crank

2-1. Mechanical crank

Mechanical crank is a stationary deformation of the kiln shell axis. It exists in the kiln
whether hot or cold and cannot be affected by conditions of operation.
A mechanical crank may occur if an unsuitable procedure has been chosen in connection
with straightening and welding together of the individual kiln sections, or if the work is
not done with sufficient care.
Mechanical cranks are frequently caused by unprofessional repair of the kiln shell, e.g.
when replacing large pieces of plate. If sufficient attention is not paid to the contraction
of the material at welded joints, the side of the kiln shell on which welding operations
have been carried out may in some cases become shorter than the opposite side, resulting
in a mechanical crank.
2-2. Thermal crank

Thermal crank results from an uneven kiln surface temperature distribution. It exists in
the hot kiln only and can be affected by conditions of operation.
Areas of the shell showing larger temperature variations in the perimeter directions are
unfailing signs of the existence of a thermal crank. Generatrices in the hot areas become
longer than generatrices in the colder areas resulting in warpage of the kiln.
This phenomenon is particularly pronounced if stable coating formation in the burning
zone is not achieved. When the insulation consisting of lining and coating becomes thin,
the radial heat transmission will increase. This will make the kiln shell temperature rise,
and the plate will expand. If this phenomenon occurs down through the kiln in a way
which is more or less symmetrical in respect of rotation there is no danger. However, in
case of concentration at a minor part of the circumference and if the axial expansion is
considerable, it is quite certain that the kiln shell has a thermal crank.
If there are sudden losses of lining resulting a so-called hot spot can result. However, in
such a case, the kiln plate is locally heated to temperatures of more than approx. 500oC.
Due to the local character of this phenomenon, the expansion of the kiln plate cannot be
fully absorbed as elastic deformation by the surrounding material. The result is
compression of the plate material in the hot spot and a thermal crank in the kiln.
When the cause of the hot spot is eliminated, i.e. after re-formation of the coating or after
repair of the lining (the latter alternative is to be preferred), the variation in the kiln shell
temperature along the perimeter returns to the normal level, and the thermal crank
disappears.
But the kiln still has a crank. The compression of the plate material in the place of the
former hot spot has resulted in a stationary shortening of the generatrices in this place
 ASEC Academy
Kiln shell and Tyers Page 16 of 38

compared with the others. Therefore, the kiln shell will tend to warp towards the centre in
this place, and in this way the original, thermal kiln crank has become a mechanical
crank.
2-3. Elimination or repair of cranks

Re-conditioning of a kiln with a crank is usually a complicated and costly task. This is
primarily due to the fact that the repair as a rule means a shutdown of the kiln for a long
period of a time. A number of cuts of the kiln are required as well as straightening,
welding together of kiln sections, and finally fitting new lining in the deformed part of the
kiln shell.
However, in some cases an alternative method will be successful: straightening of the kiln
by application of heat. Shutdown is thus not required. The kiln is in normal operation
during the heat straightening process, meaning that clinker production can be maintained
and only short kiln stoppages are required.
The principle of the straightening of the kiln by the heat method is that the part of the kiln
shell with the crank is heated to a temperature of approx. 600oC by means of the kiln's
own process heat. At this temperature, the yield stress of the plate material is reduced so
much that it is exceeded by the stresses generated by the crank. Plastic deformation of the
kiln shell will occur, resulting in straightening of the kiln.
The desired kiln plate temperature of approx. 600oC is obtained by covering the part of
the kiln shell to be straightened by a suitable layer of mineral wool. The thickness of this
insulating layer is determined by a calculation of the heat transmission causing the kiln
temperature to rise to the level as precisely required during the subsequent, normal
operation of the kiln. The process proceeds under constant supervision.
A necessary condition for using the heat straightening method is that the temperature
distribution of the kiln in the zone in question is reasonably uniform, as sporadic
overheating can otherwise hardly be avoided. In case of large temperature variations,
postponement of the heat straightening operation until after replacement of the lining in
the deformed part of the kiln shell is advisable.
The heat straightening method is potentially a very risky procedure and should be
constantly and professionally supervised for the whole of the typical duration of approx.
72 hours.
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3. Kiln Shell Ovality

3-1. Kiln Shell Ovality Based On Migration

The live ring migration is equal to the relative rolling movement between kiln shell and
live ring during one revolution of the kiln. This migration is an indirect measure of the
ovality of the kiln shell and therefore an important indicator of the mechanical condition
of the kiln. The live ring migration is measured during normal operation of the kiln by
means of an instrument, which is shown in figure 19. Then the live ring migration can be
measured directly as the length of the cycle of the graph drawn

The live ring migration of a new kiln will be approx. 10 mm per revolution of the kiln
under normal operating conditions. This corresponds to a relative ovality of approx.
0.30% and to a calculated value of the tangential bending stress in the kiln shell of
approx. 300 kp/cm2. Generally, relative ovality corresponding to live ring migration of
10 - 15 mm will not have any harmful effect on the kiln lining. However, if the live ring
migration exceeds approx. 20 mm, this indicates that the ovality of the kiln shell has
reached a size which will most probably contribute to a reduction of the life of the lining.

Such an increase in the ovality will also add to the stresses in kiln shell and welds, and
this may contribute to crack formation. Consequently, it is recommended the measuring
of the live ring migration and of the related temperatures on the surface of the live rings
and on the kiln shell on both sides of the live rings to form an integral part of the normal,
preventive maintenance program. In so doing, it will be possible to follow the variations
in the live ring migration and take the necessary steps to meet any problems.
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Figure 9 Measuring of Live Ring Migration

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3.1.1. Shell Ovality Measurement And Correction

Kilns can be designed to have simple "floating" or "migrating" types of live-rings with a
certain diameter difference between live-ring and kiln shell (supporting blocks). Kiln tube
and live-rings are dimensioned so that the inside diameter (D) of a live-ring is somewhat
bigger than the outside diameter (d) of the kiln tube, measured on the live-ring pads(or the
kiln tube). The diameter difference is necessary, because of the larger thermal expansion of
the kiln tube.

The absolute diametric difference, i.e. the diameter difference between a circular live-ring
and a circular kiln shell is designated 2s. See Figure 10

Figure 10. Kiln shell in live-ring.

As the kiln rotates, the diameter difference will cause what looks like a relative movement
between live-ring and kiln shell due to the different developed lengths of the two joint faces.
The live-ring movement relative to the kiln shell (perimeter difference) is called live-ring
migration. The live-ring migration pr. one kiln revolution is designated by the letter V.

Since kiln tube and live-ring are not absolutely rigid, the weight of the parts will lend them a
certain elasticity in the cold as well as in the hot state.
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Figure 11Ovality. Ideal and real conditions.

The left half of Figure 11 shows what it would look like if kiln tube and live-ring were
absolutely rigid, whereas the right half of the figure - somewhat exaggerated - shows how
the parts are exposed to elastic deformation in practice.

The deformation of the kiln cross section is largest under the live-rings and reduced fast as
the distance from the supports increases. The deformation is normally referred to as the
ovality of the kiln. The term ovality is often used in different senses. It is therefore important
to stick to a defined terminology and defined symbols when dealing with the relationships
mentioned herein.
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Figure 12 Elastic Deformation

The elastic deformation see fig. 12 (ovality) wo of the kiln shell can be expressed as the
difference between the horizontal and vertical diameter of the kiln tube during the elastic
deformation i.e.
Wor = dov - dol

The relative ovality Wor of the kiln is expressed in percent and derives from:

where do is the nominal diameter of the kiln.

To take an example, kilns are normally dimensioned to have a relative ovality of approx.
0.3% during normal operation corresponding to a live-ring migration of approx. 10 mm/rev.
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Figure 13. Live - ring migration.

3.1.2. Clearance / Live.Ring Migration

It is important to keep the clearance between kiln tube and live-ring within certain
empirically established values.
As shown in fig. 13 Theoretical Clearance = 2 S= DL - DO

If the kiln tube temperature becomes extremely high, so that there is a large temperature
difference between kiln tube and live-ring, the clearance between them may become zero. If
the temperature of the kiln shell rises any higher the part of the shell which is under the live
ring is not allowed any diametral expansion but is forced to compress the shell on both sides
of the live-ring will expand further resulting in a permanent deformation called
"constriction".

When the kiln shell temperature goes back to normal and the shell contracts correspondingly
and the clearance between the live-ring and the kiln becomes excessive. See Figure 14
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Figure 14 Constriction of kiln shell

This risk is highest at the live-rings around the burning zone. Therefore it is important to
check the relative migration between kiln and live-rings.

In case of permanent kiln tube deformations an increased diametral difference may cause
lining troubles, and it may become necessary to reduce the clearance between live-ring and
live-ring blocks by inserting shim plates under the blocks.

To protect the rotary kiln against deformations and/or lining damages caused by overheating
during operation, it is necessary to carefully check and, if possible, make operational
corrections so as to keep the diameter difference between kiln and live-ring at an acceptable
level, so that the ovality is maintained within the permissible limits. A simple and accurate
check of the actual diameter difference during kiln operation is made by measuring the live-
ring migration i.e. the relative kiln movement of the live-rings.
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3.1.3. Measurement Of Live-Ring Migration

The kiln supports are designed so that there will be a minimum diameter difference between
hot kiln tube and live-ring. As an example, this difference is 0-3 mm.
As mentioned, the diameter difference or clearance between kiln shell and live-ring causes a
relative movement between the two components. The theoretical diameter difference 2s
causes a relative movement which is

v = π (DL - Do)
2s = (DL - Do)
v = π x 2s

as shown on Figure 9

This relative movement v between the deformed kiln shell and the live-ring will, as a rule be
one and a half to twice the top clearance d. One and a half for large kilns (Do > 4m) and
twice for small kilns (Do < 4m).

The theoretical and the actual live-ring migration are, of course, the same irrespective of the
deformation.

It is not possible to measure the diameter difference on a hot kiln, but since the live-ring
migration is a function of the diameter difference, same can be checked indirectly by
checking the live-ring migration.

Automatic equipment for monitoring and controlling the live-ring migration can be installed.
It is of course also possible to measure the live-ring migration manually.

The simplest way of measuring the live-ring migration is to plot corresponding marks on
live-ring and kiln tube. After the kiln has completed for instance 10 revolutions, measure the
displacement between these marks, after which the migration can be calculated easily.

Clearance ΔD can then be found by dividing v by 1.5 to 2, that is

ΔD = v/1.5 to 2

Dividing the migration v by it results in

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Δ=V/P = 2s, that is

The theoretical clearance for circular kiln tube /live-ring.

A more practical method of measuring v, for instance, during the start-up period, is to use
measuring instrument as shown on Figure 15

Figure 15 A practical method of measuring V.

The measuring instrument consists of a frame (02) which is placed on one of the supporting
blocks by means of magnet base (01). The frame supports a spring-loaded, horizontally
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placed pencil (03) which is pressed against a piece of paper attached with adhesive tape to a
plate (04), which is fixed to the live-rings by means of magnet blocks,

Figure 16 Kiln revolution curves

As the kiln rotates, the pencil will scribe a curve as shown in Figure 20.

The shown curve corresponds to five kiln revolutions, and the values v and d can be
measured directly on the curve.

As mentioned previously, it is important that the clearance between kiln shell and live-ring is
kept within certain limits.

If, during kiln start-up, the pencil begins to scribe ever smaller curves, this means that v and
5D approach zero, and interference may be required in order to avoid the before mentioned
"constriction".
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3.1.4. Interpreting The Migration

Generally, relative ovality corresponding to live-ring migration of 10- 15 mm will not have
any harmful effect on the kiln lining or shell. However, if the live-ring migration exceeds
approx. 20 mm, this indicates that the ovality of the kiln shell has reached a size which will
most probably contribute to a reduction of the life of the lining.

Such an increase in the ovality will also add to the stresses in kiln shell and welds, and this
may contribute to crack formation. Consequently, it is recommended that the measuring of
the live-ring migration and of the related temperatures on the surface of the live-rings and on
the kiln shell on both sides of the live-rings to form an integral part of the normal, preventive
maintenance program. In doing so, it will be possible to follow the variations in the live-ring
migration and take the necessary steps to meet any upcoming problems.

Normally, an increase in the live-ring migration is caused by:

* Wear on the supporting blocks where such do not exist, on the kiln shell itself, caused by
ineffective lubrication between live-ring and live-ring supporting blocks, which can,
e.g. be the case when the environment at the live-ring is very dirty. To ensure effective
lubrication, it is necessary to use:
• correct Lubricant,
• correct Lubricating method,
• correct Lubricating frequency,
As will be described later in this section.
* Constriction as described previously in this section.

3.1.5. Live-Rings - Reduction Of Migration

If the kiln has a constriction, it may be impossible to do a proper lining work resulting in an
unacceptably short life of the lining. In such a situation, the kiln section in question should
be replaced.

In case the live-ring migration increases due to wear to such an extent that the ovality and
bending stress values approach an unacceptable level, corrective action should be taken to
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reduce the ovality in order to avoid a real breakdown. The choice of method depends on the
type of kiln shell: with or without live-ring supporting blocks.

3.1.6. Kiln Shell With Live-Ring Supporting Blocks

For this type of kiln shell, the clearance between supporting blocks and live-ring is reduced
by inserting shims between the live-ring pads and the kiln shell. The mean thickness T of
such shims is calculated according to the following formula where "v" is the live-ring
migration:

t = (v - 10)/2p ("t" and "v" in mm)

By inserting shims the mean thickness of which is "t" mm, the live-ring migration will be
reduced to 10 mm per revolution of the kiln.

Before deciding on the thickness of the shims to be inserted under the live-ring supporting
blocks, the following measuring program should be earned out:

* Live-ring migration
* Temperature on the surface of the live-ring
* Temperature on the kiln shell on the inlet side and on the outlet side of the live-ring.

These measurements are to be taken at least twice every 24 hours for a period of 2-3 weeks.
Moreover, the condition of the lining and the stability of the coating in the kiln area in
question should be evaluated.

3.1.7. Kiln Shell Without Live Ring Supporting Blocks

In order to reduce the live-ring migration of this type of kiln shell, one of the following three
solutions can be chosen:

* The heavy kiln section at the live-ring in question can be replaced so that it will have a
live-ring migration of approx. 10 mm.
* Mounting of a new live-ring with larger inside and outside diameter permitting
supporting blocks to be mounted on the existing kiln section.
* Mounting of a new, "reversed" kiln section as shown in Figure 17 The existing live-ring
can be used for this kiln section which is supplied with live-ring supporting blocks.
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However, the latter solution necessitates very careful lining work in the diameter transition
zones of the lain. It will be necessary to cut the bricks to size between the cylindrical and the
conical sections. Therefore, before choosing this solution, it is recommended to make sure
that the lining installation company is capable of doing this kind of work in a satisfactory
manner.

Figure 17 Reversed Kiln Section '

3.1.8. Live-Ring – Lubrication

In connection with maintenance of the live-rings, choosing the correct lubricating method is
of paramount importance in the following two places:

1) The contact faces between live-ring and supporting blocks or lain shell
2) The contact faces between live-ring and side guides

The following lubricants are suitable for the purpose:

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Lubrication should be carried out by means of a pump to ensure that the lubricant is
distributed over the entire contact face. Lubricant should be applied once or twice a month.

3.2. Kiln Shell Ovality Based On Radial Deformation

Ovality of the kiln shell means the magnitude or degree of deformation. In a theoretical
model where the circular kiln shell is deformed to an ellipse , the ovality can be defined as
follows (Fig. 18) :
 Difference between horizontal and vertical diameter
Ovality  = dh - dv
 Twice the difference between horizontal and vertical semi-axes
Ovality  = 2 (a - b)
In order to compare the ovality behavior of kilns of different sizes , the ovality is expressed
as an percentage of the kiln nominal diameter (di).
Absolute ovality a = 2 (a - b) {mm}
 a − 100
Relative ovality r = {%}
d
i
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Ovality Definition
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Fig. (18)
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In order to counteract the increase in the rate of lining wear and / or dropping out of the
bricks , the ovality should not exceed certain limits.
The determination of these limits is difficult and depends among other factors on the size of
kiln and the actual coating conditions.
Ovality values below 0.3 % can be considered as low and are only found in well
dimensioned and maintained kilns. Values above 0.5 % are in most cases critical and a
negative influence on the refectory lining cannot be excluded.
In Fig. 18 (below) the recommended ovality range is shown as a function of the kiln
diameter, found by experience. For a kiln with a diameter of 5.2 m the diameter difference
(dh - dv = ovality) should not exceed 26 mm in order to keep the relative ovality below 0.5
%.

3.2.1 Principle of the measurement

The kiln deformation under running conditions can be measured by means of special type of
instrument, called “Shelltest” , introduced by Holder bank . The principle of the Shelltest
measurement can be described as follows (Fig. 19) :
A beam (A) provided with sets of magnets (B) at both ends is fastened to the kiln vertically
to the center axis.
In this position the gauge spans a circular sector with the basis length of 1 m and the sector
height h. When the rotary motion takes place , the radial deformation is shown as a change
in the sector height h from a maximal to a minimal value .This change , h, is detected by a
feeler pin of a recorder which is in contact with the shell . The radial movement is
transferred to the recorder’s pencil, magnified 15 times.
 (paper reading ) = 15. h
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Principle of the Measurment

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Fig. (19)
A diagram disc is fastened to the recorder’s shaft and is kept in position by a weight of a
pendulum disc. In the course of the rotation of the instrument a relative movement takes
place and after one revolution, a closed line graph is produced which is a geometrically
similar representation of the deformed kiln shell.
The greatest difference of the two half axes of the diagram curve is a measure for the
deformation of the kiln shell.
Shelltest diagram can above all be used for qualitative evaluations. Due to the representation
of the deformation in a polar coordinate system, any local distortion of the shell can be
easily located, because the axes of the diagram coordinate system correspond to the axes of
the kiln cross section . For instance , we can easily detect a significant deformation in the
appex point or in the roller area or in both.

3.2.2. Measurement procedure

Deformations of a rotary kiln are decreased by increasing the distance from the tyre.
Therefore Shelltest measurements are always taken as near as possible to the tyre from both
inlet and outlet sides (Fig. 20).
In order to obtain definite results concerning the extent of the deformations, each measuring
plane is subdivided in three points which are located on three shell lines, offset at 120 .
Three individual Shelltest records of one measuring plane will result.

3.2.3. Calculation of the shell ovality based on “Shelltest” records

In order to evaluate the ovality from the “Shelltest” record, a mathematical relationship is
required between the ovality as defined of difference in diameter
(d = dh - dv) and the maximum deformation (hmax = ) as indicated on the “Shelltest”
record, since d is not identical with h (Fig. 21). h is the shell deformation based on a
circular segment length L = 1 m.
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Measuring Practice

Fig.(20)
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dh - dv = d  h
2
4  d
Ovality   2 (a - b) =     [mm]
3  L

Relative Ovality r%=  x 100 = 4 d2 .  x 100

d 3 L2 d x 1000

 r% = 4 . d . 
30
whereas
d = kiln inside diameter in meters
 = max. deformation, indicated on the record (paper) in mm

A graph in Fig. 10 illustrates the relationship between the max. deformation  and the
relative ovality, based on various kiln diameters. Also the recommended ovality range (limit)
is indicated.
The following examples give an idea about the admissible shell deformation when the
recommended ovality limit is met. In order to keep the shell ovality within the limit the
deformation  should be kept below 0.75 mm for 4 m diameter and below 0.65 mm for a 7 m
diameter kiln.
This means, the maximum deflection of the shell in the course of one kiln revolution and
based on 1m circular segment length must not exceed 0.75mm and 0.65 mm respectively.
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3.2.4. Interpretation of the Shelltest Record

In the following some typical shell test records are interpreted and discussed in order to give
a feeling for assessment.
Relationship Ovality- Deformation

Fig. (21)