Tyre With Splined Kiln Tyre Fastening System, Type 1

Machine manual
en-KP.TYR.001.C
Tyre with splined kiln tyre fastening system, type 1
Code word
Order number
POLYSIUS Order Code (POC)

Machine manual Contents
Tyre with splined kiln tyre fastening system, type 1
Contents
1 Safety 1-1
2 Technical data 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-5
4 Transport and assembly 4-1
4.1 Transport and storage instructions 4-1
4.2 Assembly 4-1
4.3 Sequence of assembly 4-2
5 Lubrication 5-1
6 Commissioning 6-1
6.1 Preparation for test run 6-1
6.2 Checks prior to the test run 6-1
6.3 Commissioning 6-2
6.4 Test run 6-2
7 Maintenance 7-1
7.1 Safety instructions 7-1
7.2 Inspection 7-2
7.3 Servicing 7-3
7.4 Repair 7-4
8 Trouble shooting 8-1
9 Spare parts9-1
9.1 Suggestions for enquiries and orders of spare parts 9-1
9.2 Spare parts9-1
10 Appendix 10-1
10.1 Technical drawings 10-1
en-KP.TYR.001.C
Machine manual Safety
Tyre with splined kiln tyre fastening system, type 1 1
1 Safety
Note
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
● The tyres with fastening system are part of the rotary kiln. Be sure to comply
with the specification of the intended use in section Technical data.
● Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owner's own risk.
● The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Transport and assembly
● All transportation instructions in this machine manual refer exclusively to
transportation of the machine at the plant site.
● Only use suitable hoisting gear and load-carrying equipment which is in
serviceable order and has a sufficient load-bearing capacity.
● Never work under a suspended load.
Operation
● Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
● The plant management has to ensure that the whole area of the rotary kiln is
cordoned off, so that it is impossible for persons to come into contact with
rotating parts.
● If changes in the machine or its operating behaviour occur that are relevant to
safety, shut it down immediately.
en-KP.TYR.001.C
Safety Machine manual
2 Tyre with splined kiln tyre fastening system, type 1
Maintenance
● It is forbidden to carry out work at the rotating kiln.
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Before beginning any repair work, make absolutely sure that the machine has
swung to a complete stop in its centre of gravity position and has been
secured by means of the holding brake.
● Work on the stopped rotary kiln must only be carried out when suitable
protection devices against falling have been provided.
● Before performing any work on the machine, make sure there is no risk of
suffering burns when touching it.
● Disconnect the power supply of all electrical components before beginning
any maintenance work.
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.
● Be sure to strictly comply with the welding instructions when performing any
welding work.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● Remount all protection devices when the maintenance work has been
finished. Make absolutely sure that no persons are inside the plant component
before you properly close the inspection and service covers.
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Machine manual Technical data
2 Technical data
Note
Refer to the separate electrical documentation or to the subsuppliers'
documentation for information on the electrical equipment.
Specifications of the intended use

See the operating manual of the rotary No.
kiln plant
Basic data
Year of manufacture
Nominal diameter of the rotary kiln mm
Station I
Outside diameter of the tyre mm
Width of the tyre mm
Number of tapered sides Pce
Number of fastenings Pce
Station II
Outside diameter of the tyre mm
Width of the tyre mm
Number of tapered sides Pce
Number of fastenings Pce
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Machine manual Components and mode of functioning
3 Components and mode of functioning

3.1 Components
Note
Some details of the drawings in this manual may not be identical with the
contract-specific drawings.
en-KP.TYR.001.C
Components and mode of functioning Machine manual
Fig. 1: Tyre
en-KP.TYR.001.C
No. Name Description

1 Tyre with internal toothing
2 Kiln tyre fastening system type 1, complete
2.1 Bridge plates
2.2 Axial stops for the tyre
2.3 Axial stops for the bridge plates
2.4 Tangential stops for the bridge plates
2.5 Wedge
2.6 Clamping device complete
2.7 Auxiliary assembly device not illustrated
A1 Tyre-bearing shell section
A2 Transition shell section
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Components and mode of functioning Machine manual
Fig. 2: Clamping device (2.6)
No. Name
2.5 Wedge
2.6.1 Stud bolt
2.6.2 Hexagon nuts
2.6.3 Spring
2.6.4 Pipe
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3.2 Mode of functioning

The tyres (1) transfer the loads caused by the rotary kiln via the supporting roller
stations to the foundations. The tyre (1) must have a high rigidity to ensure that
the linear supported loads that particularly occur at the supporting rollers only
have a slight effect on the rotary kiln shell. As the radial expansion of the rotary
kiln shell is greater than that of the tyre (1), the rotary kiln shell is fastened to the
tyre fastening system (2) providing a gap (usually called "design clearance") for
adjustment to the expected temperature differences.
As a rule, the tyre (1) consists of high-quality alloyed cast steel. The cross-section
is so selected that a high inherent rigidity is achieved.
The kiln tyre fastening system (2) transmits the load to be supported from the
rotary kiln shell by means of the tangential stops (2.4) welded to the tyre-bearing
shell section (A1), the bridge plates (2.1) and the wedges (2.5) to the tyre splines
and thus into the tyre (1).
Axial forces occurring due to shrinkage of the rotary kiln shell, angling of the
supporting rollers and of the rotary kiln axial thrust system are absorbed by the
axial stops (2.3). The axial stops (2.3) are supported at the face of the tyre
splines and are welded on the other end to the rotary kiln shell.
The bridge plates (2.1) are axially secured by the axial stops (2.3).
The wedges (2.5) are uniformly pretensioned with the clamping device (2.6).
The rotary kiln shell is concentrically mounted in the tyre by means of the tyre
fastening system (2).
Although, compared to other designs of the tyre (1) and the tyre fastening system
(2), you can choose a larger clearance in cold condition in order to prevent
constriction of the rotary kiln shell, this has no negative effect on the ovality of the
rotary kiln shell.
It is not possible for the rotary kiln shell ovality to be greater than the (very small
degree of) inherent ovality of the tyre (1). This is an optimum condition with
regard to the service life of the refractory lining.
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Machine manual Transport and assembly
4 Transport and assembly

4.1 Transport and storage instructions
The machine is transported in individual parts or in subassemblies. Make
absolutely sure that suitable lifting equipment is employed for lifting all the parts
from the transport vehicles and transferring them to the storage area.
Upon arrival at the site, all parts must be inspected for transport damage and
placed on wooden beams with the provision of suitable protection against
moisture, soiling and damage. Never place the parts directly on the ground.
Tyres must be stored in a lying position and at least at 4 points on suitable
supports. Make sure that the supports are not more than 1 m from each other and
that they are aligned horizontally.
Check and if necessary repair the temporary anti-corrosion coating for the tyre
(on the contact surface, on the tooth flanks and on the tapered side).
If lengthy storage is required, check the protective coating and repair it if
necessary.
4.2 Assembly
Required personnel
A pre-requisite for correct performance of the work is careful selection of field
assembly personnel who are specially trained for the tasks involved.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need hydraulic pumps and
torque wrenches of a bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
mounting supports, depends on the conditions in your plant.
Note
The fundamental safety instructions must be complied with. Also refer to the
section Safety.
NOTICE
Welding current
Moving connecting elements or sliding surfaces can be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.
en-KP.TYR.001.C
Transport and assembly Machine manual
Note
The following assembly description does not detail the individual steps for
assembling the machine but rather gives an overview of the work to be
performed.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.
Note
It is a prerequisite of our warranty that assembly supervision and assembly
inspection are performed by a specialist from POLYSIUS AG.
Note
Mounting work is limited to aligning and welding of the complete tyre-bearing
shell section. If necessary, the clamping devices have to be fitted and the
springs have to be preloaded to the degree shown in the drawing.
4.3 Sequence of assembly
Assembly of the type preassembled at the factory

The tyre and the fastening are preassembled on the tyre-bearing shell section. As
a rule, the axial stops (2.2) are not welded on at the factory. This enables precise
realignment of the tyre.
Mounting work is limited to the following activities:
● aligning and welding of the complete tyre-bearing shell section
● realigning the tyre if necessary
● mounting all axial stops (2.2)
● mounting the clamping devices (2.6)
● preloading the springs to the size specified in the drawing supplied under the
contract
Assembly of the type not preassembled
Note
We recommend having the following work carried out by specialists from
POLYSIUS AG.
Course of assembly
For the assembly, observe and comply with the inspection instructions for splined
tyre fastenings (450-62201) of POLYSIUS AG.
● The preassembly of tyre and kiln shell section are performed in a turning
device.
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Machine manual Transport and assembly
Note
In the area of the tyre fastening, the kiln shell section must be thoroughly
cleaned of dirt, scale, paint and rust by grinding or sandblasting.
● Weld 4 auxiliary axial stops uniformly distributed over the circumference of the
kiln shell onto the tyre-bearing shell section in order to position the tyre on the
tyre-bearing shell section. Take the row of punch marks inscribed during
processing as a basis for exact positioning of these auxiliary stops.
● Fit the tyre onto the tyre-bearing shell section until it is in contact with the
auxiliary stops. Then fix 4 auxiliary stops on the opposite side.
Note
The kiln shell section must be positioned to ensure that the longitudinal welds of
the kiln shell section are not situated in the area of the weld of a tangential stop.
● Measure the actual dimensions of the tyre and the tyre-bearing shell section
(measurement record).
● Centre up the tyre on the tyre-bearing shell section by means of hydraulic
pumps using centering plates that have to be installed in the area of the
internal toothing of the tyre.
● Provide an twist preventer for the tyre.
Mount the individual components of the kiln tyre fastening system in the 12
o'clock position.
Note
The contact surfaces of the splines, the bridge plates, the wedges, the
tangential stops and at the kiln shell (in the area of the weld joints) have to be
cleaned of any paint, oil, grease, rust and scale.
● Insert 2 wedges (2.5) by approximately 80% and lay the wedges next to the
tyre splines.
● Insert 2 bridge plates (2.1), shift them against the wedges and locate them
centrally to the tyre.
● Insert 2 tangential stops (2.4) and align them.
● Push in both wedges (2.5) evenly until the tangential stops (2.4) are fixed. It is
important that the two wedges are pushed in to the same length at each side.
Note
Check and ensure contact with zero clearance of all sections, also check and, if
necessary, correct the gap between the tangential stop (2.4) and the kiln shell
(see Inspection instructions for splined tyre fastenings 450-62201).
● Tack weld the tangential stops (2.4) and weld the root pass.
● Position the axial stops (2.3) and tack weld.
● Evenly press in wedges on both sides using hydraulic pumps (see data in the
drawing) and secure with temporary axial securing devices.
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Transport and assembly Machine manual
● Provide an twist preventer for the tyre.

The kiln section can then be turned further and assembly of the next fastening
unit can be performed.
Note
Before the kiln shell section is turned further, it must be ensured that the tack-
welds and root passes have sufficient strength (see Inspection instructions for
splined tyre fastenings 450-62201).
● Install the tyre-bearing shell section during kiln shell assembly after the
installation of all kiln tyre fastening systems.
● Measure the axial runout of the tyre in installed condition before welding the
circumferential welds (measurement record). Realign the tyre-bearing shell
section when a set axial runout tolerance of the tyre has been exceeded.
● Weld the circumferential welds in the kiln shell.
● Measure the axial runout of the tyre after the welding (measurement record); if
necessary, realign the tyre (this is only permissible to a limited extent).
The other parts of the individual components of the kiln tyre fastening system also
have to be assembled in the 12 o'clock position.
● Mount and tack weld the axial stops for the tyre (2.2) removing the respective
centering devices.
● Mount the clamping device (2.6).
● Weld all parts of this individual component.
The kiln section can then be turned further and assembly of the individual
component of the next fastening unit can be performed.
● Perform a weld test according to the instructions given by POLYSIUS AG.
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Machine manual Lubrication
5 Lubrication
Note
This machine/unit requires no lubrication.
Note
The lubrication between the tyre and the supporting roller is described in the
machine manual of the supporting roller station.
en-KP.TYR.001.C
Machine manual Commissioning
6 Commissioning
6.1 Preparation for test run
Note
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
6.2 Checks prior to the test run

Note
After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the list below.
Make absolutely sure that all material remnants, tools and auxiliary assembly
devices have been carefully removed.
● Are the tyres (1) and the tyre fastening systems (2) free of tramp material?
● Is the inlet gap between the tyre and the supporting roller free of tramp
material?
● Is uniform load bearing of the tyre (1) and the supporting rollers ensured?
● Have all welds been checked for freedom from cracks?
● Have the clamping devices (2.6) been set to the required dimension (in
accordance with the drawing)?
● Have all the protection devices been mounted?
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Commissioning Machine manual
6.3 Commissioning
Starting the rotary kiln at temperatures below 0 °C

At temperatures below 0 °C, the notch impact strength of the cast steel used
decreases considerably.
In the case of temperatures below 0 °C prior to the start of the rotary kiln, we
therefore recommend uniformly heating up the tyres around the entire
circumference to approx. 25 °C by means of gas burners. The heating up has to
be started approximately 24 hours before the kiln is rotated for the first time.
We recommend gas burners (with a soft flame), IR emitters or electric heating
pads for the heating up.
Heating up the rotary kiln

When kiln shell temperatures exceed 250 °C during the heating-up process, there
is the danger that the kiln tyres might pinch (constrict) the shell section.
We therefore recommend that - in addition to the normal inching operation - you
should turn the kiln by one full rotation and check the relative movement every 30
minutes when the shell temperature exceeds 250 °C.
You must alter the heating-up process, additionally heat the kiln tyre with an
external heater or externally cool the kiln shell in order to ensure that there is a
clearance between the tyre and the kiln shell.
6.4 Test run

As a rule, cold test runs are dispensed with to protect the refractory lining.
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Machine manual Maintenance
7 Maintenance
7.1 Safety instructions
DANGER
The rotary kiln is hot.
You may suffer very severe burns.
Always wear the required protective clothing.
DANGER
It is forbidden to carry out work on rotating machines.
You could be very severely injured.
The plant management has to ensure that the whole area of the machine is
cordoned off, so that it is impossible for persons to come into contact with
rotating parts.
DANGER
Never open doors or manholes during operation!
You could be very severely injured by moving parts.
I. Always observe the respective signs!
II. Only specially authorised and trained personnel may open the
inspection ports.
DANGER
Before beginning any maintenance work, make absolutely sure that the
rotary kiln has swung to a complete stop in its centre of gravity position
and has been secured by means of the holding brake.
You could fall from the rotary kiln.
Do not work on the rotary kiln without suitable fall protection.
WARNING
The machine contains parts under voltage.
Disconnect the power supply of all electrical components before
beginning any maintenance work.
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Maintenance Machine manual
7.2 Inspection
No. Work to be performed Frequency Note
1 Visual inspection of the tyre surface contact Daily
pattern
2 Visual inspection for local overheating of the kiln 1 x per shift See machine
shell in the zone of the tyre fastening systems manual for the
Rotary kiln shell.
3 Visual inspection of the preloading of the clamping Monthly Target: max. 240
devices (2.6) (check of the spring length) mm.
If any spring has
been preloaded to
the extent that its
individual coils are in
contact without any
gap between them:
do no slacken it!
4 Visual inspection of the welds Annually During stoppages
5 Inspection of the welds by means of MP or FE Every 2 years
testing
Note
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7.3 Servicing
No. Work to be performed Frequency Note
1 Retensioning the clamping devices (2.6) with a spring As required Retension
length of more than 240 mm during the next
stoppage of
the machine.
Preload to
approx. 200
mm.
2 Material beading at the tyre contact surfaces and edges As required Grind the
contact
surface and
the radii.
Note
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7.4 Repair
Required personnel
To ensure correct performance of the work, only assign repair work to personnel
that have received special training for the tasks to be performed.
Note
We recommend having the repair work carried out under the supervision of an
expert from POLYSIUS AG.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoisting gear,
depends on the operating conditions in your plant.
General
Note
The fundamental safety instructions must be complied with. Also refer to the
section Safety.
Switch off the power supply to all electrical components before beginning any
repair work.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives or other sensitive parts of the machine
or plant.
Do not remove or open any covers or protection devices before all rotating parts
have come to a complete standstill.
NOTICE
Welding current
Moving connecting elements or sliding surfaces can be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.
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NOTICE
Tyres may be damaged!
Never carry out any electrical or autogenous welding and flame-cutting
work on the tyres as these points may become starting points of cracks.
Never connect earthing cables to the tyres either.
NOTICE
Welding work on the tyre may only be performed by a specialist from
POLYSIUS AG.
Finally, the seam must be checked by ultrasonic testing.
Cracks in the welds of the kiln tyre fastening system

● Professional opening of the welds and rewelding.
● The entire area of the crack must be excavated.
● Reweld the components of the tyre fastening system.
● The welds must be surface-crack-tested.
Crack in the tyre

● Professional opening and grinding out of the area of the crack.
● The entire area of the crack must be excavated.
● Repair welding of the area of the crack.
● Check the seams by ultrasonic testing.
Note
Durable repair welding on tyres is not possible with the means available at
present.
But, normally, operation can continue for a period of approx. 1 year after the
repair welding.
We urgently recommend you to purchase a replacement tyre if cracks in the tyre
occur.
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Grinding work on the tyre

After elimination of the causes always grind the surface until it is cylindrical and
free of cracks.
We recommend using for this purpose the tyre/supporting roller grinder specially
developed by POLYSIUS AG for this type of grinding work. A cylindrical surface
can only be ground with this device.
The total grinding process can be performed without interrupting operation and is
performed with the rotary kiln at operating temperature.
Note
The supporting rollers also have to be ground after the grinding work at the tyre.
Note
After you have completed the repair work, you must check the machine/plant
again in accordance with section Checks prior to the test run.
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Machine manual Trouble shooting
8 Trouble shooting
CAUTION
It is forbidden to carry out work at the rotating kiln.
I. The plant management has to ensure that the whole area of the rotary
kiln is cordoned off, so that it is impossible for persons to come into
contact with rotating parts.
II. Before beginning any repair work, make absolutely sure that the rotary
kiln has swung to a complete stop in its centre of gravity position and
has been secured by means of the holding brake.
III. Disconnect the power supply of all electrical components before
beginning any maintenance work.
Note
Consult the subsuppliers' documentation for additional information on faults,
their causes and their elimination.
Fault Cause Elimination

Bad contact pattern between The supporting rollers Check and adjust the supporting
tyre and supporting rollers are not parallel to the rollers and bearings.
(less than 70 % of the tyre rotary kiln axis. (See machine manual for the
width) Supporting roller station.)
Deformation of the See machine manual for the Rotary
rotary kiln shell kiln shell.
Foundation settlements A specialist from POLYSIUS AG has
or tilting to remeasure and correct the total
rotary kiln and correct the
supporting rollers with the
POLSCAN® measuring system by
order and for account of the
customer.
Scoring or vibration marks at Roller axle alignment is Check the roller and correct the
the lateral contact face incorrect (skewing or alignment.
(only at kiln stations with axial shaft misalignment). (See machine manual for the
thrust system or with axial Rotary kiln axial thrust system.)
positioning system) Then grind or turn the lateral contact
face on the tyre and the contact
surface of the roller .
Roller bearing is faulty. Replace the roller bearing.
(See machine manual for the
Rotary kiln axial thrust system.)
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Trouble shooting Machine manual
Fault Cause Elimination

Damage to the tyre surface Overloading due to See machine manual for the Rotary
due to overloading, bad distorted rotary kiln shell kiln shell.
contact pattern, tramp metal,
no or inadequate axial Bad contact pattern See fault.
movement of the rotary kiln Bad contact pattern
Tramp material in the Grind free from scoring with
tyre surface portable grinder.
Inadequate axial Set the required axial movement by
movement (tyre wears checking the axial thrust system and
into the rollers) adjusting the rollers.
(See machine manual for the
Rotary kiln axial thrust system.)
Formation of lateral burr at the Overloading due to Grind off the burr down to the
tyre inadequate axial structure that is free of cracks.
movement or bad Radius at the corners
contact pattern approx. 10 mm. Eliminate the
cause.
The position of the Axially shift the supporting roller
supporting rollers station.
relative to the tyre is not We recommend having these
correct. measures performed in consultation
with POLYSIUS AG.
Cracking of the weld seams of Overloading due to See machine manual for the Rotary
the tyre-bearing shell section distorted rotary kiln shell kiln shell.
Local overheating Replacement of the area of the
crack or the total section
Note
After you have completed the repair work, you must check the machine/plant
again in accordance with section Checks prior to the test run.
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Machine manual Spare parts
9 Spare parts
9.1 Suggestions for enquiries and orders of spare parts
Dear Customer, POLYSIUS AG want to make spare part enquiries and spare part
order placement as easy and efficient as possible. For this purpose we have
prepared a table containing all data required by our spare parts department to
ensure optimum processing in the quickest and most trouble-free manner. Please
copy the title page and the page with the corresponding table. Complete the
columns for quantity and units. Mark the parts you require with a cross in the
column Order or in the column Enquiry. Send the title page and the table to the
POLYSIUS AG spare parts department. If the table refers to more than one
machine, please also inform us of the POLYSIUS Order Code (POC) of the
machine for which you require the spare parts.
9.2 Spare parts
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Spare parts Machine manual
Fig. 3: Tyre
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Machine manual Spare parts
No. Name Qty. Unit Order Enquiry

1 Tyre, station I 1 Pce
1 Tyre, station II 1 Pce
2.5 Wedge, station I 1 Set
2.5 Wedge, station II 1 Set
2.6 Clamping device, station I 1 Set
2.6 Clamping device, station II 1 Set
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Machine manual Appendix
10 Appendix
10.1 Technical drawings
Note
For drawing numbers, please refer to the table of contents of this folder.
Assembly drawing (station I)

Assembly drawing (station II)
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Tyre With Splined Kiln Tyre Fastening System, Type 1

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Machine manual

Tyre with splined kiln tyre fastening system, type 1

POLYSIUS Order Code (POC)

Specifications of the intended use

Nominal diameter of the rotary kiln mm

Width of the tyre mm

Number of tapered sides Pce

Number of fastenings Pce

Width of the tyre mm

Number of tapered sides Pce

Number of fastenings Pce

3 Components and mode of functioning

No. Name Description

Fig. 2: Clamping device (2.6)

3.2 Mode of functioning

4 Transport and assembly

4.3 Sequence of assembly

Assembly of the type preassembled at the factory

Assembly of the type not preassembled

● Provide an twist preventer for the tyre.

6.2 Checks prior to the test run

Starting the rotary kiln at temperatures below 0 °C

Heating up the rotary kiln

6.4 Test run

Cracks in the welds of the kiln tyre fastening system

Crack in the tyre

Grinding work on the tyre

Fault Cause Elimination

Fault Cause Elimination

9.2 Spare parts

No. Name Qty. Unit Order Enquiry

Assembly drawing (station I)

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