Kiln Mechanics - (1.3) - ''Design''.pps

Kiln Mechanics – Design
Pierre TARASSEVITCH
Training “Kiln Mechanics” – Tula (Mexico) – June 2008
Content
1 Kiln support
2 Kiln roller base plate
3 Kiln roller bearing
4 Kiln roller shaft
5 Kiln tyre fixation
Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 2

Content
6 Kiln tyre
7 Kiln shell
8 Kiln drive
9 Kiln thrust system

1 Kiln support

Kiln support
 Kiln support
 Ground, soil
 Piles
 Civil works, foundation

Kiln support
 Different designs of concrete support

Kiln support
 Support requirements
 Solid foundations
 Settlement less than 10mm
 Main problems observed
 Settlement (record 170mm !)
 Differential settlement (only one side is sinking)
 Water table under concrete support without piles
 Leading to up/down level variations
 Mostly linked to rain season
 Concrete damages

Kiln support
 Concrete support & kiln alignment

Important
 Sensitivity of alignment displacement
compared to height
Small
displacement
SAME DIFFERENTIAL
SETTLEMENT
Kiln support
 Concrete support and settlement

 In the first year
 Generally 1-2mm
 Sometimes 5-10mm (check alignment)
 Abnormal 10-20mm (check alignment)
 After 1 year, foundations do not settle any more
except
 Water drainage problems (cable trenches)
 Ground moves
 Too high periodic overloads
 Crankshaft
 Alignment problems
2 Kiln roller base plate

Kiln roller base plate
 Roller station base base plate

 Adjusted and levelled with shims
 Tolerance
 Lateral < 0.1mm / m
 Axial (slope) < 0.1mm / m
 Tightened by anchor bolts

 Grouting layer between concrete and base plate
(<80mm)
 Embedded in concrete, for protection
 No mechanical purpose except weight of concrete

base Shims
plate
Anchor bolt
Concrete
Anchor bolts

base
plate
Grouting
Shims
Concrete


 Note that in case of repair or replacement of base
plate, special procedure must be applied to check
that
 the base plate is correctly seated on concrete
 the base plate is correctly tightened on concrete
 A base base plate CANNOT hold the kiln load

alone without proper shimming and concrete
 Cracks can appear
 Deformation can happen
 Check-list for proper behaviour

 Limit overload
 Alignment defect and crankshaft
 Correct installation on concrete through shims
 To avoid levelling defect
 Bolts tightened at normal torque
 To avoid moves or deformations
 No oil on the base plate
 To avoid concrete damage, or clearances
 No water on the base plate
 To avoid base plate corrosion (beware of water tank!)
3 Kiln roller bearing

Kiln roller bearing
 Kiln roller bearing with liner: 3 families

 With spherical seat, split housing
 FLS, FCB, VICKERS, KAWASAKI, IHI ...
 Without spherical seat, split housing
 POLYSIUS, KOBE, CLE...
 Without spherical seat, but common housing support
 KHD, ...

Kiln roller bearing
 Bearing with spherical seat, split housing

 FLS
Shaft
Liner
Sph. seat

Kiln roller bearing

 FCB
Shaft
Liner
Sph. seat

Kiln roller bearing

 IHI
Shaft
Liner
Sph. seat

Kiln roller bearing
 Bearing without spherical seat, split housing

 POLYSIUS
Shaft
Liner
Liner seated on
the housing
Kiln roller bearing
 Bearing without spherical seat, split housing

 KOBE
Shaft
Liner
Liner seated on
the housing
Kiln roller bearing
 Without spherical seat, but common housing

 KHD
Single
Liner part

Kiln roller bearing
 Spherical seat design advantage

 Auto-adjustment of the liner slope on shaft
 No need of a one-step machined base plate
 Lower plane tolerance of the base plate
 Without spherical seat design advantage
 Low level of shaft on base plate: no need of
fixation, more stable
 Very simple design
 less expensive to produce
 Fewer spare parts

Kiln roller bearing
 Liner without spherical seat : Axial stability

 POLYSIUS
Force
Stable support
Kiln roller bearing
 Liner with spherical seat: not stable, need bolts

 FLS
Force
Small support
Kiln roller bearing
 Spherical seat design inconvenient

 More expensive
 Maximum roller skewing reduced
 Half thrust ring = less thrust surface
 Without spherical seat design inconvenient
 In case of base plate problem, new shimming and
adjustment to be done
 Replacement of a worn liner very often leads to
replacement of the other liner

Kiln roller bearing
 Replacement of liner,influence on the other side

Roller
Shaft
A B
Liner Liner
Worn 100% Worn 15%
Replacement
liner A on design NEW Old
WITH liner liner
spherical seat
A B
Replacement
liner A on design NEW Old
WITHOUT liner liner
spherical seat
A B
Kiln roller bearing
 So on POLYSIUS, KOBE, KHD kilns

 We should always have 2 spare liners for each size
 A liner replacement must always be followed by
verification of contact on the other side liner !

Kiln roller bearing

 Liner in good condition
 Contact with shaft >80% of length, angle<15°
 Clean oil
 Sufficient water flow for cooling
 No coating inside water jackets
 Decrease cooling efficiency
 Heat shield, side of the kiln
 Heat shield, on the shaft axis
 Seals in good condition

4 Kiln roller shaft

Kiln roller shaft
 A roller shaft can be divided in

 A cast or forged roller
 A forged shaft
 superficial heat treatment (Kawasaki, KHI)
 Some tightening elements (flange, bolts, …)
 The roller is shrink-fitted on the shaft
 By cooling/heating (most of cases)
 With a hydraulic press (rare)

Kiln roller shaft
 Roller main design parameters
Diam. = Tyre diameter / 3.3

(except with planetary coolers)
Width: based on
max. pressure
Kiln roller shaft
 Very different designs

Kiln roller shaft
 Three categories of flanges

 Thrust flange at the ends
 POLYSIUS, FLS (old), FCB, CLE (new)
 Thrust flange on roller side
 FLS (new), KAWASAKI, KHD
 No thrust flange, contact on shaft end
 KOBE, CLE (old)

Kiln roller shaft
 Thrust flange at the ends

 FLS (old), POLYSIUS, FCB, CLE (new)

Kiln roller shaft
 Thrust flange on roller side

 FLS (new), KAWASAKI, KHD

Kiln roller shaft
 No thrust flange, contact at end

 KOBE, CLE (old)

Kiln roller shaft
 Roller design
 Full section, cast or forged
 More heavy, very resistant
 More expensive
 Transmit more temperature to the shaft
 Hollow cast (not supplied any more)
 More light
 Very frequent cracks in web
 Forged, machined
 Lighter
 Very resistant
Kiln roller shaft

 Shaft must be
 clear of defects (no scratch, no corrosion, no rust)
 cylindrical (defect <0.1mm on length)
 free of cracks
 NDT (US) every 2 years (notice : special probe)
 Roller must be
 cylindrical (defect <2mm on diameter)
 Thrust flanges (or end shaft) must
 be perpendicular to shaft
 be flat, with no scratch, no corrosion, no rust
5 Kiln tyre fixation

Kiln tyre fixation
 Kiln tyre fixation : “floating” or “loose”

 ALL SUPPLIERS
 Tyre is
 Floating on the shell on “pads”
 Axially tightened by “rings” and fixations
 Rotating around the shell.
 Tyre internal diameter > fixation external diameter

Kiln tyre fixation
 “Floating” or “loose”
 FLS

Kiln tyre fixation
 Polysius

Kiln tyre fixation
 Advantages
 Low cost of the tyre (a simple ring)
 Simple design
 Very easy insertion of shim
 Inconvenient
 Tyre is rotating, thus creating wear on tyre, pads, side
rings
 If wear of pads is too high, major shell ovality will
occur, leading to brick failures
 Problems with bolted design (FLS)
Kiln tyre fixation
 Check-list for proper behaviour (floating fix.)

 Tyre internal surface must be greased
 Migration < 25mm/kiln revolution, to check weekly
 Total axial clearance < 10mm
 Wobbling < 2-3mm
 Pads must not be broken
 All repair welding must be done properly (small
repairs are useless on a tyre fixation)

Kiln tyre fixation
 Kiln tyre fixation : “splined” or “fixed”

 Splined : POLYSIUS, CLE (old)
 Tyre has some internal teeth
 Avoid any relative rotation to the shell
 Fixed : FLS
 Brackets are bolted on tyre flanks and guided on
the shell
 These systems give less ovality than loose fixation

Kiln tyre fixation
 “Splined” or “fixed”
 Polysius (old design)

Kiln tyre fixation
 Polysius (new design)

Kiln tyre fixation
 FLS (new design)

Kiln tyre fixation
 Advantages
 Lower ovality than loose tyre (fewer brick problems)
 Inconvenient
 No design has been fully reliable until now
 More expensive than a loose fixation
 Tyre is fixed on the shell; any crankshaft leads to high
wobbling of the tyre

Kiln tyre fixation
 Check-list for proper behaviour (splined fix.)

 Check wobbling periodically and adjust if needed
 Needs supervision
 Check tightening of keys periodically and adjust
 Check the shell for cracks in fixation device to the
shell

6 Kiln tyre

Kiln tyre
 Design
 A simple steel ring
 Cast (mainly)
 Forged (small and middle tyres)
 With or without thrust face

Kiln tyre
 The tyre seems solid, can it resist to anything?

 No.
 Similar to other kiln parts, it is designed for a certain
kiln load, and cannot resist to any overload
 It is even subject to deformation
 by the kiln load (bricks+material+shell)
 by roller contact pressure

Kiln tyre
 Deformation during rotation

Original Tyre shape
tyre shape under load
Roller
influence
Kiln tyre
 Do we really need full contact between tyre and

roller?
 Yes.
 The supplier designed a certain width of tyre and
roller to spread the load and to avoid
 tyre and roller local deformation
 tyre and roller cracks
 plastic deformation under pressure
 Criterion: Hertz pressure in daN/mm2
 If the contact is reduced, some problems could occur.

Kiln tyre
 Contact with the roller

Normal situation - Slope defect
- Shape defect
- Wobbling
P1 ~= P+90%

Kiln tyre

 Tyre must be
 free of scratch
 free of cracks
 NDT (US) inspection every 2 years
 Check contact between tyre and roller (!!SAFETY!!)

 Best way is to use your eyes, from under the tyre
 Lead wire can be used, with the correct procedure
 Alignment control (avoid overloads)
 Shape control of tyre and rollers (diameters)

7 Kiln shell

Kiln shell
 Kiln shell design

 Steel tubes welded together
 Calculated to hold vertical load, but not to remain
cylindrical during rotation
 Shell relative ovality (variation of shape during
rotation) can be very high
 Shell is very weak regarding loads: it never stays
round during kiln rotation!

Kiln shell
 What is the relative ovality?

 Mathematical definition
 R.Ovality (mm) is the distance between one elliptic
shape and its base circle of diameter D
 R.Ovality (%) = R.Ovality(mm) / D
 Ovality = Dmax - Dmin
R.Ovalitymm
Di
am
R.Ovalitymm
.D
Kiln shell
 Could the ovality be a problem?

 Yes.
 Everything welded or fixed to the shell can be subject
to ovality problems
 Bricks
 Welded rings
 Fixation devices
 Shell itself (fatigue stress)
 …
 It is very important to check regularly the ovality

Kiln shell
 Is it really an ellipse?
 In fact it looks like a skull…
Influence of rollers on the tyre

(area of the tyre only)
Kiln shell
 What is the range of deformations?

 Some examples
Shell diam. 4800mm

R.Ovality = 0.52%
25 mm !!!

Kiln shell
 How to measure ovality?

 It can be measured with the “Shell Test” device
 Major suppliers can provide this service
 Polysius
 Refratechnik
 FLS
 Phillips Rema
 …

Kiln shell
 Shell test
 This tool can be bought (15k€)
 Principle:
 A measuring beam is fixed on the shell with magnets
 During one rotation, it records the move of its middle
point compared to its ends
 Data are transmitted to computer once measurements
are finished
 Ovality is calculated and shown on a graph
 User must be a good technician assisted for safety
purposes

Kiln shell
 Shell test

Kiln shell
 How can shell ovality be reduced?

 Except design problem (check with your T.C.),
problems are mainly due to
 High tyre migration
 Alignment problems
 Crankshaft problems
 Action levers are
 Regularly check tyre migrations
 Reduce tyre migration by shimming when needed
 Do not forget: check regularly your kiln alignment

Kiln shell
 Other typical problems

 Shell cracks
 Due to wear and weakening
 Due to corrosion (thickness reduction)
 Due to kiln excessive misalignment and/or crankshaft
 Due to excessive shell ovality
 On cooler port shell
 Due to poor casting
 Due to poor quality outlet box
 Shell deformed
 Due to heat (see previous presentation)
Kiln shell

 Check tyre migration every week
 Check alignment once a year
 Check shell thickness (wear/corrosion) every year
 Check shells for deformations and cracks every time
bricks are removed
 On each tyre side, check the first 2 circular welds for
cracks at each long kiln stoppage

Kiln shell : doors
 Shell doors are useful

 To remove bricks
 Shell door creates additional stress in shell
 Because it is an opening
 Because it will not have the same behaviour than the
shell
 Remember ovality!
 The door base plate is being deformed at each
rotation
 A kiln shell door base plate should be watched
 For leakages
Kiln shell: doors

 Check the door base plate for cracks weekly
 Check the door base plate for leakage daily
 At each opening, tighten the bolts or locking device
properly, with the original sealing design
 Be cautious when replacing the door with other
design
 Ovality!
 Special attention to hot-spots near the door
 Known to lead to crack very quickly

8 Kiln drive

Kiln drive
 Kiln drive rotates the kiln

Kiln drive
 It is split into several parts

 Girth-gear
 Pinion(s)
 Torsion shaft (s)(in general)
 Main gearbox(s)
 Main motor(s)
 Barring gearbox(s)
 Barring motor(s)
 Emergency power generator(in general), or diesel
engine

Kiln drive: girth-gear
 Girth-gear
 Most sensitive item on the kiln
 Expensive part
 Manufacturing is long (1 year)
 It is in general cast, then machined
 (some forged gears recently appeared on market)
 Teeth repairs are generally not possible (break
quickly)
 Girth-gear must be watched very often to ensure
long lifetime
 Recent designs: approx. 10 years/face
 Girth-gear fastening system

 2 families
Fixed pre-tightened spring Tangential spring plates

plates (Polysius) (Others)

 What is important?
 Geometry
 Radial run-out: ensure the root clearance stays almost
the same
 Axial run-out (wobbling): ensure that the girth-gear is
almost perpendicular to the rotation axis.
 All parameters are adjusted by the supplier?
 Yes.
 But production problems (hot spots, damages to the
kiln shell) can
 deform the kiln axis
 change meshing conditions

Kiln drive : girth-gear
 Girth-gear : Geometry control

 Procedure and excel spreadsheet available
Dial gauge 3
Dial gauge 1

 How to lose the geometry?
Original tube
Big hot spot leading to permanent

Thermal expansion
deformation of the tube
Creation of radial run-

out AND wobbling

Kiln drive: girth-gear and pinion
 Adjustment of the pinion

 Adjustment of the pinion is a very accurate operation
 Root clearance parallelism < 0.1mm
 Contact parallelism < 0.05mm
 This operation must be done by a specialist
 Contact pinion/girth-gear must be checked
 At each replacement of bearing or liner
 In case of major kiln alignment modification

 Adjustment of the pinion
Left
Center
Right
Root clearance and radial run-out Contact with girth-gear

 Blue check is useful!

Wrong pinion adjustment
Girth-gear wobbling

 Blue check is useful!

Kiln drive: lubrication
 Girth-gear
 Lubrication is essential to avoid wear
 Several lubrication system
 Continuous transfer lubrication (paddle wheel)
 Continuous circulation lubrication
 Intermittent automatic spray (most used)
 Checking correct function of lubrication system is very
important!
 Check nozzles periodically
 Check girth-gear and pinion aspect

Kiln drive : lubrication
 Continuous transfer lubrication (paddle wheel)
Note that
sometime,
paddle wheel is
installed on
girth-gear.
It is important to
check sump and
paddle wheel
regularly

 Continuous circulation lubrication
Lubrication to be
applied uniformy
Filters must be
checked
regularly

 Intermittent automatic spray

 Spray system with barrel pump

 Checking spray system is very important

 TIP: Use wood plate to check nozzles

 Spray nozzles out of order can lead to very

important damages!

Kiln drive: torsion shaft
 Torsion shaft (if any)

 Purpose
 to filter shocks coming from pinion to avoid damage on
main reducer and/or main motor
 to permit an alignment defect between pinion and gear
box
 because pinion is aligned to girth-gear and cannot
be moved
 because main reducer is aligned with at least 3
machines and then is difficult to move

Kiln drive: main reducer
 Main reducer
 Expensive part of the kiln
 Generally, no spare parts available on site
 Long lifetime depending on lubrication
 Important remark
 Lubrication failure quickly leads to desastrous results
 Preventive maintenance is very important
 Periodical check of filters
 Periodical check of pumps and safety sensors
 Periodical check of water cooling

 Failures
 Lubrication problem = 50% of gearbox failures
 Maintenance is very important
 Cleaning of the area,too
 Avoid dust contamination
 Oil leakage = dust can also enter!

 TIP :
 Think of number of cycles for each shaft
 Replace parts according to number of cycles
 The first seal to fail is always on the input shaft
 Bearings are generally failing on the input shaft
 Gear problems are in general on the input shaft
 …

9 Kiln thrust system

Kiln thrust system
 The kiln has a slope of 3 to 4%

Kiln thrust system
 It should normally go downwards with rotation

 Ex: kiln 1200t at 3.5%
 Axial load = 1.200 t x 3.5% = 42 t to hold !
42 t

Kiln thrust system
 Need for axial thrust rollers

 30 years ago, fixed rollers
 tyre blocked between two rollers, with clearance equal
to travel movement (35 to 50mm)
Kiln thrust system
 Problems
 Travel is a consequence of roller skewing and friction
 What pressure on which roller?
 no information on axial load
 The kiln can be operated a long time in the same
position
 Wear on rollers
 Wear on tyre
 Wear on girth-gear and pinions
Kiln thrust system
 Recent kilns (<20 years)

 Axial fixation is made through a horizontal roller
 With hydraulic jack
 Downhill side of one tyre
Kiln thrust system
 Typical installation
Tyre
Fixed roller Thrust roller
Nitrogen
Trolley accumulator
CCR PLC Hydraulic

or sensors thrust unit
Kiln thrust system
 So, can it react to anything?

 No.
 The axial reaction load of the kiln can be really
different from the (3..% x load of the kiln) nominal
value
 Axial loads depends on
 The axial load of rotating equipment (coating, bricks,…)
 Skewing of each roller
 The friction factor between roller and tyres (depending
on graphite, oil, dust,…)
Kiln thrust system
 Normal roller skewing adjustment

 All rollers are oriented in order to contribute to axial
load sharing
A1 A3 A5
KILN LOAD Thrust1 Thrust2
A2 A4 A6
Kiln thrust system
 Abnormal roller skewing condition

 Some of the rollers are too skewed
 Some of them are skewed, but reversed
A1 A3 A5
KILN LOAD Thrust1 Thrust2
A2 A4 A6
Kiln thrust system
 What can happen if axial load is not balanced?

 Unstable axial behaviour of the kiln
 Depending on production, it can move quickly upwards
or downwards
 Hydraulic pressure fluctuates erratically
 Roller thrust bearing flange overheating
 Roller which are not adjusted have excessive pressure
on thrust disc; this can lead to overheating
 Too high pressure on hydraulic thrust roller leading to
 roller bearing failure
 problems with roller condition
 thrust roller shaft rupture or crack
Kiln thrust system
 How to understand the hydraulic thrust pressure?

 P < 40 bars : too low
 Risk of kiln moving suddenly upwards
 40 < P < 60 bars
 Correct pressure, if all rollers are well adjusted
 60 < P < 100 bars
 Pressure a little bit high
 100 < P : Too high pressure
 Wear will happen on roller and tyre
 Risk of hydraulic failure, bearing and shaft failure,...
Kiln thrust system
 Thrust pressure is going up and down regularly

 It corresponds in general to tyre wobbling
 It can be a sign of an accumulator problem
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Kiln Mechanics – Design

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 2

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 3

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 4

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 5

 Different designs of concrete support

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 6

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 7

 Concrete support & kiln alignment

 Concrete support and settlement

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 10

 Roller station base base plate

 Axial (slope) < 0.1mm / m

 Tightened by anchor bolts

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 11

 Roller station base base plate

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 12

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 13

 Roller station base base plate

 A base base plate CANNOT hold the kiln load

 Check-list for proper behaviour

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 16

 Kiln roller bearing with liner: 3 families

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 17

 Bearing with spherical seat, split housing

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 18

 Bearing with spherical seat, split housing

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 19

 Bearing with spherical seat, split housing

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 20

 Bearing without spherical seat, split housing

 Bearing without spherical seat, split housing

 Without spherical seat, but common housing

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 23

 Spherical seat design advantage

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 24

 Liner without spherical seat : Axial stability

 Liner with spherical seat: not stable, need bolts

 Spherical seat design inconvenient

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 27

 Replacement of liner,influence on the other side

 So on POLYSIUS, KOBE, KHD kilns

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 29

 Check-list for proper behaviour

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 30

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 31

 A roller shaft can be divided in

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 32

 Roller main design parameters

Diam. = Tyre diameter / 3.3

 Very different designs

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 34

 Three categories of flanges

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 35

 Thrust flange at the ends

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 36

 Thrust flange on roller side

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 37

 No thrust flange, contact at end

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 38

 Check-list for proper behaviour

Kiln Mechanic Tula (Mexico) – 17, 18 & 19th June 2008 41

 Kiln tyre fixation : “floating” or “loose”